INTEGRALLY KNIT LOWER-BODY GARMENT

Information

  • Patent Application
  • 20250151819
  • Publication Number
    20250151819
  • Date Filed
    November 11, 2024
    7 months ago
  • Date Published
    May 15, 2025
    27 days ago
Abstract
Examples herein are directed to a knit lower-body garment, methods of manufacturing and/or forming the knit lower-body garment using a flat knitting process, and knit blanks used to form the knit lower-body garment. In examples, the knit lower-body garment is formed from a one-piece knit textile blank that includes partial-length knit courses in select locations and a crotch gusset to provide three-dimensional shaping to the resulting knit lower-body garment. Linking courses are used to reduce tension and reduce grinning issues between portions of the lower-body-garment that are integrally knit together. The use of different (e.g., denser) knit structures in selective regions of the knit lower-body garment is also disclosed. A knitting technique and pattern for simulating the visual effect of a conventional ottoman stitch pattern but in a different orientation is also disclosed.
Description
TECHNICAL FIELD

Examples herein relate to a knit lower-body garment, a knit blank used to form the knit lower-body garment, methods of manufacturing the knit blank for the knit lower-body garment, and methods of forming the knit lower-body garment using the knit blank.


BACKGROUND

Conventional lower-body garments, including those formed from a knit textile, are generally made using a cut-and-sew construction that introduces multiple seam lines. Conventional pattern pieces for knit lower-body garments also generally lack three-dimensional shaping.





BRIEF DESCRIPTION OF THE DRAWINGS

Examples of an integrally knit lower-body garment are described in detail below with reference to the figures listed below.



FIGS. 1A-B illustrate front and back perspective views of a knit lower-body garment (in a worn state) in accordance with examples of this disclosure.



FIG. 2 illustrates a front view of the knit lower-body garment of FIG. 1 (in an unworn state) in accordance with examples of this disclosure.



FIG. 3 illustrates a bottom view of the knit lower-body garment of FIG. 1 (in an unworn state) in accordance with examples of this disclosure.



FIG. 4 illustrates an example knit blank used to form the knit lower-body garment of FIG. 1 in accordance with examples of this disclosure.



FIGS. 4A-E illustrate close-up views of portions of the knit blank of FIG. 4 in accordance with examples of this disclosure.



FIG. 5A and 5B illustrate example loop diagrams of different knit structures taken at the areas indicated in FIG. 2 in accordance with examples of this disclosure.



FIG. 6 illustrates an example loop diagram of the knit structure used to knit, for example, a waistband of the knit lower-body garment of FIG. 1 in accordance with examples of this disclosure.



FIG. 7 illustrates an example loop diagram of the knit structure used to knit, for example, a leg band of the knit lower-body garment of FIG. 1 in accordance with examples of this disclosure.



FIG. 8 illustrates a flow diagram of an example method of manufacturing a one-piece knit blank for a knit lower-body garment using a flat knitting process and forming the knit blank into the lower-body garment in accordance with examples of this disclosure.



FIG. 9 illustrates a flow diagram of an example method of manufacturing a knit lower-body garment in accordance with examples of this disclosure.



FIG. 10 illustrates a flow diagram of an example method of manufacturing an array of knit lower-body garments having a crotch gusset in accordance with examples of this disclosure.



FIG. 11 illustrates another example of a knit blank in accordance with examples of this disclosure.



FIG. 12 illustrates a side view of a knit component formed by the loop diagram of FIG. 6.





DETAILED DESCRIPTION

This disclosure is related to an integrally knit lower-body garment. In at least some examples, the integrally knit lower-body garment includes one or more integrally knit sections that are configured to provide a form fit without excess stitch tension. By minimizing tension (or stretching or strain) imparted on a stitch when the garment is worn, examples of the present disclosure can reduce the stretching of the stitch loop, and in turn, the opening or gap in the knit textile at the stitch.


Conventional lower-body garments, including those formed from a knit textile, are often made using a cut-and-sew construction that produces multiple seam lines. The multiple seam lines can introduce points of structural weakness as well as potentially causing wearer discomfort due to chafing. As well, conventional lower-body garments generally lack three-dimensional shaping such that the garment does not closely conform to a wearer's body, which may negatively impact the aerodynamic profile of the lower-body garment, impede athletic performance, and/or cause distraction to the wearer due to excess material.


Some conventional lower-body garments can be formed of multiple portions that are integrally knit together. However, in many instances these conventional lower-body garments lack sufficient shaping to correspond with the wearer's body. In addition, some conventional garments lack sufficient linking structures between integrally-knit portions, such that the stitches between the integrally knit portions are stretched to a point at which the opacity of the fabric in this area is compromised (this phenomena is also known as “grinning”).


The present disclosure describes several concepts for addressing the issue of grinning described above. Examples herein relate to a knit lower-body garment, a knit blank used to form the knit lower-body garment, methods of manufacturing the knit blank for the knit lower-body garment, and methods of forming the knit lower-body garment using the knit blank.


In examples, the lower-body garment comprises one or more various knit portions, which can include different knit patterns or structures. For example,, areas that experience greater tension due to the construction of the garment may use a knit structure having an increased knit stitch density, which can subsequently decrease the likelihood of grinning in the completed lower-body garment when worn. In an example, computational design may be used to identify areas of the knit blank where greater tension in the knit structure is anticipated.


In an example, the lower-body garment may be formed from a knit blank that includes one or more sets of linking courses to reduce the tension in the loops of courses that knit together different portions of the knit blank where the loops of one portion of the knit blank, during the knitting process, are held over a number of courses before being integrally knit with another portion of the knit blank. The linking courses act as bridges between portions of the knit blank where the loops joining them together would otherwise experience a large amount of tension. This technique reduces grinning in these areas and may also improve the fit of the lower-body-garment, which may now be more relaxed and comfortable in these regions for the wearer.


In an example, a set of linking courses, which may be a subset of the courses that also form the body of the crotch gusset, extend from the body of the crotch gusset and are integrally knit to both the first torso portion and the second torso portion of the knit blank. The use of this set of linking courses alleviates tension in the knit structure across the front section of the lower-body garment formed by the first torso portion and the second torso portion. In another example, one or more sets of linking courses may be used to alleviate tension in the knit structure that forms a lower leg portion of the lower-body garment, allowing for additional contouring to be incorporated into the design of the lower-body garment.


To form the lower-body garment from the fully knitted knit blank, an upper part of the first back seam edge is affixed to an upper part of the second back seam edge, a middle part of the first back seam edge is affixed to the first gusset back edge of the crotch gusset, a lower part of the first back seam edge is affixed to a lower part of the first front torso portion edge, a middle part of the second back seam edge is affixed to the second gusset back edge of the crotch gusset; and a lower part of the second back seam edge is affixed to a lower part of the second front torso portion edge. In examples, a single seam may be used to join the various edges of the knit blank together to form the lower-body knit garment, with the seam appearing to form an inverted “Y” shape, with the upper arms of the Y running along the inseams of the leg portions of the lower-body garment, and the lower “body” of the Y running along the middle of the back torso of the lower-body garment.


As used herein, the term “lower-body garment” means a garment configured to cover a lower torso and/or legs of a wearer. As such, the lower-body garment may include a short, a pant, a three-quarter pant, a tight, a unitard, a skirt, and the like. In one example, the lower-body garment includes a short. Positional terms used when describing the lower-body garment such as front, back, sides, upper, lower, and the like are used in relation to the lower-body garment being worn as intended by a wearer standing in an upright position. Thus, the front of the lower-body garment is configured to cover or be positioned adjacent to a front lower torso portion and/or front leg areas of the wearer, and the back of the garment is configured to cover or be positioned adjacent to a back lower torso portion (e.g., gluteal region) and/or back leg areas of the wearer. The sides of the lower-body garment are configured to cover or be positioned adjacent to the sides of the wearer's lower torso portion and/or side leg areas of the wearer. The term “upper” when used in relation to the lower-body garment means located closer to a head area of the wearer when the garment is worn, and the term “lower” means located closer to a foot area of the wearer when the garment is worn.


The term “crotch gusset” as used herein means an area of the lower-body garment configured to cover a crotch area between the wearer's legs when the lower-body garment is worn. The use of the term “gusset” means an extra volume of material created through the knitting process. The term “seam” as used herein means a structure that affixes two free edges of a textile together. The term “affixing” as used herein means joining two textile free edges together using affixing technologies known in the art such as one or more of stitching, bonding, welding, adhesives, and the like. In examples, the seam is created in a post-processing step after the one-piece knit textile is knit.


The term “one-piece knit textile” as used herein means a knit component formed of a unitary knit construction through a knitting process. That is, the knitting process substantially forms the various features and structures of the one-piece knit textile without the need for significant additional manufacturing steps or processes. The one-piece knit textile may include structures or elements that include one or more courses of yarn or other knit material that are joined such that the structures or elements include at least one course in common and/or share a common yarn, and/or include courses that are substantially continuous between each of the structures or elements. The term “integrally knit with” when describing different portions of the one-piece knit textile means the portions include at least one course in common and/or share a common yarn.


The term “knit blank” as used herein means the knit textile as it comes off the knit machine, where the knit blank is later used to form the lower-body garment. Examples herein contemplate using a flat knitting process on a two-bed (V-bed) weft knit machine where the needles are arranged in a straight line to create the knit blank that forms the lower-body garment. Use of a two-bed weft knit machine allows for the creation of a fully fashioned knit blank having a specified shape with one or more finished edges free from surrounding textile as the knit blank comes off the machine (a finished edge may also be known herein as a “free edge”). Having finished edges as the knit blank comes off the machine eliminates post-processing steps such as cutting pattern shapes, finishing edges, and the like.


The term “boundary” as used herein refers to a border of a portion of a knit blank as illustrated in the drawings herein. A boundary may be, but is not necessarily, a free edge of the knit blank, or it may be part of a perimeter of a knit blank portion that is subsequently knit together with a boundary of one or more other knit blank portions. A boundary may run along the length of a single course, or may run along the ends of multiple courses. One of skill in the art will appreciate that the boundaries of two or more knit portions described herein may be, as part of the knitting process, be integrally knit with each other, resulting in a seamless joining of the two or more portions.


The term “knit course” as used herein refers to a predominantly horizontal row of knit loops (in an upright textile as knit) that are produced by adjacent needles during the same knitting cycle. The knit course may include one or more stitch types such as a knit stitch, a held stitch, a float stitch, a tuck stitch, a transfer stitch, and the like as these terms are known in the art of knitting. The term “knit stitch” as used herein refers to the basic stitch type where the yarn is cleared from the needle after pulling a loop of the yarn through a previous stitch. Because a two-bed weft knit machine is being used, a knit stitch performed by a needle on the front bed will result in the legs of the stitch appearing on the technical face of the knit textile and the top and bottom of the stitch appearing on the technical back of the textile, which may be referred to herein as a “front stitch.” Conversely, a “back stitch” as used herein refers to a knit stitch performed by a needle on the back bed, resulting in the legs of the stitch appearing on the technical back of the knit textile and the top and bottom of the stitch appearing on the technical front of the textile.


The term “wale” as used herein is a predominantly vertical column of intermeshed or interlooped knit loops, generally produced by the same needle at successive (but not necessarily all) courses or knitting cycles. The terms “horizontal” and “vertical” as used herein are relative to an upright textile as knit in which the heads of knit loops face toward the top of the textile and the course knit first is oriented toward the bottom of the textile.


The term “partial-length knit course” or “short row” as used herein is a term in the art that generally refers to a knit course that is turned before reaching the end of a knitting cycle or that begins after a knitting cycle is initiated (i.e., the course is not fully knitted). Stated differently, a partial-length knit course can include a knit course that is between two other courses and that has a fewer number of stitches than the other courses, which are directly interlooped with one another. A “full-length knit course” refers to a knit course that is knit to the end of a knitting cycle. Partial-length knit courses introduce additional knit stitches into the knit textile beyond the knit stitches used to knit full-length knit courses. Strategically locating partial-length knit courses within areas of a knit textile adds extra volume of material to the textile and creates 3-D shaping of the knit textile. In other words, use of partial-length knit courses may introduce changes in dimension in the positive or negative z-direction to an otherwise planar knit textile.


Turning now to the figures herein, FIGS. 1A, 1B, 2 and 3 illustrate a knit lower-body garment 600. The knit lower-body garment 600 includes a front side 602, a back side 604, a left side 606 and a right side 608. Left lower leg portion 610 and left lower leg portion 612 each include an inseam 614, 616, and a back seam 618 runs along the middle of the upper back 620 of the knit lower-body garment 600. In examples, the upper front section 622 is seamless. A waistband 113 encircles the top opening of the knit lower-body garment 600, and first and second leg bands 119, 141 encircle the lower leg openings of each lower leg portion 610, 612. As seen in FIG. 3, the inseams 614, 616 and back seam 618 join at junction 650. In some examples, the inseams 614, 616 and back seam 618 thus form a single seam 901 that has the shape of an inverted Y.


As seen in FIGS. 2 and 3, in between the inseams 614, 616 and upper front section 622 is a crotch gusset 120. The crotch gusset 120 provides additional material in the crotch area to provide additional fit and comfort and allows for extra movement. In examples, the crotch gusset 120 may include a plurality of perforations 630. The perforations 630 may be formed in any suitable pattern and can be the same size or a plurality of different sizes. Because of their positioning, the perforations 630 do not present modesty concerns while providing additional breathability to this area of the knit lower-body garment 600. In examples, perforations may also be formed in other areas of the knit lower-body garment 600, such as in transition zones 632 along the right and left sides of the knit lower-body garment 600. While the perforations may be formed using any number of suitable manufacturing methods, the perforations may also be knit into the fabric of the crotch gusset 120 and the as further described herein.



FIG. 4 depicts a knit blank 100 that may be used to form the lower-body garment of FIG. 1. Knit blank 100 is positioned to reflect how the knit blank 100 would come off the knit machine used to knit the knit blank 100. Thus, arrow 101 reflects the knitting direction 101. The knit blank 100 is used to form the knit lower-body garment as described herein. In examples, the knit blank 100 is knit using elastic yarns, such as LYCRA®, that are covered with, for example, polyester and/or nylon. In examples, the polyester and/or nylon may be treated with a durable water repellant.


The knit blank 100 includes a first back seam edge 110. The first back seam edge 110 may, in examples, forms a finished edge free from surrounding textile and includes a full-length course. In other examples, the first back seam edge 110 may be a knit structure that demarcates a separation line from an integrally knit second knit blank. In other words, it is contemplated herein that the knit blank 100 may be singly knitted or may be knit as a run of blanks and then later separated or cut from the run of blanks.


A first back torso portion 112 extends from the first back seam edge 110. In examples, the first back torso portion 112 of the knit blank 100 forms a left gluteal region of the resulting lower-body garment. The first back torso portion 112 includes a first edge 114 and a second edge 116. When formed into the lower-body garment, the first edge 114 may be known as the upper edge 114, and the second edge 116 may be known as the lower edge 116. In examples, the first edge 114 and the second edge 116 may form finished edges free from surround textile. Alternatively, the first edge 114 and the second edge 116 may not constitute finished edges free from surrounding textile. In examples, the knit courses used to knit the first back torso portion 112 are oriented generally perpendicular to the first edge 114. As shown in FIG. 1, the second edge 116 may be gently curved.


While the first back seam edge 110 may be started with a series of one or more consecutive and interlooped full length knit courses, it may be desirable for the knit blank to provide additional 3-D shaping to the final assembled garment by having additional contouring of the edges of the knit blank that will be joined together with a seam. In an example, therefore, the first back torso portion 112 may have one or more sections in which a widening or narrowing reciprocated section is knit using a set of needles such that some needles of the set are active when knitting particular sections of the first back torso portion 112 and the other needles are inactive, with one or more of the boundaries of the sections defining a contour. For example, in the knit blank 100 of FIG. 4 and the close-up view shown in FIG. 4C, a first back seam edge portion 400 extends immediately from the first back seam edge 110, with a rear boundary 402 that is opposite the first back seam edge 110. Adjacent the first back seam edge portion 400 is a contouring section 498 with a lower contour boundary 450 and an upper contour boundary 460.


Along the length of the lower contour boundary 450 are a first set of linking courses 410, a second set of linking courses 420, and a third set of linking courses 430, which extend from the lower contour boundary 450 perpendicular to the knitting direction 101. Each set of linking courses has a forward boundary and a rear boundary, e.g., the first set of linking courses 410 has a forward boundary 414 and a rear boundary 412, the second set of linking courses 420 has a forward boundary 424 and a rear boundary 422, and the third set of linking courses 430 has a forward boundary 434 and a rear boundary 432.


The arrows 405 shown in the magnified view of FIG. 4C represent areas where inactive needles hold the last course of loops from the rear boundary 402 of the first back seam edge portion 400 while the active needles knit the intervening part of the first back torso portion 112 in the knitting direction 101 between the rear boundary 402 and the first set of linking courses 410. Since the lower contour boundary 450 is angled with respect to the knitting direction 101, as the knitting of the knit blank 100 progresses the inactive needles progressively become active and integrally knit the rear boundary 402 to the lower contour boundary 450. Once the forward boundary 414 of the first set of linking courses 410 is reached, the rest of the previously inactive needles become active to integrally knit the rear boundary 402 of the first back seam edge portion 400 to the forward boundary 414 of the first set of linking courses 410. The needles then continue to knit the rest of the first set of linking courses 410 and the corresponding parts of the first back torso portion 112.


Similarly, once the rear boundary 412 of the first set of linking courses 410 is knit then a portion of the knitting needles become inactive and hold their loops, while the part of the lower contour boundary 450 and the first back torso portion 112 between the first set of linking courses 410 and the second set of linking courses 420 are knit. Since the lower contour boundary 450 is angled with respect to the knitting direction 101, as the knitting of the knit blank 100 progresses the inactive needles progressively become active to integrally knit the rear boundary 412 of the first set of linking courses 410 to the lower contour boundary 450. Once the forward boundary 424 of the second set of linking courses 420 is reached, all of the previously inactive needles become active to integrally knit the rear boundary 412 of the first set of linking courses 410 to the forward boundary 424 of the second set of linking courses 420. The needles then continue to knit the rest of the second set of linking courses 420 and the corresponding parts of the first back torso portion 112.


Once the rear boundary 422 of the second set of linking courses 420 is knit then a portion of the knitting needles become inactive and hold their loops, while the part of the lower contour boundary 450 and the first back torso portion 112 between the second set of linking courses 420 and the third set of linking courses 430 are knit. Since the lower contour boundary 450 is angled with respect to the knitting direction 101, as the knit blank progresses the inactive needles progressively become active to integrally knit the rear boundary 422 of the second set of linking courses 420 to the lower contour boundary 450. Once the forward boundary 434 of the third set of linking courses 430 is reached, all of the previously inactive needles become active to integrally knit the rear boundary 422 of the second set of linking courses 420 to the forward boundary 434 of the third set of linking courses 430. The needles then continue to knit the rest of the third set of linking courses 430 and the corresponding parts of the first back torso portion 112.


Once the rear boundary 432 of the third set of linking courses 430 is knit then a portion of the knitting needles become inactive and hold their loops, while the remainder of the lower contour boundary 450 between the third set of linking courses 430 and the lower edge 116 of the knit blank 100 are knit. Since the lower contour boundary 450 is angled with respect to the knitting direction 101, as the knitting of the knit blank 100 progresses the inactive needles progressively become active to integrally knit the rear boundary 432 of the third set of linking courses 430 to the lower contour boundary 450.


The sets of linking courses 410, 420, 430 allow the inactive needles that are holding the last course of loops from the boundary of a previous knit section or set of linking courses to release the loops by integrally knitting them to the linking courses. This periodic release of held loops prevent excess tension from building up in the held loops that might otherwise persist in the completed lower-body garment and distorting the fit of the garment and/or causing grinning.


Turning back to FIG. 4 and the upper part of the knit blank 100, the upper contour boundary 460 is similarly knit. Once the body of the first back seam edge portion 400 is completed and the rear boundary 402 is knit, a portion of the knitting needles become inactive and hold their loops, while the upper contour boundary 460 and the corresponding portions of the first back torso portion 112 are knit. Since the upper contour boundary 460 is angled with respect to the knitting direction 101, as the knitting of the knit blank 100 progresses the inactive needles progressively become active to knit the rear boundary 402 of the first back seam edge portion 400 to the upper contour boundary 460. In contrast to the lower part of the knit blank 100 in FIG. 4, the tension in the held loops of the upper portion of the rear boundary 402, once integrally knit with the loops of the upper contour boundary 460, may not be high enough to require the use of one or more sets of linking courses. However, in other example knit blanks that have different contouring, one or more sets of linking courses may be appropriate.


While the contour boundaries 450, 460 of the knit blank 100 in FIG. 4 are curved, it is to be appreciated that the contour boundaries of a knit blank can take on other geometries. For example, the contour boundaries may be straight or may include a combination of curves and straight line segments. Furthermore, while three sets of linking courses are used for the lower portion of the first back torso portion 112 in the knit blank 100 of FIG. 4, it is to be appreciated that more or fewer sets of linking courses may be used as appropriate for a given geometry and dimension of a contour boundary or other portion of the knit blank where tension from held loops may exist. Additionally, while the above description relates to a particular region of the knit blank 100 shown in FIG. 4, it is to be appreciated that examples of this disclosure may be used in knit blanks for other types of garments.


Turning to FIG. 4A, the first front torso portion 118 extends from and is integrally knit with the first back torso portion 112. The first front torso portion 118, in examples, forms a left front region of the resulting lower-body garment. The first front torso portion 118 includes the first edge 114 and the second edge 116. In examples, knit courses used to knit the first front torso portion 118 are oriented generally perpendicular to the first edge 114.


The portions of the knit blank 100 may be knit so that one or more visible patterns can be seen in the knit structure. This may include the use of multi-color patterns, trademarks, or other aesthetic designs. In other examples, there may be a visual demarcation between the first back torso portion 112 and the first front torso portion 118. In addition, one or more areas of the portions of the knit blank may be modified so that one or more perforations are formed in the fabric. For example, the knit blank of FIG. 4 has a plurality of perforations in transition zones 632 between the first front torso portion 118 and the first back torso portion 112.


In examples, the knit blank 100 is knit with a double jersey knit structure. An example knit structure 550 for portions of the knit blank 100 is shown in FIG. 5A. Three yarns 501, 502, 503 are knit to form one course, with the first yarn 501 looped on both the front and back layers at every wale, and yarns 502 and 503 alternating floats and loops on the back layer.


In examples, different yarns may be used for the front and back layers of the double jersey knit fabric. In some examples, the yarns can be transferred from one layer to the other to create different aesthetic patterns. For example, a first yarn used to knit the front layer can be transferred to or interknit with the back layer and a second yarn used to knit the second layer can be transferred to or interknit with the front layer in the same location on the knit blank 100 (or lower-body garment 600), or in different locations.


Additionally, the first yarn and the second yarn may be of different colors, and/or of the same color but a different shade or hue. In one example, a first yarn having a first color is used to knit the front (or face) layer of the knit blank, and a second yarn having a second color is used to knit the back layer of the knit blank. In another example, the first yarn and the second yarn can be the same color but of different shades, with the second yarn being of a darker shade than the first yarn. In other examples, the first yarn can be of a darker color or darker shade than the second yarn. Using different colored and/or shaded yarns, in addition to allowing for the creation of different aesthetic features, may also create a visual effect that mitigates any gapping that occurs in the in the fabric.


For those regions of the knit blank 100 where it is expected that more tension is present (even with the integration of the linking courses disclosed herein) such as regions 500 in FIG. 4, a tighter knit structure may be utilized; an example knit structure 560 for these regions 500 is shown in FIG. 5B. The knit structure 560 of FIG. 5B, which includes two yarns 511 and 514 that include tuck stitches on the back layer in alternating wales, along with two pairs of yarns (512, 513 and 515, 516), alternating back loops with floats, results in a tighter (i.e. denser) knit structure, which may be beneficial in those regions where greater tension is anticipated.


The knit blank 100 may also utilize one or more partial-length knit courses or short rows to further aid in the shaping and contouring of portions of the lower-body garment. A partial knit course can start from either the first edge 114 or the second edge 116, and turns before it reaches the second edge 116 or first edge 114, respectively. A partial knit course can also start at least one wale away from an edge of the knit blank and end at the opposite edge of the knit blank or at least one wale prior to the opposite edge of the knit blank. In the knit blank 100 illustrated in FIGS. 4, 4A and 4B, gaps in the knit blank knitting pattern due to the use of partial-length knit courses are shown by lines 190. In some examples, a plurality of partial knit courses can be interspersed among a plurality of full-length courses, with at least one full-length course between adjacent partial-knit courses. As shown in FIG. 4, a staggered pattern of partial-knit courses can be used to create longer or shorter gaps 190 throughout the torso and leg portions of the knitting pattern of the knit blank 100. The partial-knit courses thus provide more material in specific areas to enhance and tailor the fit of the resulting lower-body garment.


In other examples, consecutive courses may be partial-length knit courses of the same or different lengths. For example, another example knit blank 1100 is illustrated in FIG. 11, which may be used to form a lower-body garment such as leggings that included extended lower leg portions 1110. Multiple partial length courses of different lengths are knit consecutively with each other such that gaps 1122 having a staggered or stepped profile are created in the lower leg portion 1110 of the knitting pattern of the knit blank 1100, growing wider as they get closer to the ends 1119 and 1141 of the lower leg portions 1110. Because there is less material being used to form the knit blank 1100 in these areas, the resulting lower-body garment will have lower leg portions with a more naturally tapered shape.


The knit blank 100 further includes a crotch gusset 120 having a central gore 300, a first gore 121 and a second gore 129. With respect to the crotch gusset 120, and as best shown in the magnified view of FIG. 4D, the crotch gusset 120 is knit with a number of widening reciprocated sections and narrowing reciprocated sections using a set of needles such that some needles of the set of needles are active when knitting particular sections of the crotch gusset and other needles of the set of needles are inactive. The arrows shown in the magnified view represent areas where inactive needles hold the last course of loops from the previously knit sections while other sections of the crotch gusset 120 are knit in the knitting direction 101. Once a particular section is knit, the inactive needles begin knitting to join together the different knit sections. For instance, arrows 301 graphically represent where the first gore 121 of the crotch gusset 120 is integrally knit with the central gore 300. Arrows 302 graphically represent where the central gore 300 is integrally knit with the second gore 129 of the crotch gusset 120. The crotch gusset 120 includes a first gusset back edge 133 that forms a finished edge free from surrounding textile and a second gusset back edge 135 that forms a finished edge free from surrounding textile.


The boundary 210 of the first gore 121 is integrally knit with a second boundary 123 of the first front torso portion 118. In one example, the crotch gusset 120 is knit in a reciprocating motion with a first subset of active needles that are a subset of the set of needles used to knit the first front torso portion 118. In other examples, the crotch gusset 120 may be knit with a separate set of needles (a separate feeder or feeders) than the needles used to knit the first front torso portion 118. Regardless, while the first gore 121 of crotch gusset 120 is being knit, the inactive needles hold the last course of loops from the boundary 125 of the first front torso portion 118.


The section of the first front torso portion 118 that is lower than the crotch gusset 120 may end with a finished first front lower leg edge 990 free from surrounding textile. The needles that finish this first front lower leg edge 990 may remain inactive while the crotch gusset 120 is knit and become active again when the second front torso portion 126 is knit.


Once the first gore 121 of the crotch gusset 120 is knit, the central gore 300 is knit, including the crotch gusset linking courses 310. Once the crotch gusset linking courses 310 is reached in the knitting process, the inactive needles holding the last course of loops from the boundary 125 of the first front torso portion 118 (together with the already active needles) knit the front boundary 311 of the crotch gusset linking courses 310; this is graphically represented by arrows 702. Thus, the loops of the front boundary 311 of the crotch gusset linking courses 310 is integrally knit with the loops of the boundary 125 of the first front torso portion 118. In an example, the crotch gusset linking courses 310 may be as few as two courses in width. In the knit blank 100 of FIG. 4, the crotch gusset linking courses 310 may be about eight courses in width.


The crotch gusset may also have a plurality of perforations 630 integrally knit into the first gore 121 and the second gore 129. The positioning of the first gore 121 and the second gore 129 in the final assembled lower-body garment is such that modesty concerns are not an issue, and the perforations 630 may provide additional ventilation and comfort to the wearer of the lower-body garment.


In the crotch gusset 120 of FIG. 4, bottom edges 220 of first gore 121 and bottom edge 221 second gore 129 are substantially straight, while top edge 223 of the first gore 121 and top edge 224 of the second gore 129 are curved. The central gore 300 is generally triangular in shape, with scalloped first top edge 225 and second top edge 226 and a generally straight bottom edge 227. It is to be understood that the shape of the crotch gusset 120 in FIG. 4 is illustrative only, and it is contemplated herein that the crotch gusset 120 may have different shapes than shown. Furthermore, short-rowing may also be used to further affect the shaping and fit of the crotch gusset 120.


The second front torso portion 126 is integrally knit with and extends from the crotch gusset 120 and the crotch gusset linking courses 310. With respect to FIG. 4 and the magnified view shown in FIG. 4A, the second boundary 211 of the second gore 129 is integrally knit with a second boundary 128 of the second front torso portion 126, and the rear boundary 312 of the crotch gusset linking courses 310 is integrally knit with the first boundary 127 of the second front torso portion 126. As with the first front torso portion 118, the second front torso portion 126 also includes a second lower leg edge 991 that may form a finished edge free from surrounding textile. In an example, the second lower leg edge 991 is knit with the needles that were last active in finishing the first front lower leg edge 990 of the first front torso portion 118.


The second front torso portion 126 forms, in examples, a right front region of the resulting lower-body garment. The second front torso portion 126 includes a first edge 142 and second edge 144. In examples, the first edge 142 may include a continuous linking courses of the top edge of the crotch gusset linking courses 310, and the second edge 144 may be separated from the second edge 116 of the first front torso portion 118 and the first back torso portion 112 by the crotch gusset 120. Thus, in examples, the second edge 144 may not include a continuous linking courses of the second edge 116. When formed into the lower-body garment, the first edge 142 may be known as the upper edge 142, and the second edge 144 may be known as the lower edge 144. In examples, the first edge 142 and the second edge 144 may form finished edges free from surrounding textile. Alternatively, the first edge 142 and the second edge 144 may not constitute finished edges free from surrounding textile. The knit courses used to knit the second front torso portion 126 are oriented generally perpendicular to the first edge 142. As shown in FIG. 4, the second edge 144 may be gently curved.


A second back torso portion 140 extends from and is integrally knit with the second front torso portion 126. In examples, the second back torso portion 140 forms a right gluteal region of the resulting lower-body garment. The second back torso portion 140 includes the first edge 142 and the second edge 144. The second back torso portion 140 terminates at a second back seam edge 146. The second back seam edge 146 may, in examples, includes a finished edge free from surrounding textile. In other examples, the second back seam edge 146 may be a knit structure that demarcates a separation line from an integrally knit additional knit blank. As mentioned, it is contemplated herein that the knit blank 100 may be singly knitted or may be knit as a run of blanks and then later separated or cut from the run of blanks.


In some examples, the transition from the second front torso portion 126 to the second back torso portion 140 may be a gradual transition without a visual demarcation. In other examples, there may be a visual demarcation between the second front torso portion 126 and the second back torso portion 140 similar to that described for the first back torso portion 112 and the first front torso portion 118, and perforations may also be formed in the fabric in this transition zone 632.


As with the first back torso portion 112 described above, in an example the second back torso portion 140 may include one or more sections in which a widening or narrowing reciprocated section is knit using a set of needles such that some needles of the set are active when knitting particular sections of the second back torso portion 140 and the other needles are inactive, with one or more of the boundaries of the sections defining a contour. For example, in the knit blank 100 of FIG. 4 and the close-up portion shown in FIG. 4E, a second back seam edge portion 510 extends immediately from the second back seam edge 146, with a front boundary 517 that is opposite the second back seam edge 146. Adjacent the second back seam edge portion 510 is a contouring section 499 with a lower contour boundary 497 and an upper contour boundary 496.


As shown in FIG. 4E, sets of linking courses 491, 492, 493 extend from the lower contour boundary 497 and are knit similarly to the sets of linking courses 410, 420, 430.


The knit blank 100 further includes an optional waistband 113, an optional first leg band 119, and an optional second leg band 141. Once the knit blank 100 is fully knit, the waistband 113 extends continuously from a first waistband seam edge 102 to a second waistband seam edge 104. In examples, the first waistband seam edge 102 linearly extends from the first back seam edge 110, and the second waistband seam edge 104 linearly extends from the second back seam edge 146. The waistband 113 includes a first edge 115 and an opposite second edge 117. When the knit blank 100 is formed into the knit lower-body garment 600 of FIG. 1, the first edge 115 may be referred to as a lower waistband edge 115, and the second edge 117 may be referred to as an upper waistband edge 117. In examples, the first edge 115 extends from and is integrally knit with the first edge 114 of the first back torso portion 112 and the first front torso portion 118, the edge of the crotch gusset linking courses 310, and the first edge 142 of the second front torso portion 126 and the second back torso portion 140. In examples, the second edge 117 of the waistband 113 includes a finished edge free from surrounding textile. In the knit blank 100 shown in FIG. 4, there is no portion of the waistband 113 that extends from the end of the first back seam edge portion 400 or the second back edge seam portion 440. Therefore, when the first waistband seam edge 102 and the second waistband seam edge 104 are joined together, the circumference of the waistband 113 is less than the circumference of the upper edge of the lower-body garment.


In an example, the waistband 113 may be knitted using a pattern of stitches that results in a knit component that simulates the visual ribbed effect of a conventional Ottoman stitch pattern. In a conventional Ottoman stitch pattern, the ribs run perpendicular to the knitting direction of the knit component. In contrast, a knit component having the knit pattern described herein will appear to have ribs running parallel to the knitting direction of the knit component. This allows for a designer to be able to simulate the visual effect of an Ottoman stitch for a knit component even when that knit component is being knit in a direction perpendicular to the conventional direction.


Looking now at FIG. 6 and with reference to FIG. 12, a loop diagram 700 for a knitting a specific example of this knit component is provided. Four ends of yarn 701, 702, 703 and 704 form one course across five consecutive wales (corresponding to needle positions 711, 712, 713, 714, 715), which would be repeated to form the knit component. For the two needle positions 711 and 712 on the left of the loop diagram, the yarns 701, 702 move between the two needle beds to secure the front knit layer 1204 and the back knit layers 1202 together, forming a secured area 1206. The right three needle position 713, 714, 715 produce two knit layers knit on separate beds (yarns 702 and 704 forming the front knit layer 1204, yarns 701 and 703 forming the back knit layer 1202) so that the front knit layer 1204 and the back knit layer 1202 are separable. As seen in FIG. 6, yarn 702 and yarn 704 for the front knit layer 1204 are looped at every needle position, but yarn 701 and 703 forming the back knit layer 1202 alternate floats and loops. The resultant course knit with these four ends of yarn 701, 702, 703704 will result in a float stitch and a loop stitch at every needle position in the raised structure area 1208 formed by needles 717, 718, 720. The float stitches cause tension that effectively shorten the back knit layer 1202 at the raised structure areas 1208, causing the front knit layer 1204 to balloon out so that the overall knit component externally resembles a conventional Ottoman pattern.


The knit component thus comprises a first knit layer (the front knit layer 1204) and a second knit layer (the back knit layer 1202), with a plurality of raised knit structures 1208 (formed at needle positions 713, 714, 715) extending in a wale-wise direction and separated from an adjacent raised knit structure 1208 by a secured area 1206 (formed at needle positions 71, 712), the first knit layer extending away from the second knit layer at each raised knit structure 1208, and the first knit layer being secured to the second knit layer at each secured area 1206, with each course of second knit layer having a greater quantity of float stitches than the first knit layer at each raised knit structure 1208. In examples, at each raised knit structure, each course of the first knit layer may include two ends of a yarn each forming at least three knit loops along the same wales. Using two ends of yarn to form loops at the same needles in parallel may create additional build up of the first knit layer to enhance the raised feature.


A knit component that is knit with the knit pattern of FIG. 6 will result in a fabric with a ribbed appearance with the ribs running in the wales-wise direction. Due to the machine direction of the knit blank 100, the ribs run side to side, around the circumference of the waistband.


The first leg band 119 includes a first end 148 that terminates at the first back seam edge 110, and a second end 150 that terminates at the first front lower leg edge 990 of the first front torso portion 118. In examples, the first end 148 linearly extends from the first back seam edge 110. The first leg band 119 further includes a first edge 137 and an opposite second edge 139. When the knit blank 100 is formed into the lower-body garment, the first edge 137 may be referred to as an upper leg band edge 137, and the second edge 139 may be referred to as a lower leg band edge 139. In examples, the first edge 137 of the first leg band 119 extends from and is integrally knit with the second edge 116 of the first back torso portion 112 and the first front torso portion 118. In examples, the second edge 139 of the first leg band 119 includes a finished edge free from surrounding textile.


The second leg band 141 includes a first end 152 that terminates at the second back seam edge 146 and a second end 154 that terminates at the second lower leg edge 991 of the second front torso portion 126. In examples, the first end 152 linearly extends from the second back seam edge 146. The second leg band 141 further includes a first edge 143 and an opposite second edge 145. When the knit blank 100 is formed into the lower-body garment, the first edge 143 may be referred to as an upper leg band edge 143, and the second edge 145 may be referred to as a lower leg band edge 145. In examples, the first edge 143 of the second leg band 141 extends from and is integrally knit with the second edge 144 of the second front torso portion 126 and the second back torso portion 140. In examples, the second edge 145 of the second leg band 141 forms a finished edge free from surrounding textile.


In an example, the first leg band 119 and the second leg band 141 may be formed using the stitch pattern or structure shown in the loop diagram 580 of FIG. 7.


Leg bands using the knit structure shown in FIG. 7, which includes a yarn 582 stitched with a one-by-one tuck stitch pattern to provide rigidity to the leg band, may better resist shifting or rolling upwards on the wearer's leg during movement, e.g., during a workout. Additionally, a plurality of ribs 198, 199 may be integrated into the structure of the leg bands 119, 141. The ribs 198, 199 may be knit from the same yarn or type of yarn used to knit the leg bands, or a different yarn, such as a grip yarn. In an example, the yarn used to knit the ribs 198 on the front layer of the leg band (that faces outwardly) is knit with the same type and color of yarn as the rest of the leg band, while the yarn used to knit the ribs 198 on the back layer (that faces inwardly and touches the skin of the wearer) is knit with a different yarn, which may be a grip yarn. The ribs 198, 199 may further enhance the leg bands' ability to prevent shifting or rolling up during movement.



FIGS. 8-10 depict flow diagrams of example methods as discussed herein. FIG. 8 depicts a flow diagram, referenced generally by the numeral 800, of an example method of manufacturing a knit blank, such as the knit blank 100, for a lower-body garment, such as the knit lower-body garment 600. At a step 810, and beginning at a first back seam edge, such as the first back seam edge 110, a first back torso portion, such as the first back torso portion 112, is knit. At a step 820, subsequent to knitting the first back torso portion, a first front torso portion, such as the first front torso portion 118, is integrally knit with the first back torso portion. At a step 830, subsequent to knitting the first front torso portion, a crotch gusset, such as the crotch gusset 120, together with a third front torso portion, such as the crotch gusset linking courses 310, is integrally knit with the first front torso portion.


At a step 840, subsequent to knitting the crotch gusset and third front torso portion, a second front torso portion, such as the second front torso portion 126, is integrally knit with the crotch gusset and the third front torso portion. At a step 850, subsequent to knitting the second front torso portion, a second back torso portion, such as the second back torso portion 140 is integrally knit with the second front torso portion. The second back torso portion terminates at a second back seam edge, such as the second back seam edge 146. At a step 860, the completed knit blank, such as knit blank 100, is formed in to a lower-body garment, such as knit lower-body garment 600.


The method of manufacture 800 may also optionally include knitting a waistband, such as the waistband 113, where the waistband is integrally knit with a first edge of the first back torso portion, the first front torso portion, the third front torso portion, the second front torso portion, and the second back torso portion. The method of manufacture 800 may also optionally include knitting a first leg band, such as the first leg band 119, where a first edge of the first leg band is integrally knit with a second edge of the first back torso portion and the first front torso portion and knitting a second leg band, such as the second leg band 141, where a first edge of the second leg band is integrally knit with a second edge of the second front torso portion and the second back torso portion. The method of manufacture 800 may additionally include a step of forming the knit blank into a lower-body garment by at least affixing together a first portion of the first back seam edge with a first portion of the second back seam edge as indicated at a step 860. The step 860, in examples, may occur at the same facility used to form the knit blank. Alternatively, the step 860 may occur at a different facility than the one used to form the knit blank.



FIG. 9 illustrates a flow diagram of an example method 900 of forming a lower-body garment from a one-piece knit blank produced by the method of manufacture 800. The one-piece knit blank includes the first back torso portion having a first back seam edge, a second back torso portion having a second back seam edge, a front torso portion formed from a first front torso portion, a second front torso portion, and third front torso portion extending from a crotch gusset, such as the crotch gusset linking courses 310. The crotch gusset further includes a first gusset back edge, such as the first gusset back edge 133, and a second gusset back edge, such as the second gusset back edge 135.


At a step 910, an upper part of the first back seam edge, such as the upper part 174, is affixed to an upper part of the second back seam edge, such as the upper part 175, to form a first part of a seam, such as the first part 951 of the seam 901. At a step 920, a middle part of the first back seam edge, such as the middle part 173, is affixed to the first gusset back edge, such as first gusset back edge 133, to form a first segment of a second part of the seam, such as the segment 952 of the seam 901. At a step 930, a lower part of the first back seam edge, such as the lower part 172 is affixed to a lower edge of the first front torso portion, such as first front lower leg edge 990, to form a second segment of the second part of the seam, such as segment 953 of the seam 901. At a step 940, a middle part of the second back seam edge, such as the middle part 176, is affixed to the second gusset back edge, such as second gusset back edge 135, to form a first segment of a third part of the seam, such as the segment 954 of the seam 901. At a step 950, a lower part of the second back seam edge, such as the lower part 177 is affixed to a lower edge of the second front torso portion, such as second lower leg edge 991, to form a second segment of the third part of the seam, such as segment 955 of the seam 901.


In examples, the first part, the second part, and the third part of the seam 901 continuously extend from each other and form an inverted Y-shape. In examples, the remaining portions of the lower- body garment are seamless.


In an example, the same knit pattern for the crotch gusset of FIG. 1 can be used for an array of lower-body knit garments of different sizes. For example, shorts are conventionally retailed in up to five different sizes, extra small (XS), small(S), medium (M), large (L) and extra large (XL). By using the same knit pattern for the crotch gusset, designing the rest of the garment in different sizes is simpler, since one set of variables (the dimensions of the crotch gusset) are anchored in place. One of skill in the art will appreciate that the crotch gusset linking courses 310 extending from the crotch gusset 120 are easily lengthened or shortened to accommodate a taller or shorter front torso portion.


In an alternative example, other portions of the crotch gusset may change proportionally in a linear fashion with respect to changes in one or more other measurements of the knit garment.


It is to be understood that the dimensions of the knit blank 100 and the knit garment shown in FIGS. 1-4 are illustrative only, and it is contemplated herein that the knit blank 100 and lower body garment may have different shapes than shown. For example, the knit blank 1100 shown in FIG. 11 has longer lower leg portions 1110 and may be used to form a pair of leggings. The knit blank 1100 may also be one of an array of knit blanks used to form an array of garments of different sizes. Accordingly, while the size and shape of gusset 1101 may be the same between the knit blanks used to form different sized garments, the distance between, for example, the gusset 1101 and the edges of the lower log portions 1119, 1141 (which may include leg bands) will be different.


The following clauses represent examples of concepts contemplated herein. Any one of the following clauses may be combined in a multiple dependent manner to depend from one or more other clauses. Further, any combination of dependent clauses (clauses that explicitly depend from a previous clause) may be combined while staying within the scope of examples contemplated herein. The following clauses are examples and are not limiting.


Clause 1. A lower-body garment comprising: a knit textile comprising a front torso portion, a first back torso portion with a first back seam edge, a second back torso portion with a second back seam edge, a first leg seam edge, a second leg seam edge, and a crotch gusset, wherein the crotch gusset includes a first gusset back edge and a second gusset back edge; and a first seam that affixes together: an upper part of the first back seam edge and an upper part of the second back seam edge, a middle part of the first back seam edge and the first gusset back edge, a middle part of the second back seam edge and the second gusset back edge, a lower part of the first back seam edge and the first leg seam edge, and a lower part of the second back seam edge and the second leg seam edge.


Clause 2. The lower-body garment according to clause 1, wherein the first seam is continuous and forms a Y-shape.


Clause 3. The lower-body garment according to clause 2, wherein, other than the first seam, the front torso portion, the first back torso portion and the second back torso portion are seamless.


Clause 4. The lower-body garment according to any of clauses 1 through 3, wherein the knit textile comprises a plurality of short rows interspersed between a plurality of full-length knit courses.


Clause 5. The lower-body garment according to clause 4, wherein the plurality of short rows comprises a first short row having a first length and a second short row having a second length, and wherein the first length is longer than the second length.


Clause 6. The lower-body garment according to clause 5, wherein the first short row and the second short row are knit next to each other.


Clause 7. The lower-body garment according to clause 6, further comprising a third short row knit next to the second short row and having a third length that is shorter than the second length.


Clause 8. A lower-body garment comprising: a knit textile comprising a left front torso portion, a right front torso portion, and a crotch gusset, the crotch gusset further comprising a central gore, a first gusset back edge, a second gusset back edge, and a set of front linking courses extending from the central gore; wherein the set of front linking courses is integrally knit with the left front torso portion and the right front torso portion.


Clause 9. The lower-body garment according to clause 8, wherein the set of front linking courses comprises at least one course that is integrally knit with the central gore.


Clause 10. The lower-body garment according to clause 9, wherein the crotch gusset further comprises a first gore adjacent a first side of the central gore, and a second gore adjacent a second side of the central gore opposite the first side.


Clause 11. The lower-body garment according to clause 10, wherein the first gore and the second gore comprises a plurality of perforations.


Clause 12. The lower-body garment according to any of clauses 10 through 11, wherein the first gusset back edge runs along a bottom edge of the first gore and a first portion of a bottom edge of the central gore.


Clause 13. The lower-body garment according to clause 8 through 12, further comprising: a left back torso portion integrally knit with the left front torso portion, a right back torso portion integrally knit with the right front torso portion, and a seam that joins the left back torso portion to the right back torso portion, the left back torso portion to the first gusset back edge, and the right back torso portion to the second gusset back edge.


Clause 14. The lower-body garment according to clause 13, wherein the seam further joins the left front torso portion to the left back torso portion, and the right front torso portion to the right back torso portion.


Clause 15. An array of lower-body garments of different sizes, each lower-body garment in the array comprising a crotch gusset having a central gore, wherein the central gore for each knit component is knit using a first knit pattern.


Clause 16. The array according to clause 15, wherein the crotch gusset of each lower-body garment in the array further comprises a first portion integrally knit with the central gore, the first portion of a first lower-body garment in the array having a length that is different than the length of the first portion of at least one other lower-body garment in the array.


Clause 17. The array according to clause 16, wherein the first portion is a lower leg piece having a leg band, and the distance between the central gore and the leg band of the first lower-body garment is different than the distance between the central gore and the leg band of the at least one other lower body garment.


Clause 18. The array according to any of clauses 15 through 17, wherein the crotch gusset of each lower body-garment in the array further comprises a left gore and a right gore integrally knit with the central gore.


Clause 19. A method of forming a lower-body garment from a one-piece knit blank comprising a first back torso portion having a first back seam edge, a second back torso portion having a second back seam edge, a first front torso portion, a second front torso portion, and a crotch gusset comprising a first gusset back edge, a second gusset back edge, and a third front torso portion, the method comprising: affixing together at a seam: an upper part of the first back seam edge and an upper part of the second back seam edge to form a first part of the seam, a middle part of the first back seam edge and the first gusset back edge to form a second part of the seam, and a middle part of the second back seam edge and the second gusset back edge to form a third part of the seam; and affixing together by integrally knitting: the first front torso portion and the third front torso portion, and the second front torso portion and the third front torso portion.


Clause 20. The method according to clause 19, wherein: the first front torso portion comprises a first lower leg edge, the second front torso portion comprises a second lower leg edge, and the step of affixing further comprises: affixing together with the second part of the seam a lower part of the first back seam edge with the first lower leg edge; and affixing together with the third part of the seam a lower part of the second back seam edge with the second lower leg edge.


Clause 21. The method according to any of clauses 19 through 20, wherein the third front torso portion is integrally knit with the crotch gusset.


Clause 22. A method of forming a lower-body garment, comprising the steps of: knitting a one-piece knit blank, comprising the steps of: knitting a first back torso portion comprising a first back seam edge; knitting a first front torso portion that is integrally knit with the first back torso portion; knitting a crotch gusset and a third front torso portion, the third front torso portion being integrally knit with the crotch gusset and the first front torso portion being integrally knit with the crotch gusset and the third front torso portion; knitting a second front torso portion, the second front torso potion being integrally knit with the crotch gusset and the third front torso portion; and knitting a second back torso portion comprising a second back seam edge; and attaching the first back seam edge to the second back seam edge.


Clause 23. The method according to clause 22, wherein the first front torso portion includes a first leg edge and the second front torso portion comprises a second leg edge, and the method further comprises the steps of: attaching the first back seam edge to the crotch gusset; attaching the second back seam edge to the crotch gusset; attaching the first leg edge to the first back seam edge; and attaching the second leg edge to the second back seam edge.


Clause 24. The method according to clause 23, wherein each of the attaching steps comprises using a seam.


Clause 25. The lower body garment according to any of clauses 1 through 7, wherein the knit textile is a double jersey knit comprising a front layer and a back layer.


Clause 26. The lower body garment according to clause 25, wherein the first layer comprises a first yarn and the second layer comprises a second yarn.


Clause 27. The lower body garment according to clause 26, wherein the first yarn and the second yarn are different colors.


Clause 28. The lower body garment according to clause 26, wherein the first yarn and the second yarn are different hues of the same color.


Clause 29. The lower body garment according to clause 25, wherein the first yarn is interknitted with the back layer and/or the second yarn is interknitted with the front layer.


Clause 30. The lower body garment according to clause 29, wherein the first yarn is interknitted with the back layer and the second yarn is interknitted with the front layer in the same location on the lower-body garment.


Clause 31. The lower body garment according to clause 29, wherein the first yarn is interknitted with the back layer and the second yarn is interknitted with the front layer in different locations on the lower-body garment.


Clause 32. The lower-body garment according to clause 8, wherein the crotch gusset comprises a plurality of perforations.


Clause 33. The lower-body garment according to clause 32, wherein the plurality of perforations are located adjacent to an edge of the crotch gusset.


Clause 34. A lower-body garment comprising: a knit component comprises a first knit layer and a second knit layer, the knit component further comprising a plurality of raised knit structures extending in a wale-wise direction and defined by a plurality of secured areas, the first knit layer extending away from the second knit layer at each raised knit structure, and the first knit layer being secured to the second knit layer at each secured area, wherein at each raised knit structure, each course of the second knit layer comprises a greater quantity of float stitches than the first knit layer.


Clause 35. The lower-body garment according to clause 34, wherein the knit component is a knit waistband.


Clause 36. The lower-body garment according to any of clauses 34 to 35, wherein, at each raised knit structure, each course of the second knit layer comprises at least 3 float stitches.


Clause 37. The lower-body garment of according to clause 36, wherein, at each raised knit structure, each course of the first knit layer has no float stitches.


Clause 38. The lower-body garment according to any of clauses 34 to 37, wherein, at each raised knit structure, each course of the second knit layer comprises a 1:1 ratio of float stitches to wales.


Clause 39. The lower-body garment according to any of clauses 34 to 38, wherein, at each raised knit structure, each course alternates between floating one end of yarn and floating a second end of yarn.


Clause 40. The lower-body garment according to any of clauses 34 to 39, wherein, at each raised knit structure, each course of the first knit layer comprises at least three knit loops of a first yarn.


Clause 41. The lower-body garment according to any of clauses 34 to 40, wherein, at each raised knit structure, each course of the first knit layer comprises two ends of a yarn each forming at least three knit loops along the same wales.


The subject matter of the present disclosure is described with specificity herein to meet statutory requirements. However, the description itself is not intended to limit the scope of this disclosure. Rather, the inventors have contemplated that the claimed or disclosed subject matter might also be embodied in other ways, to include different steps or combinations of steps similar to the ones described in this document, in conjunction with other present or future technologies. Moreover, although the terms “step” and/or “block” might be used herein to connote different elements of methods employed, the terms should not be interpreted as implying any particular order among or between various steps herein disclosed unless and except when the order of individual steps is explicitly stated.

Claims
  • 1. A lower-body garment comprising: a knit textile comprising a front torso portion, a first back torso portion with a first back seam edge, a second back torso portion with a second back seam edge, a first leg seam edge, a second leg seam edge, and a crotch gusset, wherein the crotch gusset includes a first gusset back edge and a second gusset back edge; anda first seam that affixes together: an upper part of the first back seam edge and an upper part of the second back seam edge,a middle part of the first back seam edge and the first gusset back edge,a middle part of the second back seam edge and the second gusset back edge,a lower part of the first back seam edge and the first leg seam edge, anda lower part of the second back seam edge and the second leg seam edge.
  • 2. The lower-body garment of claim 1, wherein the first seam is continuous and forms a Y-shape.
  • 3. The lower-body garment of claim 1, wherein, other than the first seam, the front torso portion, the first back torso portion and the second back torso portion are seamless.
  • 4. The lower-body garment of claim 3, wherein the knit textile comprises a plurality of short rows interspersed between a plurality of full-length knit courses.
  • 5. The lower-body garment of claim 4, wherein the plurality of short rows comprises a first short row having a first length and a second short row having a second length, and wherein the first length is longer than the second length.
  • 6. The lower-body garment of claim 5, wherein the first short row and the second short row are knit next to each other.
  • 7. The lower-body garment of claim 6, further comprising a third short row knit next to the second short row and having a third length that is shorter than the second length.
  • 8. The lower body garment of claim 1, wherein the knit textile is a double jersey knit comprising a front layer and a back layer.
  • 9. The lower body garment of claim 8, wherein the first layer comprises a first yarn and the second layer comprises a second yarn.
  • 10. The lower body garment of claim 9, wherein the first yarn and the second yarn are different colors.
  • 11. The lower body garment of claim 8, wherein the first yarn is interknitted with the back layer and the second yarn is interknitted with the front layer.
  • 12. The lower body garment of claim 11, wherein the first yarn is interknitted with the back layer and the second yarn is interknitted with the front layer in the same location on the lower-body garment.
  • 13. A lower-body garment comprising: a knit textile comprising a left front torso portion, a right front torso portion, and a crotch gusset, the crotch gusset further comprising a central gore, a first gusset back edge, a second gusset back edge, and a set of front linking courses extending from the central gore;wherein the set of front linking courses is integrally knit with the left front torso portion and the right front torso portion.
  • 14. The lower-body garment of claim 13, wherein the set of front linking courses comprises at least one course that is integrally knit with the central gore.
  • 15. The lower-body garment of claim 14, wherein the crotch gusset further comprises a first gore adjacent a first side of the central gore, and a second gore adjacent a second side of the central gore opposite the first side.
  • 16. The lower-body garment of claim 15, wherein the first gusset back edge runs along a bottom edge of the first gore and a first portion of a bottom edge of the central gore.
  • 17. The lower-body garment of claim 13, further comprising: a left back torso portion integrally knit with the left front torso portion,a right back torso portion integrally knit with the right front torso portion, anda seam that joins the left back torso portion to the right back torso portion, the left back torso portion to the first gusset back edge, and the right back torso portion to the second gusset back edge.
  • 18. A method of forming a lower-body garment from a one-piece knit blank comprising a first back torso portion having a first back seam edge, a second back torso portion having a second back seam edge, a first front torso portion, a second front torso portion, and a crotch gusset comprising a first gusset back edge, a second gusset back edge, and a third front torso portion, the method comprising: affixing together at a seam: an upper part of the first back seam edge and an upper part of the second back seam edge to form a first part of the seam,a middle part of the first back seam edge and the first gusset back edge to form a second part of the seam, anda middle part of the second back seam edge and the second gusset back edge to form a third part of the seam; andaffixing together by integrally knitting: the first front torso portion and the third front torso portion, andthe second front torso portion and the third front torso portion.
  • 19. The method of claim 18, wherein: the first front torso portion comprises a first lower leg edge,the second front torso portion comprises a second lower leg edge, andthe step of affixing further comprises: affixing together with the second part of the seam a lower part of the first back seam edge with the first lower leg edge; andaffixing together with the third part of the seam a lower part of the second back seam edge with the second lower leg edge.
  • 20. The method of claim 19, wherein the third front torso portion is integrally knit with the crotch gusset.
CROSS-REFERENCE TO RELATED APPLICATIONS AND PRIORITY CLAIM

This non-provisional patent application claims priority to co-pending U.S. provisional patent app. No. 63/598,446, filed on Nov. 13, 2023, and titled “INTEGRALLY KNIT LOWER-BODY GARMENT,” the contents of which is incorporated herein by reference in the entirety.

Provisional Applications (1)
Number Date Country
63598446 Nov 2023 US