Patent Abstract:
A circular knit blank for use in the manufacture of undergarments and the garments so manufactured comprising a tubular knit body having an elastomeric yarn on selected courses, wherein said tubular body contains at least one area of control that has a stitch pattern increasing the modulus by about 8%, to provide a balance of comfort and control. The stitch pattern is preferably a 1 by 1 alternating tuck.

Full Description:
BACKGROUND OF THE INVENTION  
         [0001]    1. Field of the Invention  
           [0002]    The present invention relates generally to a control garment and a method for providing additional control to selected portions of a garment. More particularly, the present invention relates to seamless garments provided with additional control through the use of elastomeric yarn and purpose-specific knitting techniques, and methods for providing such control.  
           [0003]    Consumers desire an undergarment that provides control or support in specific areas of the body, such as hips and waist, and is not bulky or unsightly.  
           [0004]    2. Description of the Prior Art  
           [0005]    Previously known techniques used for adding support to an undergarment include that disclosed in U.S. Pat. No. 2,736,036 to Sinigagliesi. This patent provides a seamless undergarment knitted as a single piece of tubular knitted fabric, but containing a strengthening patch.  
           [0006]    U.S. Pat. No. 3,425,246 to Knohl provides a knitted brassiere having extra courses of elastic yarn knitted into the breast cups to shape the cups by providing fullness therein.  
           [0007]    U.S. Pat. No. 3,906,754 to Sackman provides an undergarment having a plurality of integrally knitted panels. Each panel extends circumferentially around the garment. Certain of the courses of each panel are knitted of elastomeric yarn to impart an elastic character to the area.  
           [0008]    A more recent technique for imparting support to selected area of garments is shown in U.S. Pat. No. 5,479,791 to Osborne. This patent provides a brassiere having a support area between the pair of breast cups in which the courses vary between simple knits, such as plain knit, and welt knit, such as miss-stitch.  
           [0009]    U.S. Pat. No. 5,572,888 to Browder, Jr. et al. provides a seamless undergarment knit from a first yarn. A control area is formed by knitting in a second, heavier yarn on designated courses along with the first yarn. A predetermined configuration of plain jersey stitch loops and tuck loops are utilized in the control area to achieve the characteristics of a foundation garment.  
           [0010]    U.S. Pat. No. 5,590,548 to Osborne provides a circularly knit legged panty having knit-in shaping panels. The panels are formed by modifying the knit structure in selected areas to form regions having a greater resistance, particularly coursewise resistance, to stretch than the remainder of the tubular body. The patent provides that greater resistance to stretch can be accomplished by using conventional knitting structures, such as floating in an elastic yarn or tucking a yarn in selected alternating courses.  
           [0011]    U.S. Pat. No. 5,592,836 to Schuster et al. provides a brassiere having at least two support panels formed by tucking specific stitches for a predetermined number of courses and extending generally walewise, thus, giving greater resistance to coursewise stretch. Preferably, each support panel is described as preferably located on the outside edge of a breast cup and roughly in the form of a “C” partially encircling the breast cup.  
           [0012]    U.S. Pat. No. 5,605,060 to Osborne provides a circularly knit body suit in which the middle torso portion is knit with a predetermined cross-stretch that is less than that of the breast supporting section of the garment.  
           [0013]    However, a perpetual need exists for improved seamless undergarment provided with control areas shaped specifically to affect certain areas of the body, such as the hips, waist, and even under a woman&#39;s breasts. All such control areas need to be formed integrally with the garment so as to appear as an aesthetic, non-bulging feature and, thus, no different than the remainder of the integral garment.  
         BRIEF SUMMARY OF THE INVENTION  
         [0014]    It is the object of the present invention to provide an improved seamless garment having areas of additional control that are shaped to affect specifically chosen areas of the body.  
           [0015]    It is another object of the present invention to provide such a garment that has a control area formed by an alternating tuck stitch pattern in the undergarment.  
           [0016]    It is yet another object of the present invention to provide such a garment in which the tuck stitch pattern is a 1 by 1 (1×1) alternating tuck stitch.  
           [0017]    It is a further object of the present invention to provide such a garment as an undergarment.  
           [0018]    It is still a further object of the present invention to provide a method of manufacturing the blank and the garment of the type set forth herein.  
           [0019]    In accordance with the present invention, a circular knitting machine knits a single tubular blank including a tubular knit body. The tubular knit body contains an elastomeric yarn added along designated courses. The tension of the elastomeric yarn is constant throughout the entire garment. However, in the area of the garment where increased control is desired, a 1×1 alternating tuck stitch pattern is used. The 1×1 tuck stitch tightens the fabric and increases the modulus of the elastomeric yarn. Thus, the stitch pattern decreases the amount of stretch in the fabric. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0020]    [0020]FIG. 1 is a frontal view of a brief that uses the present invention;  
         [0021]    [0021]FIG. 2 is a rear view of the brief of FIG. 1;  
         [0022]    [0022]FIG. 3 is a frontal view of a high waist brief that uses the present invention;  
         [0023]    [0023]FIG. 4 is a rear view of the high waist brief of FIG. 3;  
         [0024]    [0024]FIG. 5 is a frontal view of a half-slip that uses the present invention;  
         [0025]    [0025]FIG. 6 is a rear view of the half-slip of FIG. 5;  
         [0026]    [0026]FIG. 7 is a frontal view of a thigh-slimmer that uses the present invention;  
         [0027]    [0027]FIG. 8 is a rear view of the thigh-slimmer of FIG. 7;  
         [0028]    [0028]FIG. 9 is a bottom view of the thigh-slimmer of FIG. 7, but with the legs expanded;  
         [0029]    [0029]FIG. 10 is a maternity brief that uses the present invention; and  
         [0030]    [0030]FIG. 11 is a maternity brief that uses the present invention;  
         [0031]    [0031]FIG. 12 is a brassiere that uses the present invention; and  
         [0032]    [0032]FIG. 13 is a graphic depiction of the 1×1 alternating tuck stitch pattern.  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0033]    Referring to the drawings and, in particular FIGS. 1 and 2, there is illustrated a brief according to the present invention generally represented by reference numeral  10 . Brief  10 , as with all the embodiments of the present invention, is formed as a unitary, seamless knit, tubular garment blank or body  15  having a waistband  20  formed as a turned welt.  
         [0034]    The fabric, which forms the turned welt, is knit on circular needles and dial bits in a well-known manner. Knitting machines for producing a fabric in the form of a turned welt are widely used in the industry, and their construction and mode of operation are well-known. Alternatively, waistband  20  may be an attached piece of elastic banding. As stated below, waistband or torso-band  20  is made of a combination of spandex covered with nylon and nylon. Such a high denier spandex is preferred in order to make certain that brassiere  130  stays in place on the wearer&#39;s body.  
         [0035]    Brief  10  is preferably integrally knit to the turned welt. The tubular knit body  15  has a front portion  16 , a rear portion  17 , and side portions  18 . Additionally, the undergarment can have binding or trim that aesthetically finishes and more comfortably defines the leg openings  21  and  23 .  
         [0036]    Preferably, the undergarment of all embodiments of the present invention, including brief  10 , have body  15  made of either nylon microfiber in the 40 to 120 denier range or 40/1&#39;s to 60/1&#39;s cotton yarn. Such yarns provide softness, comfort, and desired wicking properties. The knit construction may be any combination of conventional knit stitches.  
         [0037]    The body  15  of brief  10 , as with all embodiments of the present invention, includes an elastomeric yarn, such as spandex. Preferably, the elastomeric yarn is knit throughout the garment at an even tension. More preferably, the tension of the elastomeric yarn is 5 to 7 grams throughout the garment. The elastomeric yarn is preferably spandex, and most preferably 70 denier spandex.  
         [0038]    Control area  25  is an area of of the undergarment, in this example brief  10 , where increased control is desired. Increased control in control area  25  is accomplished by tightening the fabric of brief  10  by using a 1 by 1 (1×1) alternating tuck stitch pattern. Thus, the 1×1 alternating tuck stitch pattern increases the modulus of the fabric. By increasing the modulus of the fabric, the fabric stretches less and controls more. Preferably, the modulus of the fabric is increased between about 6% and about 10%, more preferably about 8%. Increasing the modulus by about 8% provides a desirable compromise between control and comfort.  
         [0039]    Control area  25  of brief  10  is apron shaped, covering only the stomach area and the area of the hips, then gradually transitioning over the rear portion, ultimately becoming a narrow, horizontal band integral to welt  20 . The border between control area  25  and crotch portion  27  may be of any functional and aesthetically pleasing shape.  
         [0040]    [0040]FIGS. 3 and 4 illustrate a high waist brief  30  according to the present invention. High waist brief  30  is knit using the same method as that for the brief  10 . However, control area  35  of high waist brief  30  is extended over the abdomen and ends below the wearer&#39;s breasts. Thus, the entire abdominal area, and the area, preferably all, of the hips are covered. Control area  35  is relatively smaller over rear portion  37  of high waist brief  30  with a rounded transition area extending from front portion  36  of high waist brief  30  and over rear portion  37 . The border between control area  35  and crotch portion  38  may be of any functional and aesthetically pleasing shape.  
         [0041]    [0041]FIGS. 5 and 6 show a half-slip  50  according to the present invention. Half-slip  50  is knit using the same method as that of the embodiments of FIGS. 1 through 4, but absent the leg openings. Control area  65  of half-slip  50  is shaped similarly to control area  25  of brief  10  and high waist brief  30 . On the front portion  61  of half-slip  50 , the border between control area  65  and skirt portion  62  is angled. However, the border between control area  65  and skirt portion  62  may be of any aesthetic or functional shape. It is preferable that half slip  50  has a first waistband  52  at the waist of the half-slip  50  and a second bond  54  at the lower end of the half-slip  50 . The waistband  52  is a turned welt waistband that is integrally formed with half-slip  50 . As with waistband  20  shown in FIGS. 1 and 2, first waistband  52 , as well as band  54 , are preferably a combination of spandex covered with nylon and nylon, with the most preferred being about 265 to about 420 denier spandex covered with nylon and nylon.  
         [0042]    [0042]FIGS. 7 and 8 show a thigh-slimmer according to the present invention. The thigh-slimmer  70  is knit using the same method as the undergarments of FIGS. 1 through 6. Control area  85  is shaped similarly to control area  65  in FIGS. 5 and 6. Optionally, control areas may be placed on leg portions  81  and  82 . In addition, leg portions  81  and  82  are seamlessly knit to front portion  80 . The thigh slimmer can have binding or trim that aesthetically finishes and more comfortably defines leg openings  86  and  87  In an alternative embodiment shown in FIG. 9, thigh slimmer  70  may include a seamed gusset panel  75  to improve fit and comfort. The gusset panel  75  is made of the same material as the body of thigh slimmer  70 , but preferably also includes a cotton liner  78 . The gusset panel  75  is sewn to thigh slimmer  70  so that cotton liner  78  is either wrapped about the gusset panel, or is positioned between the gusset panel and the underside of thigh slimmer  70 .  
         [0043]    In FIG. 10, there is illustrated a body-slip according to the present invention. Body-slip  90  is knit by the method used for the undergarments of FIGS. 1 through 8. Control area  105  is apron shaped, but extends over the abdomen and ends below the wearer&#39;s breasts. The borders of control area  105  are shaped to follow the shape of the wearer. Thus, the abdominal area, and the area of the hips are covered. Front portion  106  has an upper border  103  of control area  105  that is scalloped to follow the breast line and a lower border  104  of control area  105  that is scalloped to allow less restricted movement of the wearer&#39;s legs. Control area  25   b  is relatively smaller over rear portion  107  of body slip  90  with a rounded transition area extending from the front portion  106  and over the rear portion  107 . On the front portion of body slip  90 , the border between control area  105  and skirt portion  107  is angled. However, the border between control area  105  and skirt portion  107  may be of any functional or aesthetically pleasing shape.  
         [0044]    [0044]FIG. 11 shows a maternity brief according to the present invention. Maternity brief  110  is knit using the method described in reference to brief  10  and high waist brief  11 . However, control area  125  extends over rear portion  121  and also extends onto front portion  122  covering the wearer&#39;s groin. The portion covering stomach area  123  is specifically knitted without any control areas so as to allow the portion covering the stomach to expand as needed. Thus, control area  125  controls the wearer&#39;s buttocks and hips, while simultaneously lifting the wearer&#39;s stomach area.  
         [0045]    Referring to FIG. 12, there is provided a brassiere according to the present invention generally represented by numeral  130  with an upper torso part  141 . Brassiere  130  is produced from a seamless blank that is formed by a conventional high speed circular knitting machine. Upper torso part  141  is integrally joined to turned welt or torso-band  147  in a seamless manner.  
         [0046]    Upper torso part  141  preferably has formed therein breast cups  142  and  143 . Upper torso part  141  may also have a first or right strap or strap portion  148 , and a second or left strap or strap portion  149 .  
         [0047]    Turned welt or torso-band  147  is preferably an elastomeric yarn or material. More preferably, torso-band  147  is made of a combination of nylon covered spandex and nylon. Most preferably, torso-band  147  is made of a 265 to 420 denier nylon covered spandex and nylon. Such a high denier spandex is preferred in order to make certain that brassiere  130  stays in place on the wearer&#39;s body.  
         [0048]    Upper torso part  141  is, as with the other undergarments of the present invention, preferably made of flat nylon ground yarn and a cotton and/or nylon yarn. Flat yarn is used because it has no stretch. The fabric also includes an elastomeric yarn, such as spandex. The combination of yarns forms a pattern that is in the range of 60/1&#39;s to 40/1&#39;s cotton count or about 40 to 120 denier, preferably about 80 to about 120. The flat nylon ground yarn is about 20 to about 40 denier, preferably about 20 denier.  
         [0049]    Brassiere  130  is formed mostly with simple knit constructions, such as plain, tuck, pearl and combinations thereof. Welt knit stitches may suitably be used to provide special features at various locations. However, in the areas of brassiere  130  where increased control is desired, a 1×1 alternating tuck stitch pattern is used. Such areas are shown generally as  145  and  146 . The 1×1 alternating tuck stitch pattern tightens the fabric of brassiere  130  and, thus, increases the modulus of the fabric. By increasing the modulus of the fabric, the fabric stretches less and controls more. Preferably, the modulus of the fabric is increased between about 6% and about 10%, more preferably about 8%. Increasing the modulus by about 8% provides a desirable compromise between control and comfort.  
         [0050]    In the example illustrated as FIG. 12, control areas  145 , 146  are narrow bands located underneath breast cups  142 , 143  and extending coursewise in the area of transition between upper torso portion  141  and torso-band  147 . In this way, control areas  145 ,  146  take the place of traditional underwires. However, control areas may be located in other areas of the brassiere, such as between the cups or on the outside edge of the cups. Additionally, control areas for brassiere  130  need not be shaped as narrow bands. If the purpose of the brassiere  130  is to pull the breast together, an hourglass-shaped control area between the breast cups could be employed.  
         [0051]    [0051]FIG. 13 is a graphic representation of the 1×1 alternating tuck stitch pattern used in the present invention.  
         [0052]    The present invention having thus been 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.

Technology Classification (CPC): 0