Method for manufacturing a dressing item with a circular knitting machine, and item obtained with the method

Abstract: A method for manufacturing a dressing item such as an undershirt, body suit or the like with a circular knitting machine, and an item obtained thereby, said method comprising: at least one first step (A), during which an annular border (1) is formed which constitutes the neck of the item; at least one second step (B), during which a first tubular portion (2) of knitting is formed starting from the annular border (1); at least one third step (C), during which a second tubular portion (3) of knitting is formed to continue the first tubular portion (2) of knitting; and a fourth step (D), during which a completion portion (4) of the item is formed. The annular border (1) is formed by means of at least one prestretched elastic yarn and/or by using a limited number of needles with respect to the number used to form the first tubular portion (2) of knitting and/or the second tubular portion (3) of knitting, so as to obtain an item with a neck having a smaller diameter than the remaining part of the item and without seams in the shoulder region.

Description: The present invention relates to a method for manufacturing a dressing item such as an undershirt, body suit or the like with a circular knitting machine, and to an item obtained with the method. It is known that undershirts, some body suits or similar items of clothing are generally manufactured by cutting the front portion and the rear portion of the item from large pieces of knitted fabric and by subsequently stitching along the sides and shoulders of the item, or by starting from a substantially tubular item produced with circular knitting machines. This basic item can have a perfectly tubular shape, i.e., with a diameter which is substantially constant along its extension. In this case, the item is then subjected to cutting operations in order to form the neck-hole and the openings for the passage of the user's arms and to stitching operations to join the front side to the rear side at the shoulders, to optionally apply the sleeves and to apply borders at the neck and optionally at the arm-holes. In some cases, the basic item has a contoured shape, with a neck-hole at the neck region and two pairs of flaps of fabric which are meant to be stitched in pairs to form the shoulders of the undershirt. In any case, undershirts or body suits obtained with conventional methods starting from an item manufactured with circular knitting machines have, in the shoulder region, a seam which joins the front part of the undershirt to the rear part and runs from the neck region to the lateral arm-holes or to the sleeves. This seam, besides having an aesthetically unpleasant effect, can be uncomfortable for the user. PCT Patent Application WO 97 47794 A discloses shirt blanks shirts and methods of manufacturing same. US Patent 4624115 discloses a method for manufacturing a dressing item and the item itself of the same kind of those set forth in Independent claims 1 and 18 respectively. The aim of the present invention is to solve the above-described problem by providing a method which allows to produce, with a circular knitting machine, a dressing item for manufacturing undershirts, body suits or the like without a seam in the shoulder region. Within the scope of this aim, an object of the invention is to provide a method which can be performed on a wide range of currently commercially available circular knitting machines. Another object of the invention is to provide a method which allows to obtain a semifinished component which requires finishing operations which can be performed with low costs. This aim, these objects and others which will become apparent hereinafter are achieved by a method according to claim 1 for manufacturing a dressing item such as an undershirt, body suit or the like with a circular knitting machine, that comprises in particular: at least one first step, during which an annular border is formed which constitutes the neck of the item; at least one second step, during which a first tubular portion of knitting having a gradually increasing diameter is formed starting from said annular border; at least one third step, during which a second tubular portion of knitting is formed to continue said first tubular portion of knitting; and a fourth step, during which a completion portion of the item is formed. The item obtained with the method according to the invention is defined in claim 18 and comprises a knitted tubular body which has, starting from one of its longitudinal ends: an annular border; a first tubular portion of knitting, which has no longitudinal seams and has a diameter which increases starting from said annular border; a second tubular portion of knitting; and a completion portion of the item. Further characteristics and advantages of the present invention will become apparent from the following detailed description of two preferred but not exclusive embodiments of the method according to the invention, illustrated only by way of non-limitative example in the accompanying drawings, wherein: Figure 1 is a schematic view of an item obtained with the method according to the invention in a first embodiment; Figure 2 is a schematic view of an item obtained with the method according to the invention in a second embodiment. With reference to Figure 1, the method according to the invention, in a first embodiment, comprises: at least one first step A, during which an annular border 1 is formed which constitutes the neck of the item; at least one second step B, during which a first tubular portion of knitting 2 is formed starting from the annular border 1; at least one third step C, during which a second tubular portion of knitting 3 is formed to continue the first tubular portion of knitting 2; and a fourth step D, during which a completion portion 4 of the item is formed. Preferably, the first tubular portion of knitting 2 has a diameter which gradually increases starting from the annular border 1. This can be achieved by forming the annular border 1, during the first step A, by knitting, at one or more feeds or drops of the machine, with only some of the needles of the machine, for example one needle in every two contiguous needles, or one needle in three, or one needle in four, or one needle in five, or one needle in six, in seven, eight, nine, ten etcetera. As an alternative, it is possible to knit, at one or more feeds of the machine, with two contiguous needles in every four or in every six and so forth, so as to obtain a border 1 which has a significantly smaller diameter than the tubular portion 3 knitted in the third step C. During the second step B, the needles that knit at the various feeds of the machine are gradually increased so as to obtain a tubular portion 2 whose diameter increases gradually starting from the annular border 1. As an alternative, the annular border 1 can have the same diameter, during knitting, as the first tubular portion of knitting 2 and optionally as the second tubular portion of knitting 3, in that it can be knitted with the same number of needles used to knit the tubular portions of knitting 2 and 3. In this case, the annular border 1 is formed by using at least one prestretched elastic yarn so that the item, at the end of the process, still has an annular border 1 constituting the neck, which has a smaller diameter than the tubular portions 2 and 3 owing to the elastic reaction of the yarn or yarns used. Even if the annular border 1 is formed with a reduced number of needles, it can still be formed by using at least one prestretched elastic yarn, so as to increase the reduction in the diameter of the item at the annular border 1 with respect to the remaining part of the item and allow it to widen when the item is to be put on. The border 1 can be formed with single-thickness knitting or with double-thickness knitting, for example by using the needles of the cylinder and the hooks of the dial of the machine, in a manner which is similar to the knitting of the double-thickness top of socks, or by using only the needles of the cylinder with drop-stitch knitting of a per se known type. With these kinds of knitting, the initial row of knitting of the border 1 is retained by the hooks of the dial of the machine or by some of the needles used to form the border 1, while other needles continue to form the knitting at the subsequent feeds of the machine. The initial row is then knitted in with the first row of the tubular portion 2 at the beginning of the second step B. At least one elastic yarn, or at least one elastic yarn and one or more nonelastic yarns knitted together, are used to form the tubular portion 2 as well. During the execution of the second step B, portions of knitting 5 are formed, at two diametrically opposite regions of the tubular portion 2, which are visually different from the remaining part of the knitting of the tubular portion 2 and are meant to be subsequently removed to obtain two openings for the passage of the arms of the wearer or for applying the sleeves. The visual differentiation, which is used in the subsequent step for cutting and for optionally applying the sleeves, can be obtained for example by knitting the portions 5 by means of two sets of needles arranged in two substantially diametrically opposite positions of the needle cylinder, with a single yarn, while the remaining part of the first tubular portion 2 is formed by using two or more yarns, optionally with pattern effects for aesthetic reasons. The yarn used to form the portions 5 can be a cheaper yarn, since the portions 5 are meant to be removed. As an alternative, the first tubular portion of knitting 2 can be formed by using a single yarn both for the portions 5 and for the remaining part of the first tubular portion 2, and the portions 5 can be delimited by stitches of a different kind, for example tuck stitches, or of a different color with respect to the adjacent stitches. Another alternative, instead of knitting the portions 5, is to cut and clamp the yarns, at the beginning of these portions, directly on the machine during the forming of the various rows, so as to obtain directly on the machine the openings for the passage of the arms or for applying the sleeves. In this type of knitting, the takeup of the yarn or yarns used to form the tubular portion 2, at the rows of knitting that affect the portions 5, is interrupted for a preset number of needles which can vary row by row so as to achieve the intended shape for the openings at the portions 5. The third step C forms the tubular portion 3, which preferably has a substantially constant diameter along its extension although, if a particular shape of the item is required, it is possible to knit said tubular portion 3 with a variable diameter. According to the requirements, the number of stitches per row of knitting used to form said tubular portion 3 is preferably between two and ten times the number of stitches that compose each row of the border 1. The second tubular portion 3 can be formed by using, for each stitch, a single yarn or two or more elastic and nonelastic yarns, optionally forming patterns which can be obtained in a per se known manner. In the fourth step D it is possible to simply form a limited number of completion rows or a double-thickness border, formed in a manner similar to the one described with reference to the annular border 1. With reference to Figure 2, the method according to the invention, in a second embodiment, comprises: a first step A', during which an annular border 1 is formed; a second step B', during which a first tubular portion 2 with an increasing diameter is formed; and a third step C', during which a second tubular portion 3 is formed which has a preferably substantially constant diameter, as described with reference to steps A, B and C of the first embodiment. In a fourth step D', instead of simply forming a completion border, two portions 10 and 11 are knitted in two diametrically mutually opposite regions, extending the second tubular portion 3 on the front side and on the rear side of the item. The two portions 10 and 11 are meant to be mutually stitched proximate to their lower end to form the crotch region of an item such as a body suit. The portions 10 and 11 can be formed by using two sets of needles of the needle cylinder of the machine which are located in two substantially diametrically mutually opposite regions and by varying the number of active needles row by row, so as to obtain the intended shape of the borders of the portions 10 and 11 that constitute the leg openings of the body suit. The yarn or yarns used to form the portions 10 and 11 are cut and clamped at the end of the set of active needles and are then fed again to the subsequent set of active needles. As an alternative, the fourth step D' can be performed by activating the needles of the machine that are meant to form the portions at the leg openings, but excluding said needles from knitting at some feeds of the machine so as to obtain, in the regions that correspond to the leg openings, a smaller number of rows than the rows of the portions 10 and 11, thus obtaining, directly in the machine, part of the leg openings, which can be completed by removing the row portions knitted with a reduced number of feeds. As an alternative, the portions related to the leg openings can be knitted with a single yarn, while the portions 10 and 11 are knitted with at least two yarns, or the portions that correspond to the leg openings and are meant to be removed can be simply knitted with a pattern effect or other stitches so as to visually differentiate them from the portions 10 and 11 to facilitate the subsequent removal operation. Another alternative is knitting all of the additional tubular portion to continue the second tubular portion with a single yarn, delimiting the portions that are meant to be removed to form the leg openings by means of stitches of a different type, for example tuck stitches, or of a different color with respect to the adjacent stitches. The item obtained with the method according to the invention substantially has, starting from one of its longitudinal ends: an annular border 1, which has a reduced diameter; a first tubular portion of knitting 2, which has no longitudinal seams and whose diameter increases starting from the annular border 1; a second tubular portion of knitting 3, which has a substantially constant diameter; and a completion portion of the item which, depending on the type of the item to be formed, can be simply constituted by a border, by a double-thickness border 4, or by two portions 10 and 11 which are meant to be stitched together to form the crotch region of a body suit. The item thus produced can be subjected to finishing treatments by stitching borders at the openings for the arms of the user or by applying sleeves and by applying borders along the sides of the portions 10 and 11, if provided. In practice it has been observed that the method according to the invention fully achieves the intended aim, since it allows to obtain an item such as an undershirt, body suit or the like without seams in the shoulder region. The method thus conceived is susceptible of numerous modifications and variations, all of which are within the scope of the inventive concept; all the details may also be replaced with other technically equivalent elements. In practice, the materials employed, as well as the dimensions, may be any according to requirements and to the state of the art. The disclosures in Italian Patent Application No. MI97A02870 from which this application claims priority are incorporated herein by reference. Where technical features mentioned in any claim are followed by reference signs, those reference signs have been included for the sole purpose of increasing the intelligibility of the claims and accordingly, such reference signs do not have any limiting effect on the interpretation of each element identified by way of example by such reference signs.

Claims: A method for manufacturing a dressing item such as an undershirt, body suit or the like with a circular knitting machine, comprising: at least one first step (A,A'), during which an annular border (1) is formed which constitutes the neck of the item; at least one second step (B,B'), during which a first tubular portion (2) of knitting having a gradually increasing diameter is formed starting from said annular border (1); at least one third step (C,C'), during which a second tubular portion (3) of knitting is formed to continue said first tubular portion (2) of knitting; and a fourth step (D,D'), during which a completion portion (4) of the item is formed; characterized in that said annular border (1) is formed by using a smaller number of needles of the machine than the number used to form the remaining parts (2, 3, 4) of the item. The method according to claim 1, characterized in that said annular border (1) is formed by using at least one prestretched elastic yarn. The method according to one or more of the preceding claims, characterized in that said first tubular portion (2) of knitting, during said second step (B), is formed by gradually increasing the active needles of the machine with respect to the needles used to form said annular border (1) during the first step (A). The method according to one or more of the preceding claims, characterized in that the ratio between the number of stitches per row of said annular border (1), formed during said first step (A), and the number of stitches per row of said second tubular portion (3) of knitting, formed during said third step (C), is substantially between 1:10 and 1:2. The method according to one or more of the preceding claims, characterized in that during said first step (A) said annular border (1) is formed with double-thickness knitting. The method according to one or more of the preceding claims, characterized in that during said second step (B) two portions (5) are formed which are located in two diametrically mutually opposite regions and are visually different from the remaining part of said first tubular portion (2) of knitting, said two portions (5) being meant to be removed in order to form in the item two arm passages for the arms of the user or for applying sleeves. The method according to one or more of the preceding claims, characterized in that said two portions (5) are knitted with a single yarn, while the adjacent parts are knitted with at least two yarns. The method according to one or more of the preceding claims, characterized in that said two portions (5) are delimited by stitches of a different type or color with respect to the adjacent stitches. The method according to one or more of the preceding claims, characterized in that during said second step (B) knitting is interrupted, in two diametrically mutually opposite regions of the first tubular portion (2) of knitting being formed, by cutting and clamping the yarns and by deactivating two sets of needles located in two diametrically opposite regions of the needle cylinder, so as to form, at said regions, two openings for arm passage for the arms of the user or for applying sleeves. The method according to one or more of the preceding claims, characterized in that said fourth step (D) comprises the forming of a completion border (4). The method according to one or more of the preceding claims, characterized in that said completion border (4) is formed with a double thickness. The method according to one or more of the preceding claims, characterized in that said fourth step (D') comprises the forming, in two diametrically mutually opposite regions, of two portions (10,11) to continue said second tubular portion (3) of knitting formed during said third step (C'). The method according to one or more of the preceding claims, characterized in that said fourth step (D') comprises the forming of an additional tubular portion (3) of knitting to continue said second tubular portion of knitting formed during said third step (C'); said additional tubular portion of knitting having, in two diametrically mutually opposite regions, portions (10,11) which are visually different from the remaining part of said additional tubular portion of knitting and are meant to be removed to obtain two lateral leg openings proximate to the completion end of the item. The method according to one or more of the preceding claims, characterized in that said visually different portions (10,11), during said fourth step (D'), are knitted with a smaller number of yarns than the remaining part of the additional tubular portion of knitting formed during said fourth step (D'). The method according to one or more of the preceding claims, characterized in that during said fourth step (D') said two visually different portions (10,11) are delimited by stitches of a different type or color with respect to the adjacent stitches. The method according to one or more of the preceding claims, characterized in that said fourth step (D') comprises the forming of an additional tubular portion of knitting to continue the tubular portion (3) of knitting formed during said third step (C'); two mutually diametrically opposite regions (10,11) of the item being formed by using a smaller number of feeds than the number used to form the remaining part of the additional tubular portion of knitting formed during said fourth step (D') in order to form two lateral leg openings proximate to the completion end of the item. The method according to one or more of the preceding claims, characterized in that said fourth step (D') comprises the forming of an additional tubular portion (3) of knitting to continue said second tubular portion of knitting formed during said third step (C'), interrupting the knitting by cutting and clamping the yarns, deactivating two sets of needles arranged in two diametrically opposite regions of the needle cylinder, in order to form two lateral leg openings proximate to the completion end of the item. A dressing item such as an undershirt, body suit or the like, manufactured with a circular knitting machine, comprising a tubular knitted body which has, starting from one of its longitudinal ends: an annular border (1); a first tubular portion (2) of knitting without longitudinal seams, whose diameter increases starting from said annular border (1); a second tubular portion (3) of knitting; and a completion portion (4) of the item; characterized in that said annular border (1) is formed by a smaller number of wales than the number which forms the remaining parts (2, 3, 4) of the item. The item according to claim 18, characterized in that said second tubular portion (3) of knitting has a substantially constant diameter. The item according to claim 18, characterized in that the ratio between the number of stitches per row of said annular border (1) and the number of stitches per row of said second tubular portion (3) of knitting is substantially between 1:10 and 1:2. The item according to one or more of claims 18-20, characterized in that said annular border (1) is composed of at least one elastic yarn. The item according to one or more of claims 18-21, characterized in that said annular border (1) is of the double-thickness type. The item according to one or more of claims 18-22, characterized in that said first tubular portion (2) of knitting has, at two diametrically mutually opposite regions, arm openings for the passage of the arms of the user or for the application of sleeves. The item according to one or more of claims 18-23, characterized in that said first tubular portion (2) of knitting has, in two diametrically mutually opposite regions, parts (5) which are visually different from the remaining part of said first tubular portion (2) of knitting and are meant to be removed in order to form in the item two arm passages for the arms of the user or for applying sleeves. The item according to one or more of claims 18-24, characterized in that said visually different parts (5) of said first tubular portion (2) of knitting are delimited by stitches of a different type or color with respect to the adjacent stitches. The item according to one or more of claims 18-25, characterized in that said first tubular portion (2) of knitting has, in two mutually diametrically opposite regions, portions (5) which are formed with a single yarn, whilst the adjacent parts are knitted with stitches formed by at least two yarns. The item according to one or more of claims 18-26, characterized in that said completion portion (4) of the item is constituted by a double-thickness border. The item according to one or more of claims 18-27, characterized in that said completion portion (4) of the item comprises two portions (10,11) which extend, in two mutually diametrically opposite regions, from said second tubular portion (3) of knitting. The item according to one or more of claims 18-28, characterized in that said completion portion of the item comprises an additional tubular portion of knitting to continue said tubular portion of knitting and has, in two mutually diametrically opposite regions, parts (10,11) which are visually different from the remaining part of said additional tubular portion of knitting, said two parts (10,11) being removable to obtain two lateral leg openings proximate to the completion end of the item. The item according to one or more of claims 18-29, characterized in that said parts (10,11) of said completion portion of the item are knitted with a single yarn, while the adjacent parts are knitted with stitches composed of at least two yarns. The item according to one or more of claims 18-30, characterized in that said visually different parts (10,11) of said additional tubular portion of knitting are delimited by stitches of a different type or color with respect to the adjacent stitches.

Inventors: LONATI ETTORE, LONATI FAUSTO, LONATI FRANCESCO, LONATI TIBERIO, LONATI, ETTORE, LONATI, FAUSTO, LONATI, FRANCESCO, LONATI, TIBERIO
Applicants: SANTONI & C SPA, SANTONI S.P.A.
Application year: 1998
Main classification: D04B1
IPC codes: A41B9, D04B1, A41C1