Mask usage has increased markedly due primarily to the coronavirus pandemic. However, prior loops or straps are typically formed either solely of elastic or of a combination of elastic with fabric in a formed loop. In one prior exemplary strap, elastic narrow fabric with short stretch cut to lengths forms the predominate mode of manufacture of ear loops for face masks. However, because of their limited stretch and because of their typically small diameter, elastic narrow fabric loops can be uncomfortable and can impart a sensation of "cutting" into the back of the ear, shoulder, or other area. An improved attachment means is needed to improve comfort of masks and/or other garments.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated herein and constitute part of this specification, illustrate the presently preferred embodiments of the disclosure, and, together with the general description given above and the detailed description given below, serve to explain the features of the disclosure. In the drawings:

FIG. 1 shows exemplary embodiments of knitted loops and of knitted loops cut to provide two ends of fabric.

FIG. 2 shows one exemplary process of attaching loops to a mask.

FIG. 3 shows an exemplary face mask with two knitted loops cut and sewn into place.

FIG. 4 shows a flowchart of steps for an exemplary method of producing knitted loops.

FIG. 5 shows exemplary jersey stitch configuration used to produce the knitted loops.

FIG. 6 shows an exemplary tube of fabric along an axis with widths of loop cuts.

DETAILED DESCRIPTION

In the drawings, like numerals indicate like elements throughout. Certain terminology is used herein for convenience only and is not to be taken as limiting. The terminology includes the words specifically mentioned, derivatives thereof and words of similar import. The embodiments illustrated below are not intended to be exhaustive or to limit to the precise form disclosed. These embodiments are chosen and described to best explain the principles, application, and practical use, and to enable others skilled in the art to best utilize the present disclosure.

Knitted loops for face masks or other garments that utilize straps, including dresses, lingerie, undergarments, etc. are detailed herein. Among other attributes, knitted loops are more comfortable than elastic fabric loops, especially when used to secure a face mask in place or when used in place of elastic straps for garments.

FIG. 1 shows exemplary embodiments of knitted loops 10 formed of a natural soft rolled fabric and, in at least one embodiment, utilize a microfiber cover on spandex that provides softness and comfort. In at least one exemplary embodiment, the knitted loops 10 can be produced from circular knitting machines, instead of comparatively narrow fabric machines. The knitted loops 10 can be formed, e.g. by using a jersey stitch (see FIG. 5) to form courses (or rows) of fabric. Additionally, the knitted loops 10 can be cut from a tube of fabric to a specific length (number of courses) to obtain individual loops or can be knitted individually by the machine program specifying the number of courses of fabric. The knitted loops 10 can have a tubular or ring shape as shown at 20 or can be cut as shown at 30 and can provide two ends 32, 34 of fabric. The knitted loops 10 can be kept as continuous knitted loops and attached at one end into a garment or the knitted loops 10 can be cut to form two ends and the two ends can be attached into a mask or garment.

FIG. 2 shows one exemplary process at 100 of attaching a cut knitted loop 30 to a mask or other garment 110. The knitted loop 10 can be attached in any manner to the mask or garment 110, including, for example, by sewing, tacking, gluing, or otherwise attaching the knitted loop 10 to the mask or garment 110. FIG. 3 shows a completed exemplary face mask 200 with two cut knitted loops 30 and sewn into place onto mask 110. The mask 200 and/or the knitted loops 10 can be dyed a color or different colors at any point in the manufacturing process prior to packaging. Additionally, the mask 200 can be provided with additional features or attachments during manufacture to accommodate specific designs.

FIG. 4 shows a flowchart of steps 300 for producing knitted loops in one exemplary embodiment. As shown in FIG. 4, either covered elastic/spandex yarn constructed with staple natural/synthetic fibers at 302 or covered elastic/spandex yarn constructed with continuous filament synthetic fibers at 304 are provided, then the process proceeds to a decision block at 306 where the decision is made to form individual loops or tubes of fabric.

If individual loops are to be made, the process proceeds to 308 where the yarn and synthetic fiber or yarn fiber are knitted to form an individual loop.

Alternatively, if a tube of fabric is to be made, the process proceeds to 307 where the yarn and synthetic fiber or yarn fiber is knitted to form a fabric tube. The process then continues to 309 where the fabric tube is cut into specific width individual loops.

Following either path past 308 or alternatively past 307 and 309, the process then proceeds to a decision block at 310 where the decision is made whether the individual loop is to remain a continuous loop or whether the individual loop is to be cut. If the individual loop is to be cut, the process proceeds to 312 where the individual loop is cut to form two ends. Alternatively, if the individual loop is to be kept continuous, the process does not proceed to cutting at 312 and instead proceeds to 314.

The process then proceeds to 314 where at least a part of the knitted fiber is sewn or otherwise attached to a face mask or garment.

In one option, if the individual loop remained continuous, the loop can be attached to the face mask, in this example, at an upper and lower portion to form two ear loop— one on either side of the face mask. If the individual loop was cut to form two ends, in another option, either (1) one end can be attached to the face mask and the other end not attached to the mask, or (2) both ends can be attached to one side of the face mask to form an ear loop, or, neither end of the individual loop can be attached to the face mask and the cut individual loop can be attached at a middle portion of the face mask to allow the free ends to extend from the face mask. Any free ends can be used, e.g. by tying together, to secure the face mask onto a person's head, for example. Otherwise, if an ear loop is formed, the face mask can be disposed on a person's head with the ear loop secured around the person's ear.

Instead of being disposed on a face mask, the knitted fiber can be disposed on a garment to either be a tie or form a loop.

FIG. 5 shows exemplary jersey stitch configuration 400 used to produce knitted loops, as individual loops or as a tube of fabric which is cut into specific width individual loops. In one embodiment, jersey knit structure can utilize all needles to knit a continuous row of stitches; each row or course of stitches, shown in FIG. 5 at 402, 404, 406, 408, continues for every revolution of the knitting cylinder. As shown in the figures, the exemplary knitted loops 10 formed were knitted on a 4" diameter circular knitting machine with 352 needles and the machine was set-up to knit 4 rows (courses) of fabric for every revolution of the knitting cylinder.

FIG. 6 shows an exemplary tube of fabric 500 with an exemplary axis A along which the tube 502 extends and with widths of loop cuts being made normal or perpendicular to the axis A to form individual loops (e.g., 309 in FIG. 4). The width of each cut can vary as desired, with cut outlines shown at 510, 512, and 514. One exemplary loop cut 516 is shown separated from tube 502. The individual loop 516 includes an interior opening at 518.

In one embodiment, the fabric construction can be an engineered yarn, including an elastic/spandex component and a nylon or polyester component. In one exemplary embodiment, the engineered yarn can be high elongation engineered yarn constructed of spandex fiber and synthetic fiber (such as nylon, polyester).

One exemplary embodiment provides a configuration manufactured with yarn that is 70 denier

Lycra Type 162 clear single and that is covered with 80 denier/92 filament nylon. Additionally, in at least one embodiment, the nylon is classified as a microfiber due to its filament count being higher than the denier size of the yarn. Alternatively, other materials may also be utilized.

In one exemplary embodiment, the knitted loop can be formed on a circular knitting machine with an NPI (needles per inch) of 20 or higher (the loops shown in the figures were knitted on 28NPI machines).

One exemplary benefit of knitted loops is that knitted loops will naturally roll to look like a spandex cord and are highly stretchable to accommodate a range of sizes. The knitted loops are comfortable at least due to the stretch characteristic of jersey knit fabric and are soft at least due to the high filament count of the yarn.

In one aspect, the present disclosure provides a knitted loop for a garment that is formed by a process including: providing a yarn, knitting the yarn to form an individual loop, cutting the individual loop to form two ends, and attaching at least one end of the two ends to a garment. Further, the yarn can be constructed of staple natural and synthetic fibers, or can be constructed of continuous filament synthetic fibers. Further still, the knitting in the process can comprise a jersey stitch. Even further still, the garment formed by the process can be, for example, a face mask, or a dress or shirt. Additionally, in at least one embodiment, both of the two ends can be attached to the garment.

In another aspect, the present disclosure provides a knitted loop for a garment, the knitted loop formed by a process including: providing a yarn, knitting the yarn to form a fabric tube, cutting the fabric tube into at least one individual loop, and attaching the at least one individual loop to a garment. Further, the yarn can be constructed of staple natural and synthetic fibers, or can be constructed of continuous filament synthetic fibers. Further still, the knitting in the process can comprise a jersey stitch. Even further still, the garment formed by the process can be, for example, a face mask, or a dress or shirt. Additionally, in at least one embodiment, both of the two ends can be attached to the garment. In yet another aspect, the present disclosure provides a method of forming a garment with at least one knitted loop, the method including: providing a yarn, knitting the yarn to form a fabric tube, cutting the fabric tube into at least one individual loop, and attaching the at least one individual loop to a garment. Further, the yarn can be constructed of staple natural and synthetic fibers, or can be constructed of continuous filament synthetic fibers. Further still, the knitting in the method can comprise a jersey stitch. Even further still, the garment formed by the method can be, for example, a face mask, or a dress or shirt. Additionally, in at least one embodiment, both of the two ends can be attached to the garment. Yet further, prior to the attaching the at least one individual loop, the method additionally can include: cutting the at least one individual loop to form two ends.

It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept thereof. For example, the loop(s) could include additional features. It is understood, therefore, that this disclosure is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present disclosure as defined by the appended claims.

The present disclosure can be understood more readily by reference to the instant detailed description, examples, and claims. It is to be understood that this disclosure is not limited to the specific systems, devices, and/or methods disclosed unless otherwise specified, as such can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.

The instant description is provided as an enabling teaching of the disclosure in its best, currently known aspect. Those skilled in the relevant art will recognize that many changes can be made to the aspects described, while still obtaining the beneficial results of the present disclosure. It will also be apparent that some of the desired benefits of the present disclosure can be obtained by selecting some of the features of the present disclosure without utilizing other features. Accordingly, those who work in the art will recognize that many modifications and adaptations to the present disclosure are possible and can even be desirable in certain circumstances and are a part of the present disclosure. Thus, the instant description is provided as illustrative of the principles of the present disclosure and not in limitation thereof.

As used herein, the singular forms "a," "an" and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to a "body" includes aspects having two or more bodies unless the context clearly indicates otherwise.

Ranges can be expressed herein as from "about" one particular value, and/or to "about" another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent "about," it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

As used herein, the terms "optional" or "optionally" mean that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.

Although several aspects of the disclosure have been disclosed in the foregoing specification, it is understood by those skilled in the art that many modifications and other aspects of the disclosure will come to mind to which the disclosure pertains, having the benefit of the teaching presented in the foregoing description and associated drawings. It is thus understood that the disclosure is not limited to the specific aspects disclosed hereinabove, and that many modifications and other aspects are intended to be included within the scope of the appended claims. Moreover, although specific terms are employed herein, as well as in the claims that follow, they are used only in a generic and descriptive sense, and not for the purposes of limiting the described disclosure.