Patent Publication Number: US-9850601-B2

Title: Knitted athletic performance garment

Description:
BACKGROUND 
     Field 
     Embodiments of the present invention relate to athletic performance garments. Specifically, embodiments of the present invention relate to warp-knitted athletic performance garments having areas of differing characteristics within the same seamless panel. 
     Background 
     Physical activity is important to maintaining a healthy lifestyle and individual well-being. There are many activities in daily life that require individuals to use their strength, agility, posture, and balance, and maintaining physical fitness can help individuals complete these activities with minimum disruption to their lives. Maintaining physical fitness has also been shown to strengthen the heart, boost HDL cholesterol, aid the circulatory system, and lower blood pressure and blood fats, translating to lower risk for heart disease, heart attack, and stroke. Physical activity also strengthens muscles, increases flexibility, and promotes stronger bones, which can help prevent osteoporosis. 
     Performance apparel may be worn by a wearer during periods of athletic activity. For example, while running, swimming, or playing a sport. Such activity may involve substantial energy expenditure, relative movement of limbs and other body parts, and perspiration. Such motion is typically intended to be optimized to achieve a goal (e.g., running or swimming a target distance and/or speed). Performance apparel may be designed not to impede such motion, or even to enhance it. Performance apparel may also be worn after an activity, for example, to assist a wearer&#39;s muscles in recovering more quickly after exercise. Garments are known that purport to assist a user in achieving a variety of fitness goals, including increasing muscle activation in desired locations. However, existing garments often suffer from problems such as poor functionality, uncomfortable fit, high cost, and undesirable aesthetics. 
     BRIEF SUMMARY 
     At least some of the embodiments of the present invention satisfy the above needs and provide further related advantages as will be made apparent by the description that follows. 
     Some embodiments of the present invention provide a knitted athletic performance garment including a seamless panel to cover a portion of a wearer&#39;s body, and a first performance zone and a second performance zone formed in the seamless panel, wherein the first performance zone is formed of a first warp knit stitch construction and has a first modulus, wherein the second performance zone is formed of a second warp knit stitch construction and has a second modulus, wherein the first warp knit stitch construction is different from the second warp knit stitch construction, wherein the first modulus is different from the second modulus, and wherein the difference in modulus between the first performance zone and the second performance zone is due to the difference in stitch construction between the first performance zone and the second performance zone. 
     Some embodiments of the present invention provide an athletic performance garment including a knitted high-power zone having a high-power knit construction, and a knitted low-power zone having a low-power knit construction, wherein the high-power zone and low-power zone are seamlessly formed together in a flat pattern, and wherein an average underlap of the high-power zone is longer than an average underlap of the low-power zone. 
     Some embodiments of the present invention provide an athletic performance garment including a knitted high-power zone having a high-power knit construction, and a knitted low-power zone having a low-power knit construction, wherein the high-power zone and low-power zone are seamlessly formed together in a flat pattern, and wherein an average stitch angle of the high-power zone is smaller than an average stitch angle of the low-power zone. 
     Additional features of embodiments of the invention will be set forth in the description that follows, and in part will be apparent from the description, or may be learned by practice of the invention. Both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
       The accompanying figures, which are incorporated herein, form part of the specification and illustrate embodiments of the present invention. Together with the description, the figures further serve to explain the principles of and to enable a person skilled in the relevant arts to make and use the invention. 
         FIG. 1A  illustrates a front view of a knitted athletic performance garment, according to embodiments presented herein. 
         FIG. 1B  illustrates a rear view of the knitted athletic performance garment of  FIG. 1A , according to embodiments presented herein. 
         FIG. 2  illustrates a front view of a knitted athletic performance garment pattern, according to embodiments presented herein. 
         FIGS. 3-5  illustrate exemplary basic stitch types according to embodiments presented herein. 
         FIGS. 6-9  illustrate exemplary knit constructions according to embodiments presented herein. 
         FIG. 10  illustrates continuous knit construction of different performance zones in a seamless knitted panel according to embodiments presented herein. 
         FIG. 11A  illustrates a front view of a knitted athletic performance garment, according to embodiments presented herein. 
         FIG. 11B  illustrates a rear view of the knitted athletic performance garment of  FIG. 11A , according to embodiments presented herein. 
         FIG. 11C  illustrates a side view of the knitted athletic performance garment of  FIG. 11A , according to embodiments presented herein. 
         FIG. 12A  illustrates a front view of a knitted athletic performance garment, according to embodiments presented herein. 
         FIG. 12B  illustrates a rear view of the knitted athletic performance garment of  FIG. 12A , according to embodiments presented herein. 
         FIG. 13A  illustrates a rear view of a knitted athletic performance garment, according to embodiments presented herein. 
         FIG. 13B  illustrates a front view of the knitted athletic performance garment of  FIG. 13A , according to embodiments presented herein. 
         FIG. 14A  illustrates a rear view of a knitted athletic performance garment, according to embodiments presented herein. 
         FIG. 14B  illustrates a front view of the knitted athletic performance garment of  FIG. 14A , according to embodiments presented herein. 
     
    
    
     DETAILED DESCRIPTION 
     Embodiments of the present invention will now be described in detail with reference to embodiments thereof as illustrated in the accompanying drawings, in which like reference numerals are used to indicate identical or functionally similar elements. References to an “embodiment” indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, descriptions of embodiments do not necessarily refer to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to effect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described. 
     The following examples are illustrative, but not limiting, of the present invention. Other suitable modifications and adaptations of the variety of conditions and parameters normally encountered in the field, and which would be apparent to those skilled in the art, are within the spirit and scope of the invention. 
     Performance apparel according to some embodiments of the present invention may fit a wearer in close contact with the wearer&#39;s skin, and may in some cases be worn under other apparel. In this way, the apparel can provide performance benefits to the wearer. For example, the close fit of an article of performance apparel may help minimize wind resistance, minimize flapping of apparel material, maintain proper position of the apparel relative to areas of the wearer&#39;s body, minimize uncomfortable movement of some parts of a wearer&#39;s body relative to other parts of the wearer&#39;s body, wick away perspiration, provide compressive force, and facilitate muscle movement by storing and releasing elastic energy in response to wearer motion. 
     In some embodiments of the present invention, performance apparel may have different performance characteristics at different zones relative to the body of a wearer. For example, performance apparel may apply relatively higher compression to relatively larger muscle groups, may apply relatively lower compression to relatively smaller muscle groups, and may provide relatively high ventilation to areas of the body that generate relatively high heat and sweat. 
     In some embodiments of the present invention, apparel may be formed from a number of discrete seamless textile panels joined together at seams (e.g., by fusion, gluing, sewing, stapling, or heat-bonding, usually near the edges of the panels). For instance, textile panels of different performance characteristics may be joined together at their edges to form a finished article. In some embodiments of the present invention seams are minimized in a performance apparel garment by forming the garment of seamless textile panels that themselves include multiple zones having different performance characteristics. As performance apparel may be tight fitting, minimizing seams between textile panels of different performance characteristics may help to eliminate discomfort to a wearer (e.g., from scratching or chafing due to seams). In other words, within each textile panel there may be at least two zones having different performance characteristics, with no seam therebetween. For example, a textile panel forming a portion of a garment according to an embodiment of the present invention may include no seams between zones having different performance characteristics. In this way, multiple zones having different performance characteristics may be integrally and continuously manufactured in a seamless panel, thereby simplifying garment manufacture by minimizing the number of separate panels that must be sewn or otherwise connected together to form the finished garment. 
     A knitted garment  100  according to an embodiment of the present invention may be constructed of a plurality of seamless panels  110 . For example, knitted garment  100  as depicted in  FIGS. 1A and 1B  is a pair of pants  510 , and includes four seamless panels  110  to cover portions of a wearer&#39;s body: one for each leg, and one each for the front and back of the midsection. Other exemplary knitted garments are depicted in  FIGS. 11A-11C  (pants  520 ),  12 A and  12 B (shirt  530 ),  13 A and  13 B (shirt  540 ), and  FIGS. 14A and 14B  (leg sleeves  550 ). The sizes, shapes, numbers, and types of seamless panels  110  may be varied to suit the desires of a designer, and are not limited to those depicted. For example, an entire garment may be formed of a single seamless panel  110 , or only two panels with a seam therebetween. Further, in some embodiments the seamless panel may include an opening or void therethrough, for example to expose a portion of a wearer&#39;s body or to facilitate airflow and cooling. 
     Each seamless panel  110  may include one or a plurality of performance zones  200  having different performance characteristics (e.g., modulus, ventilation). For example, a single seamless panel  110  may include two or more of a low-power zone  210 , a medium-power zone  220 , a high-power zone  230 , and a ventilation zone  240 . In some embodiments performance zones  200  of different types may be differently-colored, and performance zones  200  of the same type may be similarly-colored (e.g., to facilitate identification of performance zone type, and/or for aesthetic purposes). The different colors may be applied to the knitted garment  100  (or a knitted garment pattern  102 ) by, for example, a dyeing or printing process. 
     Knitted garment  100  may be constructed from garment pattern  102  (see  FIG. 2 ). Knitted garment pattern  102  may be seamlessly formed in a continuous warp knitting process (e.g., by a warp knitting machine) and may be knit in flat patterns as shown. Warp knitting may impart a flatter, closer, better elastic recovery character to its textile, and may be more durable or more powerful than other forms of knitting. This can increase the configurability and control of performance and ventilation characteristics of performance zones  200  of seamless panels  110  through selective use of different warp knit stitch types, as will be described. 
     In some embodiments, each performance zone within seamless panel  110  is continuously knitted together with other performance zones  200 . In this way performance zones  200  of a seamless panel  110  are continuously formed, without seams between different performance zones  200  of the same seamless panel  110 . Each seamless panel  110  may be cut from knitted garment pattern  102  along its panel edge  112 . Panel edges  112  (see  FIG. 2 ) of cut seamless panels  110  may be joined together to form garment seams  120  (see  FIG. 1 ), thereby forming knitted garment  100 . Garment seams  120  may be formed in any size, shape, pattern, form, or design desired by a designer, and are not limited to the seams  120  depicted. As used herein in reference to seamless panels  110 , “seamless” does not preclude seamless panels  110  from forming seams along their panel edges  112  with other panel edges  112  or from having edge stitching along uncoupled free edges thereof, but conveys the absence of seams within seamless panels  110  individually. 
     To maintain textile continuity between different performance zones  200  of a seamless panel  110 , a knit construction of textile fibers  114  forming seamless panel  110  may change at a transition  202  between different performance zones  200  (see, e.g.,  FIGS. 1, 2, and 10 ). This avoids a seam at transition  202 . For example, textile fibers  114  of a seamless panel  110  may form low-power zone  210  of a low-power knit construction  410 , medium-power zone  220  of a medium-power knit construction  420 , high-power zone  230  of a high-power knit construction  430 , and ventilation zone  240  of a ventilation knit construction  440 , with transitions  202  in between. Textile fibers  114  may be any suitable type of fiber, for example, yarn, silk, acetate, nylon, polyester, rayon, flax, wool, cotton, spandex or any elastic yarn, polypropylene, or combinations thereof, and may be formed of one or more filaments (e.g., monofilament or multifilament). Textile fibers  114  may be elastic or inelastic. Elastic fibers may contribute to elasticity of performance zones  200 . Elasticity of performance zones  200  including only inelastic fibers may rely on stitch types used therein for elasticity. All textile fibers  114  in seamless panels  110  may be of the same type, but need not be. Textile fibers  114  may be selected for their properties individually or in combination with other types of fibers. For example, nylon may be selected for its high strength, durability, abrasion resistance, elongation, and/or resistance to chemicals, mold, and mildew, relative to other fiber types. Also for example, spandex may be selected for its high strength and elasticity, relative to other fiber types. 
     Different knit constructions can be formed from different basic stitch types and combinations thereof. For example, a first basic warp-knit stitch type  310  (see  FIG. 3 , depicting an exemplary 2×1 lap stitch) may have a first basic stitch underlap  312  spanning three wales  116 , and may have a first basic stitch angle  314  (i.e., angle of first basic stitch underlap  312 ). An underlap is the segment of textile fiber  114  extending between successive stitches of the fiber in the lapping on the technical back of a warp-knitted material. A second basic warp-knit stitch type  320  (see  FIG. 4 , depicting an exemplary 1×1 lap stitch) may have a second basic stitch underlap  322  spanning two wales  116 , and may have a second basic stitch angle  324  (i.e., angle of second basic stitch underlap  322 ). Second basic stitch angle  324  may be greater than first basic stitch angle  314 . A third basic warp-knit stitch type  330  (see  FIG. 5 , depicting an exemplary open pillar stitch) may lack a connecting underlap, and so may span a single wale  116 . Other stitch types not explicitly described herein may also be used with embodiments of the present invention (e.g., a 3×1 lap stitch, a 4×1 lap stitch, etc.). 
     In some embodiments, low-power knit construction  410  is formed entirely of textile fibers  114  forming second basic stitch type  320  (see  FIG. 6 ). This pattern may repeat throughout low-power zone  210 . 
     In some embodiments, medium-power knit construction  420  is formed of textile fibers  114  forming first basic stitch type  310  and textile fibers  114  forming second basic stitch type  320  in about a 2:1 ratio. For example, in  FIG. 7 , a pair of textile fibers  114  forming second basic stitch type  320  are disposed between pairs of textile fibers  114  forming first basic stitch type  310 . This pattern may repeat throughout medium-power zone  220 . 
     In some embodiments, high-power knit construction  430  is formed of textile fibers  114  forming first basic stitch type  310  and textile fibers  114  forming second basic stitch type  320  in about a 5:1 ratio. For example, in  FIG. 8 , five consecutive textile fibers  114  forming first basic stitch type  310  are disposed adjacent a single textile fiber  114  forming second basic stitch type  320 . This pattern may repeat throughout high power zone  230 . 
     In some embodiments, ventilation knit construction  440  is formed of textile fibers  114  forming second basic stitch type  320  and textile fibers  114  forming third basic stitch type  330  in about a 1:1 ratio. For example, in  FIG. 9 , a single textile fiber  114  forming second basic stitch type  320  is disposed adjacent a pair of textile fibers  114  forming third basic stitch type  330  that are disposed adjacent a pair of textile fibers  114  forming second basic stitch type  320  that are disposed adjacent a single textile fiber  114  forming third basic stitch type  330 . This pattern may repeat throughout ventilation zone  240 . 
     The present invention is not limited to the particular knit constructions or combinations depicted, but can be applied to other knit constructions not explicitly described herein in some embodiments of the present invention. 
     Knit constructions may change at interfaces  202  between performance zones  200 , and may maintain continuity of textile fibers  114  from one performance zone  200 , across transition  202 , to an adjacent performance zone  200 , as shown, for example, in  FIG. 10 .  FIG. 10  shows continuous textile fibers  114  spanning low-power zone  210 , medium-power zone  220 , high-power zone  230 , and ventilation zone  240 . Transitions  202  between adjacent performance zones  200  need not be straight across wales  116  as shown in  FIG. 10 , but may alternatively or additionally transition at various angles across wales  116  to form performance zones  200  of varying shapes and sizes, as shown, for example, in  FIGS. 1 and 2 . 
     Different basic stitches and combinations thereof may impart different performance characteristics to different performance zones  200 . For example, selection of basic stitches may influence the modulus of a performance zone  200 . Modulus is a measure of power in textile fabrics in the cross direction (i.e., perpendicular to the warp direction). For example, it can be characterized as tensile stress of a fabric at a selected elongation (e.g., 40% elongation). A higher modulus corresponds to higher power and compression of a performance zone  200 . 
     In some embodiments, different basic stitches may have different underlap lengths in the lapping between wales  116 . A longer straight underlap in the lapping between wales  116  may contribute to a higher modulus, thereby contributing higher power and higher compression to a performance zone  200 . A shorter straight underlap in the lapping between wales  116  may contribute to a lower modulus, thereby contributing lower power and lower compression to a performance zone  200 . For example, first basic stitch type  310  may have a longer underlap between wales  116  and higher modulus than second basic stitch type  320 . 
     Further, different basic stitches may have different stitch angles. A smaller stitch angle may contribute to a higher modulus, thereby contributing higher power and higher compression to a performance zone  200 . A larger stitch angle may contribute to a lower modulus, thereby contributing lower power and lower compression to a performance zone  200 . For example, first basic stitch type  310  may have a smaller stitch angle and higher modulus than second basic stitch type  320 . 
     Further, different basic stitches can be used in combination within a textile part or portion (e.g., seamless panel  110 ), and their ratios can affect characteristics of the textile part or portion as a function of their component properties (e.g., underlap length and angle). For example, the greater the proportion of first basic stitch type  310  to second basic stitch type  320  in a fabric part or portion, the higher the overall modulus of the fabric part or portion (and the greater its power and compression properties), all else being equal. Also for example, the greater the proportion of first basic stitch type  310  to second basic stitch type  320  in a fabric part or portion, the denser and heavier the fabric part or portion may become due to the relatively higher yarn consumption in the underlap, all else being equal. 
     Different performance zones  200  may include different ratios of first basic stitch type  310 , second basic stitch type  320 , third stitch type  330 , and other stitch types to achieve desired performance characteristics. For example, low-power zone  210  may have a shorter average underlap between wales  116  than medium-power zone  220 , such that medium-power zone  220  has a higher modulus than low-power zone  210 . This may be attributable to a greater proportion of stitch types having a shorter underlap between wales  116  in low-power zone  210 . For example, as shown in the exemplary low-power knit construction  410  of  FIG. 6  and medium-power knit construction  420  of  FIG. 7 , low-power knit construction  410  includes 100% second basic stitch type  320 , and medium-power knit construction  420  includes 33% second basic stitch type  320  and 67% first basic stitch type  310 . Since second basic stitch underlap  322  between wales  116  is shorter than first basic stitch underlap  312  between wales  116 , low-power knit construction  410  may have a lower modulus than medium-power knit construction  420 , due to its relatively higher proportion of second basic stitch type  320 . 
     Also for example, medium-power zone  220  may have a shorter average underlap between wales  116  than high-power zone  230 , such that high-power zone  230  has a higher modulus than both low-power zone  210  and medium-power zone  220 . This may be attributable to a greater proportion of stitch types having a shorter underlap between wales  116  in low-power zone  210  and medium-power zone  220  than in high-power zone  230 . For example, as shown in the exemplary high-power knit construction  430  of  FIG. 8 , high-power knit construction  430  includes 17% second basic stitch type  320  and 83% first basic stitch type  310 . Since second basic stitch underlap  322  between wales  116  is shorter than first basic stitch underlap  312  between wales  116 , low-power knit construction  410  and medium-power knit construction  420  may have lower moduli than high-power knit construction  430 , due to their relatively higher proportions of second basic stitch type  320 . 
     Also for example, low-power zone  210  may have a larger average stitch angle than medium-power zone  220 , such that medium-power zone  220  has a higher modulus than low-power zone  210 . This may be attributable to a greater proportion of stitch types having a larger stitch angle in low-power zone  210 . Since second basic stitch angle  324  is larger than first basic stitch angle  314 , the exemplary low-power knit construction  410  of  FIG. 6  may have a lower modulus than the exemplary medium-power knit construction  420  of  FIG. 7 , due to its relatively higher proportion of second basic stitch type  320 . 
     Also for example, medium-power zone  220  may have a larger average stitch angle than high-power zone  230 , such that high-power zone  230  has a higher modulus than both low-power zone  210  and medium-power zone  220 . This may be attributable to a greater proportion of stitch types having a larger stitch angle in low-power zone  210  and medium-power zone  220  than in high-power zone  230 . Since second basic stitch angle  324  is larger than first basic stitch angle  314 , low-power knit construction  410  and medium-power knit construction  420  may have lower moduli than high-power knit construction  430 , due to their relatively higher proportions of second basic stitch type  320 . 
     In some embodiments, knitted garment  100  may include one or more ventilation zones  240 , to facilitate airflow and cooling of a wearer. A ventilation stitch type may be incorporated into any of the previously-described knit constructions or other knit construction. For example, a ventilation knit construction  440  may include third basic stitch type  330 , which may be a ventilation stitch type. In some embodiments, third basic stitch type  330  may include no connecting underlap between wales, to facilitate airflow by avoiding airflow impedance due to underlap between wales. For example, as shown in the exemplary ventilation knit construction  440  of  FIG. 9 , ventilation knit construction  440  includes 50% third basic stitch type  330 , thereby facilitating airflow and ventilation through the textile material of ventilation zones  240  formed of ventilation knit construction  440 . Ventilation knit construction  440  may include a greater proportion of third basic stitch type  330  to increase ventilation properties of ventilation knit construction  440 , or may include a lesser proportion of third basic stitch type  330  to decrease ventilation properties of ventilation knit construction  440 . 
     Knit construction of a performance zone  200  may include a greater or lesser proportion of first basic stitch type  310  to increase or decrease, respectively, the modulus of the performance zone  200 . Knit construction of a performance zone  200  may include a greater or lesser proportion of second basic stitch type  320  to decrease or increase, respectively, the modulus of the performance zone  200 . Knit construction of a performance zone  200  may include a greater or lesser proportion of third basic stitch type  330  to increase or decrease, respectively, ventilation of the performance zone  200 . Other stitch types may be included in knit construction of a performance zone  200  instead of or in addition to basic stitch types described herein. First basic stitch type  310  and second basis stitch type  320  are described herein in terms of their relative properties (e.g., underlap length between wales, stitch angle) as they contribute to performance characteristics of performance zones  200 , and are not limited to the specific stitches depicted in the figures. Third basic stitch type  330  is described herein in terms of its ventilation properties as they contribute to ventilation of performance zones  200 , and is not limited to the specific stitch depicted in the figures. 
     Knitted garment  100  may be designed to include various combinations of different basic stitches at various locations relative to an intended wearer&#39;s body. These combinations can be used to define areas having different properties located throughout the garment to suit the design of a garment designer (e.g., performance zones  200 ). For example, the designer may define stitch combinations to create a high-power, high-density, heavy-weight zone (e.g., high-power zone  230 ), a low-power, low-density, light-weight zone (e.g., low-power zone  210 ), a medium-power, medium-density, medium-weight zone (e.g., medium-power zone  220 ), or a high-ventilation zone (e.g., ventilation zone  240 ). The sizes, shapes, numbers, and types of performance zones  200  may be varied to suit the desires of a designer, and are not limited to those depicted. 
     The designer may define the desired garment construction including stitch types, knit constructions, and/or performance zones (including, for example, the exemplary constructions described herein), and may transfer the stitch structures for knitted garment  100  into knitting electronic files. A knitting machine may then be programmed using the knitting electronic files to knit each seamless panel  110  of knitted garment  100  seamlessly into a single piece of fabric. Each seamless panel  110  may be cut from the single piece of fabric (e.g., when laid flat, see  FIG. 2 ) and sewn together into the finished knitted garment  100  (see  FIG. 1 ). 
     The foregoing description of the specific embodiments of the warp-knitted athletic performance garment described with reference to the figures will so fully reveal the general nature of the invention that others can, by applying knowledge within the skill of the art, readily modify and/or adapt for various applications such specific embodiments, without undue experimentation, without departing from the general concept of the present invention. 
     While various embodiments of the present invention have been described above, they have been presented by way of example only, and not limitation. It should be apparent that adaptations and modifications are intended to be within the meaning and range of equivalents of the disclosed embodiments, based on the teaching and guidance presented herein. It therefore will be apparent to one skilled in the art that various changes in form and detail can be made to the embodiments disclosed herein without departing from the spirit and Scope of the present invention. For example, the embodiments discussed above related to athletic performance pants, but the principles of the invention are generally applicable to and readily useable with all types of garments, including shirts (e.g., shirt  530  of  FIGS. 12A .  12 B or shirt  540  of  FIGS. 13A and 13B ), bras, hats, socks, gloves, vests, shorts, arm sleeves, leg sleeves (e.g., leg sleeves  550  of  FIGS. 14A and 14B ) etc. The elements of the embodiments presented above are not necessarily mutually exclusive, but may be interchanged to meet various needs as would be appreciated by one of skill in the art. 
     It is to be understood that the phraseology or terminology used herein is for the purpose of description and not of limitation. The breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents.