Patent Application
20240352632
The present disclosure relates to knits, and more specifically, to weft knits, methods of making the same, and garments using the same.
Conventional knit fabrics for manufacture of hosiery products (such as pantyhose stockings, socks, and tights) include Lycra®, Spandex®, often in combination with nylon or polyester. However, these fabrics tend to rip or tear when subjected to frictional forces. It has been observed that hosiery products such as sheer hosiery products (e.g. 30 denier and below) made using these fibers are very fragile. They can easily be ripped by hand, foot or hang nail, and are generally considered disposable. Therefore, there remains a need for commercially viable sheer and semi-sheer elastic knits that are not easy to rip.
Ultra-high molecular weight polyethylene (UHMWPE) fiber is considered an ideal reinforcing component due to its high impact strength, low density, low elongation at break, low moisture absorption, and low coefficient of friction. The knits including UHMWPE fibers in combination with stretch fibers such as Spandex®, nylon covered Spandex®, nylon or polyester have shown increased rip resistance, as described for example in US Publication No. 2018/0368483A1 and US Publication No. 2022/0056620A1, each of which are herein incorporated by reference in their entirety. However, UHMWPE fibers are very expensive. A single 0.5 kilometer bobbin of UHMWPE may cost around $250, which greatly increases overall product costs. The quality of UHMWPE fibers from suppliers also varies from batch to batch. Lower quality UHMWPE fibers may result in defects, such as yarn ring or barre, which lead to damaged hosiery that can not be used in inventory and thus becomes waste.
Therefore, there remains a need for commercially viable knits for making garments, such as hosiery, that allow utilizing a lower amount, and/or lower grade UHMWPE fibers while maintaining the desired rip resistance and durability properties.
In brief, embodiments of the present disclosure are directed to knits containing less UHMWPE fibers, methods for their preparation, and garments containing the same.
In one aspect of the present disclosure, a method for forming a knit is provided. The method comprises knitting a UHMWPE fiber in a first feed, and knitting a stretch fiber in a second feed with a first needle knitting the stretch fiber and a second needle holding a corresponding loop of the UHMWPE fiber in the first feed to form an 1×1 tuck stitch.
In another aspect of the present disclosure, a knit is provided. The knit comprises a first fiber including a first portion and a second portion. The knit further comprises a second fiber including a third portion and a fourth portion, the third portion disposed between the first portion and the second portion, and the third portion and the fourth portion spaced apart from each other by the second portion of the first fiber. The knit further comprises a plurality of columnar knit loop regions. Each one of the knit loop regions includes a first axis, a first knit loop of the first portion along the first axis, a second knit loop of the third portion that wraps around the first portion, the second knit loop being aligned with the first knit loop along the first axis, a third knit loop of the second portion that wraps around the third portion, the third knit loop being aligned with the first and second knit loops along the first axis, a fourth knit loop of the fourth portion that wraps around the second portion, the fourth knit loop being aligned with the first knit loop, the second knit loop, and the third knit loop along the axis. The knit further comprises a plurality of columnar tuck loop regions, the plurality of columnar tuck loop regions separating each one of the plurality of columnar knit loop regions from each other, each one of the columnar tuck loop regions including: a second axis spaced apart from the first axis, a first tuck loop of the first portion, a second tuck loop of the third portion that wraps around the first portion, the second tuck loop being aligned with the first tuck loop along the second axis, a third tuck loop of the second portion that wraps around the third portion, the third tuck loop being aligned with the first and second tuck loops along the second axis, and a fourth tuck loop of the fourth portion that wraps around the second portion, the fourth tuck loop being aligned with the first, second, and third tuck loops along the second axis.
In still another aspect of the present disclosure, a knit is provided. The knit includes a UHMWPE fiber, a stretch fiber knitted with the UHMWPE fiber, one or more columnar knit loop regions including: one or more first knit loops of the UHMWPE fiber that wrap around the stretch fiber; and one or more second knit loops of the stretch fiber that wrap around the UHMWPE fiber, and one or more columnar tuck loop regions, respective ones of the one or more columnar tuck loop regions separate respective ones of the columnar knit loop regions. The one or more columnar tuck loop regions includes first columnar tuck loop regions that include third knit loops of the UHMWPE fiber wrap around the UHMWPE fiber, the third knit loops being larger than the first and second knit loops, and first tuck loops of the stretch fiber wrap around the UHMWPE fiber, each one of the first tuck loops being partially sandwiched between portions of the UHMWPE fiber. The one or more columnar tuck loop regions further includes second columnar tuck loop regions that include fourth knit loops of the stretch fiber wrap around the stretch fiber, the fourth knit loops being larger than the first and second knit loops, and second tuck loops of the UHMWPE fiber wrap around the stretch fiber, the second tuck loops being partially sandwiched between portions of the stretch fiber.
In still another aspect of the present disclosure, a garment comprising the knit of the present disclosure is provided.
The present disclosure is best understood from the following detailed description when read in conjunction with the accompanying drawings. It is emphasized that, according to common practice, the various features of the drawings are not necessarily to scale. On the contrary, the dimensions and spatial relationship(s) of the various features may be arbitrarily enlarged or reduced for clarity. Like reference numerals denote like features throughout specification and drawings.
In the following description, certain specific details are set forth in order to provide a thorough understanding of various embodiments. However, one skilled in the art will understand that the invention may be practiced without these details. In other instances, well-known structures have not been shown or described in detail to avoid unnecessarily obscuring descriptions of the embodiments. Unless the context requires otherwise, throughout the specification and claims which follow, the word “comprise” and variations thereof, such as, “comprises” and “comprising” are to be construed in an open, inclusive sense, that is, as “including, but not limited to.” Further, headings provided herein are for convenience only and do not interpret the scope or meaning of the claimed invention.
Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, the appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. Also, as used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the content clearly dictates otherwise. It should also be noted that the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise. Further, as used in this specification and the appended claim, the term “about” has the meaning reasonably ascribed to it by a person of ordinary skill in the art when used in conjunction with a stated numerical value or range, i.e., denoting somewhat more or somewhat less than the stated value or range, to within a range of ±20% of the stated value; ±19% of the stated value; ±18% of the stated value; ±17% of the stated value; ±16% of the stated value; ±15% of the stated value; ±14% of the stated value; ±13% of the stated value; ±12% of the stated value; ±11% of the stated value; ±10% of the stated value; ±9% of the stated value; ±8% of the stated value; ±7% of the stated value; ±6% of the stated value; ±5% of the stated value; ±4% of the stated value; ±3% of the stated value; ±2% of the stated value; or ±1% of the stated value.
As used herein, and unless the context dictates otherwise, the following terms have the meanings as specified below.
The term “UHMWPE” refers to for ultra-high molecular weight polyethylene, also known as high-modulus polyethylene (HMPE), or high-performance polyethylene (HPPE).
The term “fiber” as used herein refers to a single origin base material made up of one or more filaments. It has an elongate body, the length dimension of which is much greater than the transverse dimensions of width and thickness.
The term “filament” as used herein refers to a single fibril of material that can be on its own a fiber or can be combined with other filaments to create a multifilament fiber. A single fiber may be formed from just one filament or from multiple filaments. The term “denier” used herein refers to a unit of weight indicating the fineness of fiber
filaments. It can be measured in mass in grams per 9,000 meters of fiber. A lower denier indicates a finer fiber and a higher denier indicates a thicker or heavier fiber.
The term “decitex or “dtex” as used herein refers to an alternate unit of weight indicating the fineness of fiber filaments. It can be measured in mass in grams per 10,000 meters.
The term “tensile strength” as used herein relates to the durability and/or strength of the garment and is measured by the maximum stress that a material can withstand while being stretched or pulled before breaking. It is measured as force per unit area and can be expressed in units of gram force (gf) and centi-newton (cN) per dtex.
The term “elongation” as used herein refers to the stretch of individual fibers and composite fibers which results in the elasticity of the final embodiment of the present disclosure. Elongation is measured as a percentage of the starting length.
The term “natural fiber” as used herein refers to class of fibers obtainable from material of natural sources.
The term “synthetic fiber” as used herein is used to a class of fibers delineated from the natural fibers. Synthetic fibers therefore comprise polymeric material, synthesized by polymerization of monomers, fibers obtained by regeneration of natural fibers, for instance after dissolution in a solvent, and glass fibers.
Term “stretch fiber” as used herein refers to a class of fibers that, upon application of a force, is stretchable to a stretch of at least about 130% of its original dimension without breaking,
The term “pilling” as used herein refers to a surface defect that occurs in hosiery when and individual fiber or filament gets caught and pulls away from the rest of the knit. Pilling is considered unsightly and can render a pair of sheer hosiery unusable.
The term “knit” as used herein refers to the fabric created by combining one or more fibers on a flat or circular knitting machine.
The term “gauge” as used herein refers to the number of needles on a knitting machine. A high gauge knitting machine (e.g. 32 gauge and above) is required to produce sheer hosiery like sheer tights, stockings and trouser socks and a low gauge knitting machine (e.g. 18 to 32 gauge) is used to produce heavier garments like, without limitation, leggings, bodysuits, socks, shirts and other active wear. Gauge is also used to refer to the knit that has been produced by a machine: in other words, a knit made on a 32 gauge machine is a 32 gauge knit.
The term “plating” as used herein refers to a technique of knitting two fibers together in two distinct layers. Where one fiber stays in the back, behind the front fiber despite being knit in the same stitch.
The term “serving” as used herein refers to the process of spinning two fibers together to produce a composite fiber.
“Tensile properties” are properties measured when a material is subjected to stretching forces, and also the properties measured when the stretching forces are removed. Examples of tensile properties include but are not limited to tensile strength at break, percent elongation to break, modulus of elasticity, toughness or tensile energy to break, permanent set, tensile load at specified elongations, etc. Tensile properties of polymer films can be determined by standard test methods such as ASTM D2256/D2256M-21, “Tensile Properties of Yarns by the Single-Strand Method”.
The term “barre” as used herein is defined as unintentional, repetitive visual pattern of continuous bars or stripes usually parallel to the filling of woven fabric or to the courses of circular knit fabric.
The present disclosure provides knits having a specific combination of UHMWPE fiber and stretch fiber which allows using less UHMWPE material.
The knits of the present disclosure have desirable characteristics for hosiery, including softness, hydrophobicity, surface lubricity, abrasion resistance, ripping resistance, improved drape, pilling resistance, and antimicrobial properties, but with a significantly reduced amount of UHMWPE fibers. As a result, the manufacturing cost can be greatly reduced.
In some embodiments, the knit comprises knitted UHMWPE and stretch fibers.
The use of UHMWPE fiber provides benefits to knits such as cooling effect, light weight, moisture wicking, and/or antimicrobial properties. The antimicrobial and moisture wicking properties stem from the UHMWPE being hydrophobic. The desirable tensile properties of the UHMWPE fiber also make the knit resistant to ripping or otherwise wearing out or failing of the knit.
In some embodiments, the knit comprises a single UHMWPE fiber e.g. a single UHMWPE multifilament fiber or a single UHMWPE monofilament fiber. In some other embodiments, the knit comprises a plurality of UHMWPE fibers, optionally comprising UHMWPE monofilament and/or multifilament fibers.
In some embodiments, the UHMWPE fiber has a weight average molecular weight (Mw) of at least about 200,000. In some embodiments, the UHMWPE fiber has a weight average molecular weight (Mw) ranging from about 300,000 to about 7,000, 000, from about 700,000 to about 5,000,000, or from about 900,000 to about 4,000,000. A molecular weight distribution of the UHMWPE fiber, that is the ratio of the weight average molecular weight (Mw) to a number average molecular weight (Mn) of the UHMWPE fiber is of about 5.0 or less, about 4.0 or less, or about 3.0 or less.
In some embodiments, the UHMWPE fiber has a cross-sectional shape substantially resembling a circle. In some embodiments, the UHMWPE fiber has a cross-sectional shape substantially resembling an oval. In some embodiments, the UHMWPE fiber has a cross-sectional shape substantially resembling a stadium. In some embodiments, the UHMWPE fiber has a cross sectional shape substantially resembling an ellipse. In some embodiments, the UHMWPE fiber has a cross-sectional shape which remains substantially constant along the length of the fiber. In instances where the knit comprises a plurality of UHMWPE fibers, the plurality of UHMWPE fibers may have the same or different cross-sectional shapes from each other.
In some embodiments, the UHMWPE fiber is a monofilament fiber. In some other embodiments, the UHMWPE fiber is a multifilament fiber comprising multiple filaments. In some embodiments, each of the filaments in the UHMWPE fiber has a denier of about 5 of less, about 4 or less, about 3 or less, about 2.5 or less, about 2 or less, about 1.5 or less, about 1 or less, about 0.9 or less, about 0.8 or less, about 0.7 or less, about 0.6 or less, or less or about 0.5 or less.
The UHMWPE fiber may include any suitable number of filaments. In some embodiments, the UHMWPE fiber comprises 2 to 400 filaments, 5 to 300 filaments, 20 to 200 filaments, or 2 to 100 filaments. In some embodiments, the UHMWPE fiber comprises 10 to 50 filaments. In some embodiments, the UHMWPE fiber comprises 5 to 50 filaments. In some embodiments, the UHMWPE fiber comprises 5 to 40 filaments. In some embodiments, the UHMWPE fiber comprises 5 to 30 filaments. In some embodiments, the UHMWPE fiber comprises 5 to 25 filaments. In some embodiments, the UHMWPE fiber comprises 10 to 25 filaments. In some embodiments, the UHMWPE fiber comprises 10 to 20 filaments. In some embodiments, the UHMWPE fiber comprises 5, 7, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 25, 30, 35, 40, 45, or 50 filaments. In instances where the knit comprises a plurality of UHMWPE fibers, the plurality of UHMWPE fibers may have the same or different number of filaments from each other.
The UHMWPE fiber may be of any suitable denier. In some embodiments, the UHMWPE fiber has a denier about 500 or less, about 450 or less, about 300 or less, about 200 or less, about 150 or less, or about 50 or less. In some embodiments, the UHMWPE fiber has a denier ranging from about 5 to about 450. In some embodiments, the UHMWPE fiber has a denier ranging from about 5 to about 60. In some embodiments, the UHMWPE fiber has a denier ranging from about 10 to about 50. In some embodiments, the UHMWPE fiber has a denier ranging from about 20 to about 40. In some embodiments, the UHMWPE fiber has a denier ranging from about 25 to about 35. In some embodiments, the UHMWPE fiber has a denier ranging from about 150 to about 450. In some embodiments, the UHMWPE fiber has a denier of about 10, about 15, about 20, about 25, about 30, about 40, about 50, about 60, about 70, about 75, about 80, about 90, about 100, about 110, about 120, about 125, about 130, about 140, about 150, about 175, about 200, about 225, about 250, about 300, about 350, about 400, or about 450. In some embodiments, the UHMWPE fiber has a denier of 50 or less. In some embodiments, the UHMWPE fiber has a denier of 40 or less. In some embodiments, the UHMWPE fiber has a denier of 30 or less. In some embodiments, the UHMWPE fiber has a denier of about 30. In instances where the knit comprises a plurality of UHMWPE fibers, the plurality of UHMWPE fibers may have the same or different deniers from each other.
In some embodiments, the UHMWPE fiber has a variation of the denier along the length of said UHMWPE fiber. In some embodiments, a variation of the denier along the length of said UHMWPE fiber is less than ±2.5%, less than ±3%, less than ±3.5%, less than ±4%, less than ±5%, less than ±6%, less than ±7%, less than ±8%, or less than ±9%, or less than ±10%. In some embodiments, the UHMWPE fiber has a variation of the diameter along the length of said UHMWPE fiber is less than ±2.5%, less than ±3%, less than ±3.5%, less than ±4%, less than ±5%, less than ±6%, less than ±7%, less than ±8%, or less than ±9%, or less than ±10%. In instances where the knit comprises a plurality of UHMWPE fibers, the plurality of UHMWPE fibers may have the same or different variations of deniers from each other. In some embodiments, a variation of the denier among the plurality of UHMWPE fibers is from less than ±2.5% to less than ±10%. In some embodiments, a variation of the denier among the plurality of UHMWPE fibers is less than ±2.5%, less than ±3%, less than ±3.5%, less than ±4%, less than ±5%, less than ±6%, less than ±7%, less than ±8%, or less than ±9%, or less than ±10%.
In some embodiments, the UHMWPE fiber has a tensile strength (i.e., tenacity) of at least about 20 cN/dex, at least about 25 cN/dex, at least about 30 cN/dtex, at least about 35 cN/dtex, at least about 40 cN/dtex, at least about 45 cN/dtex, at least about 50 cN/dtex, or at least about 60 cN/dtex. In some embodiments, the UHMWPE fiber has a tensile strength of about 26 cN/dex, about 28 cN/dex, about 30 cN/dex, about 32 cN/dex, about 38 cN/dex, about 40 cN/dex, about 45 cN/dex, or about 50 cN/dex. In instances where the knit comprises a plurality of UHMWPE fibers, the plurality of UHMWPE fibers may have the same or different tensile strengths from each other. In some embodiments, a variation of the tensile strength among the plurality of UHMWPE fibers is from less than ±2.5% to less than ±10%. In some embodiments, a variation of the tensile strength among the plurality of UHMWPE fibers is less than ±2.5%, less than ±3%, less than ±3.5%, less than ±4%, less than ±5%, less than ±6%, less than ±7%, less than ±8%, or less than ±9%, or less than ±10%.
In some embodiments, the UHMWPE fiber has a modulus of about 1000 cN/dtex or greater, about 1100 cN/dtex or greater, about 1200 cN/dtex or greater, about 1300 cN/dtex or greater, about 1400 cN/dtex or greater, about 1500 cN/dtex or greater, or about 1600 cN/dtex or greater. In some embodiments, the UHMWPE fiber has a modulus of about 1400 cN/dtex, about 1420 cN/dtex, about 1450 cN/dtex, about 1500 cN/dtex, or about 1360 cN/dtex. In instances where the knit comprises a plurality of UHMWPE fibers, the plurality of UHMWPE fibers may have the same or different moduli from each other. In some embodiments, a variation of the modulus among the plurality of UHMWPE fibers is from less than ±2.5% to less than ±10%. In some embodiments, a variation of the modulus among the plurality of UHMWPE fibers is less than ±2.5%, less than ±3%, less than ±3.5%, less than ±4%, less than ±5%, less than ±6%, less than ±7%, less than ±8%, or less than ±9%, or less than ±10%.
In some embodiments, the UHMWPE fiber allows an elongation of no more than about 10%, no more than about 8%, no more than about 5%, no more than about 4%, no more than about 3.5%, no more than about 3%, no more than about 2.5%, no more than about 2%, or no more than about 1.5%. In instances where the knit comprises a plurality of UHMWPE fibers, the plurality of UHMWPE fibers may have the same or different elongations from each other. In some embodiments, a variation of the elongation among the plurality of UHMWPE fibers is from less than ±2.5% to less than ±10%. In some embodiments, a variation of the elongation among the plurality of UHMWPE fibers is less than ±2.5%, less than ±3%, less than ±3.5%, less than ±4%, less than ±5%, less than ±6%, less than ±7%, less than ±8%, or less than ±9%, or less than ±10%.
In some embodiments, the UHMWPE fiber has a breaking force of about 10 N or greater, about 11 N or greater, about 12 N or greater, about 13 N or greater, about 14 N or greater, about 15 N or greater, about 16 N or greater, about 18N or greater, or about 20 N or greater. In instances where the knit comprises a plurality of UHMWPE fibers, the plurality of UHMWPE fibers may have the same or different breaking forces from each other. In some embodiments, a variation of the breaking force among the plurality of UHMWPE fibers is from less than ±2.5% to less than ±10%. In some embodiments, a variation of the breaking force among the plurality of UHMWPE fibers is less than ±2.5%, less than ±3%, less than ±3.5%, less than ±4%, less than ±5%, less than ±6%, less than ±7%, less than ±8%, or less than ±9%, or less than ±10%.
In some embodiments, the UHMWPE fiber has a breaking work of at least about 100 N·mm, at least about 110 N·mm, at least about 120 N·mm, at least about 130 N·mm, at least about 140 N·mm, at least about 150 N·mm, at least about 160 N·mm, or at least about 170 N·mm. In instances where the knit comprises a plurality of UHMWPE fibers, the plurality of UHMWPE fibers may have the same or different breaking work from each other. In some embodiments, a variation of the breaking work among the plurality of UHMWPE fibers is from less than ±2.5% to less than ±10%. In some embodiments, a variation of the breaking work among the plurality of UHMWPE fibers is less than ±2.5%, less than ±3%, less than ±3.5%, less than ±4%, less than ±5%, less than ±6%, less than ±7%, less than ±8%, or less than ±9%, or less than ±10%.
In some embodiments, the UHMWPE fiber is a colored UHMWPE fiber comprising a dye. In some embodiments, the dye has a color selected from black, blue, grey, red, blue, brown, yellow, green, orange, and nude. In instances where the knit comprises a plurality of UHMWPE fibers, the plurality of UHMWPE fibers may have the same or different colors from each other.
In some embodiments, the UHMWPE fiber comprises multiple filaments which are not twisted. In some other embodiments, to keep the filaments together and to increase strength and reduce pilling, the UHMWPE fiber is twisted. To maintain the strength, it is desirable that the twists per inch (TPI) not be too high. In some embodiments, the UHMWPE fiber has a TPI between 1 and 30, between 1 and 25, between 1 and 15, between 1 and 10, between 1 and 8, between 4 and 25, between 6 and 20, or between 8 and 16. In some embodiments, the UHMWPE fiber has a TPI of 1. In some embodiments, the UHMWPE fiber has a TPI of 2. In some embodiments, the UHMWPE fiber has a TPI of 3. In some embodiments, the UHMWPE fiber has a TPI of 4. In some embodiments, the UHMWPE fiber has a TPI of 5. In some embodiments, the UHMWPE fiber has a TPI of 6. In some embodiments, the UHMWPE fiber has a TPI of 7. In some embodiments, the UHMWPE fiber has a TPI of 8. In some embodiments, the UHMWPE fiber has a TPI of 9. In some embodiments, the UHMWPE fiber has a TPI of 10. In some embodiments, the UHMWPE fiber has a TPI of 12. In some embodiments, the UHMWPE fiber has a TPI of 15. In some embodiments, the UHMWPE fiber has a TPI of 16. In some embodiments, the UHMWPE fiber has a TPI of 18. In some embodiments, the UHMWPE fiber has a TPI of 20. In some embodiments, the UHMWPE fiber has a TPI of 25. In some embodiments, the UHMWPE fiber has a TPI of 30. In instances where the knit comprises a plurality of UHMWPE fibers, the plurality of UHMWPE fibers may have the same or different TPIs from each other.
The amount of the UHMWPE fiber in the knit may be in the range of from about 5% by weight to about 90% by weight based on the total amount of fibers in the knit. In some embodiments, the amount of the UHMWPE fiber in the knit ranges from about 5% by weight to about 80% by weight, from about 10% by weight to about 80% by weight, from about 10% by weight to about 60% by weight, from about 10% by weight to about 40% by weight, from about 10% by weight to about 30% by weight, from about 15% by weight to about 40% by weight, from about 15% by weight to about 35% by weight, from about 15% by weight to about 30% by weight, from about 15% by weight to about 80% by weight, from about 20% by weight to about 80% by weight, from about 30% by weight by weight to about 70% by weight or from about 40% by weight to about 60% by weight. A higher UHMWPE fiber content means a more durable end product with greater antimicrobial properties.
The stretch fiber is selected to enhance the stretchability of the knit. In some embodiments, the knit comprises a single stretch fiber. In some other embodiments, the knit comprises a plurality of stretch fibers. Examples of stretch fibers include those made of nylon, polyamide, polyurethane, polyolefin such as low molecular weight polyethylene or polypropylene, polyester, Spandex/Lycra (a polyether-polyurea copolymer) and the like.
In some embodiments, the stretch fiber is a composite fiber formed by covering a first fiber with a second fiber. In some embodiments, the stretch fiber is formed by covering a Lycra fiber, for example a monofilament Lycra fiber, with a nylon fiber, for example a multifilament nylon fiber (i.e. nylon-covered Lycra). The nylon fiber may include any suitable number of filaments. In some embodiments, the filaments in the nylon fiber may range from about 2 to about 400, about 10 to about 300, or about 20 to about 200. In some embodiments, the nylon fiber includes about 10 to about 50 filaments, about 5 to about 50 filaments, or about 5 to about 25 filaments. In some embodiments, the nylon fiber includes 10, 13, 20, 25, 30, 34, 36, 40, 45, 60, 68, or 70 filaments. In some embodiments, the filaments in the nylon fiber are twisted with a TPI ranging from 2 to 25. In some embodiments, the first fiber and the second fiber are twisted with a TPI ranging from 2 to 25.
The stretch fiber may include any suitable number of filaments. In some embodiments, the stretch fiber comprises about 2 to about 400 filaments, about 10 to about 300 filaments, about 10 to about 200 filaments, about 10 to about 150 filaments, about 10 to about 100 filaments, about 10 to about 50 filaments, about 5 to about 50 filaments, or about 20 to about 200 filaments.
The stretch fiber may be of any suitable denier. In some embodiments, the stretch fiber has a denier ranging from about 2 to about 1000, from about 10 to about 1000, from about 20 to about 1000. In some embodiments, the stretch fiber has a denier ranging from about 2 to about 100, from about 5 to about 100, from about 10 to about 100, or from about 15 to about 100. In some embodiments, the stretch fiber has a denier of about 5, about 10, about 13, about 15, about 17, about 20, about 25, about 30, about 50, about 40, about 60, about 70, about 130, about 150, about 390, about 450, or about 900. In instances where the knit comprises a plurality of stretch fibers, the plurality of stretch fibers may have the same or different deniers from each other.
In some embodiments, the stretch fiber allows an elongation of greater than 100%. In some embodiments, the stretch fiber has an elongation of about 130% or greater, about 200% or greater, about 300% or greater, or about 400% or greater. In instances where the knit comprises a plurality of stretch fibers, the plurality of stretch fibers may have the same or different elongations from each other.
In some embodiments, the stretch fiber is a colored fiber comprising a dye. In some embodiments, the stretch fiber has black, blue, grey, red, blue, brown, yellow, green, orange, or nude color. In some embodiments, the stretch fiber is white. In some embodiments, the stretch fiber is nude. In some embodiments, the stretch fiber is black. In some embodiments, the stretch fiber is the same color as the UHMWPE fiber. In some embodiments, the stretch fiber is a composite fiber formed by covering a first fiber with a second colored fiber (e.g. clear Lycra covered with colored nylon). In some other embodiments, the stretch fiber has a different color from the UHMWPE fiber.
In some embodiments, the knit has a high dimensional stability. In some embodiments, the dimension dimensional stability of the knit in each of a length direction and a width direction is of about ±6%, about ±4%, about ±2%, about ±1%, or about ±0.5%. As used herein, “dimensional stability” refers to a knit or fabric's ability to withstand change in dimension being subjected to wear and domestic laundering, as measured using for example standard test methods such as AATCC Test Method 150, Dimensional Change of Fabrics After Home Laundering Scope.
In some embodiments, the knit is substantially hydrophobic. In some embodiments, the knit has a contact angle with water ranging from about 45 degrees to about 135 degrees, when measured in air. In some embodiments, the contact angle of the knit with water is greater than about 45 degrees, greater than about 50 degrees, greater than about 60 degrees, greater than about 80 degrees, greater than about 90 degrees, greater than about 100 degrees, greater than about 110 degrees, greater than about 120 degrees, greater than about 125 degrees, or greater than about 130 degrees, when measured in air. In some embodiments, the contact angle of the knit with water is about 90 degrees to about 130 degrees, when measured in air. In some embodiments, the contact angle of the knit with water is about 100 degrees to about 130 degrees, when measured in air. In some embodiments, the contact angle of the knit with water is about 110 degrees to about 130 degrees, when measured in air. In some embodiments, the contact angle of the knit with water is about 120 degrees, when measured in air.
In some embodiments, the knit is biologically inert, and thus does not stimulate undesired growth nor is sensitive to any attack by micro-organisms. In some embodiments, the knit decreases undesired growth or is less sensitive to attack by micro-organisms. In some embodiments, the knit provides an antimicrobial reduction in the range of about 25% to about 100% comparing to a knit comprised of cotton. In some embodiments, the knit provides an antimicrobial reduction in the range of about 25% to about 75% comparing to the knit comprised of cotton. In some embodiments, the knit provides an antimicrobial reduction in the range of about 25% to about 50% comparing to the knit comprised of cotton. In some embodiments, the knit provides at least 50% of antimicrobial reduction comparing to the knit comprised of cotton.
In some embodiments, the knit has a good odor resistance and does not substantially absorb smell or body odor.
In some embodiments, the knit has a denier of about 300 or less, about 250 or less, about 200 or less, 150 or less, 100 or less, about 80 or less, about 60 or less, or about 30 or less. In some embodiments, the knit has a denier of about 20 to about 120. In some embodiments, the knit has a denier of about 30 to about 110. In some embodiments, the knit has a denier of about 40 to about 100. In some embodiments, the knit has a denier of about 20 to about 100. In some embodiments, the knit has a denier of about 20 to about 80. In some embodiments, the knit has a denier of about 20 to about 60. In some embodiments, the knit has a denier of about 20 to about 45. In some embodiments, the knit has a denier of about 45.
In some embodiments, the knit includes a UHMWPE fiber and a nylon covered Lycra fiber as the stretch fiber. Both the UHMWPE fiber and the stretch fiber may be textured or flat. In some embodiments, the nylon has a denier ranging from 1 to 20. In some embodiments, the nylon has a denier ranging from 5 to 20. In some embodiments, the nylon is a multifilament fiber including 5 to 16 filaments. In some embodiments, the stretch fiber is a nylon covered Lycra fiber formed by covering a monofilament Lycra fiber having a denier ranging from 10 to 40, for example a denier of 17, with a nylon fiber containing 5 to 20 filaments and having a denier ranging from 1 to 20. In some embodiments, the spandex fiber is a monofilament fiber having a denier of 40 and the nylon fiber is a multifilament fiber containing 7 filaments and having a denier of 20. In some embodiments, the resulting knit has a denier ranging from 15 to 60. In some embodiments, the resulting knit has a denier of about 20 to 100. In some embodiments, the resulting knit has a denier of about 30 to 90. In some embodiments, the resulting knit has a denier of about 20 to 80. In some embodiments, the resulting knit has a denier of about 20 to 60. In some embodiments, the resulting knit has a denier of about 30 to 50. In some embodiments, the resulting knit has a denier of about 40. In some embodiments, the resulting knit has a denier of about 45.
In some embodiments, the knit is produced using a UHMWPE fiber and a nylon fiber. For example, the nylon fiber is a multifilament fiber containing 40 filaments and having a denier of 40.
In some embodiments, the entire knit once produced can be dyed. For example, the knit is dyed by contacting the knit with a dyeing medium comprising a supercritical liquid and a dye. This allows achieving uniform color for all the components in the knit. In some other embodiments, the dying of the knit is performed using acid or disperse dye process.
In some embodiments, the UHMWPE and stretch fibers are knitted using a two (2) feed knitting program that does not require looping the UHMWPE fiber in every feed, thereby allowing forming knits of the present disclosure with less amount of UHMWPE fibers than traditional knits.
With reference to
The first and third fibers 802, 806 are UHMWPE fibers, which may be colored UHMWPE fibers, e.g. black UHMPWE fibers. In some embodiments, the first and third fibers 802, 806 may be portions of a single, continuous UHMWPE fiber. In other words, the first fiber 802 may be a first portion of a single, continuous UHMWPE fiber and the third fiber 806 may be a second portion of the single, continuous UHMWPE fiber. The first and third fibers 802, 806 may be referred to as fiber portions of the single, continuous UHMWPE fiber.
The second and fourth fibers 804, 808 are stretch fibers such as nylon covered spandex for providing stretch to the knit 800. In some embodiments, the second and fourth fibers 804, 808 are a polyester-polyurethane material. For example, the second and fourth fibers 804, 808 are synthetic fibers such as Lycra (Spandex) fibers, polyurethane fibers, polyester fibers, nylon fibers, nylon covered Lycra fibers, or some other type of synthetic fibers. In some embodiments, the second and fourth fibers 804, 808 may be a single, continuous stretch fiber. The second fiber 804 may be a first portion of a single, continuous stretch fiber and the fourth fiber 808 may be a second portion of the single, continuous stretch fiber. The second and fourth fibers 804, 808 may be referred to as fiber portions of the single, continuous stretch fiber.
When the first and third fibers 802, 806 are a single, continuous UHMWPE fiber and the second and fourth fibers are a single, continuous stretch fiber, the knit 800 may include a construction including at least one UHMWPE fiber and at least one stretch fiber. In some embodiments, the knit 800 includes one UHMWPE fiber and one stretch fiber. The knit 800 may be created by using more than one UHMWPE fiber and/or more than one stretch fiber. For example, the knit 800 may be created by using two or more UHMWPE fibers and two or more stretch fibers.
The first, second, third, and fourth fibers 802, 804, 806, 808, respectively, are knitted to form the knit 800. For example, the first, second, third, and fourth fibers 802, 804, 806, 808 may be knitted together utilizing a weaving or knitting machine such as a fabric loom to interknit the first, second, third, and fourth fibers 802, 804, 806, 808 as shown in
For example, when the knit 800 is formed utilizing a 2-feed machine, a first feed of the feed machine may run at least one UHMWPE fiber, which is utilized to knit the first fiber 802 and the third fiber 806 of the knit 800 as shown in
Still referring to
Based on the orientation as shown in
The 3×1 tuck pattern, or knitting of the first and third fibers 802, 806 includes each of the first and third fibers 802, 806, respectively, having three knit loops successively followed by one tuck loop when moving along the
The first fiber 802 includes tuck loops 810 and knit loops 812a, 812b as shown in
The third fiber 806 includes tuck loops 814 and knit loops 816a, 816b as shown in
The tuck loops 810 of the first fiber 802 and the knit loops 820b of the second fiber 804 form respective tuck stitches of the knit 800. The respective tuck stitches formed by the tuck loop 810 and the knit loop 820b may hold a previous knit loop of a respective stretch fiber.
The tuck loops 814 of the third fiber 806 and the knit loops 824b of the fourth fiber 808 form respective tuck stitches of the knit 800. The respective tuck stitches formed by the tuck loops 814 and the knit loops 824b may hold the knit loops 820b of the second fiber 804.
The tuck loops 818 of the second fiber 804 and the knit loops 816b of the third fiber 808 form respective tuck stitches of the knit 800. The respective tuck stitches formed by the tuck loops 818 and the knit loops 816b may hold the knit loops 812b of the first fiber 802.
The tuck loops 822 of the fourth fiber 808 and knit loops 826 of the fifth fiber 828 form respective tuck stitches of the knit 800. The respective tuck stitches formed by the tuck loops 822 and the knit loops 826 may hold the knit loops 816b of the third fiber 806. The second and fourth fibers 804, 808, respectively, have a 1×1 tuck pattern. The 1×1 tuck pattern of the second and fourth fibers 804, 808 includes each of the second and fourth fibers 804, 808 having one tuck loop followed by one knit loop and so on, such that the tuck loops and the knit loops switch back and forth one by one along the second and fourth fibers 804, 808. Each of the tuck loops of the second fiber 804 is adjacent to two knit loops of the second fiber 804 and each of the tuck loops of the fourth fiber 808 is adjacent to two knit loops of the fourth fiber 808. The 1×1 tuck pattern of the second and fourth fibers 804, 808, respectively, is to provide support to the 3×1 tuck pattern, as the 3×1 tuck pattern is less strong than the 1×1 tuck pattern. In other words, the 3×1 tuck pattern of the first and third fibers 802, 806 reduces the amount of material needed to form the knit 800 while the 1×1 tuck pattern provides the knit 800 with enough robustness and tensile strength to reduce the likelihood of ripping and tearing (e.g., shear tearing or ripping). This results in a balance between the cost of manufacturing the knit 800, while maintaining the robustness and tensile strength of the knit 800.
The second fiber 804 includes tuck loops 818 and knit loops 820a, 820b as shown in
The fourth fiber 808 includes tuck loops 822 and knit loops 824a, 824b as shown in
Each one of the tuck loops 810 of the first fiber 802 overlap with a corresponding one of the second knit loops 820b of the second fiber 804. The tuck loops 810 of the first fiber 802 may physically contact the second knit loops 820b of the second fiber 804 such that the tuck loops 810 are at least partially positioned between the second fiber and a respective fiber (not shown) of which the tuck loops 810 and the second knit loops 820b wrap around. The respective fiber would be above the first fiber 802 based on the orientation as shown in
Each one of the tuck loops 814 of the third fiber 806 overlap with a corresponding one of the second knit loops 824b of the fourth fiber 808. The tuck loops 814 of the third fiber 806 may physically contact the second knit loops 824b of the fourth fiber 808 such that the tuck loops 814 are at least partially positioned between the fourth fiber 808 and the second fiber 804. The tuck loops 814 and the second knit loops 824b wrap around the second fiber 804.
Each one of the tuck loops 818 of the second fiber 804 overlap with a corresponding one of the second knit loops 816b of the third fiber 806. The tuck loops 818 of the second fiber 804 may physically contact the second knit loops 816b of the third fiber 806 such that the tuck loops 818 are at least partially positioned between the third fiber 806 and first fiber 802. The tuck loops 818 and the second knit loops 816b wrap around the first fiber 802.
Each one of the tuck loops 822 of the fourth fiber 808 overlap with a corresponding one of knit loops 826 of a fifth fiber 828, which are represented by dotted lines at the bottom of
The first knit loops 812a of the first fiber 802 wrap around respective fibers (not shown) that would be above the first fiber 802 based on the orientation as shown in
The knit 800 includes knit loop regions 830 in which the first knit loops 812a, 820a, 816a, 824a of the first, second, third, and fourth fibers 802, 804, 806, 808 extend along an axis passing through each one of the first knit loops 812a, 820a, 816a, 824a. Based on the orientation as shown in
Each one of the knit loop regions 830 is adjacent to two of the tuck loop regions 832 such that each of the knit loop regions 830 is separated from other ones of the knit loop regions 830 by the tuck loop regions 832. Each one of the tuck loop regions 832 is adjacent to two of the knit loop regions 830 such that each of the tuck loop regions 832 is separated from other ones of the tuck loop regions 832 by the knit loop regions 830.
While the embodiment as shown in
For example, when the first and third fibers 802, 806 have a 5×1 tuck pattern, each one of the knit loop regions 830 will be spaced apart from each other by five tuck loop regions 832. Similarly, when the first and third fibers 802, 806 have a 7×1 tuck pattern each one of the knit loop regions 830 will be spaced apart from each other by seven tuck loop regions 832.
As the tuck pattern of the first and third fibers 802, 806 is increased the tensile strength of the knit 800 reduces. For example, the knit 800 with the first and third fibers 802, 806 having the tuck pattern of 3×1 will be stronger than a knit in which the first and third fibers 802, 806 having a tuck pattern of 5×1, 7×1, 9×1, and so forth.
While
Knitting together the first, second, third, and fourth fibers 802, 804, 806, 808, respectively, provide ample tensile strength and robustness against tearing of the knit 800 when utilized in clothing such as pantyhose or other like types of undergarments or clothing. Knitting together the first, second, third, and fourth fibers 802, 804, 806, 808, respectively, also reduces the amount of UHMWPE utilized to form the knit 800 as compared to a knit that only includes knit loops the same or similar to the knit loops 812a, 812b, 816a, 816b, 820a, 820b, 824a, 824b as discussed with respect to
The knit as shown in
The speed at which the knit 800 as shown in
The reduced amount of UHMWPE material to form the knit 800 advantageously reduces the cost of manufacturing the knit 800 relative to the traditional knit made with UHMWPE in every feed as shown in
In an embodiment, when the knit 800 is used for sheer hosiery or similar garments (e.g., hosiery garments), the knit 800 can be prepared using a mono or multifilament UHMWPE fiber of 30 denier or below, and a stretch fiber exhibiting elongation above 30% in deniers between 5 and 100, knit together on a 32 gauge or higher knitting machine. In another embodiment, for non-sheer applications, like semi-opaque to opaque hosiery and activewear, the knit 800 can be prepared using a mono or multifilament UHMWPE and a stretch fiber exhibiting elongation above 30%, the combined denier of the knit being between 30 and 220 denier, knit together on 18 gauge or higher knitting machine.
In view of the above discussions, the costs may be reduced by reducing the amount of UHMWPE as a 0.5-kilogram (kg) bobbin of UHMWPE may cost around $250.00 US, whereas, by comparison, a 2.5-kilogram (kg) bobbin of 20 denier single covered/40 denier nylon (20/40/34) fibers costs approximately $69.00 US. By reducing the amount of UHMWPE to produce the knit 800 while at the same time using less expensive 20/40/34 fiber, the tensile strength of the knit is maintained while keeping costs relatively low as compared to utilizing more UHMWPE.
In view of the above discussions, if UHMWPE fibers are of lower quality than expected to be utilized in the formation of the knit 800, which may be used to form hosiery garments, the lower grade UHMWPE fibers may not be able to be utilized to form the knit. However, the 2-feed knitting technique of the present disclosure allows for the hiding of barre or irregularities if these subpar quality UHMWPE fibers are utilized to produce the knit 800. As a result, hosiery with attractive appearance can be produced with subpar UHMWPE fibers. By reducing the amount of the UHMWPE fibers, the likelihood of forming hosiery garments of insufficient quality such that the hosiery garments become waste may be reduced. By reducing this waste, the overall impact on the environment may be reduced as well. Reducing the amount of UHMWPE fibers may also reduce the likelihood of yarn ring issues. These yarn ring issues may be similar to the “barre” lines.
The knit 800 may have an aesthetically pleasing look while also being resistant to sheer tearing and ripping, being durable, and being comfortable for an individual to wear. For example, knits may have one of the patterns as shown in
The knits of the present disclosure may be produced by plating or serving.
The knits of the present disclosure can be produced by knitting the UHMWPE fiber and the stretch fiber using a knitting machine. The appropriate gauge of the knitting machine is selected according to the end use of the knit, particularly when used in sheer or semi-sheer hosiery that includes pantyhose, leggings, stockings, and socks. The gauge number of the knitting machine can affect the stretchability and basis weight of the resulting knit. The knit may for example have a gauge ranging from 10 to 40. In some embodiments, the knit has a gauge ranging from 10 to 15 suitable for producing a knit for socks. In some other embodiments, the knit has a gauge ranging from 28 to 32 suitable for producing a knit for pantyhose or sheer hosiery. In some embodiments, the knit may have a gauge of at least 32.
In some embodiments, a knitting machine of a single knit type is used. The cylinder size of the knitting machine is selected according to the end use of the knit. In some embodiments, the knitting machine has a cylinder having a size from about 3 inches to about 7 inches suitable for producing knit for making pantyhose. In some embodiments, the knitting machine has a cylinder having a size from about 5 inches to about 14 inches suitable for producing a knit for socks. In some embodiments, the knitting machine has a cylinder having a size from about 10 inches to about 14 inches suitable for producing a knit for hosiery. In some embodiments, the knitting machine has a cylinder having a size from about 10 inches to about 22 inches suitable for producing leggings. In some embodiments, no cylinder is used.
In knitting the fabric of the present disclosure, one can use a conventional knitting machine as a base. The knitting machine can have any desired number of feeds, depending on the number needed to cover the number of fiber types being knitted and the speed at which the knitting will occur. Typically knitting machines have 2, 4, or 8 feeds, with the most common being 4 or 8 feeds. In some embodiments, knitting machines can be used with more than 8 feeds. In some embodiments, knitting machines can be used with more than 16 feeds. In one embodiment of the present disclosure, the garment is made using a four-feed hosiery knitting machine. In knitting the hosiery of the present disclosure, each feed can use fibers having deniers ranging from 10 to 50 denier. The total denier of the fibers making up the hosiery can be any desired, depending on the weight of hosiery to be produced and the level of sheer desired. In some embodiments, all of the feeds are used. In some embodiments, 5 feeds are used. In some embodiments, the same UHMWPE fibers with the same properties and the same variations in properties are used on all feeds looping UHMWPE fibers. In some embodiments, the same UHMWPE fibers with the same properties and different variations in properties are used on all feeds looping UHMWPE fibers. In some embodiments different UHMWPE fibers with different properties and different variations in properties are used on all feeds looping UHMWPE fibers. In some embodiments different UHMWPE fibers with different properties and the same variations in properties are used on all feeds looping UHMWPE fibers.
In some embodiments, the knitting machine can be fitted with tensioners to maintain constant tension on each of the fiber feeds. In some embodiments, the tension is constant along the length of the individual fiber feed. In some embodiments, the tension along the length of each of the individual fiber feeds is constant. In some embodiments, the variation in the tension along the length of the UHMWPE fiber feed is less than ±2.5%, less than ±3%, less than ±3.5%, less than ±4%, less than ±5%, less than ±6%, less than ±7%, less than ±8%, or less than ±9%, or less than ±10%. In some embodiments, the variation in the tension between the different UHMWPE fiber feeds is less than ±2.5%, less than ±3%, less than ±3.5%, less than ±4%, less than ±5%, less than ±6%, less than ±7%, less than ±8%, or less than ±9%, or less than ±10%.
The present disclosure further provides articles of clothing made from the knit described above. The articles of clothing include socks, pantyhose, leggings, tights, stocks, and the like. In some embodiments, the article of clothing does not substantially exhibit any barre. In some embodiments, the article of clothing exhibits barre less than 5%, less than 10%, less than 20%, or less than 30%. The reduction in barre is due to the fiber properties, knitting process conditions and variations in processing performed on the UHMWPE fibers described above.
Due to the hydrophobic nature of the knit, the article of clothing is substantially hydrophobic with a contact angle with water greater than 90 degrees when measured in air. The article of clothing can result in an antimicrobial reduction of at least 50% below the same article of clothing comprised of cotton. The article of clothing can also reduce the naturally occurring body odors of a person wearing the article of clothing.
While the pantyhose 900 are shown as including the knit 800, it will be readily appreciated that the knit 800 may be utilized to manufacture other types of hosiery garments, underwear, or other like clothing or garments. For example, the knit 800 may be utilized in manufacturing full body hosiery.
A knit having a fine rib pattern as shown in
A knit having a fine mesh pattern as shown in
A knit having a fine herringbone pattern as shown in
A traditional knit having UHMWPE fibers looped in every feed is produced as a comparison. The knit is used to make the leg portion of sheer tights, as shown in FIG. 3. The knit is formed by knitting a 30 denier UHMWPE black fiber and a 17 denier lycra core yarn covered with a single nylon yarn of 13 denier composed of 10 filaments (17sc13/10 s). Table 4 shows consumption of various fibers in the Sheer tights. As shown in Table 4, the consumption of the UHMWPE fiber in a pair of size small sheer tights is about 29.60%, and the consumption of the UHMWPE fiber in a pair of size large sheer tights is about 29.87%, both of which are higher than the consumption of the UHMWPE fibers in the pairs of tights formed by knits of the present disclosure, for example as described in Examples 1, 2 and 3. The two-feed knitting technique of the present application may thus decrease the usage amount of the UHMWPE fibers in the tights, which leads to decrease in production costs.
The foregoing outlines features of several embodiments so that those skilled in the art may better understand the aspects of the present disclosure. Those skilled in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that they may make various changes, substitutions, and alterations herein without departing from the spirit and scope of the present disclosure.
This application claims the benefit of U.S. provisional application Ser. No. 63/240,349, filed Sep. 2, 2021, which is incorporated herein by reference in its entirety.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2022/042383 | 9/1/2022 | WO |
| Number | Date | Country | |
|---|---|---|---|
| 63240349 | Sep 2021 | US |
