TUBULAR GARMENT

Methods of manufacturing a tubular garment using a knitting machine having a first knitting bed and a second knitting bed are disclosed. An embodiment of the method includes knitting a first fabric panel in the first knitting bed and knitting a second fabric panel in the second knitting bed. The first fabric panel and the second fabric panel being joined to define a first tubular portion of the tubular garment. The method includes temporarily transferring the first fabric panel from the first knitting bed to the second knitting bed and knitting a third fabric panel in the first knitting bed. The method includes joining the third fabric panel to the first fabric panel to define a second tubular portion of the tubular garment. The method includes disposing an electrically conductive bus through the second tubular portion for electrical communication with at least one conductive yarn integrated within the tubular garment.

TECHNICAL FIELD

The disclosure relates generally to wearable electronics, and more specifically to smart textiles.

BACKGROUND

Smart textiles are materials that sense and/or react to environmental conditions or stimuli, such as those from mechanical, thermal, chemical, electrical, magnetic or other sources. There is a need for improved ways for forming smart textiles into wearable garments of different types and configurations.

SUMMARY

In an aspect, there is provided a method of manufacturing a tubular garment using a knitting machine that includes a first knitting bed and a second knitted bed. The method includes: knitting a first fabric panel using a first subset of knitting needles of the first knitting bed and knitting a second fabric panel using a first subset of needles of the second knitting bed, the first fabric panel and the second fabric panel being joined to define a first tubular portion of the tubular garment; transferring the first fabric panel from the first knitting bed to the second knitting bed, the first fabric panel thereupon being held by a second subset of needles of the second knitting bed; knitting a third fabric panel on the first knitting bed using a second subset of needles of the first knitting bed; joining the third fabric panel to the first fabric panel to define a second tubular portion of the tubular garment; disposing an electrically conductive bus in the second tubular portion for electrical communication with at least one conductive yarn integrated within the tubular garment.

In another aspect, there is provided a first fabric panel; a second fabric panel that is adjoined to the first fabric panel, the second fabric panel being formed integrally with the first fabric panel to define a first tubular portion of the tubular garment; a third fabric panel that is adjoined to the first fabric panel on a surface of the first fabric panel, the third fabric panel and the first fabric panel defining a second tubular portion, wherein a conductive bus is disposed within the second tubular portion for electrical communication with at least one conductive yarn integrated within the tubular garment.

DETAILED DESCRIPTION

The following description discloses tubular garments and methods useful for manufacturing a tubular garment.

In some embodiments, a tubular garment disclosed herein include a first tubular portion defined by a first fabric panel and a second fabric panel and a second tubular portion defined by the first fabric panel and a third fabric panel. A conductive bus including one or more electrically conductive wires may be disposed within the second tubular portion between the first fabric panel and the third fabric panel. The conductive bus may be electrically coupled to at least one electrically conductive yarn integrated within the tubular garment.

In some embodiments, the methods disclosed herein for manufacturing the tubular garment may include knitting the first fabric panel in a first knitting bed of a knitting machine and knitting the second fabric panel in a second knitting bed of the knitting machine. In some embodiments, the methods disclosed herein may include temporarily transferring the first fabric panel from the first knitting bed to the second knitting bed to allow the third fabric panel to be knitted in the first knitting bed.

Aspects of various embodiments are described through reference to the

FIG.1is a schematic diagram of a system10for manufacturing tubular garment22(as shown inFIG.2A-2D). System10may include controller14and one or more user input devices12(referred hereinafter in the singular). Controller14may be configured to receive input from user input device12via one or more communication terminals/ports.

Controller14may include one or more data processors20(referred hereinafter in the singular) and one or more computer-readable memories16(referred hereinafter in the singular) storing machine-readable instructions18executable by data processor20and configured to cause data processor20to generate one or more outputs (e.g., signals) for causing the execution of one or more steps of the methods described herein.

Data processor20may include any suitable device(s) configured to cause a series of steps to be performed by controller14so as to implement a computer-implemented process such that instructions18, when executed by controller14or other programmable apparatus, may cause the functions/actions specified in the methods described herein to be executed. Data processor20may include, for example, any type of general-purpose microprocessor or microcontroller, a digital signal processing (DSP) processor, an integrated circuit, a field programmable gate array (FPGA), a reconfigurable processor, other suitably programmed or programmable logic circuits, or any combination thereof.

Memory16may include any suitable machine-readable storage medium. Memory16may include non-transitory computer readable storage medium such as, for example, but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any suitable combination of the foregoing. Memory16may include a suitable combination of any type of computer memory that is located either internally or externally to controller14. Memory16may include any storage means (e.g. devices) suitable for retrievably storing machine-readable instructions18executable by data processor20.

User input device12may be an electronic device having a graphical user interface (GUI) such as a desktop computer, laptop computer or a mobile device such as a tablet for example. User input device12may be configured to receive user inputs from an operator. The user inputs may include computer-readable instructions related to a desired knitting pattern for a textile article.

The computer-readable instructions may include manufacturing instructions for controlling the operation of a knitting machine to construct tubular garment22.

Tubular garment22may be formed of one or more fabric panels24A-24C (as shown inFIGS.2A-2D) (hereinafter collectively referred to as “fabric panels24”) composed yarn. This yarn includes non-conductive yarn, and as detailed below, may also include conductive yarn. The non-conductive yarn can include any textile material such as cotton, spandex, nylon, polyester, and/or various synthetic materials. The computer-readable instructions may indicate an arrangement of the non-conductive yarn in fabric panels24. In some embodiments, conductive yarn may be inlaid within one or more fabric panels24to provide conductive paths.

The computer-readable instructions may indicate the material of the non-conductive yarn and the material of the conductive yarn used to manufacture tubular garment22. The computer-readable instructions may indicate one or more locations where a conductive path electrically couples a conductive bus that is not inlaid within the one or more fabric panels. In some embodiments, the locations may be on a surface of one of the fabric panels.

Controller14may be configured to process the computer-readable instructions to determine a set of operating parameters for one or more machines. Controller14may be further configured to generate a plurality of signals indicative of the determined operating parameters for the one or more machines. Controller14may be configured to transmit each signal of the plurality of signals to a respective machine of the one or more machines via the one or more communication terminals/ports. The one or more machines may include knitting machine21.

In some embodiments, system10may include a suitable combination for machines for forming electrical connections in tubular garment22, e.g., between any combination of electrically conductive yarns, a conductive bus, conductive wires, and electronic components of tubular garment22. Such machines may include, for example, a soldering machine and/or a welding machine, embodiments of which are described, for example, in PCT Patent Application No. WO2021/119828, entitled “METHOD OF MANUFACTURING TEXTILES WITH INTEGRATED ELECTRICAL PATHS AND ELECTRONICS” (hereinafter referred to as the '828 patent application), the entire contents of which are herein incorporated by reference.

In some embodiments, system10may include one or more sewing machines, e.g., for sewing on trim or other features of tubular garment22.

In some embodiments, system10may include machines for implementing wet processing of tubular garment22, including washing and drying machines.

Knitting machine21may be a computerized flat bed knitting machine. Knitting machine21may include first knitting bed80A and second knitting bed (hereinafter referred to as “knitting beds80”, as shown inFIGS.6A-6C). Knitting machine21may include a cam system for independently controlling a position of one or more knitting needle in a knitting bed80. Each knitting needle may be positioned to be in a non-working position or a working position. Needles in a non-working position may not move or knit when a carriage of knitting machine21is moved. In some embodiments, knitting machine21is a flat bed knitting machine that has a v-shaped bed configuration and may be referred to as a v-bed knitting machine.

In some embodiments, knitting machine21could be a suitable machine manufactured by Stoll, Shima Siekie or any other suitable flat bed knitting machine that allow for the transfer and temporary holding of a fabric panel on needles not being used for knitting.

Knitting machine21may be configured to receive one or more signals indicative of operating parameters for knitting machine21from controller14. Knitting machine21may include a separate controller having one or more data processors and one or more computer-readable memories storing machine-readable instructions executable by the one or more data processors (not depicted). In some embodiments, the one or more signals from controller14may be received by the controller of knitting machine21. In response to receiving the one or more signals, knitting machine21may be configured to operate under the defined operating parameters set out in the one or more signals received. When operating under these operating parameters, knitting machine21may be configured to form tubular garment22by knitting non-conductive yarn and/or conductive yarn in accordance with the desired knitting pattern received from user input device12.

In some embodiments, controller14may be part of knitting machine21and the operation of knitting machine21may be directly controlled by such an integrated controller14.

FIGS.2A-2Dshow a top view, front perspective view, side view and front view, respectively, of tubular garment22. Tubular garment22may include first fabric panel24A, second fabric panel24B, and third fabric panel24C. Each fabric panel24may include one or more non-conductive layers. In some embodiments, first fabric panel24A and second fabric panel24B may be integrally formed to define first tubular portion26. First tubular portion26may define an opening between first fabric panel24A and second fabric panel24B for receiving a limb (or other body portion) of a wearer of tubular garment22. In use, a portion of the limb of the wearer may be covered by first fabric panel24A and second fabric panel24B. In some embodiments, tubular garment22may be a wearable sock having first tubular portion26sized to fit a foot of a wearer of tubular garment22. In a situation where tubular garment22is a sock, first tubular portion26may have an open end and a closed end (not depicted). In use, the closed end may be positioned in the region of the wearer's toes and the open end may be positioned between the wearer's calf muscle and the wearer's knee.

Although tubular garment22is depicted as being a sock inFIGS.2B and2D, it should be understood that in alternate embodiments, tubular garment28may be a knee brace, elbow sleeve, multiclava, neck warmer, stocking, legging, or the like.

Third fabric panel24C may be joined to first fabric panel24A on surface of first fabric panel24A. As depicted, surface30of first fabric panel24A faces away from second fabric panel24B. First fabric panel24A and third fabric panel24C may define a second tubular portion40of tubular garment22. Second tubular portion40may be a close-ended tube defining cavity32between first fabric panel24A and third fabric panel24C. As depicted inFIGS.2B and2D, cavity32may include narrow portion32A and wide portion32B. Third fabric panel24C may be stitched to first fabric panel24A along a perimeter of third fabric panel24C. Tubular garment22may also have one or more additional stitches31between a lower portion of third fabric panel24C that defines wide portion32B of cavity32and first fabric panel24A. Stitches31between the lower portion of third fabric panel24C and first fabric panel24A cause the lower portion of third fabric panel24C to be closely pressed up against surface30of first fabric panel24A. The one or more additional stitches31may extend horizontally across tubular garment22. Such stitches31may also serve to divide wide portion of cavity32into a plurality of horizontal regions. As shown inFIG.2B, additional stitches31may be used to join first fabric panel24A and second fabric panel24B. As shown inFIG.2C, additional stitches31may be used to join first fabric panel24A and third fabric panel24C.

As depicted inFIG.2B, tubular garment22may include conductive bus28disposed within second tubular portion40to provide electrical communication with at least one conductive yarn34integrated in tubular garment22. Conductive bus28may include one or more conductive wires that are electrically coupled to power source38(e.g., a battery). Conductive bus28may be disposed within narrow portion32A of cavity32and may be electrically coupled to conductive yarn34at locations36A and36B. Conductive bus28may be easily accessible in cavity32by a person. Power source28may be external to tubular garment22or may be disposed within cavity32. Power source28may be easily accessible by a person allowing quick replacement of power source28if required. Conductive yarn34may be made of any conductive material including conductive metals such as stainless steel, silver, aluminium, copper, etc. As depicted inFIG.2B, first conductive wire28A of conductive bus28may connect conductive yarn34to a positive terminal of power source38, and a second conductive wire28B may connect conductive yarn23to a negative terminal of power source38.

In some situations, as depicted inFIGS.2B-2C, conductive yarn34may be disposed within cavity32between first fabric panel24A and third fabric panel24C. In these situations, conductive yarn34may be disposed within wide portion32B of cavity32and locations36A and36B may be at an interface between narrow portion32A and wide portion32B of cavity32. In some embodiments, conductive yarn34may be soldered or ultrasonically welded to first conductive wire28A and second conductive wire28B at locations36A and36B, respectively, in order to provide said electrical coupling. In some embodiments, the methods of forming an electrical connection between conductive yarn34and conductive bus28are similar to the methods described in the '828 patent application.

Conveniently, disposing at least part of conductive bus28and/or at least part of conductive yarn34within cavity32inhibits contact of such parts with skin of a wearer of tubular garment22. This may improve comfort and/or safety of wearer. This may also improve durability tubular garment22, e.g., by reducing wear caused by contact of such parts with the wearer.

In some situations, conductive yarn34may be inter-knit with non-conductive yarns of tubular garment22.FIG.3shows a cross-sectional view of first fabric panel24A having conductive yarn34inlaid within first fabric panel24A. As depicted inFIG.3, at least a portion of conductive yarn34may be disposed between non-conductive yarns of first fabric panel24. At least a portion of conductive yarn34may be inlaid within first fabric panel24A such that conductive yarn34is at sufficient distance from surface42of first fabric panel24. Surface42of first fabric panel is opposite surface30and may be in contact with a limb of a wearer when tubular garment22is worn by the wearer. Conductive yarn34being disposed at a sufficient distance from surface42may provide thermal and/or electrical protection for the wearer. In some embodiments, a substantial portion of conductive yarn34may be disposed in a middle section of first fabric panel24A. Conductive yarn34may extend from the middle section to surface30of first fabric panel24A to be electrically coupled to conductive bus28at locations36A and36B. In some embodiments, the conductive yarn34may be soldered or ultrasonically welded to conductive bus28in order to provide said electrical coupling.

In some embodiments, at least a portion of conductive yarn34is inlaid within second fabric panel24B. In some embodiments, at least a portion of conductive yarn34is inlaid within third fabric portion24C. In some embodiments, conductive yarn34may be knitted on a surface of one of fabric panels24A,24B,24C that faces an internal cavity of tubular garment22such as, for example, cavity32or a cavity formed between first fabric panel24A and second fabric panel24B. In some embodiments, conductive yarn34may be knitted between transfer points90to ensure accurate positioning.

In some embodiments, conductive yarn34may be arranged in textile garment22to provide resistive heating. Conductive yarn34may act as an electrically resistance element and a voltage may be supplied by power source38to conductive yarn24. The temperature of conductive yarn34may be increased due to the thermal coefficient of resistance of conductive yarn24.

AlthoughFIG.2Bshows tubular garment22having one conductive yarn34, it should be understood that tubular garment22may have a plurality of conductive yarns defining a plurality of conductive paths. It should be understood that conductive yarns34may be integrated in any one of the panels24. It should be understood that the conductive bus28disposed in second tubular portion40may be configured to provide electrical communication with conductive yarns34integrated in any one of the panels24.

In some embodiments, tubular garment22may include one or more electronic components. Tubular garment22may be used to detect and monitor a wide range of health issues, including: tracking of gait, pressure sensing, electromyography (EMG), heat stimulation and electrical muscle stimulation (EMS).

FIGS.4A-4Cshow different perspective views of an embodiment of tubular garment22having a plurality of electronic components46,48,56,58integrated within first tubular portion26of tubular garment22. Electronic components46,48,56,58may be embedded within first fabric panel24A and/or second fabric panel24B and may be electrically coupled to conductive bus28via a plurality of conductive yarns34(not depicted). Electronic components46,48,56,58may also be in communication with controller60via conductive yarns34. Controller60may be configured to receive signals from electronic components46,48,56,58. Controller60may be configured to control the operation of one or more of the electronic components46,48,56,58based on the received signals.

Referring toFIG.4A, tubular garment22(shown by example only as a sock) may have inertial measurement unit (IMU) sensor46connected to body49of first tubular portion26that measures and reports a body's (e.g. limb of the wearer) specific force, angular rate, and/or sometimes the magnetic field surrounding the body, using a combination of accelerometers and gyroscopes, sometimes also magnetometers. Body49may refer to the portion of first tubular portion26consisting of non-conductive interlaced yarns. Example configurations of IMU sensor46can be used to detect linear acceleration of the wearer's limb using one or more onboard accelerometers and rotational rate using one or more onboard gyroscopes. Some IMU sensors46can also include an onboard magnetometer used as a heading reference. Typical configurations of IMU sensors46contain one accelerometer, gyro, and magnetometer per axis for each of the three axes: x, y and z.

Tubular garment22may have one or more stretch/strain sensors48positioned on/in body49and across intermediate region50of first tubular portion26in order to detect flexure of the wearer's joint underlying intermediate region50, as the wearer moves the limb during physical activity (e.g. walking, running, lifting, carrying, or otherwise engaging relative movement of the limb with respect to the rest of the wearer's body). Top region52and bottom region54of first tubular portion26may be oriented at an angle to one another about intermediate region50. For example, stretch/strain sensors48may be applied to a surface of body49(e.g. consisting of nonconductive interlaced yarns). Alternatively, stretch/strain sensors48may be composed of conductive fibers/yarns that are interlaced (e.g. knit or woven) with the non-conductive yarns of body49.

Tubular garment22may also have electromyography (EMG) sensors56on/in the body49used for evaluating and recording/detecting electrical activity produced by skeletal muscles (e.g. calf muscles, forearm muscles, bicep/tricep muscles, hand muscles, and general foot/leg muscles such as but not limited to dorsiflexor and plantarflexor muscles). EMG sensors56can be used to detect/record the electric potential generated by muscle cells when these cells are electrically or neurologically activated (e.g. by the wearer's brain in order to effect movement of the limb). The EMG signals detected by EMG sensors56may be analyzed to detect medical abnormalities, activation level, or recruitment order, or to analyze the biomechanics of human or animal movement. For example, EMG sensors56may be applied to a surface of body49(e.g. consisting of nonconductive interlaced fibres). Alternatively, EMG sensors56may be composed of conductive fibers/yarns that are interlaced (e.g. knit or woven) with the nonconductive yarns of body49.

Tubular garment22may also have electrical muscle stimulation (EMS) actuators58, also known as neuromuscular electrical stimulation (NMES) or electromyostimulation, which is the elicitation of muscle contraction using electric impulses applied by the EMS actuators58. The impulses can be transmitted to the EMS actuators58and delivered through the electrodes (i.e. the EMS actuators58) on the wearer's skin near to the muscles being stimulated. The EMS actuators58may be pads that are positioned or otherwise biased into engagement with the skin. For example, the non-conductive yarns of body49can be resilient (e.g. elastic) in nature and thus promote contact of the sensors56,58with the skin of the wearer underlying body49. As such, the EMS impulses applied by the EMS actuators58can mimic the action potential that comes from the central nervous system, causing the underlying muscles to contract and thus promote movement of the underlying skeletal structure of the limb. For example, EMS actuators58can be applied to a surface of body49(e.g. consisting of nonconductive interlaced yarns). Alternatively, EMS actuators58may be composed of conductive yarns that are interlaced (e.g. knit or woven) with the non-conductive yarns of body49material. It is recognized that EMS actuators58and EMG sensors59can be the same, or different, electronic components connected to controller60via conductive yarns34.

The electrically conductive fibers/yarn incorporated into tubular garment22as one or more electronic components46,48,56,58can be made of any conductive material including conductive metals such as stainless steel, silver, aluminium, copper, etc. In one embodiment, the conductive yarn can be insulated. In another embodiment, the conductive yarn can be uninsulated.

Other examples of electronic components that may be incorporated into tubular garment22are disclosed in International Patent Publication No. WO2019134033A2, entitled “MULTI-FUNCTIONAL TUBULAR WORN GARMENT”, the entire contents of which are herein incorporated by reference.

FIG.5is a flowchart illustrating an example method62for manufacturing tubular garment22in accordance with an embodiment. Method62can be performed using system10described herein or using another system. It is understood that aspects of method62can be combined with aspects of other methods described herein. In various embodiments, method62includes:

knitting a first fabric panel using a first subset of knitting needles of a first knitting bed and knitting a second fabric panel using a first subset of needles of a second knitting bed, the first fabric panel and the second fabric panel being joined to define a first tubular portion of the tubular garment (block64);

transferring the first fabric panel from the first knitting bed to the second knitting bed, the first fabric panel thereupon being held by a second subset of needles of the second knitting bed (block66); and

knitting a third fabric panel on the first knitting bed using a second subset of needles of the first knitting bed (block68);

joining the third fabric panel to the first fabric panel to define a second tubular portion of the tubular garment (block70); and disposing an electrically conductive bus through the second tubular

portion for electrical communication with one or more conductive yarns integrated within the tubular garment (block72).

FIG.6Ashows a perspective view of a configuration of knitting machine21when knitting first fabric panel24A and second fabric panel24B. As depicted, first fabric panel24A may be knitted using first subset of knitting needles82A of first knitting bed80A and second panel24B may be knitted using first subset of knitting needles82B of second knitting bed80B. Second subset of knitting needles84A of first knitting bed80A and second subset of knitting needles84B of second knitting bed80B may be in a non-working position during the knitting of first fabric panel24A and second fabric panel24B. As depicted, first subset of knitting needles82A of first knitting bed80A and second subset of knitting needles84A of first knitting bed80A are alternatingly arranged in first knitting bed80A. Similarly, first subset of knitting needles82B of second knitting bed and second subset of knitting needles84B of second knitting bed80B are alternatingly arranged in second knitting bed80B. So arranged, on each knitting bed, one subset of knitting needles may be referred to as odd needles and the other subset of knitting needles may be referred to as even needles.

Although it not depicted inFIG.6A, first fabric panel24A may be joined to second fabric panel24B. First fabric panel24A and second fabric panel24B may be integrally formed to define first tubular portion26. In some embodiments, strands of yarn may be passed between first knitting bed80A and second knitting bed80B during knitting to integrally form first fabric panel24A and second fabric panel24B.

In some embodiments, knitting first fabric panel24A may include inlaying at least one conductive yarn34within first fabric panel24A such that the at least one conductive yarn34is disposed between non-conductive yarns of first fabric panel24A.

FIG.6Bshows a perspective view of a configuration of knitting machine21after first fabric panel24A is temporarily transferred from first knitting bed to second knitting bed80B and during knitting of third panel24C. As depicted, first fabric panel24A may be held by second subset of needles84B of second knitting bed80B when transferred to second knitting bed80B. Third fabric panel24C may be knitted using second subset of needles84A of first knitting bed80A. First subset of knitting needles82A of first knitting bed80A and first subset of knitting needles82B of second knitting bed80B may be in a non-working position when knitting third fabric panel24C. By temporarily transferring fabric panel24A to second knitting bed80B, it advantageously allows third fabric panel24C to be knitted alongside first fabric panel24A and second fabric panel24B in a single knitting process. Although it not depicted inFIG.6B, third fabric panel24C may be joined to first fabric panel24A to define second tubular portion40during the knitting process. Joining third fabric panel24C to first fabric panel24A may include stitching third fabric panel24C to first fabric panel24A along a perimeter of third fabric panel24C. In some embodiments, joining third fabric panel24C to first fabric panel24A may include stitching a lower portion of third fabric panel24C to first fabric panel24A such that the lower portion of third fabric panel24C is closely pressed up against surface30of first fabric panel24A.

FIG.6Cshows a perspective view of a configuration of knitting machine21after first fabric panel24A is transferred back to first knitting bed80A and after at least a portion of third fabric panel24C has been knitted. As depicted, first fabric panel24A is held by first subset of knitting needles82A of first knitting bed80A after first fabric panel24A is transferred back to first knitting bed80A. Second subset of needles84B of second knitting bed80B holding third fabric panel24A may be retracted and may be in a non-working position after first fabric panel24A is transferred back to first knitting bed80A. In some embodiments, an extension may be knitted to first fabric panel24A using first subset of knitting needles82A of first knitting bed80A and an extension may be knitted to second fabric panel24B using first subset of knitting needles82B of second knitting bed80B.

During knitting of tubular garment22, first fabric panel24A may be transferred back and forth between first knitting bed80A and second knitting For example, first fabric panel24A can be transferred back to first knitting bed80A to place first fabric panel24A into a knitting position that allow knitting of first fabric panel24A to resume (on first knitting bed80A) and knitting of second fabric panel24B to resume (on second knitting bed80B). During this time, third fabric panel24C may be maintained in a holding position at second knitting bed80B. Subsequently, first fabric panel24A can be transferred again to the second knitting bed80A and maintained in a holding position at second knitting bed80B, thereby freeing first knitting bed80A to resume knitting third fabric panel24C while third fabric panel24C is in this knitting position. In this way, fabric panels are shifted repeatedly between holding positions and knitting positions to build the courses for each of the fabric panels as required, e.g., in accordance with instructions18.

FIG.6Dshows a perspective view of a configuration of knitting machine21for joining first fabric panel24A and second fabric panel24B. As depicted, each of first fabric panel24A and second fabric panel24B extends from a first end92of knitting machine21to a second end94of knitting machine21, with portions each of these panels omitted for clarity of depiction.

At each of ends92and94, a pair of needles, namely a needle82A of first knitting bed80A and a needle82B of second knitting bed80B, cross at a stitch transfer point90. Each stitch transfer point90defines the location where a stich is passed from a needle82A to a needle82B, or vice versa, as first fabric panel24A and second fabric panel24B are knit. In this way, one or more stitches are shared between first knitting bed80A and second knitting bed80B, with the one or more stitches transferred from one knitting bed to the other upon reaching a stitch transfer point. This manner of stitching causes first fabric panel24A and second fabric panel24B to be joined as they are knitted, thereby forming tubular portion26. As will be appreciated, the width of each fabric panel (and hence the width of tubular portion26) is defined by the number of needles of the corresponding knitting bed which are in a working position between the two stitch transfer points90.

The configuration of knitting machine21described with reference toFIG.6Dmay also be used in similar manner for joining first fabric panel24A and third fabric panel24C to form second tubular portion40.

FIG.7is a perspective view of tubular garment22in accordance with one embodiment before conductive bus28is disposed in second tubular portion As depicted, third fabric panel24C may be stitched to first fabric panel24A along a perimeter of third fabric panel24C. However, in this depiction, a lower portion of third fabric panel24C is not stitched to first fabric panel24A such that the lower portion of third fabric panel24C is closely pressed up against surface of first fabric panel24A.

After first fabric panel24A is transferred back to first knitting bed80A and third fabric panel24C has been knitted, conductive bus28may be disposed within second tubular portion40to provide electric communication with conductive yarn34. Establishing an electrical coupling between conductive bus28and conductive yarn34may involve soldering or welding at an interface between conductive bus28and conductive yarn34.

In a situation where conductive yarn34is inlaid within first fabric panel24A, conductive bus28may electrically coupled to conductive yarn34at one or more locations36on surface30of first fabric panel24A.

In a situation where conductive yarn34is not inlaid within first fabric panel24A, conductive yarn may be disposed within cavity32and then electrically coupled to conductive bus28which is also disposed within cavity32.

A method is provided to form a heel in embodiments of tubular garment22having a heel. According to this method, fabric is knit on first knitting bed80A and second knitting bed80B with unbalanced courses. For example, fabric on the heel side of tubular garment22may be knit with a 3-1, 4-1, 5-1, or other suitable course ratio. The use of such unbalanced course ratios produces greater fabric area (more courses) on the heel side of tubular garment22, allowing the heel side to bend at the wearer heel or contour around it, while maintaining consistent fabric density with minimal stretching.

Importantly, according to this method, layers of fabric on both sides of tubular garment22(e.g., first fabric panel24A, second fabric panel24B, and third fabric panel24C) are passed at the same time between first knitting beds and second knitting beds80B.

Embodiments of manufacturing systems employing this method may avoid friction that is created when holding fabric on one knitting bed while knitting on the opposite knitting bed, as associated with a conventional Goring method. Conveniently, such embodiments may produce multi-tubular garments with consistent quality of stitch formation.

This method may be applied to various types of tubular construction, including construction of angular bends, curvatures or pocket type zones.

Due to the discrete nature, size and comfort, a tubular shaped garment, such as a sock, knee brace, elbow sleeve, stocking, legging, and the like are especially attractive form factors for a smart textile in particular for applications involving health and wellness and performance sports, where a sock can be used to detect and monitor a wide range of health issues, including: tracking of gait, pressure sensing, electromyography (EMG), heat stimulation and electrical muscle stimulation (EMS) of the calf for improved circulation and bio-impedance feedback for sub-skin infection monitoring and other combined features.

In some embodiments, at least part of tubular garment22may be formed of other textile forms and/or techniques such as weaving, knitting (warp, weft, etc.) or the like. In some embodiments, tubular garment22includes any one of a knitted textile, a woven textile, a cut and sewn textile, a knitted fabric, a non-knitted fabric, in any combination and/or permutation thereof. Example structures and interlacing techniques of textiles formed by knitting and weaving are disclosed in U.S. patent application Ser. No. 15/267,818, entitled “Conductive Knit Patch”, the entire contents of which are herein incorporated by reference.

As used herein, “textile” refers to any material made or formed by manipulating natural or artificial fibres to interlace to create an organized network of fibres. Generally, textiles are formed using yarn, where yarn refers to a long continuous length of a plurality of fibres that have been interlocked (i.e. fitting into each other, as if twined together, or twisted together). Herein, the terms fibre and yarn are used interchangeably. Fibres or yarns can be manipulated to form a textile according to any method that provides an interlaced organized network of fibres, including but not limited to weaving, knitting, sew and cut, crocheting, knotting and felting.

Different sections of a textile can be integrally formed into a layer to utilize different structural properties of different types of fibres. For example, conductive fibres can be manipulated to form networks of conductive fibres and non-conductive fibres can be manipulated to form networks of non-conductive fibers. These networks of fibres can comprise different sections of a textile by integrating the networks of fibres into a layer of the textile. The networks of conductive fibres can form one or more conductive pathways that electrically connect with actuators and sensors embedded in tubular garment22, for conveying data and/or power to and/or from these components.

In some embodiments, multiple layers of textile can also be stacked upon each other to provide a multi-layer textile.

As used herein, “interlace” refers to fibres (either artificial or natural) crossing over and/or under one another in an organized fashion, typically alternately over and under one another, in a layer. When interlaced, adjacent fibres touch each other at intersection points (e.g. points where one fibre crosses over or under another fibre). In one example, first fibres extending in a first direction can be interlaced with second fibres extending laterally or transverse to the fibres extending in the first connection. In another example, the second fibres can extend laterally at 90° from the first fibres when interlaced with the first fibres. Interlaced fibres extending in a sheet can be referred to as a network of fibres.

As used herein “integrated” or “integrally” refers to combining, coordinating or otherwise bringing together separate elements so as to provide a harmonious, consistent, interrelated whole. In the context of a textile, a textile can have various sections comprising networks of fibres with different structural properties. For example, a textile can have a section comprising a network of conductive fibres and a section comprising a network of non-conductive fibres. Two or more sections comprising networks of fibres are said to be “integrated” together into a textile (or “integrally formed”) when at least one fibre of one network is interlaced with at least one fibre of the other network such that the two networks form a layer of the textile. Further, when integrated, two sections of a textile can also be described as being substantially inseparable from the textile. Here, “substantially inseparable” refers to the notion that separation of the sections of the textile from each other results in disassembly or destruction of the textile itself.

The above description is meant to be exemplary only, and one skilled in the relevant arts will recognize that changes may be made to the embodiments described without departing from the scope of the invention disclosed. The present disclosure may be embodied in other specific forms without departing from the subject matter of the claims. The present disclosure is intended to cover and embrace all suitable changes in technology. Modifications which fall within the scope of the present invention will be apparent to those skilled in the art, in light of a review of this disclosure, and such modifications are intended to fall within the appended claims. Also, the scope of the claims should not be limited by the preferred embodiments set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole.