Field of invention

The present invention relates to a knitted fabric band attached or attachable to a fabric garment and in particular, although not exclusively, to a waist or torso band having different axial zones with different tension extending in the circumferential direction.

Background

Intimate or body-hugging apparel such as shapewear, leggings, sports bras etc., tend to move or not maintain close contact with regions of the body when worn. In particular, garment gaping at the centre of the lower back can be observed as a wearer adopts a squat position. Accordingly, it is conventional to provide an elastic, tensioned band at an end region of the garment to try and maintain a close fitting or body hugging configuration. Preventing apparel movement and gaping at specific regions becomes more important for extended wear periods and/or during times of high activity such as when exercising. Various attempts have been made to try and address these problem. US 2019/0297976 discloses a waist band for clothing that incudes additional adhesive, mesh and inner fabric layers to enhance elastic stretch of the waist band. The band also includes a draw string mounted within a circumferentially extending seam. WO 2007/025701 describes a shaped waist band for an item of clothing having a circumferentially extending seam incorporating an additional elastic tape having a length to approximately match a waist of a wearer.

However, existing attempts to address the problem of garment movement and gaping tend to be either uncomfortable, in that high constriction elastic cords press into the waist or are ineffective particularly during periods of high activity or when a wear adopts a particular position. Accordingly, what is required is a garment band that addresses the above problems.

Summary of the Invention

It is one objective of the present invention to provide a band attachable to a garment configured specifically to maintain close body contact with a wearer at all regions of the garment. It is a specific objective to provide a band attachable to a garment that is not susceptible to gaping when a wearer adopts one or more particular positions. For example where the band is attached to leggings, the band is adapted to avoid gaping at the lower back region during a squatting position.

It is a further specific objective to provide a fabric band for a fabric garment having a seamless construction in both the circumferential and axial directions. It is a further specific objective to provide a band that provides a uniform tension at the various positions in the axial direction, from the region of attachment to a garment to the open end of the waistband.

It is a further specific objective to provide a knitted fabric band for a fabric garment that is devoid of additional/ supplementary high tension and/or elastic cord, strip, yarn or tape that would otherwise be uncomfortable to a wearer. The objectives are achieved via a knitted fabric band attached or attachable to a fabric garment having a plurality of knitted tubular axial zones that differ via their structure and/or thread composition. Such a configuration provides a strap for a torso or waist of a wearer with circumferentially extending axial zones that differ in their respective modulus or alternatively expressed as a resistance to elongation in the circumferential direction. The present graduated strap (for a torso or waist) has different tubular zones each with a respective "tightness Such a configuration is configured to maintain the close touching contact between the strap and the body and specifically to avoid the strap moving in a direction away from the body which is associated with gaping.

In particular, a first tubular zone, positioned immediately adjacent an end region of a garment, may be comprise a first tightness, tension and/or modulus in the circumferential direction) to provide a first amount of resistance to elongation and close contact with the body at the torso or waist. Additionally, a second tubular zone, extending from or coupled to the first tubular zone (and positioned furthest from the garment) has a second circumferential tension configured to provide greater resistance to elongation relative to the first zone to retain the strap against the body and specifically avoid gaping. Accordingly, the present fabric band via the multiple axial zones is adapted to provide a tapered waist band configuration. Due to the different levels of tension in the circumferential direction (via the first, second or optionally third axial zones), the present band is adapted to taper radially inwardly in a direction away from the garment and towards an open axial end of the band when the band is not being worn. The tapered configuration may be incorporated within the strap during manufacture and may result from the different respective circumferential lengths of the different axial zones where the first axial zone comprises a greater circumferential length than the second zone and optionally a third zone having circumferential length that of the first and second zones.

According to a first aspect of the present invention there is provided a knitted fabric band attachable to a fabric garment comprising: a first knitted tubular zone having a circumferentially extending attachment end attachable to the garment and a circumferentially extending transition end; a second knitted tubular zone having a circumferentially extending open end and a circumferentially extending transition end joined to the transition end of the first knitted tubular zone; the first and second tubular zones being seamless in circumferential direction and the fabric band being seamless in the axial direction across the joined transition ends of the first and second tubular zones; and wherein a structure and/or thread composition of the first and second tubular zones is different such that a circumferential length of the open axial end is less than that of the attachment and the transition ends.

Reference within the specification to an ‘ attachment end’ refers to an axial end of the tubular zone that is attached or attachable to a circumferential extending end region of the garment. Additionally, reference within the specification to a ‘transition end’ of the different tubular zones, encompasses a circumferential extending end that is coupled, joined or is positioned adjacent to an axially neighbouring tubular zone.

Additionally, reference within the specification to the fabric band and/or tubular zones being ‘seamless’ in the axial and circumferential directions encompasses configurations in which the knit structure is continuous via the looped construction having rows (courses) and wales that are seamlessly continuous or uninterrupted in their respective circumferential and axial directions (relative to waist or torso of a wearer).

Preferably, the first and second tubular zones are formed integrally as a unitary body. The unitary configuration provides a seamless construction in the axial direction such that the present band (in the axial direction) does not comprise a seam that may be formed as a rib, ridge or other projection either radially inward or radially outward that would otherwise affect the comfort of a wearer of the fabric band. The unitary construction is provided via the present knit structure.

Optionally, a stitch type and/or thread is the same at both the first and second tubular zones. In particular, the stitch type may be a rib knit structure. Preferably, the thread is a multiyam thread. Whilst the stitch type and thread at the first and second tubular zones may be the same generally, there may be characteristics of the stitch and thread that are different within the different zones as detailed herein. Preferably, a general shape profile of the fabric band is frustoconical between the attachment and open ends. Preferably, a circumferential length of the open end of the second tubular zone is less than the circumferential length of the transition ends and the attachment end. Additionally, the transition ends comprise a circumferential length that is less than the attachment end. The construction is such that the circumference of the band decreases gradually or uniformly in the axial direction from the attachment end (of the first tubular zone) to the open axial end (of the second tubular zone). Optionally and as observed when the band is not being worn, due to the higher circumferential tension of the second tubular zone (via the different structure and/or thread composition) the band is configured to draw radially inward. Optionally, this may create a step change decrease in the radius and circumference from the first zone to the second zone. However, when worn at the waist or torso, the band may adopt a seemingly continuous frustoconical shape profile to conform ergonomically to the torso and/or waist. Preferably, the structure of the second tubular zone is tighter than the structure of the first tubular zone. Such a configuration provides the greater tension or resistance to elongation in the circumferential direction at the second tubular zone relative to the first zone when the garment is worn at the torso or waist.

Optionally, the structure of the first and second tubular zones is a rib structure. Reference within this specification to a rib knit encompasses for example a knit pattern in which a 1x1 rib is a series of knit and purls stitches matched row for row having one plain knit stitch and one purl knit stitch. A corresponding 2x1 rib is defined as two plain knit stitches and one purl knit stitch matched row by row and 3x1 rib stitch is three plain stitches and one purl knit stitch matched row by row etc. Optionally, the first tubular zone may comprise a 1x1 rib and the second tubular zone may comprise a 2x1 rib or the first tubular zone may comprise a 2x1 rib and the second tubular zone may comprise a 3x1 rib as described herein.

Optionally, a size, weight, width or diameter of the thread or yarn that forms the thread in the second tubular zone is greater than that of the first tubular zone. Optionally, reference within the specification to the "size ’ of the thread may be defined as the weight in grams of 10,000 meters of thread or yarn (dtex). In particular, the density of the thread (or yarn) that forms the thread in the second tubular zone is greater than that of the first tubular zone. Preferably, the size, weight, width or diameter of the thread (or yarn) that forms the thread refers to the face yarn in the respective first and second tubular zones. In particular, the second tubular zone comprises a higher dtex of face yarn relative to a lower dtex of the face yarn in the first tubular zone (closest to the garment relative to the second tubular zone). This provides a greater modulus (resistance to elongation in the circumferential direction) and hence tightness at the different respective zones of the band.

Optionally, a stitch length of the thread in the second tubular zone is less than that in the first tubular zone. Preferably, the stitch length is configured to tighten in a direction from the garment towards the open end of the band form the first tubular zone and to the second tubular zone. That is, the tightest stitch length is provided in the axially endmost zone furthest from the garment (e.g., the second zone) and the loosest stitch length is provided at the tubular zone immediately adjacent or closest to the garment (i.e., the first zone) to provide the decrease in the circumferential length as described herein.

Optionally, an elastic tension in the thread in the second tubular zone is greater than that in the first tubular zone. Preferably, the elastic tension in the band (in the circumferential direction) tightens in the axial direction from the region of attachment to the garment towards the open end (furthest from the garment). Accordingly, the tubular zone axially furthest from the garment comprises the tightest elastic tension and the tubular zone immediately adjacent or closest to the garment comprises the loosest elastic tension. Such a configuration provides the increased tightness/modulus of the band to maintain close contact with the body at all times. This tightness may be considered to be a compression force directed radially inward onto the body at the region of the torso or waist. Preferably, the elastic tension is the tension in the thread of the respective tubular zones extending in a circumferential direction. The elastic tension referred to herein may also be or include the tension in the kitted loops extending in the axial direction of the band (i.e., between the hips and chest when worn the band is worn). Optionally, a stretch characteristic of the first and second tubular zones is greater in the circumferential direction relative to the axial direction. Within this specification, reference to "thread’ refers to a textile cord comprising multiple yarns plied together to form a long, thin strand. In particular, the present thread may comprise a plurality of individual threads plied together, with each individual thread comprising a plurality of yams. Optionally, a composition of the thread in the first and second tubular zones comprises nylon, polyester and elastane. Reference within the specification to "elastane ’ encompasses a yarn, cord or thread comprising a polyamide, polyurea and/or a polymer blend configured to provide a construction that stretches and recovers/retums to its pre-tensioned state. Reference within the specification to "thread’ may be interchangeable with "knit ’. Optionally, each of the yarns that form the thread, may be formed, in turn, from fibres or filaments and in particular a plurality of fibres or filaments. Optionally, each of the yarns may be formed from monofilaments.

Optionally, the fabric band may comprise a third knitted tubular zone positioned axially intermediate the first and second tubular zones, the third tubular zone being seamless in a circumferential direction and fabric band being seamless in the axial direction across the transition ends of the first, second and third tubular zones. Preferably, a structure and/or thread composition of the third zone is different to that of the first and/or second tubular zones. Preferably, the third zone comprises a structure and/or thread composition consistent with that of the first and second zones but having at least on respective physical or mechanical characteristic intermediate those of the first and second tubular zones. This difference providing in turn a tapered and uniformly increasing tightness of the band in the axial direction from the zone closest to the garment (lowest tension) to the zone furthest from the garment (highest tension) over the multiple tubular zones.

Optionally, a rib knit structure of the first tubular zone may be a 1x1 rib, the second tubular zone may be a 3x1 rib and the third tubular zone may be a 2x1 rib.

Optionally, the fabric band at the transitional ends is devoid of any additional thread relative to the yarn within the respective first, second and/or third tubular zones. Reference to the "additional thread’ encompasses cord, tape, bands or straps used conventionally to "draw-in ’ a waist band for constriction or gripping. The present band does not comprise any folded regions or seams, additional layers of material or other textile or fabric components being additional relative to the looped knit structure that forms exclusively the present fabric band including in particular the first, second and optionally third knitted tubular zones. In particular and preferably, the fabric band at the open end is devoid of any additional thread/yarn relative to the thread/yarn within the respective first tubular zone.

Optionally, an axial width or thickness of each tubular zone may be uniform. Optionally, an axial thickness or width of one or more of the knitted tubular zones may be different. It is preferred that the thickness or width is the same to match the ergonomics of the waist or torso and provide a uniform tension (in the circumferential direction) over an extended surface area. Such a configuration is advantageous to provide the desired balance between maintaining the garment in close fitting contact with the wearer (avoiding gaping) and maximising the wearer comfort. The present band is adapted specifically to avoid low surface area regions (in the axial direction) of high radial compressive force referring to existing torso or waist band structures.

According to a further aspect of the present invention there is provided a garment comprising a fabric band according to the present claims. Optionally, the garment is legwear in particular leggings and the fabric band is a waist band. Optionally, the garment is a sports bra and the fabric band is a torso band to extend over a torso region of a wearer between the chest and hips.

According to a further aspect of the present invention there is provided a method of manufacturing a knitted fabric band attachable to a fabric garment, the method comprising: knitting a first tubular zone having a circumferentially extending attachment end attachable to the garment and a circumferentially extending transition end; knitting a second tubular zone having a circumferentially extending open end and a circumferentially extending transition end joined seamlessly to the transition end of the first tubular zone; the first and second tubular zones being seamless in circumferential direction and the fabric band being formed seamlessly in the axial direction across the joined transition ends of the first and second tubular zones; and wherein a structure and/or thread composition of the first and second tubular zones is different such that a circumferential length of the open end is less than the attachment and the transition ends. Optionally, the first and second tubular zones are knitted via a continuous knit process so as to be formed integrally. Optionally, the present fabric band may be manufactured via a circular knit machine according to a circular knit process. Optionally, the present band may be manufactured via a flatbed or warp-knit machine and process. Either process typically comprises multiple yarns that are fed into the knit machine. Such processing, apparatus and methods are suitable to provide a seamless tubular knitted structure.

Brief description of drawings

A specific implementation of the present invention will now be described, by way of example only, and with reference to the accompanying drawings in which:

Figure 1A is a front view of legwear, in particular leggings, provided with a multi-zone waistband having a generally inward tapered profile according to a specific implementation of the present invention;

Figure IB is a rear view of the leggings of figure 1 A;

Figure 2 is a magnified front view of the waist band of figure 1 A;

Figure 3 A is a front view of leggings provided with a waist band according to a further embodiment having three tubular zones;

Figure 3B is a rear view of the leggings of the waist band of figure 3 A;

Figure 4A is a front view of a sports bra provided with a torso band having a multi-zone configuration consistent with the embodiment of figures 1 A to 2;

Figure 4B is a rear view the sports bra of figure 4A; Figure 5A is a front view of a sports bra provided with a torso band having three tubular zones consistent with the waist band of figures 3 A and 3B;

Figure 5B is a rear view of the sports bra and torso band of figure 5A.

Detailed description of preferred embodiment of the invention

Referring to figures 1 A and B legwear, in particular leggings 10 are provided with a waist band indicated generally by reference 11 attached a circumferentially extending open end 14 of leggings 10. Leggings 10 are for example formed from a knitted fabric having a multi-yarn and/or multi-thread composition. In particular, a preferred composition of leggings 10 comprises elastane, nylon and/or polyester so as to provide an ultralightweight, stretch fabric.

Referring to figures 1 A, B and figure 2, waist band 11 comprises a multi-zone configuration and according to the embodiment of figures 1 A to 2 comprises two tubular zones. Each zone has a knitted thread composition, with each thread optionally formed from one or a plurality of threads plied together, with each thread comprising a plurality of yarns. According to the preferred embodiment, wait band 11 and in particular each tubular zone comprises individual yams of nylon, polyester and elastane knitted together according to a preferred stitch pattern having a ribbed knit structure.

Referring in particular to figure 2, waist band 11 comprises a first knitted tubular zone 12 having a circumferentially extending attachment end 14 attached to an open end 14 of leggings 10 via a suitable attachment stitch. Attachment end 15 extends circumferentially in the x-y plane around the central axis 20 of waist band 11. First tubular zone 12 comprises a transition end 16 also extending circumferentially in the x-y plane around axis 20 with a width or thickness of zone 12 defined between the respective attachment end 15 and transition end 16. Waist band 11 is also provided with a second knitted tubular zone 13 having a respective transition end 17 extending circumferentially in the x-y plane around axis 20. Second zone 13 is terminated at an opposite end by an open end 18 also extending circumferentially around axis 20 in the x-y plane. Similarly, a thickness or width of the second tubular zone 13 is defined between the respective open and transition ends 18, 17. That is, the width or thickness of tubular zones 12, 13 and waist band 11 extends in the axial direction z perpendicular to the x-y plane. As illustrated in figures 1 A, B and figure 2, waist band 11 tapers radially inward progressively in the axial z direction between attachment end 15 and open end 18. In particular, a circumferential length of attachment end 15 is greater than the corresponding circumferential length of transition end 16, 17 which, in turn, is greater than the corresponding circumferential length of open end 18. Expressed differently, a radius of the waist band 11 decreases progressively and uniformly between attachment end 15 and open end 18 over both tubular zones 12 and 13. As such, waist band 11 comprises a frustoconical shape profile between respective ends 15 and 18.

The respective transition ends 16, 17 of zones 12 and 13 define a transition region 19 extending in both the axial and circumferential direction. Transition region 19 is seamless in the axial direction in that tubular zones 12, 13 are formed integrally according to a continuous knit process. Additionally, each tubular zone 12, 13 is knitted according to a circular knit process so as to be seamless in the circumferential direction in the x-y plane as well as the band 11 being seamless in the axial z direction encompassing in particular the transition region 19.

Each knitted tubular zone 12, 13 comprises a rib knit structure in which the wales 21 of the first zone 12 and the wales 22 of the second zone 13 extend in the axial z direction and corresponding rows or courses (not shown) that extend in the circumferential direction, of the x-y plane. According to the seamless construction, the looped stitches that forms the wales 21, 22 are continuous and without end in the z axis direction between the attachment end 15 and the open end 18. Additionally, the looped stitches of the rows/courses extending in the circumferential direction in the x-y plane are also continuous and without end so as to be seamless in the circumferential direction around axis 20. First tubular zone 12 according to the embodiment of figures 1 A, B and figure 2 comprises a 2x1 rib structure and the rib structure of the second tubular zone 13 is a 3x1 rib such that the rib structure of band 11 tightens in the direction from the attachment end 15 to the open end 18. Due to this change in the rib knit structure, the second zone 13 tapers radially inward to define the conical shape profile. When worn, second zone 13 is adapted to be resistant to elongation in the circumferential direction so as to maintain close fitting contact with the wearer and avoid gaping. Accordingly, band 11 via the radially inward tapered construction is adapted to conform more accurately to the hips and waist of a wearer where the waist is of smaller circumference relative to the hips. Waist band 11 is configured to grip the waist and in particular the subcostal plane region of a wearer over an extended surface area via both tubular zones 12, 13. The present band 11 is adapted to minimise and preferably eliminate garment slip particularly during high activity periods such as when exercising. Importantly, the present band 11 is configured to distribute the various forces uniformly in both the axial z direction and in a circumferential direction corresponding to the x-y plane. The axial and circumferential seamless construction provides a fabric band 11 that does not comprise inwardly projecting ribs, seams or other projections that would otherwise be uncomfortable or irritate a wearer particularly given the tight-fitting and ergonomic configuration of the present construction.

A further embodiment of the knitted fabric band 11 is illustrated in figures 3 A and 3B, with the band 11 attached to leggings 10 as described previously. According to the further embodiment, band 11 comprises three tubular knitted zones extending circumferentially around axis 20. In particular, the further embodiment comprises a first knitted tubular zone 12 and a second knitted tubular zone 13 corresponding to the embodiment of figures 1 A, B and figure 2 in addition to a third knitted tubular zone 24 positioned intermediate the first and second zones 12, 13 in the axial z direction. In particular, third knitted tubular zone 24 comprises a first transition end 26 and a second transition end 27 attached respectively to the transition end 16 of first zone 12 and transition end 17 of second zone 13. The construction of the third zone 24 is consistent with that of the first and second zones 12, 13 having a looped knit fabric structure comprising wales and rows/courses to provide a seamless construction in the circumferential direction (x-y plane). Additionally, a transition between the respective transition ends 16, 26, 27, 17 is also seamless (in the axial z direction) so as to provide an overall seamless waist band 11 consistent with the first embodiment of figures 1 A, B and figure 2. According to the further embodiment having three knitted tubular zones, first zone 12 comprises a 1x1 rib knit; third zone 24 comprises a 2x1 rib knit and second zone 13 comprises a 3x1 rib knit structure. Accordingly, and consistent with the embodiment of figures 1 A, B and figure 2, the waist band 11 of figures 3 A and 3B has a rib structure that also tightens radially inward from the attachment end 15 along the axial z direction to the open end 18.

Figure 4A and figure 4B illustrate the dual zonal fabric band 11 of figures 1 A, B and figure 2 attached to a sports bra 25. According to this implementation, band 11 is intended to sit over the mid-torso region of a wearer between the chest and waist at the trans tubercular plane. Figures 5 A and B illustrate the respective front and rear view of a sports bra provided with a knitted fabric band 11 according to the second embodiment of figures 3 A and 3B having three tubular zones 12, 13 and 24 together with the respective axial ends 15, 16, 26, 27, 17 and 18. The construction and the physical and mechanical characteristics of the bands 11 of figures 4 and 5 are the same as described with reference to figures 1 to 3, respectively.

The axial and circumferential seamless construction having a conical tapered shape profile of the present knitted fabric band 11 may be achieved via further constructional and knit techniques as described below.

According to a further specific embodiment, the rib knit structure of the individual tubular zones 12, 13, 24 may be the same whilst a size, width, weight or diameter of the thread and/or yarn may change and be different at the different tubular zones 12, 13, 24. In particular, a size of a face yarn defined as the weight in grams of 10,000 meters of thread or yarn (dtex) may be greater in the first tubular zone 12 relative to a lower dtex at the second tubular zone 13. Accordingly, a third tubular zone 24 may comprise a respective dtex intermediate that of the first and second zones 12, 13.

According to a further embodiment, a rib knit structure at the different tubular zones 12, 13, 24 may be the same or approximately the same, whilst a stitch length at zones 12, 13, 24 is different. In particular, first tubular zone 12 may comprise a loose or ‘looses stitch length whilst second zone 13 comprises a tight or ‘tightest’ stitch length. Accordingly, a stitch length of the intermediate third zone 24 may comprise a length intermediate that of zones 12, 13.

According to a further embodiment, the rib knit structure may be the same or generally the same at all tubular zones 12, 13, 24 whilst an elastic tension in the zones 12, 13, 24 may be different. In particular, the first zone 12 may comprise a loose or "loosest’ elastic tension whilst second zone 13 may comprise a tight or "tightest’ elastic tension relative to all other tubular zones. Intermediate third zone 24 may comprise a respective elastic tension being between that of the first and second zones 12, 13.

According to all further embodiments and configurations described herein, the knitted fabric band comprises a knitted seamless construction in both the axial z and the circumferential directions (x-y plane) together with the radially inward tapered configuration between axial ends 15, 18. According to all embodiments, the fabric band 11 may comprise a radially inward tapering conical structure in which a circumferential length of transition end 16 (of first zone 12) is 5 to 15% less than the circumferential length of attachment end 15 (of first zone 12). A corresponding circumferential length of open end 18 (of second zone 13) may be 5 to 15% less than transition end 17 (of second zone 13). Similarly, the circumferential length of transition end 27 (of third zone 13) may be 5 to 15% less than that of transition end 26 (of third zone 24).

According to the various embodiments, a thickness or width of each zone 12, 13, 24 may be the same in the axial z direction or may differ as required. Optionally, the fabric band 11 may comprise additional or supplementary thread and/or yam in the form of a logo, graphic or pattern knitted or otherwise stitched into the general construction. However, such indicia would be incorporated via a knit or stitch structure to avoid the creation of ribs, ridges or projections that may otherwise provide discomfort or irritation to a wearer.

As will be appreciated, the present fabric band 11 may be attached or attachable to a variety of different garments including legwear, arm wear, garments for a torso such as a sports bra and the like. The fabric band as described, may be manufactured according to different knit processes and methods including specifically circular knit, flatbed or warp-knit apparatus and processes in which yam ends are fed into a respective knitting machine according to known methods.

It should be understood that the terms “a” and “an” as used above and elsewhere herein refer to “one or more” of the enumerated components. It will be clear to one of ordinary skill in the art that the use of the singular includes the plural unless specifically stated otherwise. Therefore, the terms “a”, “an” and “at least one” are used interchangeably within this specification.

Unless otherwise indicated, all numbers expressing quantities, properties such as size, weight and so forth used in the specification and claims are to be understood as being modified in all instances by the term “about”. Accordingly, unless indicated to the contrary, the numerical parameters set forth in this specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained by the present subject matter.

Throughout the specification, descriptions of various embodiments use “comprising” language. However, it will be understood by one of skill in the art that, in some instances, an embodiment can alternatively be described using the language “consisting essentially of’ or “consisting of’.

The present subject matter being thus described, it will be apparent that the same may be modified or varied in many ways. Such modifications and variations are not to be regarded as a departure from the spirit and scope of the present subject matter, and all such modifications and variations are intended to be included within the scope of the following claims.