Note: Descriptions are shown in the official language in which they were submitted.
PANTYHOSE ARTICLE HAVING ULTRA-HIGH MOLECULAR WEIGHT POLYETHYLENE
AND METHOD FOR MANUFACTURING THEREOF
TECHNICAL FIELD
[001] The present disclosure generally relates to a pantyhose article having
ultra-high molecular
weight polyethylene (UHMWPE) and a method for manufacturing thereof, and more
particularly,
to a pantyhose article having multiple different knits, including at least two
knits having UHMWPE.
BACKGROUND
[002] Traditional knit fabrics for manufacture of hosiery products (such as
pantyhose, stockings,
socks, and tights) include nylon in combination with elastane (e.g., LycraTM
of SpandexTm).
However, these fabrics tend to rip or tear when subjected to frictional
forces. It was observed that
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 (low denier)
elastic knits that are
not easy to rip.
[003] Ultra-high molecular weight polyethylene (UHWMPE) fiber is considered as
an ideal
reinforcing component due its high impact strength, low density, low
elongation at break,
resistance to corrosive chemicals, low moisture absorption, and low
coefficient of friction. The
knits including UHMWPE fibers in combination with stretch fibers such as
Spandex, nylon or
polyester have shown increased rip resistance. However, UHMWPE fiber is very
expensive, and
its quality varies considerably from supplier to supplier and from batch to
batch. Lower quality
UHMWPE fiber may result in defects, such as yarn ring or barre, which leads to
damaged hosiery
that cannot be used in inventory and thus becomes waste.
[004] Therefore, there remains a need for commercially viable knits for making
hosiery that allow
utilizing a lower amount, and/or lower grade UHMWPE fiber while maintaining
the desired rip
resistance and durability.
1
8086068
Date Recue/Date Received 2022-12-23
SUMMARY
[005] According to one aspect, there is provided a pantyhose article that
includes a first tubular
member. The first tubular member includes a first panty portion and a first
tubular leg portion, the
first panty portion extending from a waist end of the pantyhose article to a
bottom end of the first
panty portion and the first tubular leg portion defining a first leg cavity
and extending from a top
end thereof, corresponding to the bottom end of the first panty portion, to a
first foot end of the
first tubular leg portion, the first tubular leg portion comprising a first
principal sub-portion and a
first transitional sub-portion, the first principal sub-portion extending from
a first thigh region of the
first tubular leg portion to the first foot end and the first transitional sub-
portion extending from the
top end of the first tubular leg portion to the first thigh region of the
first tubular leg portion, the
first principal sub-portion being formed of a first knit comprising a first
ultra-high molecular weight
polyethylene (UHMWPE) fiber and at least one first companion fiber and the
first transitional sub-
portion being formed of a second knit comprising a second UHMWPE fiber and at
least one
second companion fiber, the first knit being different from the second knit.
[006] According to another aspect, there is provided a method for
manufacturing a pantyhose
article. The method includes forming a first tubular member having a first
panty portion extending
from a waist end of the pantyhose article to a bottom end of the first panty
portion and a first
tubular leg portion defining a first leg cavity and extending from a top end
thereof, corresponding
to the bottom end of the first panty portion, to a first foot end of the first
tubular leg portion, the
first tubular leg portion comprising a first principal sub-portion and a first
transitional sub-portion,
the first principal sub-portion extending from a first thigh region of the
first tubular leg portion to
the first foot end and the first transitional sub-portion extending from the
top end of the first tubular
leg portion to the first thigh region of the first tubular leg portion and
extending circumferentially
about the first tubular leg portion, the first principal sub-portion being
formed of a first knit
comprising a first ultra-high molecular weight polyethylene (UHMWPE) fiber and
at least one first
companion fiber and the first transitional sub-portion being formed of a
second knit comprising a
second UHMWPE fiber and at least one second companion fiber, the first knit
being different from
the second knit. The method also includes forming a second tubular member
having a second
panty portion extending from the top end of the pantyhose article to a bottom
end of the second
panty portion being aligned with the bottom end of the first panty portion and
a second tubular leg
2
8086068
Date Recue/Date Received 2022-12-23
portion defining a second leg cavity and extending from a top end thereof,
corresponding to the
bottom end of the second panty portion, to a second foot end of the second
tubular leg portion,
the second tubular leg portion comprising a second principal sub-portion and a
second transitional
sub-portion, the second principal sub-portion extending from a second thigh
region of the second
tubular leg portion to the second foot end and the second transitional sub-
portion extending from
the top end of the second tubular leg portion to the second thigh region of
the second tubular leg
portion and extending circumferentially about the second tubular leg portion,
the second principal
sub-portion being formed of the first knit comprising the first UHMWPE fiber
and the at least one
first companion fiber and the second transitional sub-portion being formed of
the second knit
comprising the second UHMWPE fiber and the at least one second companion
fiber. The method
further includes cutting the first panty portion along a longitudinal
direction thereof to form first
longitudinal edges therein and cutting the second panty portion along a
longitudinal direction
thereof to form second longitudinal edges therein, joining the first
longitudinal edges of the first
panty portion to the second longitudinal edges of the second panty portion to
form a panty tube
defining a panty cavity for receiving a lower torso of a wearer, the panty
cavity being in fluid
communication with the first leg cavity of the first tubular leg portion and
the panty cavity being in
fluid communication with the second leg cavity of the second tubular leg
portion, and joining the
longitudinal edges of the first panty portion to a first edge of a gusset and
joining the longitudinal
edges of the second panty portion to a second edge of the gusset.
BRIEF DESCRIPTION OF THE DRAWINGS
[007] 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.
[008] Figure 1 is a front elevation view of a pantyhose article according to
one example
embodiment when placed on a quality control apparatus;
3
8086068
Date Recue/Date Received 2022-12-23
[009] Figure 2 is a top perspective view of an inside of the pantyhose article
according to one
embodiment when placed on a quality control apparatus;
[0010] Figure 3 is a bottom view of a crotch region of the pantyhose article
according to one
embodiment when placed on a quality control apparatus;
[0011] Figure 4 is a front elevation view of the pantyhose article according
to one example
embodiment when worn;
[0012] Figure 5 is a side elevation view of the pantyhose article according to
one example
embodiment when worn;
[0013] Figure 6 is a rear elevation view of the pantyhose article according to
one example
embodiment when worn;
[0014] Figure 7 is a bottom view of the pantyhose article according to one
example embodiment
when worn; and
[0015] Figure 8 is a top view of the pantyhose article according to one
example embodiment as
if worn.
DETAILED DESCRIPTION
[0016] 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", "comprising", "includes" and "including" 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.
[0017] 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,
4
8086068
Date Recue/Date Received 2022-12-23
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.
Definitions
[0018] As used herein, and unless the context dictates otherwise, the
following terms have the
meanings as specified below.
[0019] The term "UHMWPE" stands for ultra-high molecular weight polyethylene,
also known as
high-modulus polyethylene (HM PE), or high-performance polyethylene (HPPE).
[0020] The term "colored UHMWPE" means UHMWPE that has been colored (e.g.,
made non-
white) by a non-additive coloring process.
[0021] 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.
[0022] 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.
[0023] The term "microfilament" as used herein refers to a filament having a
denier of 5 or less.
[0024] 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.
8086068
Date Recue/Date Received 2022-12-23
[0025] The term "decitex (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.
[0026] The term "tensile strength" as used herein relates to the durability 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.
[0027] 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.
[0028] The term "natural fiber" as used herein refers to class of fibers
obtainable from material of
natural sources.
[0029] The term "synthetic fiber" as used herein is used to class of fibers
made by humans.
Synthetic fibers comprise for example polymeric material, synthesized by
polymerization of
monomers, fibers obtained by regeneration of natural fibers, for instance
after dissolution in a
solvent, and glass fibers.
[0030] Term "stretch fiber" as used herein refers to class of fibers that,
upon application of a force,
is stretchable to a stretched at least about 130% of its original dimension
without breaking,
[0031] The term "non-stretch fiber" refers to class of fibers which is
substantially non-elastic with
little or no elongation.
[0032] The term "high performance fiber" as used herein refers to class of
fibers having high
values of tenacity greater, for example greater than 10 g/denier, such that
they lend themselves
for applications where high abrasion and/or cut resistance is important.
Typically, high
performance fibers have a very high degree of molecular orientation and
crystallinity in the final
fiber structure.
[0033] The term "elastomeric fiber" as used herein refers to a fiber which has
a break elongation
in excess of 100% and which when stretched and released, retracts quickly and
forcibly to
substantially its original length.
[0034] The term "thermoplastic fiber" as used herein refers to class of fibers
obtained from
polymer that is plastic or deformable, melts to a liquid when heated and
freezes to a brittle, glassy
state when cooled sufficiently.
6
8086068
Date Recue/Date Received 2022-12-23
[0035] The term "abrasion resistant fiber" as used herein refers to class of
fibers that inhibits
abrasion of the material that it is proximate to.
[0036] The term "knit" as used herein refers to the fabric created by
combining one or more fibers
on a flat or circular knitting machine.
[0037] The term "gauge" as used herein refers to the number of needles on the
knitting machine.
A high gauge knitting machine (32 gauge and above) is required to produce
sheer hosiery like
sheer tights, stockings and trouser socks and a low gauge knitting machine (18
to 32 gauge) is
used to produce heavier garments like 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.
[0038] 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.
[0039] The term "serving" as used herein refers to the process of spinning two
fibers together to
produce a composite fiber.
[0040] The term "non-additive" as used herein refers to coloring, typically
dyeing, methods that
do not increase the total denier of the fiber.
[0041] "Tensile properties" are properties measured when a material is
subjected to stretching
forces, and also the properties measured when the stretching forces are
removed. Example
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 fibers can be
determined for example by
standard test methods such as ASTM D2256/D2256M-21, "Tensile Properties of
Yarns by the
Single-Strand Method".
[0042] The term "barre" as used herein is defined as unintentional, repetitive
visual of continuous
bars or stripes usually parallel to the courses of circular knit fabric.
UHMWPE Fibers
[0043] Various aspects described herein involve UHMWPE fibers for preparing
knitted fabrics
and methods for forming the same.
7
8086068
Date Recue/Date Received 2022-12-23
[0044] In some embodiments, the UHMWPE fiber has high impact strength, low
density, low
elongation at break, resistance to corrosive chemicals, low moisture
absorption, and/or low
coefficient of friction. In other aspects, the material is self-lubricating
and highly resistant to
abrasion and odor.
[0045] 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 (Me) of the UHMWPE fiber is of about 5.0 or less,
about 4.0 or less, or
about 3.0 or less.
[0046] In some embodiments, the UHMWPE fiber is a monofilament. In some other
embodiments, the UHMWPE fiber comprises a plurality of microfilaments. In some
embodiments,
each of the microfilaments in the UHMWPE 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, or about 0.5 or less.
[0047] The UHMWPE fiber may include any suitable number of microfilaments. In
some
embodiments, the UHMWPE fiber comprises 2 to 400 microfilaments, 10 to 300
microfilaments,
to 50 microfilaments, 5 to 50 microfilaments, 5 to 25 microfilaments, or 20 to
200
microfilaments. In some embodiments, the UHMWPE fiber comprises 5, 7, 10, 15,
20, 25, 30,
35, 40, 45, or 50 microfilaments.
[0048] The UHMWPE fiber may be of any denier suitable for pantyhose. In some
embodiments,
the UHMWPE fiber has a denier ranging from about 10 to about 250. In some
embodiments, the
UHMWPE fiber has a denier ranging from about 10 to about 60. 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. In some embodiments, the UHMWPE fiber
has a denier
of 50 or less.
[0049] In some embodiments, the UHMWPE fiber is a high strength fiber. In some
embodiments,
the UHMWPE fiber has a tensile strength (i.e., tenacity) of at least 20
cN/dtex, at least 25 cN/dtex,
at least about 30 cN/dtex, at least about 35 cN/dtex, at least about 40
cN/dtex, at least about 45
8
8086068
Date Recue/Date Received 2022-12-23
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/dtex, about 28 cN/dtex,
about 30 cN/dtex,
about 32 cN/dtex, about 36 cN/dtex, about 40 cN/dtex, about 45 cN/dtex, or
about 50 cN/dtex.
[0050] 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, 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.
[0051] 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%.
[0052] 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.
[0053] 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.
[0054] 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.
[0055] In some embodiments, the UHMEPE fiber comprises multiple microfilaments
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. In some embodiments, the
UHMWPE fiber has
a twists per inch (TPI) between 1 to 30, between Ito 20, between Ito 10,
between 1 to 5, 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 8. In
some
9
8086068
Date Recue/Date Received 2022-12-23
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.
[0056] In various aspects, the UHMWPE fibers described herein can be produced
according to
methods described in U.S. publication no. U520220056620.
[0057] In some embodiments, the UHMWPE fiber has a variation of the color
along the length of
said UHMWPE fiber. In some embodiments, a variation of the color along the
length of the
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%.
[0058] The use of UHMWPE fiber provides benefits to knit such as cooling
effect, light weight,
moisture wicking, and/or antimicrobial. The tensile properties of the UHMWPE
fiber also provide
increased resistance to ripping, snagging or otherwise wearing out or failing
of the knit. 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 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.
[0059] The amount of the UHMWPE fiber in the knit may be in the range of from
about 10% by
weight to about 90% by weight based on the total amount of fibers in the knit.
In some
8086068
Date Recue/Date Received 2022-12-23
embodiments, the amount of the UHMWPE fiber in the knit ranges 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.
[0060] In some embodiments, the knit comprises a plurality of UHMWPE fibers.
Each of the
UHMWPE fibers includes multiple microfilaments, each of the microfilaments
having a denier of
or less. Each of the UHMWPE fibers may comprise 50 or less microfilaments.
[0061] The companion fiber is selected to enhance a property of the knit, such
as, but not limited
to, the comfort, durability, dyeability/printability, and/or stretchability of
the knit. In some
embodiments, the companion fiber comprises a single fiber. In some other
embodiments, the
companion fiber comprises a plurality of fibers.
[0062] The companion fiber may be a synthetic fiber, a natural fiber, a
stretch fiber, a non-stretch
fiber, a high performance fiber, an elastomeric fiber, a thermoplastic fiber,
or an abrasion resistant
fiber, or a combination of any of the foregoing fibers.
[0063] In some embodiments, the companion fiber comprises a synthetic fiber.
Examples of
organic synthetic fibers include those made of: polyolefin such as
polyethylene, polypropylene,
high molecular weight polypropylene, UHMWPE, polybutylene and the like;
polyamide such as
nylon; polyester such as polyethylene terephthalate, polyethylene naphthalate,
poly(ethylene
succinate), polymethyl methacrylate; 1,2-polybutadiene; and copolymers of
these polymers.
[0064] In some embodiments, the companion fiber comprises a natural fiber.
Examples of natural
fibers include cotton, silk, wool and the like.
[0065] In some embodiments, the companion fiber comprises a stretch fiber.
Examples of stretch
fibers include those made of polyurethane, polyolefin such as low molecular
weight polyethylene
or polypropylene, and the like.
[0066] In some embodiments, the companion fiber comprises a non-stretch fiber.
Examples of
non-stretch fibers include those made of or comprising polyester, cotton,
nylon, rayon, and/or
wool.
[0067] In some embodiments, the companion fiber comprises a high performance
fiber.
Examples of high performance fibers include high molecular weight high
molecular weight
polypropylenes, aramids, high molecular weight polyvinyl alcohols, high
molecular weight
polyacrylonitriles, and liquid crystal polyesters.
11
8086068
Date Recue/Date Received 2022-12-23
[0068] In some embodiments, the companion fiber comprises an elastomeric
fiber. Examples of
elastomeric fibers include spandex (also called elastane), lastol,
polyurethane, and
polyetherester.
[0069] In some embodiments, the companion fiber comprises a thermoplastic
fiber. Examples of
thermoplastic fibers include those made of polyamides, polyimides,
polyurethanes, polyolefins,
polystyrenes, aromatic polyesters, polycarbonates, polyketones, polyureas,
polyvinyl resins,
polyacrylates, and polymethacrylates.
[0070] In some embodiments, the companion fiber comprises an abrasion
resistant fiber.
Examples of abrasion resistant fibers include those made of nylon, polyesters
and polyamides.
[0071] The companion fiber may include any suitable number of microfilaments.
In some
embodiments, the companion fiber comprises 2 to 400 microfilaments, 10 to 300
microfilaments,
to 200 microfilaments, 10 to 150 microfilaments, 10 to 100 microfilaments, 10
to 50
microfilaments, 5 to 50 microfilaments, or 20 to 200 microfilaments.
[0072] The companion fiber may be of any denier suitable for pantyhose. In
some embodiments,
the companion 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 companion
fiber has a denier of about 5, about 10, about 13, about 15, about 17, about
20, about 25, about
30, about 50, about 60, about 70, about 80, or about 90. In instances where
the knit comprises a
plurality of companion fibers, the plurality of companion fibers may have the
same or different
deniers from each other.
[0073] In some embodiments, the companion fiber allows an elongation of
greater than 100%.
In some embodiments, the companion fiber has an elongation of about 130% or
greater, about
200% or greater, about 300% or greater, or about 400% or greater.
[0074] In some embodiments, the companion fiber is a colored fiber comprising
a dye. In some
embodiments, the companion fiber has black, blue, grey, red, blue, brown,
yellow, green, orange,
or nude color. In some embodiments, the companion fiber is white. In some
embodiments, the
companion fiber has a same color as the UHMWPE fiber. In some other
embodiments, the
companion fibers have a different color from the UHMWPE fiber.
12
8086068
Date Recue/Date Received 2022-12-23
[0075] 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%.
[0076] In some embodiments, the knit has a denier of about 150 or less, about
120 or less, about
100 or less, about 80 or less, about 60 or less, about 50 or less, about 40 or
less or about 30 or
less. For example, the knit has a denier between 10 and 200, between 20 and
100, between 20
and 50, between 10 and 40 or between 20 and 40.
Methods for manufacturing a pantyhose article comprising UHMWPE
[0077] In another aspect, methods of producing the knits described above are
provided. The knit
of the present disclosure is produced by knitting the UHMWPE fiber and the
companion fiber
using a knitting machine. The appropriate gauge of the knitting machine is
selected according to
the type of pantyhose. The gauge number of the knitting machine can affect the
stretchability and
basis weight of the resulting knit. The knit may have a gauge ranging from 10
to 40. 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.
[0078] 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
14 inches, about
to about 14 inches, or about 3 inches to about 7 inches suitable for producing
a knit for
pantyhose. In some embodiments, no cylinder is used.
[0079] 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 garments 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 garment can be any
desired, depending
13
8086068
Date Recue/Date Received 2022-12-23
on the weight of pantyhose to be produced and the level of sheerness desired.
In some
embodiments, all of the feeds are used. In some embodiments, only 1 feed is
used. In some
embodiments, only 2 feeds are used. In some embodiments, only 3 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. In some embodiments, the same UHMWPE fibers
with the same
properties and different variations in properties are used on all feeds. In
some embodiments
different UHMWPE fibers with different properties and different variations in
properties are used
on all feeds. In some embodiments different UHMWPE fibers with different
properties and the
same variations in properties are used on all feeds.
[0080] 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 is
constant 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%.
[0081] In order to effectively achieve stretch in the final knit without
compromising the strength
properties provided by the UHMWPE fiber, the knitting of the UHMWPE fiber and
the companion
fiber includes plating or serving of the UHMWPE fiber and companion fiber.
[0082] In some embodiments, to effectively achieve stretch in the final knit
without compromising
the strength properties provided by the UHMWPE fiber, the UHMWPE fiber and the
companion
fiber are knitted to form a plated knit structure. In knitting the plated
knit, a UHMWPE fiber is
required on every course of the knit and a companion fiber can be on every
course or every other
course. In some embodiments, the plated knit comprises the UHMWPE fiber on
each course and
the companion fiber on at least every other course and has a denier not
exceeding 30. In some
embodiments, the plated knit comprises the UHMWPE fiber on each course and the
companion
fiber on at least every other course and has a denier not exceeding 40. In
some embodiments,
the plated knit comprises the UHMWPE fiber on each course and the companion
fiber on at least
14
8086068
Date Recue/Date Received 2022-12-23
every other course and has a denier not exceeding 50. In some embodiments, the
plated knit
comprises the UHMWPE fiber on each course and the companion fiber on at least
every other
course and has a denier not exceeding 60. In some embodiments, the plated knit
comprises the
UHMWPE fiber on each course and the companion fiber on at least every other
course and has
a denier of about 20, about 25, about 30, about 35, about 40, about 45, about
55, about 55, or
about 65. After the knitting process, one side of the knit exposes the UHMWPE
fiber more
prominently, and the companion fiber is exposed on the other side.
[0083] In some other embodiments, to effectively achieve stretch in the final
knit without
compromising the strength properties provided by the UHMWPE fiber, the UHMWPE
fiber and
the companion fiber are twisted to form a composite fiber. This twisting forms
a served composite
fiber. In some embodiments, the UHMWPE fiber and the companion fiber are
twisted between
100 and 4500 twists per meter (TPM). A higher number of twists per meter may
be desired to
ensure more stretch in the end product, and increased durability in the final
knit as it results in a
larger surface area of the companion fiber being reinforced with the UHMWPE
fiber. In some
embodiments, the UHMWPE fiber and the companion fiber have a TPM of 100, the
UHMWPE
fiber and the companion fiber have a TPM of 500, the UHMWPE fiber and the
companion fiber
have a TPM of 1000, the UHMWPE fiber and the companion fiber have a TPM of
1500, the
UHMWPE fiber and the companion fiber have a TPM of 2000, the UHMWPE fiber and
the
companion fiber have a TPM of 2500, the UHMWPE fiber and the companion fiber
have a TPM
of 3000, the UHMWPE fiber and the companion fiber have a TPM of 3500, the
UHMWPE fiber
and the companion fiber have a TPM of 4000, the UHMWPE fiber and the companion
fiber have
a TPM of 4500. In some embodiments, the UHMWPE fiber and the companion fiber
have a TPM
between 2 and 100. In some embodiments, the UHMWPE fiber and the companion
fiber have a
twist per inch (TPI) of 3, a TPI of 5, a TPI of 10, a TPI of 15, a TPI of 20,
a TPI of 25, a TPI of 30,
a TPI of 40, or a TPI of 50.
[0084] In some embodiments, the knit is produced using a UHMWPE fiber and a
nylon covered
spandex fiber as the companion fiber. Both the UHMWPE fiber and the companion
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 microfilaments. In some embodiments, the
nylon covered
8086068
Date Recue/Date Received 2022-12-23
spandex fiber is formed by covering a monofilament spandex fiber having a
denier of 17 with a
nylon fiber containing 5 to 20 microfilaments and having a denier ranging from
1 to 20. In some
embodiments, the knit has a course alternating between the UHMWPE fiber and
the nylon
covering spandex fiber, in which the spandex fiber is a monofilament fiber
having a denier of 40
and the nylon fiber is a multifilament fiber containing 7 microfilaments 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 40.
[0085] In some embodiments, the knit is produced using a UHMWPE fiber and a
nylon fiber. The
nylon fiber is a multifilament fiber containing 40 microfilaments and having a
denier of 40.
Pantyhose articles comprising UHMWPE
[0086] In one aspect, the present disclosure provides a pantyhose article.
Referring to Figure 1,
therein is a front elevation view of a pantyhose article 1 according to one
example embodiment
when placed on a quality control apparatus. The quality control apparatus
typically has two panel
members spaced apart from one another, each panel member receiving a
respective leg member
of a pantyhose article under quality control testing. The leg members being
stretched over the
panel members allow a visual inspection of the quality of leg members of the
pantyhose article.
The body member of the pantyhose article is also stretched between the panel
members of the
quality control apparatus, which also allows for a visual inspection of the
quality of the body
member of the pantyhose.
[0087] Figures 4, 5, 6, 7, and 8 show a front elevation view, side elevation
view, rear elevation
view, bottom view and top view, respectively, of the pantyhose article 1
according to the example
embodiment when worn. When worn, knits of the pantyhose article 1 are
stretched according to
the silhouette of the wearer.
[0088] The pantyhose article 1 comprises first and second tubular members 8
and 16, and a
gusset 24, which are appropriately joined together to form the pantyhose
article 1.
[0089] The first tubular member 8 extends from a waist end 40 of the pantyhose
article 1 to a foot
end 48 of the first tubular member 8.
[0090] In the embodiment illustrated in Figures 1, 4, 5, 6, 7 and 8, the first
tubular member 8
corresponds to a right side of the pantyhose article 1, but it will be
understood that the actual side
16
8086068
Date Recue/Date Received 2022-12-23
(left or right) will depend on the direction at which the pantyhose article 1
is worn. In various
embodiments, the pantyhose article 1 is directionless in that the first
tubular member 8 can be
interchangeably worn on the left leg or right leg. Similarly, according to
such embodiments, the
second tubular member 16 can be interchangeably worn on the left leg or right
leg.
[0091] The first tubular member 8 includes a plurality of portions
corresponding to different knits
of the first tubular member 8. The first tubular member 8 includes a first
panty portion 56 that
extends from the waist end 40 of the pantyhose article 1 to a bottom end 64 of
the first panty
portion 56. The first panty portion 56 can include at least one waist band 44
at the waist end 40
for ensuring a snug fit when the pantyhose article 1 is worn.
[0092] According to the embodiment illustrated in Figures 1, 4, 5, 6, 7 and 8,
the bottom end 64
of the first panty portion 56 substantially corresponds to a crotch region of
the pantyhose article
1 along a lengthwise direction 72 thereof.
[0093] In another embodiment, the bottom end 64 of the first panty portion 56
is located along a
lengthwise direction 72 that is lower (i.e., closer towards the foot end 48)
than the crotch region
of the pantyhose article 1.
[0094] The first tubular member 8 also includes a first tubular leg portion 80
that extends from a
top end 88 thereof to the first foot end 48 of the first tubular member 8. The
top end 88 of the first
tubular leg portion 80 corresponds to the bottom end 64 of the first panty
portion 56. The first
tubular leg portion 80 of the first tubular member 56 defines a first leg
cavity 92 (Figures 2, 8).
[0095] According to one embodiment, the first foot end 48 of the first tubular
member 8 can be
closed, such as ending in a closed sock, as illustrated in Figures 1, 4, 5,
and 6. In another
embodiment, the first foot end 48 of the first tubular member 8 can have an
opening, such as a
footless pantyhose, such that the first foot end 48 is located proximate the
ankle of the wearer
when the pantyhose article 1 is worn. In yet another embodiment, the first
foot end 48 of the first
tubular member 8 can be partially open, such as a having loop member (ex:
stirrup, toe strap) for
holding the first tubular member 8 in place when worn but otherwise leaving
the foot of the wearer
at least partially exposed.
[0096] The pantyhose article 1 also includes a second tubular member 16
extending from the
waist end 40 of the pantyhose article 1 to a foot end 104 of the second
tubular member 16.
17
8086068
Date Recue/Date Received 2022-12-23
[0097] The second tubular member 16 includes a plurality of portions
corresponding to different
knits of the second tubular member 16. The second tubular member 16 includes a
second panty
portion 112 that extends from the waist end 40 of the pantyhose article 1 to a
bottom end 120 of
the second panty portion 112. The bottom end 120 of the second panty portion
112 can be
substantially aligned with the bottom end 64 of the first panty portion 56.
The second panty portion
112 can also include at least one waist band for ensuring a snug fit when the
pantyhose article 1
is worn. The waist band can be the same as the waist band 44 of the first
tubular member 8.
[0098] According to the embodiment illustrated in Figures 1, 4, 5 and 6, the
bottom end 120 of
the second panty portion 112 substantially corresponds to a crotch region of
the pantyhose article
1 along the lengthwise direction 72 thereof. In another embodiment, the bottom
end 120 of the
first panty portion 112 is located along a lengthwise direction 72 that is
lower (i.e., closer towards
the foot end 104) than the crotch region of the pantyhose article 1.
[0099] The second tubular member 16 also includes a second tubular leg portion
128 that
extends from a top end 136 thereof to the second foot end 104 of the second
tubular member 16.
The top end 136 of the second tubular leg portion 128 corresponds to the
bottom end 120 of the
second panty portion 112. The second tubular leg portion 128 of the second
tubular member 16
defines a second leg cavity 138 (Figures 2, 8).
[00100] According to one embodiment, the second foot end 104 of the second
tubular
member 16 can be closed, such as ending in a closed sock, as illustrated in
Figures 1, 4, 5 and
6. In another embodiment, the second foot end 104 of the second tubular member
16 can have
an opening, such as a footless pantyhose, such that the second foot end 104 is
located proximate
the ankle of the wearer when the pantyhose article 1 is worn. In yet another
embodiment, the
second foot end 104 of the second tubular member 16 can be partially open,
such as having a
loop member (ex: stirrup, toe strap) for holding the second tubular member 16
in place when worn
but otherwise leaving the foot of the wearer at least partially exposed.
[00101] According to one embodiment, and as illustrated in Figures 1, 4, 5
and 6, the first
tubular leg portion 80 of the first tubular member 8 includes a first
principal sub-portion 140 and
a first transitional sub-portion 148. The first principal sub-portion 140
extends from a first thigh
region 156 of the first tubular leg portion 80 to the first foot end 48 of
first tubular member 8 of the
pantyhose article 1. The first transitional sub-portion 148 extends between
the bottom end 64 of
18
8086068
Date Recue/Date Received 2022-12-23
the first panty portion 56 and the upper end of the first principal sub-
portion 140. More particularly,
the first transitional sub-portion 148 extends from the top end 88 of the
first tubular leg portion 80
to the first thigh region 156 of the first tubular leg portion 80. It will be
appreciated that the top end
of the first transitional sub-portion 148 corresponds to the top end 88 of the
first tubular leg portion
80, which also corresponds to the bottom end 64 of the first panty portion 56.
[00102] According to one embodiment, and as illustrated in Figures 1, 4, 5
and 6, the
second tubular leg portion 128 of the second tubular 16 member has a
configuration that
corresponds to that of the first tubular leg portion 80. The second tubular
leg portion 128 of the
second tubular member 16 includes a second principal sub-portion 160 and a
second transitional
sub-portion 164. The second principal sub-portion 160 extends from a second
thigh region 168 of
the second tubular leg portion 128 to the second foot end 104 of second
tubular member 16 of
the pantyhose article 1. The second transitional sub-portion 164 extends
between the bottom end
120 of the second panty portion 112 and the upper end of the second principal
sub-portion 160.
More particularly, the second transitional sub-portion 164 extends from the
top end 136 of the
second tubular leg portion 128 to the first thigh region 168 of second tubular
leg portion 128. It
will be appreciated that the top end of the second transitional sub-portion
164 corresponds to the
top end 136 of the second tubular leg portion 128, which also corresponds to
the bottom end 120
of the second panty portion 112.
[00103] Longitudinal edges 172 of the first panty portion 56 are joined to
respective
longitudinal edges 180 of the second panty portion 112 to form a panty tube
188 that defines a
panty cavity 196 (Figure 2). The edges 172 and 180 can be joined by sewing.
[00104] Figure 2 is a top perspective view of an inside of the pantyhose
article 1 according
to one embodiment when placed on a quality control apparatus. Figure 8 is a
top view of the
pantyhose article 1 according to one embodiment as if worn (the pantyhose
article 1 is shown in
a stretched state as if worn, but the body of the wearer is not shown for
greater clarity). The panty
cavity 196 is in fluid communication with the first leg cavity 92 defined by
the first tubular leg
portion 80 and is also in fluid communication with the second leg cavity 138
defined by the second
tubular leg portion 128.
19
8086068
Date Recue/Date Received 2022-12-23
[00105] When the pantyhose article 1 is worn, the panty cavity 196 receives
a lower torso
of the wearer. The first leg cavity 92 receives a first leg (ex: right leg) of
the wearer and the second
leg cavity 138 receives a second leg (ex: left leg) of the wearer.
[00106] A lower region of longitudinal edges 172 of the first panty portion
56 (i.e. the region
closer to the bottom end 64 of the first panty portion 56) are further joined
to, such as by sewing,
a corresponding lower region of longitudinal edges 180 of the second panty
portion 112 (i.e. the
region close to the bottom end 120 of the second panty portion 112) via the
gusset 24. In this
way, at least one edge of the bottom end 64 of the first panty portion 56 is
joined to, such as by
sewing, the gusset 24 and at least one edge of the bottom end 120 of the
second panty 112 is
also joined to, such as by sewing, the gusset 24.
[00107] Referring now to Figure 3, therein illustrated is a bottom view of
the crotch region
of the pantyhose article 1 according to one embodiment when placed on a
quality control
apparatus. Figure 7 is a bottom view of the pantyhose article according to one
embodiment when
worn. A first bottom edge 204 of the first panty portion 56 is directly joined
(ex: directly sewn) to
a first edge 212 at a first end of the gusset 24, a second bottom edge 220 of
the first panty portion
56 is directly joined (ex: directly sewn) to a first edge 228 at a second end
of the gusset 24, a first
bottom edge 236 of the second panty portion 112 is directly joined (ex:
directly sewn) to a second
edge 244 at the first end of the gusset 24 and a second bottom edge 252 of the
second panty
portion 112 is directly joined (ex: directly sewn) to the second edge 262 at
the second end of the
gusset 24.
[00108] According to the embodiment illustrated in Figures 1 to 8, in which
the bottom ends
64 and 120 of the first and second panty portions 56, 112 substantially
correspond to a crotch
region of the pantyhose article 1, the first transitional sub-portion 148 is
directly joined to the
gusset 24 and the second transitional sub-portion 164 is also directly joined
to the gusset 24. As
best shown in Figure 3, an intermediate region 268 of the first edge of the
gusset 24
(corresponding to the portion of the edge located between the first edge 212
at the first end and
the first edge 228 at the second end of the gusset 24) is directly joined (ex:
directly sewn) to a
portion of an edge 276 of the first transitional sub-portion 148. The joined
portion can be at the
top edge 88 of the first transitional sub-portion 148. Furthermore, an
intermediate region 284 of
the second edge of the gusset 24 (corresponding to the portion of the edge
located between
8086068
Date Recue/Date Received 2022-12-23
second edge 244 at the first end and the second edge 260 at the second edge of
the gusset 24)
is directly joined (ex: directly sewn) to a portion of an edge 292 of the
second transitional sub-
portion 164. The joined portion can be at the top edge 136 of the second
transitional sub-portion
164. Accordingly, the first panty portion 56, the second panty portion 112,
the gusset 24, the first
transitional sub-portion 148 and the second transitional sub-portion 164 are
appropriately joined
to close out (i.e., ensuring no openings or gaps) the crotch region of the
pantyhose article 1 and
to enclose the panty cavity 196.
[00109] According to an alternative embodiment in which the bottom end 64
of the first
panty portion 56 and the bottom end 120 of the second panty portion 112 are
both located along
the lengthwise direction 72 that is lower than the crotch region of the
pantyhose article 1, a first
side of the gusset 24 is directly joined (ex: directly sewn) to corresponding
regions of the
longitudinal edges 172 of the first panty portion 56 and a second side of the
gusset 24 is directly
joined (ex: directly sewn) to corresponding regions of the longitudinal edges
180 of the second
panty portion 112 to close out (i.e. ensuring no openings or gaps) the crotch
region of the
pantyhose article 1 and to enclose the panty cavity 196. According to the
alternative embodiment,
top edges 88, 136 of the first and second leg portions 80 and 128 are not
directly joined (ex:
directly sewn) to the gusset 24.
[00110] According to the embodiment illustrated in Figures 1 to 8, the
thigh region 156 of
the principal sub-portion 140, corresponding to the bottom end of first
transitional sub-portion 148,
is located at a mid-thigh region of the first tubular leg portion 80, which
corresponds to a mid-thigh
region of the first leg of the wearer when the pantyhose article 1 is worn.
Accordingly, the
transitional sub-portion 148 extends from a crotch region of the pantyhose
article 1 to the mid-
thigh region of the first tubular leg member 8. Second transitional sub-
portion 164 also extends
along corresponding regions of the second tubular leg member 16.
[00111] According to another embodiment, the thigh region 156 of the
principal sub-portion
140 is located at an upper thigh region of the first tubular leg portion 80,
which corresponds to an
upper thigh region of the first leg of the wearer when the pantyhose article 1
is worn. Accordingly,
the transitional sub-portion 148 extends from a crotch region of the pantyhose
article 1 to the
upper thigh region of the first tubular leg member 8. Second transitional sub-
portion 164 also
extends along corresponding regions of the second tubular leg member 16.
21
8086068
Date Recue/Date Received 2022-12-23
[00112] According to yet another example, the thigh region 156 of the
principal sub-portion
140 is located at a lower thigh region of the first tubular leg portion 80
(i.e., in proximity of a knee
region), which corresponds to a lower thigh region of the first leg of the
wearer when the
pantyhose article 1 is worn. Accordingly, the transitional sub-portion 148
extends from a crotch
region of the pantyhose article 1 to the lower thigh region of the first
tubular leg member 8. Second
transitional sub-portion 164 also extends along corresponding regions of the
second tubular leg
member 16.
[00113] According to yet another embodiment, the bottom end 64 of the first
panty portion
56, corresponding to a top end 88 of the first tubular leg portion 80 and also
a top end of the first
transitional sub-portion 148, is located along the lengthwise direction 72
that is lower than the
crotch region of the pantyhose article 1 and the thigh region 156 of the
principal sub-portion 140
(ex: a thigh region of first tubular member 8), corresponding to the bottom
end of the first
transitional sub-portion 148, is located at a mid-thigh region of the first
tubular leg portion 80,
which corresponds to a mid-thigh region of the first leg of the wearer when
the pantyhose article
1 is worn. Accordingly, the transitional sub-portion 148 extends from below
the crotch region of
the pantyhose article 1 to the mid-thigh region of the first tubular leg
portion 80. Second panty
portion 112 and second transitional sub-portion 164 also extend along
corresponding regions of
the second tubular leg member 16.
[00114] According to yet another embodiment, the bottom end 64 of the first
panty portion
56, corresponding to a top end 88 of the first tubular leg portion 80 and also
a top end of the first
transitional sub-portion 148, is located along the lengthwise direction 72
that is lower than the
crotch region of the pantyhose article 1 and the thigh region 156 of the
principal sub-portion 140
(ex: a thigh region of the first tubular member 8), corresponding to the
bottom end of the first
transitional sub-portion 148, is located at a lower thigh region of the first
tubular leg portion 80
(i.e. in proximity of a knee region), which corresponds to a lower thigh
region of the first leg of the
wearer when the pantyhose article 1 is worn. Accordingly, the transitional sub-
portion 148 extends
from below the crotch region of the pantyhose article 1 to the lower thigh
region of the first tubular
leg portion 80. Second panty portion 112 and second transitional sub-portion
164 also extends
along corresponding regions of the second tubular leg member 16.
22
8086068
Date Recue/Date Received 2022-12-23
[00115] It will be appreciated that in each of the embodiments described
herein in which
the first and second leg portions 80 and 128 include respective transitional
sub-portions 148 and
164, the transitional sub-portions 148, 164 always extend between bottom ends
64, 120 of the
respective panty portions 56, 112 and a respective thigh region 156, 168 of
the tubular leg portions
80, 128. The length and location of the transitional sub-portions 148, 164
vary according to
whether the top end of transitional sub-portions 148, 164 are located at a
crotch region of the
pantyhose article 1 and where the thigh regions 156 and 168 of the tubular leg
portions 80, 128
are located.
[00116] According to one embodiment, and as illustrated in the Figures,
the first principal
sub-portion 140 of the first tubular leg portion 80 is formed of a first knit
that includes a first
UHMWPE fiber and at least one first companion fiber. The first transitional
sub-portion 148 of the
first tubular leg portion 80 is formed of a second knit comprising a second
UHMWPE fiber and at
least one second companion fiber. The first knit of the first principal sub-
portion 140 of the first
tubular leg portion 80 is different from the second knit of the first
transitional sub-portion 148 of
the first tubular leg portion 80.
[00117] According to one embodiment, the first knit of the first principal
sub-portion 140 is
different from the second knit of the first transitional sub-portion 148 in
that the knitting pattern of
the first knit is different from the knitting pattern of the second knit.
Knitting pattern as it pertains
to the first knit and the second knit refers to how the UHMWPE fiber and the
at least one
companion within the given knit interfaces with one another within the knit.
The difference in
knitting pattern can include, but not limited to, how the UHMWPE fiber and the
least one
companion fiber are looped with one another, hooked with one another, and/or
which UHMWPE
fiber(s) and/or companion fibers(s) are present on courses of the knit.
[00118] According to one example embodiment, the first knit of the first
principal sub-
portion 140 is different from the second knit of the first transitional sub-
portion 148 in that the first
UHMWPE fiber of the first knit is different from the second UHMWPE fiber of
the second knit. The
first and the second UHMWPE fibers may be different in one or more of their
colors, deniers,
tensile strength, modulus, twists per turn, or being covered/uncovered.
[00119] According to one embodiment, the first knit of the first principal
sub-portion 140 is
different from the second knit of the second transitional sub-portion 148 in
that the at least one
23
8086068
Date Recue/Date Received 2022-12-23
first companion fiber of the first knit is different from the at least one
second companion fiber of
the second knit. The set of at least one first companion fiber can include at
least one companion
fiber that is not found in the set of at least one second companion fiber, or
vice versa. The at least
one second companion fiber can include at least one of the first companion
fiber but also at least
one additional second companion fiber that is not found in the set of at least
one first companion
fiber, or vice versa. In one embodiment, the set of at least one second
companion fiber includes
all of the set of at least one first companion fiber but also includes at
least one additional second
companion fiber that is not found in the set of at least one first companion
fiber. Any first fiber and
any second fiber may be different in one or more of their fiber type, fiber
material, fiber structure,
fiber construction, color, denier, tensile strength, modulus,
covered/uncovered, etc.
[00120] In one embodiment, the second knit of the first transitional sub-
portion 148 is
reinforced as compared to the first knit of the first principal sub-portion
140. For example, the
second knit of the first transitional sub-portion 148 has the same UHMWPE
fiber as the first
UHMWPE fiber of the first principal sub-portion 140 and the second knit of the
first transitional
sub-portion 148 also includes at least one companion fiber that is the same as
the at least one
first companion fiber of the first principal sub-portion 140, but the second
knit of the first transitional
sub-portion 148 includes at least one additional companion fiber that is knit
within the second knit
to provide additional reinforcement to the second knit of the first
transitional sub-portion 148
relative to the first knit of the first principal sub-portion 140.
[00121] The second knit of the first transitional sub-portion 148 can have
a greater
durability to sewing as compared to the first knit of the first principal sub-
portion 140 of the first
tubular leg portion 80. Greater durability to sewing herein refers to
durability of the second knit
being punctured by a sewing needle from a sewing operation during assembly
and/or refers to
the second knit being more resistant to tearing from a pulling force applied
by one or more threads
sewn to the second knit from the sewing operation.
[00122] The second knit of the first transitional sub-portion 148 can have
a greater
resistance to runs when torn or cut than the first knit of the first principal
sub-portion 140 of the
first tubular leg portion 80. Resistance to runs refers to resistance to a
tear or cut continuing to
run in a lengthwise direction 72 of the tubular leg member 1 after an initial
tear or cut has been
made.
24
8086068
Date Recue/Date Received 2022-12-23
[00123] According to one embodiment, the second knit of the first
transitional sub-portion
148 includes a mesh knit. The mesh knit refers to a knit in which at every
given number of courses
of a feed that is knitting the mesh knit, a loop of the yarns of that feed is
not made. For example,
the mesh knit can be a 1x1 knit, in which for every 1 course in which a loop
is made, in a second
course a loop is not made. The mesh knit can be a 3 x 1 knit, in which for
every 3 courses in
which a loop is made, in a fourth course a loop is not made. The mesh knit can
be a 5 x 1 knit, in
which for every 5 courses in which a loop is made, in a sixth course a loop is
not made. In a
preferred embodiment, the mesh knit can be 7 x 1 knit, in which for every 7
courses in which a
loop is made, in an eighth course a loop is not made. It was observed that the
mesh knit provides
resistance to runs in that any time a cut or tear in the second knit is made,
the run caused by the
cut or tear is continued until it meets a location within the knit in which a
loop was not made due
to the mesh knit. The absence of a given loop then stops the run. By having a
mesh knit in which
the absence of loop occurs sufficiently frequently, the mesh knit provides
resistance against runs
when the second knit is torn or cut.
[00124] According to one example embodiment, the mesh knit of the second
knit of the first
transitional sub-portion 148 is configured such that the location of a skipped
loop (i.e. a course
where a loop is not made) in a given row of the second knit is offset from the
location of a skipped
loop of an immediately subsequent row of the mesh knit. This non-alignment of
the locations of
the skipped loops across different rows of the mesh knit improves resistance
against runs by
ensuring that any run at any given angular position of a tubular leg member
will eventually
encounter a location of a skipped loop.
[00125] According to one example embodiment, the second knit of the first
transitional sub-
portion 148 includes a plain knit in combination with the mesh knit. The plain
knit is also commonly
called a jersey knit. The plain knit of the second knit can be formed of the
second UHMWPE and
a companion fiber of the second knit, in which the second UHMWPE is the same
as the first
UHMWPE of the first knit of the first principal leg sub-portion 140 and this
companion fiber of the
second knit is the same as the first companion fiber of the first knit. The
mesh knit of the second
knit can be formed of at least one additional companion fiber of the second
knit that is knit within
the plain knit to form the mesh knit according to the configuration of the
mesh knit. For example,
when knitting the plain knit, the at least one additional companion fiber of
the second knit are
8086068
Date Recue/Date Received 2022-12-23
appropriately looped with loops of the plain knit according to the
configuration of the mesh knit
and the at least one additional companion fiber of the second knit is
appropriately skipped (i.e.
loop not made) with loops of the plain knit according to the configuration of
the mesh knit. More
particularly, in a n x 1 mesh knit of the additional companion fiber of the
second knit, in every n
courses of the plain knit formed from the UHMWPE and the second companion
fiber, the
additional companion fiber is also looped with loops of the plain knit, and at
every n+/-th course
of the plain knit, the additional companion fiber is not looped with the plain
knit.
[00126] According to one example embodiment, the mesh knit is made within
the second
knit to provide resistance to runs in a direction along the lengthwise
direction 72 towards the foot
end 48. That is, the mesh knit provides resistance to a run that is started
(ex: from a cut or tear)
at a location closer to the top end 40 of the first tubular leg member 8 and
running towards foot
end 48, such that the run is restricted from continuing downwardly towards the
foot end 48 upon
meeting the mesh knit.
[00127] The second transitional sub-portion 164 of the second tubular leg
portion 128 can
be formed of the same second knit as the first transitional sub-portion 148 of
the first tubular leg
portion 80, being the second knit that includes the at least one second UHMWPE
fiber and the at
least one companion stretch fiber. Accordingly, the second knit of the second
transitional sub-
portion 164 is different from the first knit of the second principal sub-
portion 160 according to the
various manners described herein.
[00128] According to one embodiment, the first panty portion 56 of the
first tubular member
8 is formed of a knit that is free of (i.e., does not include) UHMWPE.
Accordingly, the first panty
portion 56 can be formed of a knit of one or more stretch fibers that is free
of UHMWPE. It was
observed that the UHMWPE fiber is by far the costliest material within the
pantyhose article 1. It
was also observed that the first panty portion 56 is typically worn underneath
one or more other
layers of clothing and is not directly exposed to environmental objects that
can cause rip, tearing
or pilling. Therefore, there is a less of a need to reinforce the first panty
portion 56 with a knit that
includes UHMWPE to obtain increased rip resistant properties. Accordingly, it
was further
observed that the first panty portion 56 is an appropriate area within the
pantyhose article 1 where
UHMWPE can be omitted without substantially reducing the performance of the
pantyhose article
1. However, and as described elsewhere herein, additional adaptions may be
required elsewhere
26
8086068
Date Recue/Date Received 2022-12-23
in the pantyhose article 1 to account for the first panty portion 56 being
formed of a knit that is
free of UHMWPE. The second panty portion 112 of the second tubular member 16
can also be
formed of a knit that is free of UHMWPE in the same manner as the first panty
portion 56. The
first panty portion 56 and the second panty portion 112 can be formed of the
same knit.
[00129] The first tubular member 8 is formed or manufactured in a
continuous knitting
operation. More particularly, the first panty portion 56, the first
transitional sub-portion 148 and
the first principal sub-portion 140 are formed within the same continuous
knitting operation.
Continuous knitting operation refers to a single continuous run by a knitting
machine, such as
circular knitting machine, such that the various portions of the first tubular
member 8 (ex: first
panty portion 56, first transitional sub-portion 148 and first principal sub-
portion 140) that results
from the continuous knitting operation are contiguous or integrally formed. In
such a continuous
knitting operation, after knitting a given portion of the first tubular member
8 (ex: the first panty
portion 56), the next portion of the first tubular member 8 (ex: the first
transitional sub-portion 148)
is knit by continuing from the last interface of fibers (ex: last loops of the
knit forming the first panty
portion 56) of the just-completed given portion. The knit is continued by
swapping from the fibers
and knitting pattern of the just-completed given portion and continuing the
knit with the appropriate
fibers and knitting pattern of the next portion of the first tubular member 8.
It will be understood
that the continuous knitting operation of the first tubular member 8 does not
produce, at any point
during the knitting operation, the first panty portion 56, the first
transitional sub-portion 140 and
the first principal sub-portion 148 as separate and discrete pieces that then
need to be joined
together in any manner, such as through sewing the pieces together.
[00130] It was observed that the interface between different knits within
the first tubular
member 8 can produce a weak spot within the first tubular member 8. This weak
spot can lead to
defects, such as tearing or ripping at such an interface, developing within
the pantyhose article 1.
The defects can develop due to repeated stresses being applied to the
pantyhose article 1, such
as from repeated pulling and stretching in the longitudinal direction 72, a
wearer is putting on the
pantyhose article 1. The transition can also cause discomfort when the
pantyhose article 1 is
worn.
[00131] The continuous knitting of the first panty portion 56 and the
second knit of the first
transitional sub-portion 148 reduces tearing along the transition between
these two sub-portions,
27
8086068
Date Recue/Date Received 2022-12-23
which transition corresponds to the bottom end 64 of the first panty portion
56. The second knit
of the first transitional sub-portion 148 is also chosen to improve durability
along this transition at
the bottom end 64 and to reduce tearing. According to one embodiment, one of
the one or more
stretch fibers used in the knit of the first panty portion 56 is also present
in the second knit of the
first transitional sub-portion 148, which ensures continuity in the knit at
the transition between the
panty portion 56 and the first transitional sub-portion 148 and thereby also
reduces likelihood of
tearing. This transition can also improve comfort.
[00132] The continuous knitting of the first transitional sub-portion 148
and the principal
sub-portion 140 reduces tearing along the transition between these two
portions, which transition
corresponds to the first thigh region 156 of the tubular leg portion 80. The
second knit of the first
transitional sub-portion 148 and the first knit of the first principal sub-
portion 140 are chosen to
improve durability along this transition at the first thigh region 156 and to
reduce tearing. According
to one embodiment, the same combination of the UHMWPE and the companion fiber
of the first
knit of the first principal sub-portion 140 is also present in the second knit
of the first transitional
sub-portion 148, which ensures continuity in the knit at the transition
between the first transitional
sub-portion 148 and the principal sub-portion 140 and thereby also reducing
likelihood of tearing.
This transition can also improve comfort.
[00133] It will be appreciated that the inclusion of the first transitional
sub-portion 148 within
the first tubular leg member 8 creates two knit transitions: the first
transition between the first
panty portion 56 and the first transitional sub-portion 148 at the bottom end
64 of the first panty
portion 56 and the second transition between the first transitional sub-
portion 148 and the first
principal sub-portion 140 at the thigh region 156. Accordingly, a pulling
force applied in a
longitudinal direction 72 of the first tubular member 8, such as from a wearer
putting on the
pantyhose article 1, is distributed between the first and second transitions.
This distribution of the
pulling force can reduce the likelihood of tearing compared to the first
tubular member 8 having a
single transition (ex: a single transition from the panty portion 56 directly
to the first principal sub-
portion 140).
[00134] As described herein above, the second knit of the first
transitional sub-portion 148
can optionally be chosen so that there is a continuity between the knit of the
first panty portion 56
and the second knit of the first transitional sub-portion 140 provided by
these two knits having a
28
8086068
Date Recue/Date Received 2022-12-23
common fiber with their respective knits. Furthermore, the second knit of the
first transitional sub-
portion 148 can optionally be chosen so that there is a continuity between the
knit of the first
transitional sub-portion 148 and the first knit of the first principal sub-
portion 140 provided by these
two knits having at least one common fiber within their respective knits. It
was observed that given
the thinness of the knit of the first panty portion 56 (ex: below 200 total
denier) so that it can be
worn discreetly under tight-fitting clothing, the direct transition of the
lower denier of the first panty
portion 56 to the first knit of the principal sub-portion 140 was prone to
tearing. The addition of
the first transitional sub-portion 148 as an intermediate knit between the
first panty portion 56 and
the first knit of the principal sub-portion 140 addresses this weakness that
would otherwise be
present in a tubular member that essentially includes only the first panty
portion and the principal
sub-portion.
[00135] According to one embodiment, the first panty portion 56 is formed
of a knit having
a total denier of about 20 to about 250. It will be appreciated that this knit
of the first panty portion
56 has a sufficiently low denier such that it can be worn underneath form-
fitting clothes, such as
a hip-hugging dress or skirt. According to one embodiment, the first panty
portion 56 is formed
essentially of a knit of a nylon fiber having a denier of about 20 to about
100 and nylon-covered
elastane fiber having a denier of about 20 to about 120. In one embodiment,
the nylon fiber is a
two-plied 40 denier nylon fiber, and the nylon-covered elastane fiber consists
of two 20 denier
elastane covered by 40 denier nylon.
[00136] It will be appreciated that the first principal sub-portion 140,
when worn on the leg,
will typically be exposed to environmental elements likely to cause ripping
and/or tearing. The first
knit of the first principal sub-portion 140 is chosen to have at least rip
resistant and pilling resistant
properties. Because the first principal sub-portion 140 is exposed and will be
visible, the first knit
is chosen to also have desired aesthetic characteristics. According to one
example embodiment,
the first UHMWPE fiber of the first knit of the first principal sub-portion
140 includes a first
UHMWPE fiber having a denier of about 10 to about 60 and the first companion
fiber has a denier
of about 10 to about 100. The first UHMWPE fiber and the first companion fiber
can be knit in a
plated knit according to various example embodiments described herein having
different
appearances.
29
8086068
Date Recue/Date Received 2022-12-23
[00137] According to one example embodiment where the first principal sub-
portion 140 is
to have a sheer appearance, the first UHMWPE fiber of the first knit has a
denier of about 25 to
about 35 and the first companion fiber essentially includes a stretch fiber
having a denier of about
to about 20. According to one example embodiment, the first UHMWPE fiber has a
denier of
about 30 and the stretch fiber is a nylon covered elastane of about 15 denier.
[00138] According to one example embodiment where the first principal sub-
portion 140 is
to have a semi-sheer appearance, the first UHMWPE fiber of the first knit has
a denier of about
25 to about 35 and the first companion fiber includes fibers having a total
denier of about 40 to
about 80. According to one example embodiment, the first UHMWPE fiber has a
denier of about
30 and the companion fiber includes one or more nylon covered elastane fiber
having a total
denier about 50.
[00139] According to one example embodiment where the first principal sub-
portion 140 is
to have an ultra-sheer appearance, the first UHMWPE fiber of the first knit
has a denier of about
10 to about 20 and the first companion fiber includes fibers having a total
denier of about 5 to
about 15. According to one example embodiment, the first UHMWPE fiber has a
denier of about
and the first companion fiber is a fiber of about 9 denier covered elastane.
[00140] According to one example embodiment, where the first principal sub-
portion 140
is to have a semi-opaque appearance, the first UHMWPE fiber of the first knit
has a denier of
about 25 to about 50 and the first companion fiber includes fibers having a
total denier of about
60 to about 150. According to one example embodiment, the first UHMWPE fiber
has a denier of
about 30 and the first companion is a fiber of about 75 denier cover elastane.
[00141] According to one example embodiment, the second knit of the first
transitional
sub-portion 148 is formed of a second UHMWPE fiber having a denier of about 10
to about 60
and the second companion fiber has a total denier of about 50 to about 150.
According to one
example embodiment of the second knit that is to be combined with the first
principal sub-portion
140 having the sheer appearance, the second UHMWPE fiber of the second knit
also has a denier
of about 25 to about 35, preferably about 30 denier, which UHMWPE is knit with
a second
companion fiber essentially including a stretch fiber having a denier of about
10 to about 20,
preferably a covered elastane of about 15 denier. The second UHMWPE fiber and
this second
companion fiber can be knit in a plated knit. It will be appreciated that this
UHMWPE fiber and
8086068
Date Recue/Date Received 2022-12-23
this companion fiber is common to both the first knit of the principal sub-
portion 140 and the first
transitional sub-portion 148. The second knit of the first transitional sub-
portion 148 also includes
a mesh knit, as described elsewhere herein. The mesh knit can be formed with
an additional
companion fiber that includes a nylon-covered lycra fiber having a denier of
about 40 to about
120, preferably two 20 denier elastane covered by 40 denier nylon. It will be
appreciated that this
additional companion fiber of the second knit of the first transitional sub-
portion 148 is also present
in the knit of the first panty portion 56.
[00142] According to one embodiment, and as illustrated in Figures 1,4, 5,
6, 7 and 8, the
first tubular member 8 is manufactured in a directionless manner about its
longitudinal axis 212.
That is, prior to being assembled with the gusset 24 and the second tubular
member 16, the first
tubular member 8 is identical at any angular position about its longitudinal
axis 212. The first panty
portion 56 extends circumferentially about the longitudinal axis 212 so that a
cut can be made at
any angular position about the longitudinal axis 212 to form its longitudinal
edges 172 for joining
to corresponding edges 180 of the second panty portion 112. The second tubular
member 16 can
be manufactured in a similarly directionless manner about its respective axis.
[00143] The first transitional sub-portion 148 also extends
circumferentially about the
longitudinal axis 212 and about the first tubular leg portion 80. According to
embodiments in which
an edge of the first transitional sub-portion 148 is directly joined to an
edge of the gusset 24, the
joint between that edge 228 of the first transitional sub-portion 148 and that
edge of the gusset
24 can be made at any angular position of the tubular leg portion 80 about the
longitudinal axis
212 (as long as this angular position is common to both the first principal
sub-portion 140 and the
first transitional sub-portion 148). That is, the joint need not be made at an
exact angular
region/position of the circumferential edge 228 of the first transitional sub-
portion 148 that is
predefined after making the first tubular leg portion 80. The second
transitional sub-portion 164
can also extend circumferentially about the second tubular leg portion 128
about its respective
axis.
[00144] Furthermore, the cut in the first panty portion 56 is made in the
longitudinal
direction 72 from the top edge 40 towards the bottom edge 64, and may extend
slightly into the
first transitional sub-portion 148. This cut would otherwise cause a run in
the first tubular member
8, but the run is restricted from continuing towards the foot end 48 of the
first tubular member 8
31
8086068
Date Recue/Date Received 2022-12-23
due to the presence of the reinforcing knit (ex: mesh knit) in the first
transitional sub-portion 148.
Furthermore, since the first transitional sub-portion 148 extends
circumferentially about the first
tubular 8, the cut can be made at any angular position about the axis 212 and
the reinforcing knit
of the first transitional sub-portion 148 will provide the restriction to the
continuing of the run. The
second transitional sub-portion 164 that extends circumferentially about its
respective axis of the
second tubular leg portion 128 provides a similar restriction to continuing of
a run caused by
making the cut in the second panty portion 112 to form longitudinal edges 180.
[00145]
As described elsewhere herein according to various embodiments, the first and
second transitional sub-portions 148, 164 of respective first and second leg
portions 80 and 128
extend between bottom ends of the respective panty portions 56, 112 and
respective thigh regions
156, 168 of the tubular leg portions 80, 128. Due to this positioning, when
the pantyhose article 1
is worn, the first and second transitional sub-portions 148, 164 will be
located at the thigh regions
of each leg of the wearer. Furthermore, since each of the first transitional
sub-portion 148 and
second transitional sub-portion 164 extend circumferentially about their
respective leg portions
80, 128, when the pantyhose article 1 worn, a first inner thigh region at the
thigh height of the first
leg of the wearer will be covered by a first corresponding angular region of
the first transitional
sub-portion 148 and a second inner thigh region at the thigh height of the
second leg of the wearer
will be covered by a second corresponding angular region of the second
transitional sub-portion
164. It will be appreciated that the first corresponding angular region of the
first transitional sub-
portion 148 will face the second corresponding singular region of the second
transitional sub-
portion 164 when the pantyhose article 1 is worn (since the first inner thigh
region of the first leg
will be facing the second inner thigh region of the second leg). It was
observed that the rubbing
of the first and second inner thigh regions of the wearer is a common cause of
wearing out or
failing of the legwear. It was further observed that the positioning of the
first transitional sub-
portion 148 and the second transitional sub-portion 164 at the thigh heights
on respective first
and second tubular leg portion offered greater protection against wearing out
or failing of the
pantyhose article 1 due to inner thigh rubbing. It will be appreciated that
the second knit of the
first and second transitional sub-portion 148, 164 is a knit that includes
UHMWPE fiber knit with
at least one companion fiber, and the inclusion of the UHMWPE fiber, being
more durable,
provides the increased protection against wearing out or failing of the knit.
32
8086068
Date Recue/Date Received 2022-12-23
[00146] According to a method for manufacturing the pantyhose article 1
according to an
embodiment, a first tubular member 8 is a manufactured. As described herein,
the first tubular
member 8 is manufactured in a continuous knitting operation, such as using a
circular knitting
machine. A second tubular member 16 is also manufactured. As described herein,
the second
tubular member 16 is also manufactured in a continuous knitting operation,
such as using a
circular knitting machine.
[00147] After forming the first tubular member 8 and the second tubular
member 16, the
tubular members 8, 16 are appropriately cut and joined to form the pantyhose
article 1. The first
tubular member 8 being manufactured in a directionless manner, in which the
first panty portion
56 extends circumferentially about the longitudinal axis 212 and the first
transitional sub-portion
148 also extends circumferentially about the longitudinal axis 212 (and the
second tubular
member 16 having these same properties) allows the pantyhose article 1 to be
assembled in a
substantially automatic process. Automatic assembly process herein refers to
carrying out one or
more machine-made cuts, alignments and/or joints (ex: sewing lines) without
manual human
intervention. After the first tubular member 8 and the second tubular member
16 have both been
knit by a knitting machine, the tubular members 8 and 16 are appropriately
loaded onto an
automatic assembly machine. Since the first tubular member 8 is directionless
and has a first
panty portion 56 that extends circumferentially about the longitudinal axis
212, a cut in the
longitudinal direction 72 can be in the panty portion 56 at any angular
position of the first tubular
member 8 to form the longitudinal edges 172 thereof. A cut can be made in a
similar manner in
the second tubular member 16 to form the longitudinal edges 180.
[00148] Furthermore, according to embodiments in which an edge of the first
transitional
sub-portion 148 is directly joined to an edge of the gusset 24, since the
first transitional sub-
portion 148 extends circumferentially about the longitudinal axis 212, any
region of the edge 228
of the top edge of the transitional sub-portion 140 is suitable for sewing to
the gusset 24. The
edge 228 of the transitional sub-portion 140, corresponding to the angular
position of the first
tubular member 8 at which the cut in the panty portion 56 is made, is joined
(ex: sewn) to the
gusset 24. The joint (ex: sewing line) to the gusset 24 can be made in a
similar manner in the
second transitional sub-portion 164.
33
8086068
Date Recue/Date Received 2022-12-23
[00149] The longitudinal edges 172 of the first panty portion 56 are
further joined (ex: sewn)
to the longitudinal edges 180 of the second panty portion 112 to form the
panty tube 188. Edges
of the panty portions 56, 112 are further sewn to corresponding edges of the
gusset 24 to close
out any gaps and enclose the panty cavity 196.
[00150] It will be understood that depending on the configuration and
capabilities of the
assembly machine, steps described above for automatically assembling the
pantyhose article 1
can be performed in a different order than as described. Furthermore, one or
more steps can be
performed in a single operation, such as sewing multiple edges together in a
single sewing
operation.
[00151] As described elsewhere herein, the first tubular member 8 and
second tubular
member 16 are made in a continuous knitting operation on a circular knitting
machine. According
to some example embodiments, the tubular leg member 8, 16 is formed by
continuously feeding
fibers from a same number of yarn feeds of the knitting machine throughout the
full continuous
knitting operation, i.e., throughout knitting the panty portion 56, 112, the
transitional sub-portion
148, 164 and the principal sub-portion 140, 160. In one embodiment, the
tubular leg members 8,
16 are each formed using 2 feeds of the knitting machine throughout the full
continuous knitting
operation.
[00152] It was observed that the first and second principal sub-portions
140, 160 and the
first and second transitional sub-portions 148, 164, which are each formed of
a knit having
UHMWPE, requires knitting at a lesser (i.e., 2 feeds or less) number feeds due
to complexities
introduces from properties of the UHMWPE. It was also observed that the panty
portion 56, 112,
being free of the UHMWPE, can be knit at a higher number of feeds (i.e.,
greater than 2 feeds,
for example 4 feeds or more) of the knitting machine. It was further observed
that transitioning
from knitting 4 feeds or more (to the knit panty portion 56, 112) to knitting
at 2 feeds or less (to
knit the transitional sub-portions 148, 164, and the principal sub-portions
140, 160) introduced a
weakness within the tubular leg members 8, 16, at the location of that
transition. This weakness
can be in the form of a hole within the tubular leg members 8, 16 at that
transition. However, it
was also observed that knitting the tubular leg members 8, 16 by continuously
feeding fibers from
a same number of feeds of the knitting machine throughout the full continuous
knitting operation
eliminated this weakness, thereby increasing the strength/durability of the
knit.
34
8086068
Date Recue/Date Received 2022-12-23
[00153]
While the above description provides examples of the embodiments, it will be
appreciated that some features and/or functions of the described embodiments
are susceptible
to modification without departing from the spirit and principles of operation
of the described
embodiments. Accordingly, what has been described above has been intended to
be illustrative
and non-limiting and it will be understood by persons skilled in the art that
other variants and
modifications may be made without departing from the scope of the invention as
defined in the
claims appended hereto.
8086068
Date Recue/Date Received 2022-12-23
