Patent Publication Number: US-2005115282-A1

Title: Seamless knit garments

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
      This application claims the benefit of U.S. Provisional Application Ser. No. 60/513,815, filed Oct. 23, 2003 the contents of which are incorporated by reference herein. 
    
    
     BACKGROUND OF THE INVENTION  
       1 . Field of the Invention  
      The present invention relates to seamless knit garments. More particularly, the present invention relates to knit garments having one or more of a first knit construction seamlessly integrated with one or more of a second knit construction.  
      2. Description of Related Art  
      Seamless knit garments can be knit on flat and/or circular knitting machines. Such machines are commercially available from, for example, the Monarch Knitting Machinery Corporation of Glendale, N.Y., Santoni S.p.A. of Brescia, Italy, Shima Seiki Manufacturing Limited of Wakayama, Japan, and others.  
      Some knitting machines can knit only a first knit construction such as, but not limited to, a plain double knit stitch or a plain single jersey knit stitch. Other knitting machines can produce a second knit construction such as, a spacer knit stitch, a rib knit stitch, a pointelle knit stitch, a mesh knit stitch, a sheer knit stitch, a quilted knit stitch, and others.  
      In order to provide garments having more than one portion with the first knit construction and/or to combine the first and second knit constructions, two or more knitted fabrics have been required. Here, the desired fabrics have been joined by way of a seam (e.g., sewing, welding, and gluing).  
      In many garments, seams and discontinuities can be physically and/or aesthetically unpleasing. For example, seams in many outerwear garments and sportswear garments can chaff, exert pressure points and, thus, can be a source of physical discomfort. In addition, seams in intimate apparel garments (e.g., a brassiere, a panty, a camisole, and others) can often be visible through outer clothing, which can be aesthetically unpleasing.  
      Accordingly, there is a need for garments having the first and second knit constructions seamlessly integrated therein.  
     BRIEF SUMMARY OF THE INVENTION  
      It is an object of the present invention to provide seamless knit garments.  
      It is another object of the present invention to provide garments having a first portion knitted with a first knit construction seamlessly knit to a second portion knitted with a second knit construction.  
      It is still another object of the present invention to provide garments having a combination of double and single jersey knit structures seamlessly knit to other knit structures such as, but not limited to, three-dimensional knit structures, sheer knit structures, decorative single jersey knit structures, or any combinations thereof.  
      It is also an object of the present invention to provide knit garments having a plurality of portions each with a different type of a first knit construction and/or second knit construction, where the plurality of portions are seamlessly knit to one another.  
      It is yet a further object of the present invention to provide a knit garment having a patterned effect provided by the seamless integration of portions having different knit constructions.  
      The above-described and other features and advantages of the present invention will be appreciated and understood by those skilled in the art from the following detailed description and drawings. 
    
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS  
       FIG. 1  is a front view of a first exemplary embodiment of a camisole according to the present invention;  
       FIG. 2  is a rear view of the camisole of  FIG. 1 ;  
       FIG. 3  is a front view of an exemplary embodiment of a brief-style panty according to the present invention;  
       FIG. 4  is a rear view of the panty of  FIG. 3 ;  
       FIG. 5  is a front view of an exemplary embodiment of a string-style panty according to the present invention;  
       FIG. 6  is a rear view of the panty of  FIG. 5 ;  
       FIG. 7  is a front view of an exemplary embodiment of a brassiere according to the present invention;  
       FIG. 8  is a front view of a second exemplary embodiment of a camisole according to the present invention;  
       FIG. 9  is a rear view of the camisole of  FIG. 8 ;  
       FIG. 10  is a front view of an exemplary embodiment of a short-style panty according to the present invention;  
       FIG. 11  is a front view of a second exemplary embodiment of a brief-style panty according to the present invention;  
       FIG. 12  is a front view of a second exemplary embodiment of a brassiere according to the present invention;  
       FIG. 13  is a front view of a third exemplary embodiment of a camisole according to the present invention;  
       FIG. 14  is a rear view of the camisole of  FIG. 13 ;  
       FIG. 15  is a front view of an exemplary embodiment of a string-style panty according to the present invention;  
       FIG. 16  is a rear view of the panty of  FIG. 15 ;  
       FIG. 17  is a front view of a third exemplary embodiment of a brief-style panty according to the present invention;  
       FIG. 18  is a front view of a third embodiment of a brassiere according to the present invention;  
       FIG. 19  is a front view of a portion of a fourth exemplary embodiment of a brassiere according to the present invention;  
       FIG. 20  is a stitch diagram illustrating an exemplary embodiment of a first knit portion seamlessly integrated with a second knit portion;  
       FIG. 21  is a front view of a first exemplary embodiment of a shirt according to the present invention;  
       FIG. 22  is a rear view of the shirt of  FIG. 21 ;  
       FIG. 23  is a front view of a second exemplary embodiment of a shirt according to the present invention;  
       FIG. 24  is a rear view of the shirt of  FIG. 23 ;  
       FIG. 25  is a front view of an exemplary embodiment of a pair of pants according to the present invention; and  
       FIG. 26  is a rear view of the pants of  FIG. 25 . 
    
    
     DETAILED DESCRIPTION OF THE INVENTION  
      Referring now to the figures and in particular to  FIGS. 1 and 2 , a garment according to the present invention is generally represented by reference numeral  10 . Garment  10  is a camisole having a knit body  12 , a pair of shoulder straps  14 , preferably at an upper edge of body  12 , and/or a welt  16 , preferably along a lower edge of the body. In a preferred embodiment, straps  14  are joined to body  12  by a seam  18 . Similarly, welt  16  can be joined to body  12  by seam  18 . Seam  18  can be formed by sewing, welding, gluing, or any combinations thereof. Alternately, straps  14  and/or welt  16  can be integrally knit as part of body  12 . Accordingly, garment  10  can include one or more garment elements (e.g., straps  14 , welt  16 , and the like) integrally knit to body  12  and/or joined to the body by seam  18 .  
      Body  12  can have a generally tubular shape defined by one or more first portions  20  and one or more second portions  22 . Body  12  is knitted using a knitting process so first and second portions  20 ,  22  are integrally knitted to one another. Thus, body  12  is free of seams joining first and second portions  20 ,  22  to one another. For example, body  12  can be knitted using a circular or weft knitting process, a flat knitting process, and others.  
      First portion  20  is knit with a first knit construction, while second portion  22  is knit with a second knit construction. As used herein, the phrase “first knit construction” shall mean knits that have one stitch formed on each needle all of the time so that an intermeshing of stitches are formed in the same direction on the technical face of the fabric and a series of loops are formed on the technical back of the fabric. For example, the first knit construction includes any one of the following knits a plain double knit, a plain single jersey knit, or any combinations thereof. The phrase “second knit construction” shall mean knits that use any combination of a plain knitted loop, a held loop with no stitch, and a tuck loop. The second knit construction can have any of these loops transferred from one set of needles to another set of needles and can have any of these loops knit stitched, tuck stitched, and miss stitched individually on each set of needles. For example, the second knit construction includes any one of the following knits a spacer knit, a rib knit, a pointelle knit, a mesh knit, a sheer knit, a quilted knit, an eyelet or open knit, or any combinations thereof.  
      In the illustrated embodiment of  FIG. 1 , first portion  20  has a plain single jersey knit  24  and second portion  22  has a sheer knit  26 , which provides a transparent or opaque aesthetic quality or look to the second portion. For example, sheer knit  26  can be knitted by two sets of needles, where one set of needles knits a foreground layer, while the second set of needles knits a background layer. The foreground layer can include a lace or embroidered pattern defined therein.  
      First and second portions  20 ,  22  can also be positioned in body  12  to provide a seamless patterned effect to garment  10 . For example, first and second portions  20 ,  22  are illustrated by way of example in  FIGS. 1 and 2  extending in a curvilinear manner vertically across body  12 . Namely, first and second portions  20 ,  22  extend from the lower edge of body  12  to the upper edge of the body in a curvilinear manner. Of course, it is contemplated by the present invention for first and second portions  20 ,  22  to have shapes other than curvilinear such as a linear shape and/or combinations of curvilinear and linear shapes.  
      In some embodiments of the present invention, garment  10  can be a shaped or fitted garment. For example, body  12  can have a length as measured from straps  14  to welt  16  and an inner diameter (not shown). The shaped aspect of garment  10  is provided by varying the inner diameter along the length of body  12 . In the embodiment illustrated in  FIGS. 1 and 2 , body  12  includes a central shaped section  25  that is narrowed with respect to other portions of the body. For example, body  12  has its maximum inner diameter where straps  14  and welt  16  are secured to the body and a minimum inner diameter at central shaped section  25 . Of course, it is contemplated by the present invention for shaped section  25  to be wider than other portions of body  12  and/or for the shaped section to be located non-central to the body.  
      Garment  10  is illustrated by way of example in  FIGS. 1 and 2  as a camisole having a combination of single jersey knit structures  24  seamlessly knit with sheer knit structures  26  in a manner that provides a seamless patterned effect to the garment.  
      It is also contemplated by the present invention for garment  10  to be any garment such as, but not limited to, a brief-style panty  28  as in  FIGS. 3 and 4 , a string-style panty  30  as in  FIGS. 5 and 6 , a brassiere  32  as in  FIG. 7 , and other intimate apparel garments, as well as outerwear garments, sportswear garments, and others.  
      The brief-style panty  28  as in  FIGS. 3 and 4  and the string-style panty  30  as in  FIGS. 5 and 6  each include a combination of single jersey knit structures  24  seamlessly knit with sheer knit structures  26  in a manner that provides a seamless patterned effect to the garment. The brassiere  32  of in  FIG. 7  includes a combination of single jersey knit structures  24  seamlessly knit with sheer knit structures  26  and rib knit structures  27  in a manner that provides a seamless patterned effect to the garment.  
      It is also contemplated by the present invention for first portion  20  and/or second portion  22  to extend horizontally and/or diagonally across body  12  as in the brassiere  32  of  FIG. 7 . Further, it is contemplated by the present invention for first portion  20  to surround second portion  22  as in the panty  30  of  FIG. 5 .  
      Referring now to  FIGS. 8 and 9 , a second exemplary embodiment of a garment illustrated as a camisole  34  is shown. Camisole  34  has a knit body  36  and a pair of shoulder straps  38 . Body  36  has a plurality of second portions  40 , each having a different second knit construction. Advantageously, body  36  is knit so that the second portions  40  are seamlessly or integrally knitted to one another. Thus, body  36  is free of seams joining the plurality of second portions  40  to one another. For example, body  36  can be knitted using a circular or weft knitting process, a flat knitting process, and others.  
      In the illustrated embodiment of  FIGS. 8 and 9 , body  36  has four-second portions  40 , each having a different second knit construction. Here, body  36  includes a second portion  42  having a pointelle knit, a second portion  44  having a mesh knit, a second portion  46  having an eyelet or open knit, and a second portion  48  having a rib knit. Thus, camisole  34  has a combination of pointelle knit portions  42 , mesh knit portions  44 , open knit portions  46 , and rib knit portion  48  seamlessly knit with one another.  
      Body  36  can include a central shaped section  45 . Here, body  36  has a maximum inner diameter at its upper and lower extents and a minimum inner diameter at central shaped section  45 .  
      Advantageously, second portions  40  can be selected and/or positioned in body  36  to provide a patterned effect to camisole  34 . For example, pointelle knit portions  42  are illustrated along the upper and lower edges of body  36 . Open knit portions  46  define a pair of breast cups  50 , a front panel  52 , a rear panel  54 , and a pair of sides  56  in body  36 . Mesh knit portions  44  are illustrated in front and rear panels  52 ,  54 , while rib knit portions  48  are illustrated in sides  56  and breast cups  50 .  
      As can be seen in  FIGS. 8 and 9 , the type of the second knit construction and position of portions  42 ,  44 ,  46 ,  48  within body  36  are used to provide a seamless patterned effect to camisole  34 .  
      Again,  FIGS. 8 and 9  illustrate the garment as a camisole  34 . Of course, it is contemplated by the present invention for the garment to be any garment such as, but not limited to, a short-style panty  58  as in  FIG. 10 , a brief-style panty  60  as in  FIG. 11 , a brassiere  62  as in  FIG. 12 , and other intimate apparel garments, as well as outerwear garments, sportswear garments, and others.  
      It should also be recognized that garment  34  is illustrated in  FIGS. 8 and 9  by way of example as having four second portions  40  (e.g., four portions with the second knit construction). Of course, it is contemplated by the present invention for garment  34  to have as any desired number of second portions  40  such as, but not limited to, two second portions as illustrated in  FIGS. 11 and 12 , three second portions as illustrated in  FIG. 10 , and more than four second portions. In some embodiments, the first and/or second portions  40 ,  42  can define a moldable portion of garment  34  as seen in the breast cup area of  FIG. 12 .  
      Referring now to  FIGS. 13 and 14 , a second exemplary embodiment of a garment illustrated as a camisole  64  is shown. Camisole  64  is a camisole having a knit body  66 , a pair of shoulder straps  68 , and a welt  70 .  
      Body  66  includes one or more first portions  72  and one or more second portions  74 . Again, body  66  is knitted so that first and second portions  72 ,  74  are integrally knitted to one another. Thus, body  66  is free of seams joining first and second portions  72 ,  74  to one another. First portions  72  can be knit with the same or different first knit constructions. Similarly, second portions  74  can be knit with the same or different second knit constructions.  
      In the illustrated embodiment, first portions  72  have a plain single-jersey knit stitch  76 , while second portions  74  have a number of different second knit constructions. For example, second portions  74  can include one or more quilt knit portions  78 , and one or more sheer knit portions  80 . Quilt knit portions  78  can be a two-yarn quilt (e.g., no filler) and/or a three-yarn quilt (e.g., filler). Further, quilt knit portions  78  can define quilted regions  82 , quilted lines  84 , or any combinations thereof.  
      Advantageously, first and second portions  72 ,  74  can be selected and positioned in body  66  to provide a patterned effect to camisole  64 . Specifically, the stitch type and position of the first and second portions  72 ,  74  within body  66  can be used to provide a seamless patterned effect to camisole  64 .  
      Again, while  FIGS. 8 and 9  illustrate the garment as camisole  64 , it is contemplated by the present invention that the garment can be any garment such as, but not limited to, a string-style panty  86  as in  FIGS. 15 and 16 , a brief-style panty  88  as in  FIG. 17 , or a brassiere  90  as in  FIG. 18 .  
      Referring now to  FIG. 19 , a third exemplary embodiment of a garment according to the present invention is shown as a brassiere  92 . Brassiere  92  has a knit body  94 , a pair of shoulder straps  96 , and a welt  98 .  
      Body  94  has one or more first portions  100  and one or more second portions  102 . Again, body  94  is knitted so that first and second portions  100 ,  102  are integrally knitted to one another. Thus, body  94  is free of seams joining first and second portions  100 ,  102  to one another.  
      First portion  100  is knit with first knit construction, while second portion  102  is knit with the second knit construction. In this embodiment, first portion  100  has a plain single jersey knit and second portion  102  has a spacer knit  104 . Spacer knit  104  has two separate face fibers combined with an inner spacer yarn or yarns in a warp-knitted construction. The spacer yarns contribute engineered properties such as thickness, elasticity, compression, physical spaces and channels, or any combinations thereof. The face fibers provide such qualities as density, water-repellency, antimicrobial attributes, softness, breathability, UV or chemical resistance, fire retardation, texture, or any combinations thereof. Spacer knit  104  can be thick or thin, and the thickness can vary across its width.  
      Referring now to  FIG. 20 , a stitch diagram illustrating an exemplary embodiment of a first portion  106  seamlessly integrated with a second portion  108  is illustrated. First portion  106  is knitted with a plain single jersey knit, while second portion  108  is knitted with a rib knit.  
      Referring now to  FIGS. 21 and 22 , an alternate exemplary embodiment of a garment according to the present invention shown as a seamless sports shirt  110 . Shirt  110  is knitted using a flat knitting process such as can be found on machines commercially available from Shima Seiki Manufacturing Limited of Wakayama, Japan.  
      Shirt  110  includes a plurality of first portions  120  and a second portion  122  seamlessly integrated with one another to form the whole garment. Here, first portions  120  are knit with the first knit construction, while second portion  122  is knit with the second knit construction. In addition, first and second portions  120 ,  122  can provide a seamless patterned effect to shirt  110 .  
      The plurality of first portions  120  include a main body  124 , a pair of armbands  126 , and a waist band  128 . Main body  124  is knit with a plain single jersey knit stitch to define the arms and torso sections of shirt  110 . Main body  124  can include a pleated section  130 , providing additional mobility and flexibility to this region of shirt  110 . Arm and waist bands  126 ,  128  are knit with a plain double knit stitch having elastic yarns so that the arm and waist bands assist in maintaining shirt  110  in the desired position when worn.  
      Second portion  122  is knit with a spacer knit to define the shoulder sections of shirt  110 . The spacer knit of second portion  122  provides attributes such as warmth, wind protection, and/or water protection to shirt  110 .  
      In the illustrated embodiment, waistband  128  is shown as a shaped band as shown and described in U.S. patent application Ser. No. 10/404,918 filed on Apr. 1, 2003, the contents of which are incorporated by reference herein. Also show in the illustrated embodiment, main body  124  includes a central shaped section  125 . Here, main body  124  has a maximum inner diameter at its upper and lower extents but a minimum inner diameter at central shaped section  125 .  
      Referring now to  FIGS. 23 and 24 , another alternate exemplary embodiment a garment according to the present invention is shown as a seamless leisure shirt. Shirt  130  is knitted using a flat knitting process.  
      Shirt  130  includes a plurality of first portions  132  and a plurality of second portions  134  seamlessly integrated with one another to form the whole garment. Here, first portions  132  are knit with the first knit construction, while second portions  134  are knit with the second knit construction. In addition, first and second portions  1320 ,  134  can provide a seamless patterned effect to shirt  130 .  
      The plurality of first portions  132  include a pair of side regions  136  and a pair of cuff bands  138 . Side regions  136  are knit with a plain single jersey knit. Side regions  136  can include one or more pocket sections  140 . In addition, side regions  136  can include one or more pleated sections  142  that provide additional mobility and flexibility to this region of shirt  130 . Cuff bands  138  are knit with a plain double knit stitch having elastic yarns so that the cuff bands assist in maintaining shirt  130  in the desired position when worn.  
      In the illustrated embodiment, shirt  130  includes a central shaped section  145 . Here, shirt  130  has a maximum inner diameter at its upper and lower extents but a minimum inner diameter at central shaped section  145 .  
      The plurality of second portions  134  includes a vest area  144  and a seat area  146 . Vest and seat areas  144 ,  146  are knit with a spacer knit to provide attributes such as warmth, wind and/or water protection, and padding to shirt  130 .  
      Referring now to  FIGS. 25 and 26 , yet another alternate exemplary embodiment of a garment according to the present invention is shown as a seamless jog pant. Pant  150  is also knitted using a flat knitting process.  
      Pant  150  includes a plurality of first portions  152  and a plurality of second portions  154  seamlessly integrated with one another to form the whole garment. Again, first portions  152  are knit with the first knit construction, while second portions  154  are knit with the second knit construction and provide a seamless patterned effect to pant  150 .  
      The plurality of first portions  152  include an inner region  156  and a pair of cuff bands  158 . Inner regions  156  are knit with a plain single jersey knit. Inner region  156  can include one or more pocket sections  160 . In addition, inner region  156  can include can include one or more pleated sections  162 , providing additional mobility and flexibility to this region of pant  150 . Cuff bands  158  are knit with a plain single jersey knit having elastic yarns so that the cuff bands assist in maintaining pant  150  in the desired position when worn.  
      The plurality of second portions  154  includes an outer region  164  and a waistband  166 . Outer region  164  and waist band  166  are knit with a spacer knit to provide attributes such as warmth, wind and/or water protection, and padding to pant  150 . In addition, waistband  166  is knit with elastic yarns so that the waistband assists in maintaining pant  150  in the desired position when worn. Waistband  166  can include one or more pleated sections  168 , providing additional mobility and flexibility to this region of pant  150 .  
      Accordingly, some embodiments of the present invention provide for seamless integration of two or more second knit constructions to one another. Other embodiments provide for seamless integration of one or more second knit constructions with one or more first knit constructions. The shape, size, and/or type of knit construction can be selected and/or positioned to provide the resultant garment with any desired patterned effect.  
      It should be recognized that the first and second knit constructions are described herein by way of example. Of course, it is contemplated for other first and/or second knit constructions, as defined herein, to fall within the scope of the present invention.  
      In addition, it should be noted that the garments of the present invention are described herein by way of example as intimate apparel garments (e.g., a brassiere, a panty, a camisole, and others). However, it is contemplated by the present invention for garment to be any garment such as, but not limited to, outerwear garments, sportswear garments, intimate apparel garments, or other garments.  
      Also, it should be noted that the terms “first”, “second”, “third”, “upper”, “lower”, and the like may be used herein to modify various elements. These modifiers do not imply a spatial, sequential, or hierarchical order to the modified elements unless specifically stated.  
      While the present invention has been described with reference to one or more exemplary embodiments, it will be understood by those skilled in the art that various modifications may be made and equivalents may be substituted for elements thereof without departing from the scope of the present invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the scope thereof. Therefore, it is intended that the present invention not be limited to the particular embodiment(s) disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.