Patent Grant
11718932
The present invention relates to a denim-like fabric and jeans. In particular, the invention relates to a denim-like knitted fabric.
Denim is one of the most popular fabrics worldwide used for clothing, especially jeans. Production of denim jeans is a labor-intensive process, requiring multiple steps, many of which are manual. Accordingly, there is a need for improved ways of producing denim.
In light of the foregoing background, it is an object of the present invention to provide a denim-like knitted fabric. The denim-like knitted fabric can be produced seamlessly with a knitting machine. Stiffness can be added to the knitted fabric to provide the feel of denim. Additionally, nylon and/or spandex yarns can be added to provide stretchability to the fabric. In some embodiments, the denim-like knitted fabric is used to make jeans.
Accordingly, the present invention provides a denim-like knitted fabric having at least one section comprising a repeating pattern, the repeating pattern comprising (1) a first course drawn into knitted loops at face and back wales, the face wales comprising cotton-like yarns and thermoplastic yarns, and the back wales comprising stretchable yarns; and (2) a second course drawn into a pattern comprising one circular knitted loop followed by two missed loops at face and back wales, wherein the face wales and the back wales comprise a predetermined combination of yarns; (3) a third course drawn into continuous circular knitted loops at face and back wales, the face wales comprising cotton-like yarns and thermoplastic yarns, and the back wales comprising stretchable yarns; and (4) a fourth course drawn into said pattern comprising one circular knitted loop followed by two missed loops at face and back wales, having alternating pattern with the second course, wherein the face wales and the back wales comprise said predetermined combination of yarns.
Other example embodiments are discussed herein.
As used herein and in the claims, “denim” means a hard-wearing cotton twill fabric used for jeans and other clothing.
As used herein and in the claims, “seamless” refers to smooth and continuous without seams or obvious joins on the fabric.
As used herein and in the claims, “course” means a horizontal row in the fabric.
As used herein and in the claims, “wale” means a vertical row in the fabric.
As used herein and in the claims, “face wale” means an external side of the wale in the fabric when the fabric is made into pants.
As used herein and in the claims, “back wale” means an internal side of the wale in the fabric when the fabric is made into pants.
As used herein and in the claims, “yarn” means a thread used for knitting.
As used herein and in the claims, “pocket facing” means a piece of shell material super-imposed on the top of the pocket material at its opening to conceal the lining.
One embodiment of the invention includes a denim-like knitted fabric having thermoplastic yarns, wherein said thermoplastic yarns provide stiffness to said fabric.
Some embodiments of the invention include that the denim-like knitted fabric having thermoplastic yarns are made into jeans, leisurewear, casualwear, waistband, or zip fly.
Some embodiments include the denim-like knitted fabric having thermoplastic yarns, wherein the knitted fabric is made of indigo cotton yarns, thermoplastic yarns and white nylon yarns with a twill knitting pattern, wherein the knitted fabric is made into jeans.
The embodiments of the invention include a denim-like knitted fabric having at least one section comprising a repeating pattern. In some embodiments, the repeating pattern comprises a first course drawn into continuously knitted loops at face and back wales, the face wales comprising cotton-like yarns and thermoplastic yarns, and the back wales comprising stretchable yarns. The repeating pattern also comprises a second course drawn into a pattern comprising one knitted loop followed by two missed loops at face and back wales, wherein the face wales and the back wales comprise a predetermined combination of yarns. The repeating pattern further comprises a third course drawn into continuously knitted loops at face and back wales, the face wales comprising cotton-like yarns and thermoplastic yarns, and the back wales comprising stretchable yarns. Lastly, the repeating pattern comprises a fourth course drawn into the pattern comprising one knitted loop followed by two missed loops at face and back wales, having an alternating pattern with the second course, wherein the face whales and the back wales comprise said predetermined combination of yarns.
In some embodiments, the thermoplastic yarn is a nylon thermoplastic yarn. In some embodiments, the thermoplastic yarn includes cotton yarns, nylon yarns, and spandex yarns. In some embodiments, the thermoplastic yarn is stretchable and includes spandex yarns.
In some embodiments, the predetermined combination of yarns comprises the face wales having cotton yarns and nylon yarns, and the back wales having nylon yarns and spandex yarns. In some embodiments, the face wales comprise 100% cotton yarns and 100% nylon thermoplastic yarns, and the back wales comprise 67% nylon and 33% spandex yarns for the first and the third course.
In other embodiments, the predetermined combination of yarns comprises the face wales having 100% cotton yarns, and the back wales having 100% nylon yarns. In some embodiments, the predetermined combination of yarns comprises the face wales having 100% nylon yarns, and the back wales having 67% nylon and 33% spandex yarns, wherein the denim-like knitted fabric is stretchable.
In other embodiments, the predetermined combination of yarns comprises the face wales having polyester Coolmax yarns and the back wales having nylon and spandex yarns. In some embodiments, the denim-like knitted fabric is stretchable and wicking. In other embodiments, the predetermined combination of yarns comprises the face wales having 100% polyester Coolmax yarns, and the back wales having 67% nylon and 33% spandex yarns, wherein the denim-like knitted fabric stretchable and wicking.
In some embodiments, the predetermined combination of yarns comprises the face wales having 100% polyester Coolmax yarns, and the back wales having 100% nylon yarns.
Denim has traditionally been made using a weaving technique. The techniques for making the denim-like knitted fabrics of the present invention have many advantages over current techniques for making denim. For example, the presently claimed knitting technique provides flexibility during the manufacturing process and can drastically reduce the cost of manufacturing denim jeans.
For example, the claimed knitting technique provides the ability to easily vary the number and types of yarns to be knitted into a single fabric. The process enables seamless yarn switching during the knitting process, thus reducing the overall waste of yarn.
Furthermore, the present invention provides a denim-like material that is soft, stretchable, and comfortable, while at the same time retaining sufficient stiffness in a way that mimics the feel of traditional woven denim.
Clothing, such as jeans, made from the denim-like knitted fabric of the present disclosure provides freedom of movement and comfort for the wearer. The claimed knitting technique generates loop structures in a fabric that easily distorts when the fabric is put under tension, thus creating a fabric that is stretchable. The fabric of the present disclosure further incorporates thermoplastic yarns during the knitting process that are later melted during a manufacturing process. The final knitted product therefore possesses a level of stiffness, thus retaining the feel of woven denim jeans.
In particular, by combining indigo cotton yarns, thermoplastic yarns and white nylon yarn with a twill (3×1 or 2×1) knitting pattern, a denim-like look (from the twill) and a denim-like feel (from the thermoplastic yarn) are achieved. Furthermore, nylon and or spandex yarns in courses can be added or adjusted to provide extra stretchability or knitting texture effect.
One example embodiment of the repeating pattern in a denim-like knitted fabric to make the fabric stretchable is shown in Table 1A. The repeating pattern comprises the first course having face and back wales, wherein the face wales comprise 100% cotton yarns and 100% nylon thermoplastic yarns, and the back wales comprise 67% nylon and 33% spandex yarns. The repeating pattern also comprises the second course having face and back wales, wherein the face wales comprise 100% nylon yarns and the back wales comprise 67% nylon and 33% spandex yarns. In some embodiments, this pattern can include the twill construction by introducing two missed loops followed by one knitted loop as explained above.
Table 1B shows some embodiments of the repeating pattern for a denim-like knitted fabric to make the fabric less stretchable than the fabric described in Table 1A. The repeating pattern comprises the first course having face and back wales, wherein the face wales comprise 100% cotton yarns and 100% nylon thermoplastic yarns, and the back wales comprise 67% nylon and 33% spandex yarns. The repeating pattern also comprises the second course having face and back wales, wherein the face wales comprise 100% cotton yarns and the back wales comprise 100% nylon yarns. In some embodiments, this pattern can include the twill construction by introducing two missed loops followed by one knitted loop as explained above.
Table 1C shows another exemplary embodiment of the repeating pattern for a denim-like knitted fabric to add the wicking function to the fabric described in Table 1A. The repeating pattern comprises the first course having face and back wales, wherein the face wales comprise 100% cotton yarns and 100% nylon thermoplastic yarns, and the back wales comprise 67% nylon and 33% spandex yarns. The repeating pattern also comprises the second course having face and back wales, wherein the face wales comprise 100% polyester Coolmax yarns and the back wales comprise 67% nylon and 33% spandex yarns. In some embodiments, this pattern can include the twill construction by introducing two missed loops followed by one knitted loop as explained above.
Table 1D shows some exemplary embodiments of the repeating pattern for a denim-like knitted fabric to add the wicking function to the fabric described in Table 1B. The repeating pattern comprises the first course having face and back wales, wherein the face wales comprise 100% cotton yarns and 100% nylon thermoplastic yarns, and the back wales comprise 67% nylon and 33% spandex yarns. The repeating pattern also comprises the second course having face and back wales, wherein the face wales comprise 100% polyester Coolmax yarns and the back wales comprise 100% nylon yarns. In some embodiments, this pattern can include the twill construction by introducing two missed loops followed by one knitted loop as explained above.
In some embodiments, the 100% cotton yarns include indigo dyeing such that the fabric has a blue color. In some embodiments, the blue color looks like the color of blue jeans. In other embodiments, the indigo dyeing can be done with sulfur color dyeing or another reactive color dyeing. In some embodiments, instead of the 100% indigo cotton, heather grey yarns, cotton/polyester (T/C) blend yarns, cotton/rayon blend yarns, cotton/Tencel blend yarns or cotton/hemp blend yarns can be used for the fabric.
In some embodiments, the 67% nylon and 33% spandex yarns are covered spandex with nylon wrapping the spandex. In other exemplary embodiments, the 67% nylon and 33% spandex can be replaced with bare lycra yarns, T400 yarns, or any stretchable yarns.
In some embodiments, the polyester Coolmax can be replaced with any other synthetic functional yarns.
In some embodiments, the repeating pattern for the denim-like knitted fabric has 3×1 or 2×1 twill pattern. In some embodiments, the denim-like knitted fabric is made into jeans.
The embodiments of the invention also include a denim-like knitted fabric for a waistband having at least one section comprising a repeating pattern. In some embodiments, the repeating pattern comprises a first course drawn into continuously knitted loops at face and back wales, wherein the face wales comprise cotton yarns and thermoplastic yarns, and the back wales comprise stretchable yarns. The repeating pattern also comprises a second course drawn into a pattern comprising one knitted loop followed by two missed loops at face and back wales, wherein the face wales and the back wales comprise a predetermined combination of yarns. The repeating pattern further comprises a third course drawn into continuously knitted loops at face and back wales, wherein the face wales comprise cotton yarns and the back wales comprise stretchable yarns. Lastly, the repeating pattern comprises a fourth course drawn into a pattern comprising one knitted loop followed by two missed loops at face and back wales, having an alternating pattern with the second course, wherein the face wales and the back wales comprise said predetermined combination yarn.
In some embodiments, the fabric for the waistband is selected from the group consisting of cotton yarn, nylon yarn, thermoplastic yarn, and stretchable yarn. In some embodiments, the stretchable yarn is spandex. In other embodiments, the thermoplastic yarn is nylon thermoplastic yarn.
In some embodiments, the face wales comprise cotton yarns and thermoplastic yarns, and the back wales comprise stretchable yarns. In some embodiments, the back wales comprise stretchable yarns for the third course. In other embodiments, the face wales comprise 100% cotton yarns and 100% nylon thermoplastic yarns, and the back wales comprise 67% nylon and 33% spandex yarns for the first course and the third course. In other embodiments, the face wales comprise 100% nylon yarns and the back wales comprise 67% nylon and 33% spandex yarns for the second and the fourth course.
In some embodiments, the face wales comprise 100% cotton yarns and 100% nylon thermoplastic yarns, and the back wales comprise 67% nylon and 33% spandex yarns for the first course, wherein the face wales comprise 100% cotton yarns and the back wales comprise 67% nylon and 33% spandex yarns for the third course. In other embodiments, the predetermined combination of yarns comprises the face wales having 100% nylon yarns and the back wales having 67% nylon and 33% spandex.
One exemplary embodiment of the repeating pattern in a denim-like knitted waistband with the button opening design is shown in Table 2A. The repeating pattern comprises a first course having face and back wales, wherein the face wales comprise 100% cotton yarns and 100% nylon thermoplastic yarns, and the back wales comprise 67% nylon and 33% spandex yarns. The repeating pattern also comprises a second course having face and back wales, wherein the face wales comprise 100% nylon yarns and the back wales comprise 67% nylon and 33% spandex yarns. The repeating pattern also comprises a third course having face and back wales, wherein the face wales comprise 100% cotton yarns and the back wales comprise 67% nylon spandex yarns. Lastly, the repeating pattern comprises a fourth course having face and back wales, wherein the face wales comprise 100% nylon yarns and the back wales comprise 67% nylon and 33% spandex yarns. In some embodiments, this pattern can include the twill construction by introducing two missed loops followed by one knitted loop as explained above.
Other exemplary embodiments of the repeating pattern in a denim-like knitted waistband with the seamless design are shown in Table 2B. The repeating pattern comprises a first course having face and back wales, wherein the face wales comprise 100% cotton yarns and 100% nylon thermoplastic yarns, and the back wales comprise 67% nylon and 33% spandex yarns. The repeating pattern also comprises a second course having face and back wales, wherein the face wales comprise 100% nylon yarns and the back wales comprise 67% nylon and 33% spandex yarns. The repeating pattern further comprises a third course having face and back wales, wherein the face wales comprise 100% cotton yarns and 100% nylon thermoplastic yarns, and the back wales comprise 67% nylon and 33% spandex yarns. Lastly, the repeating pattern comprises a fourth course having face and back wales, wherein the face wales comprise 100% nylon yarns and the back wales comprise 67% nylon and 33% spandex yarns. In some embodiments, this pattern can include the twill construction by introducing two missed loops followed by one knitted loop as explained above.
In some embodiments, the repeating pattern for the waistband has 3×1 or 2×1 twill pattern.
One embodiment of the invention includes a method of making denim-like knitted pants (i.e., jeans) with at least one seamless pocket. In some embodiments, the method comprises knitting a pocket facing with yarns for a pocket facing using a knitting machine, switching the yarns for the pocket facing to yarns for a pocket bag in the same knitting machine, and knitting, in the same knitting machine, the pocket bag with the yarns for the pocket bag. In some embodiments, the pocket facing and the pocket bag are integrated seamlessly and knitted into one single tube. In some embodiments, the yarns for the pocket facing are indigo yarns and the yarns for the pocket bag are white yarns, whereby a thinner white mesh construction is formed in the pocket bag and integrated seamlessly with the pocket facing.
Another embodiment provides a denim-like knitted jean comprising the denim-like knitted fabric of claim 1 and at least one seamless pocket. In some embodiments, the seamless pocket comprises a pocket bag, wherein the pocket bag comprises a mesh fabric that is thinner and softer compared with the denim-like knitted fabric of the jean.
Some embodiments of the invention also include a denim-like knitted zip fly and catch, wherein said knitted zip fly and catch are fused with thermoplastic yarns. In some embodiments, said knitted zip-fly and catch are made using the denim-like knitted fabric of the present disclosure.
The exemplary embodiments of the present invention are thus fully described. Although the description referred to particular embodiments, it will be clear to one skilled in the art that the present invention may be practiced with a variation of these specific details. Hence this invention should not be construed as limited to the embodiments set forth herein.
This application claims priority to, and the benefit of, U.S. Provisional Application Ser. No. 62/992,182 filed Mar. 20, 2020, entitled “A Denim-like Fabric”. The entire contents of the foregoing application are hereby incorporated by reference for all purposes
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