Patent Publication Number: US-6708530-B2

Title: Single-layer/double-layer cushion cup brassiere with terry loop stitch construction

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a brassiere having a terry loop stitch construction knitted into a fabric, a blank for making the brassiere, and methods for making the brassiere and the blank made on a circular knitting machine. More particularly, the present invention relates to a single-layer or double-layer circular knit brassiere formed from a blank of a circular knitting machine in which the brassiere includes a terry loop stitch construction knitted into one or more selected portions of the brassiere. 
     2. Description of the Prior Art 
     The use of generally cylindrical blanks in the manufacture of brassieres is known. For example, U.S. Pat. No. 6,125,664, to Browder, Jr., entitled BRASSIERE, BRASSIERE BLANK AND METHODS OF MAKING SAME describes the use of a cylindrical blank to form one double layer brassiere. The brassiere has an outer fabric and an inner fabric. The yarn and knit stitches for the inner fabric are provided to provide comfort to the wearer. The blank is formed in a generally cylindrical shape with a bottom welt band seamlessly joined to a bottom edge of an upper torso part formed in the outer fabric and to a bottom edge of an upper torso part formed in the inner fabric. Front and rear strap portions are formed in the upper torso parts. 
     However, a need exists for an improved brassiere having fabric contacting the wearer&#39;s body that provides moisture or perspiration wicking and other comfort features. 
     SUMMARY OF THE INVENTION 
     It is an object of the present invention to provide a seamless circular knit brassiere with a terry loop stitch construction knitted into the brassiere. 
     It is another object of the present invention to provide a seamless double layer circular knit brassiere formed from a blank having both an inner and outer layer of fabric, a band seamlessly joined to a bottom edge of each layer, and a terry loop stitch construction knitted into a selected portion of at least one of the layers. 
     It is yet another object of the present invention to provide a seamless circular knit brassiere formed from a substantially different fabric construction and yarn combination that utilizes a true terry loop or a mock terry loop stitch construction knitted into at least the breast cup areas of the brassiere. 
     It is a further object of the present invention to provide a seamless circular knit brassiere having an inner and outer layer formed from a substantially different fabric construction and yarn combination, that utilizes a true terry loop or a mock terry loop stitch construction knitted into at selected portions of one of the layers of the brassiere. 
     It is still a further object of the present invention to provide a brassiere having substantially functional comfort and moisture wickability properties against the body of the wearer by knitting a hydrophylic yarn in the terry loop stitch construction of the brassiere. 
     It is yet a further object of the present invention to provide a single blank for manufacturing a single-layer or a double-layer brassiere having a terry loop stitch construction knitted into a selected area of the brassiere. 
     It is still yet a further object of the present invention to provide a method of making a seamless circular knit brassiere and blank, knitting a mock terry or true terry stitch construction in at least the breast cup areas of the blank to function as a comfort cushion against the wearer&#39;s body when the brassiere is worn. 
     These and other objects, and advantages of the present invention will be achieved by a brassiere according to the present invention having an upper torso part seamlessly joined to a band, where a terry loop stitch construction is knitted into a selected portion of the upper torso part. In an alternative embodiment, the upper torso part has an outer fabric and an inner fabric, with each fabric connected to a band, and with a terry loop stitch construction knitted into at least a selected portion of the inner or outer fabric. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The above and other objects, advantages and benefits of the present invention will be understood by reference to the detailed description provided below and the accompanying drawings. 
     FIG. 1 is a perspective view of a single-layer brassiere according to the present invention; 
     FIG. 2 is front view of a generally cylindrical blank according to the present invention used in the manufacture of the brassiere of FIG. 1; 
     FIG. 3 is rear view of a generally cylindrical blank according to FIG. 2; 
     FIG. 4 is a perspective view of a double-layer brassiere according to the present invention; 
     FIG. 5 is a front perspective view of a generally cylindrical blank according to the present invention for use in the manufacture of the brassiere of FIG. 4; and 
     FIG. 6 is rear view of a generally cylindrical blank according to FIG.  5 . 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to the drawings, and in particular to FIGS. 1-3, there is provided a brassiere according to the present invention generally represented by numeral  10 . Brassiere  10  includes an upper torso part  12  formed of a single fabric or fabric layer  14  and a band  16 . Brassiere  10  is a single layer brassiere. Single layer  14  includes a terry loop  18  stitch construction knitted into the single layer. 
     Upper torso part  12  is integrally joined to band  16  in a seamless manner. Band  16  is preferably formed as a turned welt band or as an anchoring chest band. Upper torso part  12  may include breast cups or areas  20  and one or more straps  22 . In another embodiment of the invention, the upper torso part  12  may be formed without straps, or with one or more straps  22  attached to upper torso part  12  after the upper torso part is formed. 
     Single fabric  14  includes material suitable for an inner layer of brassiere  10  and is preferably formed with yarns selected for softness, comfort and wicking properties. Single fabric  14  include yarns with one or any combination of stitches chosen from a group including plain knit, miss, float, and/or tuck, to provide body comfort and support to the wearer. Single fabric  14  is made of either textured nylon having a relatively high number of fine denier filaments or a microfiber having about 20 to about 120 denier or spun yarn, such as cotton, in the size range of about 30/1&#39;s to about 70/1&#39;s cotton count. Such yarn provides softness, comfort and desired moisture wicking properties. Additionally, single fabric  14  can be formed using an elastomeric stretch yarn such as spandex in combination with said nylon or cotton non-stretch yarns. 
     Single fabric  14  includes a terry loop  18  stitch construction knitted within at least a selected area of the single fabric. Terry loop  18  stitch construction preferably has a true terry loop or mock terry loop stitch construction. Terry loop  18  stitch construction may include a combination of a mock terry loop and true terry loop. Terry loop  18  may be knitted into specific portions of the single fabric or layer  14 . For example, FIG. 1 shows the terry loop  18  stitch construction knitted in the breast cup areas  20  of single fabric  14 . Also, terry loop  18  may be knitted into at least the front portion of straps  22 , or the terry loop may be knitted any portion of the single fabric  14 , including the entire single fabric. 
     Terry loop  18  stitch construction may itself contact the body of the wearer. The brassiere  10  may provide substantially functional comfort and moisture wickability properties against the body of the wearer in contact with terry loop  18 . Terry loop  18  may have a hydrophylic yarn of any suitable material. Such yarns include, but are not limited to, cotton, textured microdenier nylon, or a synthetic continuous multifilament textured nylon having substantial wickable moisture properties. 
     Band  16  may include materials that are denser than the single layer  14 . Band  16  may also be formed, for example, as a turned welt band and/or as an anchoring chest band by adding in, during the circular knitting process, additional heavier denier bare spandex elastomeric yarn, or less preferably, a nylon covered spandex yarn thereby causing a greater fabric density in band  16 , than the fabric and yarn density used to form the single layer  14 . 
     Brassiere  10  is formed with a conventional circular knitting machine having electronic programable design capability. The program provides one or more stitch types to produce a blank  30  having an upper torso part  32  and a bottom band  34  as shown in FIGS. 2 and 3. Blank  30  is formed by a circular weft knitting machine that preferably has a computerized electronic needle and yarn feed selection system, such as circular knit machine Model No. SM8-8, or SM8-TOP as manufactured by Santoni® of Brescia, Italy. Blank  30  is a generally cylindrical tube having portions that, upon manufacture of brassiere  10 , correspond to portions of the brassiere. 
     Blank  30  is formed by a series of circular knitting courses. The courses for both the upper torso part  32  and the bottom band  34  preferably involve a course program that has plain knit or knit and miss-stitch or float stitch construction combinations. In this construction, loops in certain courses are held without additional yarns being taken and then knit into subsequent courses, thereby gathering the courses together and providing the characteristics of band  34 . 
     Upper torso part  32  has a single fabric or fabric layer  36  which may be formed mostly with simple knit constructions, such as plain, tuck, miss, float, or any combinations thereof. Upper torso part  32  may suitably be used to provide special features at various locations of blank  30 , such as support for breast areas  38 . Band  34  is seamlessly joined to the upper torso part  32 . Band  34  is preferably an elastomeric yarn or material, and more preferably, is made of a combination of nylon covered spandex and nylon, with additional supplemental heavier denier spandex threads being added in at least 25 percent of the knitted courses in the band construction of area  34 . 
     Upper torso part  32  is then patterned to define straps  40  and breast cups  38 . The patterning also defines outer side removable areas  42  that when removed form arm holes, and front and rear removable areas  44  that when removed form the neckline. A terry loop  46  stitch construction is knitted to upper torso part  32 . Terry loop  46  may be integrally stitched to any desired portion of the upper torso part  32 . Terry loop  46  stitch construction is knitted into breast cup areas  38  of blank  30  as shown in FIG.  2 . Brassiere  10  may then be formed by removing side removable areas  42  to form the arm holes and removing front and rear removable areas  44  to form the neckline. 
     The entire brassiere  10  is made from a continuous integral cylindrical blank  30  that is formed on a high speed circular knitting machine known in the art. The use of a single fabric  36  with a terry loop  46  stitch construction knitted into at least the breast cup areas  38  as shown in FIG. 2, or continuing in the strap areas, or throughout the entire single fabric, have certain features that provide comfort and wicking to the wearer of brassiere  10 . 
     Brassiere  10  may be a seamless circular knit brassiere formed from a blank  30  in which two straps  22 , arm holes  24  and a neckline  26  are defined by patterning and with the additional feature of knitting a mock terry or true terry  18  stitch construction in at least the breast cup portions  20 , functioning as a moisture removing and comfort cushion against the wearer&#39;s body. A band  16  is seamlessly joined to upper torso part  12  of brassiere  10 . 
     With reference to FIGS. 4 to  6 , there is provided a second embodiment of the present brassiere  50 . Brassiere  50  has a multi or double-layer construction. Brassiere  50  may have an outer fabric or outer layer  52 , an inner fabric or inner layer  54 , and a band  56  seamlessly joined to each fabric. Band  56  may be formed as a welt or a turn line. Preferably, band  56  is a turned welt having additional supplemental heavier denier spandex added into at least 25 percent of the knitted courses that make up the band. Brassiere  50  has a terry loop  58  stitch construction knitted into selected areas of outer fabric  52  or inner fabric  54 . 
     Outer fabric  52  includes material suitable for an outer layer of brassiere  50 . Outer fabric  52  is preferably made of synthetic continuous multifilament flat or textured polymer or spun yarn. Outer fabric  52  preferably also has an elastomeric yarn, such as bare spandex or spandex that is covered with a textured multifilament nylon yarn. The combination of yarns forms a fabric that may contain a spun yarn such as cotton in the range about 30/1&#39;s to about 70/1&#39;s count or synthetic continuous multifilament flat or textured yarn such as nylon from a range between about 10 denier to about 200 denier, and preferably from about 60 denier to about 120 denier, and a spandex yarn, from a range about 10 denier to about 140 denier, preferably about 15 denier to about 70 denier either bare or may be covered with a suitable synthetic continuous multifilament textured yarn such as nylon. 
     Outer fabric  52  is formed on a circular knitting machine using one or any combination of knit stitches. Such stitches may include, but are not limited to, plain, tuck, knit, miss or float stitches. Outer fabric  52  may have a plain appearance or, optionally, may have unique aesthetic and recognizable knitted-in characteristics including, but not limited to, a Jacquard pattern design, geometric, stylized logo, abstract, or other designs or patterns such as florals. 
     Inner fabric  54  may be of the same fabric construction as the single fabric material of the first embodiment. Inner fabric  54  may also include patterning (not shown) that outlines the shape of brassiere  50 . The patterning defines parts of the brassiere  50  to be cut and formed, such as the breast cups  60 , neckline  62 , arm holes  63  and/or straps  64 . A central gore area  66  between breast cups  60 , the area under the cups, and the lower area encircling the cups, can also be knitted with discretely placed engineered shorter stretch zones in order to give added support and shaping, as well as comfort, to the wearer of brassiere  50 . 
     Brassiere  50  includes terry loop  58  stitch construction knitted into the breast cup areas  60  and, if so desired, the front portions of the straps  64  of the inner fabric  54 . Terry loop  58  stitch construction may be a true terry loop produced using sinkers, or a mock terry loop. Terry loop  58  stitch construction may be knitted on the wearer side of inner fabric  54  of brassiere  50 . In other embodiments of the present invention, terry loop  58  stitch construction may be knitted into any selected portion of brassiere  50 , such as breast cup areas  60 , throughout straps  64 , or throughout brassiere  50 . 
     Terry loop  58  stitch construction may also be formed on a specific side of inner fabric  54  or outer fabric  52 . For example, in other embodiments of the invention, terry loop  58  stitch construction may be placed between inner fabric  54  and outer fabric  52  by knitting terry loop  58  to the outer facing portion of inner fabric  54 , or terry loop  58  may be knitted to the wearer facing portion of outer fabric  52 . Terry loop  58  stitch construction may also be provided on the outer side of outer fabric  52 . Terry loop  58  is knitted and held in position by inner fabric  54  or outer fabric  52 , and terry loop  58  stitch construction will project from both sides of the layer knitted thereto. However, the bulk of terry loop  58  stitch construction will predominately project from only one side of the layer  52 ,  54  knitted thereto, and that side can be chosen based on the design of brassiere  50 . 
     In another embodiment of the invention, the terry loop  58  stitch construction may be knitted into inner fabric  54  and a second terry loop stitch construction can be knitted into outer fabric  52  of brassiere  50 . 
     Referring to FIGS. 4 and 5, brassiere  50  may be formed from a blank  70 . Blank  70  is formed by a high speed circular knitting machine and is a generally cylindrical tube having portions that, upon manufacture of brassiere  50 , correspond to portions of the brassiere. 
     Blank  70  has an outer fabric  72 , an inner fabric  74 , a band  82 , and a terry loop  80  stitch construction knitted into at least one of the fabrics. Outer fabric  72  has an upper torso part  76 , strap portions  78 , and a lower edge  81  that is seamlessly joined to bottom band  82 . Inner fabric  74  has an upper torso part  84  and inner straps  86 . Terry loop  80  stitch construction is knitted into the breast cup areas  87  and the front portions of straps  86 . In other embodiments of the present invention, terry loop  80  stitch construction may be knitted into selected areas of inner fabric  74  such as only the breast cup areas  87  or the entire inner fabric. In further embodiments of the present invention, terry loop  80  stitch construction may be provided in selected areas of the outer fabric upper torso part  76 , such as breast cup areas, strap areas  78  of the entire outer fabric  72 . Terry loop  80  stitch construction may also be knitted into each fabric  72 ,  74 . 
     Blank  70  may be formed by a series of circular knitting courses. The courses for band  82  may include a course program that has predominately plain knit stitches, or, alternately may use stitch combinations of a plain knit and miss-stitch or float stitch construction. In this construction, loops on certain needles in certain courses are held without additional yarns being taken on those certain needles and then knit into subsequent courses, thereby gathering the courses together and providing the appearance and stretch characteristics of bottom band  82 . 
     Upper torso parts  76  and  84  are formed mostly with simple knit constructions, such as plain, tuck, miss, float, or any combinations thereof. Band  82  knit stitches may also suitably be used to provide special features at various locations of blank  80 , such as support for breast cup areas. 
     To manufacture brassiere  50 , blank  70  is formed on a circular knitting machine. Blank  70  is formed to include an inner fabric upper torso part  76  seamlessly joined to band  82 , and a outer fabric upper torso part  84  seamlessly joined to the same band  82 . Terry loop  80  stitch construction is knitted into breast cup areas  87  of inner fabric upper torso part  84 . 
     Inner fabric upper torso part  84  may then be patterned to define side removable areas  88  that when removed define armholes, and front and rear removable sections  90  that when removed define the neckline. Outer fabric upper torso part  76  is also patterned to define side removable areas  92  that define arm holes, and front and rear removable areas  94  that define the neckline. 
     After patterning the outer fabric upper torso part  76  is drawn over the inner fabric upper torso part  84 . Torso parts  76 ,  84  are then joined, for example by tacking. Side removable areas  88 ,  92  are cut from the torso parts  76 ,  84  to form arm holes. Front and rear removable areas  90  and  94  are then removed to form the neckline. The method provides a double layer brassiere  50  formed from a blank  70 . 
     The present invention having been thus described with particular reference to the preferred forms thereof, it will be obvious that various changes and modifications may be made therein without departing from the spirit and scope of the present invention as defined in the appended claims.