Note: Descriptions are shown in the official language in which they were submitted.
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TUBULAR GARMENT
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims all benefit, including priority of U.S.
Provisional
Patent Application No. 63/108,132, filed October 30, 2020, the entire contents
of
which are incorporated herein by this reference.
TECHNICAL FIELD
[0002] The disclosure relates generally to wearable electronics, and more
specifically to smart textiles.
BACKGROUND
[0003] Smart textiles are materials that sense and/or react to environmental
conditions or stimuli, such as those from mechanical, thermal, chemical,
electrical, magnetic or other sources. There is a need for improved ways for
forming smart textiles into wearable garments of different types and
configurations.
SUMMARY
[0004] In an aspect, there is provided a method of manufacturing a tubular
garment using a knitting machine that includes a first knitting bed and a
second
knitted bed. The method includes: knitting a first fabric panel using a first
subset
of knitting needles of the first knitting bed and knitting a second fabric
panel
using a first subset of needles of the second knitting bed, the first fabric
panel
and the second fabric panel being joined to define a first tubular portion of
the
tubular garment; transferring the first fabric panel from the first knitting
bed to the
second knitting bed, the first fabric panel thereupon being held by a second
subset of needles of the second knitting bed; knitting a third fabric panel on
the
first knitting bed using a second subset of needles of the first knitting bed;
joining
the third fabric panel to the first fabric panel to define a second tubular
portion of
the tubular garment; disposing an electrically conductive bus in the second
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tubular portion for electrical communication with at least one conductive yarn
integrated within the tubular garment.
[0005] In another aspect, there is provided a first fabric panel; a second
fabric
panel that is adjoined to the first fabric panel, the second fabric panel
being
formed integrally with the first fabric panel to define a first tubular
portion of the
tubular garment; a third fabric panel that is adjoined to the first fabric
panel on a
surface of the first fabric panel, the third fabric panel and the first fabric
panel
defining a second tubular portion, wherein a conductive bus is disposed within
the second tubular portion for electrical communication with at least one
.. conductive yarn integrated within the tubular garment.
[0006] Further details of these and other aspects of the subject matter of
this
application will be apparent from the detailed description included below and
the
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Reference is now made to the accompanying drawings, in which:
[0008] FIG. 1 is a schematic diagram of a system used for manufacturing a
tubular garment, in accordance with an embodiment;
[0009] FIGS. 2A-20 are a top view, front perspective view, side view and front
view, respectively, of a tubular garment, in accordance with an embodiment;
.. [0010] FIG. 3 is a cross-sectional view of a first fabric panel of a
tubular
garment having conductive yarn inlaid within the first fabric panel, in
accordance
with an embodiment;
[0011] FIGS. 4A-4C are a front perspective view, a rear elevation view, and a
rear perspective view, respectively, of a tubular garment having a plurality
of
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electronic components integrated within a tubular portion of the tubular
garment,
in accordance with an embodiment;
[0012] FIG. 5 is a flowchart illustrating an example method for manufacturing
a
tubular garment, in accordance with an embodiment;
.. [0013] FIG. 6A is a perspective view of a configuration of a knitting
machine
when knitting a first fabric panel and a second fabric panel of a tubular
garment,
in accordance with an embodiment;
[0014] FIG. 6B is a perspective view of a configuration of a knitting machine
after the first fabric panel of FIG. 5A is temporarily transferred from a
first knitting
bed to a second knitting bed and during knitting of a third fabric panel of a
tubular garment, in accordance with an embodiment;
[0015] FIG. 6C is a perspective view of a configuration of knitting machine
after
the first fabric panel of FIG. 5B is transferred back to a first knitting bed
and after
the third fabric panel of FIG. 5B is knitted, in accordance with an
embodiment;
.. and
[0016] FIG. 7 is a perspective view of a tubular garment, in accordance with
an
embodiment.
DETAILED DESCRIPTION
[0017] The following description discloses tubular garments and methods
useful for manufacturing a tubular garment.
[0018] In some embodiments, a tubular garment disclosed herein include a first
tubular portion defined by a first fabric panel and a second fabric panel and
a
second tubular portion defined by the first fabric panel and a third fabric
panel. A
conductive bus including one or more electrically conductive wires may be
.. disposed within the second tubular portion between the first fabric panel
and the
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third fabric panel. The conductive bus may be electrically coupled to at least
one
electrically conductive yarn integrated within the tubular garment.
[0019] In some embodiments, the methods disclosed herein for manufacturing
the tubular garment may include knitting the first fabric panel in a first
knitting
bed of a knitting machine and knitting the second fabric panel in a second
knitting bed of the knitting machine. In some embodiments, the methods
disclosed herein may include temporarily transferring the first fabric panel
from
the first knitting bed to the second knitting bed to allow the third fabric
panel to
be knitted in the first knitting bed.
[0020] Aspects of various embodiments are described through reference to the
drawings.
[0021] FIG. 1 is a schematic diagram of a system 10 for manufacturing tubular
garment 22 (as shown in FIG. 2A-20). System 10 may include controller 14 and
one or more user input devices 12 (referred hereinafter in the singular).
Controller 14 may be configured to receive input from user input device 12 via
one or more communication terminals/ports.
[0022] Controller 14 may include one or more data processors 20 (referred
hereinafter in the singular) and one or more computer-readable memories 16
(referred hereinafter in the singular) storing machine-readable instructions
18
executable by data processor 20 and configured to cause data processor 20 to
generate one or more outputs (e.g., signals) for causing the execution of one
or
more steps of the methods described herein.
[0023] Data processor 20 may include any suitable device(s) configured to
cause a series of steps to be performed by controller 14 so as to implement a
computer-implemented process such that instructions 18, when executed by
controller 14 or other programmable apparatus, may cause the functions/actions
specified in the methods described herein to be executed. Data processor 20
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may include, for example, any type of general-purpose microprocessor or
microcontroller, a digital signal processing (DSP) processor, an integrated
circuit, a field programmable gate array (FPGA), a reconfigurable processor,
other suitably programmed or programmable logic circuits, or any combination
.. thereof.
[0024] Memory 16 may include any suitable machine-readable storage
medium. Memory 16 may include non-transitory computer readable storage
medium such as, for example, but not limited to, an electronic, magnetic,
optical,
electromagnetic, infrared, or semiconductor system, apparatus, or device, or
any
suitable combination of the foregoing. Memory 16 may include a suitable
combination of any type of computer memory that is located either internally
or
externally to controller 14. Memory 16 may include any storage means (e.g.
devices) suitable for retrievably storing machine-readable instructions 18
executable by data processor 20.
[0025] User input device 12 may be an electronic device having a graphical
user interface (GUI) such as a desktop computer, laptop computer or a mobile
device such as a tablet for example. User input device 12 may be configured to
receive user inputs from an operator. The user inputs may include computer-
readable instructions related to a desired knitting pattern for a textile
article.
[0026] The computer-readable instructions may include manufacturing
instructions for controlling the operation of a knitting machine to construct
tubular
garment 22.
[0027] Tubular garment 22 may be formed of one or more fabric panels 24A-
24C (as shown in FIGS. 2A-20) (hereinafter collectively referred to as "fabric
panels 24") composed yarn. This yarn includes non-conductive yarn, and as
detailed below, may also include conductive yarn. The non-conductive yarn can
include any textile material such as cotton, spandex, nylon, polyester, and/or
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various synthetic materials. The computer-readable instructions may indicate
an
arrangement of the non-conductive yarn in fabric panels 24. In some
embodiments, conductive yarn may be inlaid within one or more fabric panels 24
to provide conductive paths.
[0028] The computer-readable instructions may indicate the material of the
non-conductive yarn and the material of the conductive yarn used to
manufacture tubular garment 22. The computer-readable instructions may
indicate one or more locations where a conductive path electrically couples a
conductive bus that is not inlaid within the one or more fabric panels. In
some
embodiments, the locations may be on a surface of one of the fabric panels.
[0029] Controller 14 may be configured to process the computer-readable
instructions to determine a set of operating parameters for one or more
machines. Controller 14 may be further configured to generate a plurality of
signals indicative of the determined operating parameters for the one or more
machines. Controller 14 may be configured to transmit each signal of the
plurality of signals to a respective machine of the one or more machines via
the
one or more communication terminals/ports. The one or more machines may
include knitting machine 21.
[0030] In some embodiments, system 10 may include a suitable
combination for machines for forming electrical connections in tubular garment
22, e.g., between any combination of electrically conductive yarns, a
conductive
bus, conductive wires, and electronic components of tubular garment 22. Such
machines may include, for example, a soldering machine and/or a welding
machine, embodiments of which are described, for example, in PCT Patent
Application No. W02021/119828, entitled "METHOD OF MANUFACTURING
TEXTILES WITH INTEGRATED ELECTRICAL PATHS AND ELECTRONICS"
(hereinafter referred to as the '828 patent application), the entire contents
of
which are herein incorporated by reference.
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[0031] In some embodiments, system 10 may include one or more sewing
machines, e.g., for sewing on trim or other features of tubular garment 22.
[0032] In some embodiments, system 10 may include machines for
implementing wet processing of tubular garment 22, including washing and
drying machines.
[0033] Knitting machine 21 may be a computerized flat bed knitting machine.
Knitting machine 21 may include first knitting bed 80A and second knitting bed
80B (hereinafter referred to as "knitting beds 80", as shown in FIGS. 6A-6C).
Knitting machine 21 may include a cam system for independently controlling a
position of one or more knitting needle in a knitting bed 80. Each knitting
needle
may be positioned to be in a non-working position or a working position.
Needles
in a non-working position may not move or knit when a carriage of knitting
machine 21 is moved. In some embodiments, knitting machine 21 is a flat bed
knitting machine that has a v-shaped bed configuration and may be referred to
as a v-bed knitting machine.
[0034] In some embodiments, knitting machine 21 could be a suitable machine
manufactured by Stoll, Shima Siekie or any other suitable flat bed knitting
machine that allow for the transfer and temporary holding of a fabric panel on
needles not being used for knitting.
.. [0035] Knitting machine 21 may be configured to receive one or more signals
indicative of operating parameters for knitting machine 21 from controller 14.
Knitting machine 21 may include a separate controller having one or more data
processors and one or more computer-readable memories storing machine-
readable instructions executable by the one or more data processors (not
depicted). In some embodiments, the one or more signals from controller 14
may be received by the controller of knitting machine 21. In response to
receiving the one or more signals, knitting machine 21 may be configured to
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operate under the defined operating parameters set out in the one or more
signals received. When operating under these operating parameters, knitting
machine 21 may be configured to form tubular garment 22 by knitting non-
conductive yarn and/or conductive yarn in accordance with the desired knitting
.. pattern received from user input device 12.
[0036] In some embodiments, controller 14 may be part of knitting machine 21
and the operation of knitting machine 21 may be directly controlled by such an
integrated controller 14.
[0037] FIGS. 2A-20 show a top view, front perspective view, side view and
.. front view, respectively, of tubular garment 22. Tubular garment 22 may
include
first fabric panel 24A, second fabric panel 24B, and third fabric panel 24C.
Each
fabric panel 24 may include one or more non-conductive layers. In some
embodiments, first fabric panel 24A and second fabric panel 24B may be
integrally formed to define first tubular portion 26. First tubular portion 26
may
.. define an opening between first fabric panel 24A and second fabric panel
24B
for receiving a limb (or other body portion) of a wearer of tubular garment
22. In
use, a portion of the limb of the wearer may be covered by first fabric panel
24A
and second fabric panel 24B. In some embodiments, tubular garment 22 may be
a wearable sock having first tubular portion 26 sized to fit a foot of a
wearer of
tubular garment 22. In a situation where tubular garment 22 is a sock, first
tubular portion 26 may have an open end and a closed end (not depicted). In
use, the closed end may be positioned in the region of the wearer's toes and
the
open end may be positioned between the wearer's calf muscle and the wearer's
knee.
[0038] Although tubular garment 22 is depicted as being a sock in FIGS. 2B
and 20, it should be understood that in alternate embodiments, tubular garment
28 may be a knee brace, elbow sleeve, multiclava, neck warmer, stocking,
legging, or the like.
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[0039] Third fabric panel 24C may be joined to first fabric panel 24A on
surface
30 of first fabric panel 24A. As depicted, surface 30 of first fabric panel
24A
faces away from second fabric panel 24B. First fabric panel 24A and third
fabric
panel 24C may define a second tubular portion 40 of tubular garment 22.
Second tubular portion 40 may be a close-ended tube defining cavity 32
between first fabric panel 24A and third fabric panel 24C. As depicted in
FIGS.
2B and 20, cavity 32 may include narrow portion 32A and wide portion 32B.
Third fabric panel 24C may be stitched to first fabric panel 24A along a
perimeter
of third fabric panel 24C. Tubular garment 22 may also have one or more
additional stitches 31 between a lower portion of third fabric panel 24C that
defines wide portion 32B of cavity 32 and first fabric panel 24A. Stitches 31
between the lower portion of third fabric panel 24C and first fabric panel 24A
cause the lower portion of third fabric panel 24C to be closely pressed up
against surface 30 of first fabric panel 24A. The one or more additional
stitches
31 may extend horizontally across tubular garment 22. Such stitches 31 may
also serve to divide wide portion of cavity 32 into a plurality of horizontal
regions.
As shown in FIG. 2B, additional stitches 31 may be used to join first fabric
panel
24A and second fabric panel 24B. As shown in FIG. 2C, additional stitches 31
may be used to join first fabric panel 24A and third fabric panel 24C.
.. [0040] As depicted in FIG. 2B, tubular garment 22 may include conductive
bus
28 disposed within second tubular portion 40 to provide electrical
communication
with at least one conductive yarn 34 integrated in tubular garment 22.
Conductive bus 28 may include one or more conductive wires that are
electrically coupled to power source 38 (e.g., a battery). Conductive bus 28
may
be disposed within narrow portion 32A of cavity 32 and may be electrically
coupled to conductive yarn 34 at locations 36A and 36B. Conductive bus 28 may
be easily accessible in cavity 32 by a person. Power source 28 may be external
to tubular garment 22 or may be disposed within cavity 32. Power source 28
may be easily accessible by a person allowing quick replacement of power
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source 28 if required. Conductive yarn 34 may be made of any conductive
material including conductive metals such as stainless steel, silver,
aluminium,
copper, etc. As depicted in FIG. 2B, first conductive wire 28A of conductive
bus
28 may connect conductive yarn 34 to a positive terminal of power source 38,
and a second conductive wire 28B may connect conductive yarn 23 to a
negative terminal of power source 38.
[0041] In some situations, as depicted in FIGS. 2B-2C, conductive yarn 34
may be disposed within cavity 32 between first fabric panel 24A and third
fabric
panel 24C. In these situations, conductive yarn 34 may be disposed within wide
portion 32B of cavity 32 and locations 36A and 36B may be at an interface
between narrow portion 32A and wide portion 32B of cavity 32. In some
embodiments, conductive yarn 34 may be soldered or ultrasonically welded to
first conductive wire 28A and second conductive wire 28B at locations 36A and
36B, respectively, in order to provide said electrical coupling. In some
embodiments, the methods of forming an electrical connection between
conductive yarn 34 and conductive bus 28 are similar to the methods described
in the '828 patent application.
[0042] Conveniently, disposing at least part of conductive bus 28 and/or at
least part of conductive yarn 34 within cavity 32 inhibits contact of such
parts
with skin of a wearer of tubular garment 22. This may improve comfort and/or
safety of wearer. This may also improve durability tubular garment 22, e.g.,
by
reducing wear caused by contact of such parts with the wearer.
[0043] In some situations, conductive yarn 34 may be inter-knit with non-
conductive yarns of tubular garment 22. FIG. 3 shows a cross-sectional view of
first fabric panel 24A having conductive yarn 34 inlaid within first fabric
panel
24A. As depicted in FIG. 3, at least a portion of conductive yarn 34 may be
disposed between non-conductive yarns of first fabric panel 24. At least a
portion of conductive yarn 34 may be inlaid within first fabric panel 24A such
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conductive yarn 34 is at sufficient distance from surface 42 of first fabric
panel
24. Surface 42 of first fabric panel is opposite surface 30 and may be in
contact
with a limb of a wearer when tubular garment 22 is worn by the wearer.
Conductive yarn 34 being disposed at a sufficient distance from surface 42 may
.. provide thermal and/or electrical protection for the wearer. In some
embodiments, a substantial portion of conductive yarn 34 may be disposed in a
middle section of first fabric panel 24A. Conductive yarn 34 may extend from
the
middle section to surface 30 of first fabric panel 24A to be electrically
coupled to
conductive bus 28 at locations 36A and 36B. In some embodiments, the
.. conductive yarn 34 may be soldered or ultrasonically welded to conductive
bus
28 in order to provide said electrical coupling.
[0044] In some embodiments, at least a portion of conductive yarn 34 is inlaid
within second fabric panel 24B. In some embodiments, at least a portion of
conductive yarn 34 is inlaid within third fabric portion 24C. In some
embodiments, conductive yarn 34 may be knitted on a surface of one of fabric
panels 24A, 24B, 24C that faces an internal cavity of tubular garment 22 such
as, for example, cavity 32 or a cavity formed between first fabric panel 24A
and
second fabric panel 24B. In some embodiments, conductive yarn 34 may be
knitted between transfer points 90 to ensure accurate positioning.
[0045] In some embodiments, conductive yarn 34 may be arranged in textile
garment 22 to provide resistive heating. Conductive yarn 34 may act as an
electrically resistance element and a voltage may be supplied by power source
38 to conductive yarn 24. The temperature of conductive yarn 34 may be
increased due to the thermal coefficient of resistance of conductive yarn 24.
[0046] Although FIG. 2B shows tubular garment 22 having one conductive
yarn 34, it should be understood that tubular garment 22 may have a plurality
of
conductive yarns defining a plurality of conductive paths. It should be
understood that conductive yarns 34 may be integrated in any one of the panels
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24. It should be understood that the conductive bus 28 disposed in second
tubular portion 40 may be configured to provide electrical communication with
conductive yarns 34 integrated in any one of the panels 24.
[0047] In some embodiments, tubular garment 22 may include one or more
electronic components. Tubular garment 22 may be used to detect and monitor
a wide range of health issues, including: tracking of gait, pressure sensing,
electromyography (EMG), heat stimulation and electrical muscle stimulation
(EMS).
[0048] FIGS. 4A-4C show different perspective views of an embodiment of
tubular garment 22 having a plurality of electronic components 46, 48, 56, 58
integrated within first tubular portion 26 of tubular garment 22. Electronic
components 46, 48, 56, 58 may be embedded within first fabric panel 24A
and/or second fabric panel 24B and may be electrically coupled to conductive
bus 28 via a plurality of conductive yarns 34 (not depicted). Electronic
components 46, 48, 56, 58 may also be in communication with controller 60 via
conductive yarns 34. Controller 60 may be configured to receive signals from
electronic components 46, 48, 56, 58. Controller 60 may be configured to
control
the operation of one or more of the electronic components 46, 48, 56, 58 based
on the received signals.
[0049] Referring to FIG. 4A, tubular garment 22 (shown by example only as a
sock) may have inertial measurement unit (IMU) sensor 46 connected to body
49 of first tubular portion 26 that measures and reports a body's (e.g. limb
of the
wearer) specific force, angular rate, and/or sometimes the magnetic field
surrounding the body, using a combination of accelerometers and gyroscopes,
sometimes also magnetometers. Body 49 may refer to the portion of first
tubular
portion 26 consisting of non-conductive interlaced yarns. Example
configurations
of IMU sensor 46 can be used to detect linear acceleration of the wearer's
limb
using one or more onboard accelerometers and rotational rate using one or
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more onboard gyroscopes. Some IMU sensors 46 can also include an onboard
magnetometer used as a heading reference. Typical configurations of IMU
sensors 46 contain one accelerometer, gyro, and magnetometer per axis for
each of the three axes: x, y and z.
[0050] Tubular garment 22 may have one or more stretch/strain sensors 48
positioned on/in body 49 and across intermediate region 50 of first tubular
portion 26 in order to detect flexure of the wearer's joint underlying
intermediate
region 50, as the wearer moves the limb during physical activity (e.g.
walking,
running, lifting, carrying, or otherwise engaging relative movement of the
limb
with respect to the rest of the wearer's body). Top region 52 and bottom
region
54 of first tubular portion 26 may be oriented at an angle to one another
about
intermediate region 50. For example, stretch/strain sensors 48 may be applied
to
a surface of body 49 (e.g. consisting of nonconductive interlaced yarns).
Alternatively, stretch/strain sensors 48 may be composed of conductive
fibers/yarns that are interlaced (e.g. knit or woven) with the non-conductive
yarns of body 49.
[0051] Tubular garment 22 may also have electromyography (EMG) sensors
56 on/in the body 49 used for evaluating and recording/detecting electrical
activity produced by skeletal muscles (e.g. calf muscles, forearm muscles,
bicep/tricep muscles, hand muscles, and general foot/leg muscles such as but
not limited to dorsiflexor and plantarflexor muscles). EMG sensors 56 can be
used to detect/record the electric potential generated by muscle cells when
these cells are electrically or neurologically activated (e.g. by the wearer's
brain
in order to effect movement of the limb). The EMG signals detected by EMG
sensors 56 may be analyzed to detect medical abnormalities, activation level,
or
recruitment order, or to analyze the biomechanics of human or animal
movement. For example, EMG sensors 56 may be applied to a surface of body
49 (e.g. consisting of nonconductive interlaced fibres). Alternatively, EMG
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sensors 56 may be composed of conductive fibers/yarns that are interlaced
(e.g.
knit or woven) with the nonconductive yarns of body 49.
[0052] Tubular garment 22 may also have electrical muscle stimulation (EMS)
actuators 58, also known as neuromuscular electrical stimulation (NMES) or
electromyostimulation, which is the elicitation of muscle contraction using
electric impulses applied by the EMS actuators 58. The impulses can be
transmitted to the EMS actuators 58 and delivered through the electrodes (i.e.
the EMS actuators 58) on the wearer's skin near to the muscles being
stimulated. The EMS actuators 58 may be pads that are positioned or otherwise
biased into engagement with the skin. For example, the non-conductive yarns of
body 49 can be resilient (e.g. elastic) in nature and thus promote contact of
the
sensors 56, 58 with the skin of the wearer underlying body 49. As such, the
EMS
impulses applied by the EMS actuators 58 can mimic the action potential that
comes from the central nervous system, causing the underlying muscles to
contract and thus promote movement of the underlying skeletal structure of the
limb. For example, EMS actuators 58 can be applied to a surface of body 49
(e.g. consisting of nonconductive interlaced yarns). Alternatively, EMS
actuators
58 may be composed of conductive yarns that are interlaced (e.g. knit or
woven)
with the non-conductive yarns of body 49 material. It is recognized that EMS
actuators 58 and EMG sensors 59 can be the same, or different, electronic
components connected to controller 60 via conductive yarns 34.
[0053] The electrically conductive fibers/yarn incorporated into tubular
garment
22 as one or more electronic components 46, 48, 56, 58 can be made of any
conductive material including conductive metals such as stainless steel,
silver,
aluminium, copper, etc. In one embodiment, the conductive yarn can be
insulated. In another embodiment, the conductive yarn can be uninsulated.
[0054] Other examples of electronic components that may be
incorporated into tubular garment 22 are disclosed in International Patent
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Publication No. W02019134033A2, entitled "MULTI-FUNCTIONAL TUBULAR
WORN GARMENT", the entire contents of which are herein incorporated by
reference.
[0055] FIG. 5 is a flowchart illustrating an example method 62 for
manufacturing tubular garment 22 in accordance with an embodiment. Method
62 can be performed using system 10 described herein or using another system.
It is understood that aspects of method 62 can be combined with aspects of
other methods described herein. In various embodiments, method 62 includes:
[0056] knitting a first fabric panel using a first subset of knitting needles
of a
first knitting bed and knitting a second fabric panel using a first subset of
needles
of a second knitting bed, the first fabric panel and the second fabric panel
being
joined to define a first tubular portion of the tubular garment (block 64);
[0057] transferring the first fabric panel from the first knitting bed to the
second
knitting bed, the first fabric panel thereupon being held by a second subset
of
.. needles of the second knitting bed (block 66); and
[0058] knitting a third fabric panel on the first knitting bed using a second
subset of needles of the first knitting bed (block 68);
[0059] joining the third fabric panel to the first fabric panel to define a
second
tubular portion of the tubular garment (block 70); and
[0060] disposing an electrically conductive bus through the second tubular
portion for electrical communication with one or more conductive yarns
integrated within the tubular garment (block 72).
[0061] FIG. 6A shows a perspective view of a configuration of knitting machine
21 when knitting first fabric panel 24A and second fabric panel 24B. As
depicted,
first fabric panel 24A may be knitted using first subset of knitting needles
82A of
first knitting bed 80A and second panel 24B may be knitted using first subset
of
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knitting needles 82B of second knitting bed 80B. Second subset of knitting
needles 84A of first knitting bed 80A and second subset of knitting needles
84B
of second knitting bed 80B may be in a non-working position during the
knitting
of first fabric panel 24A and second fabric panel 24B. As depicted, first
subset of
knitting needles 82A of first knitting bed 80A and second subset of knitting
needles 84A of first knitting bed 80A are alternatingly arranged in first
knitting
bed 80A. Similarly, first subset of knitting needles 82B of second knitting
bed
80B and second subset of knitting needles 84B of second knitting bed 80B are
alternatingly arranged in second knitting bed 80B. So arranged, on each
knitting
bed, one subset of knitting needles may be referred to as odd needles and the
other subset of knitting needles may be referred to as even needles.
[0062] Although it not depicted in FIG. 6A, first fabric panel 24A may be
joined
to second fabric panel 24B. First fabric panel 24A and second fabric panel 24B
may be integrally formed to define first tubular portion 26. In some
embodiments,
strands of yarn may be passed between first knitting bed 80A and second
knitting bed 80B during knitting to integrally form first fabric panel 24A and
second fabric panel 24B.
[0063] In some embodiments, knitting first fabric panel 24A may include
inlaying at least one conductive yarn 34 within first fabric panel 24A such
that
the at least one conductive yarn 34 is disposed between non-conductive yarns
of first fabric panel 24A.
[0064] FIG. 6B shows a perspective view of a configuration of knitting machine
21 after first fabric panel 24A is temporarily transferred from first knitting
bed
80A to second knitting bed 80B and during knitting of third panel 24C. As
depicted, first fabric panel 24A may be held by second subset of needles 84B
of
second knitting bed 80B when transferred to second knitting bed 80B. Third
fabric panel 24C may be knitted using second subset of needles 84A of first
knitting bed 80A. First subset of knitting needles 82A of first knitting bed
80A and
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first subset of knitting needles 82B of second knitting bed 80B may be in a
non-
working position when knitting third fabric panel 24C. By temporarily
transferring
fabric panel 24A to second knitting bed 80B, it advantageously allows third
fabric
panel 24C to be knitted alongside first fabric panel 24A and second fabric
panel
24B in a single knitting process. Although it not depicted in FIG. 6B, third
fabric
panel 24C may be joined to first fabric panel 24A to define second tubular
portion 40 during the knitting process. Joining third fabric panel 24C to
first fabric
panel 24A may include stitching third fabric panel 24C to first fabric panel
24A
along a perimeter of third fabric panel 24C. In some embodiments, joining
third
fabric panel 24C to first fabric panel 24A may include stitching a lower
portion of
third fabric panel 24C to first fabric panel 24A such that the lower portion
of third
fabric panel 24C is closely pressed up against surface 30 of first fabric
panel
24A.
[0065] FIG. 6C shows a perspective view of a configuration of knitting machine
21 after first fabric panel 24A is transferred back to first knitting bed 80A
and
after at least a portion of third fabric panel 24C has been knitted. As
depicted,
first fabric panel 24A is held by first subset of knitting needles 82A of
first knitting
bed 80A after first fabric panel 24A is transferred back to first knitting bed
80A.
Second subset of needles 84B of second knitting bed 80B holding third fabric
panel 24A may be retracted and may be in a non-working position after first
fabric panel 24A is transferred back to first knitting bed 80A. In some
embodiments, an extension may be knitted to first fabric panel 24A using first
subset of knitting needles 82A of first knitting bed 80A and an extension may
be
knitted to second fabric panel 24B using first subset of knitting needles 82B
of
second knitting bed 80B.
[0066] During knitting of tubular garment 22, first fabric panel 24A may be
transferred back and forth between first knitting bed 80A and second knitting
80B. For example, first fabric panel 24A can be transferred back to first
knitting
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bed 80A to place first fabric panel 24A into a knitting position that allow
knitting
of first fabric panel 24A to resume (on first knitting bed 80A) and knitting
of
second fabric panel 24B to resume (on second knitting bed 80B). During this
time, third fabric panel 24C may be maintained in a holding position at second
.. knitting bed 80B. Subsequently, first fabric panel 24A can be transferred
again to
the second knitting bed 80A and maintained in a holding position at second
knitting bed 80B, thereby freeing first knitting bed 80A to resume knitting
third
fabric panel 24C while third fabric panel 24C is in this knitting position. In
this
way, fabric panels are shifted repeatedly between holding positions and
knitting
positions to build the courses for each of the fabric panels as required,
e.g., in
accordance with instructions 18.
[0067] FIG. 60 shows a perspective view of a configuration of knitting machine
21 for joining first fabric panel 24A and second fabric panel 24B. As
depicted,
each of first fabric panel 24A and second fabric panel 24B extends from a
first
.. end 92 of knitting machine 21 to a second end 94 of knitting machine 21,
with
portions each of these panels omitted for clarity of depiction.
[0068] At each of ends 92 and 94, a pair of needles, namely a needle 82A of
first knitting bed 80A and a needle 82B of second knitting bed 80B, cross at a
stitch transfer point 90. Each stitch transfer point 90 defines the location
where a
stich is passed from a needle 82A to a needle 82B, or vice versa, as first
fabric
panel 24A and second fabric panel 24B are knit. In this way, one or more
stitches are shared between first knitting bed 80A and second knitting bed
80B,
with the one or more stitches transferred from one knitting bed to the other
upon
reaching a stitch transfer point. This manner of stitching causes first fabric
panel
24A and second fabric panel 24B to be joined as they are knitted, thereby
forming tubular portion 26. As will be appreciated, the width of each fabric
panel
(and hence the width of tubular portion 26) is defined by the number of
needles
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of the corresponding knitting bed which are in a working position between the
two stitch transfer points 90.
[0069] The configuration of knitting machine 21 described with reference to
FIG. 60 may also be used in similar manner for joining first fabric panel 24A
and
third fabric panel 24C to form second tubular portion 40.
[0070] FIG. 7 is a perspective view of tubular garment 22 in accordance with
one embodiment before conductive bus 28 is disposed in second tubular portion
40. As depicted, third fabric panel 24C may be stitched to first fabric panel
24A
along a perimeter of third fabric panel 24C. However, in this depiction, a
lower
portion of third fabric panel 24C is not stitched to first fabric panel 24A
such that
the lower portion of third fabric panel 24C is closely pressed up against
surface
30 of first fabric panel 24A.
[0071] After first fabric panel 24A is transferred back to first knitting bed
80A
and third fabric panel 24C has been knitted, conductive bus 28 may be disposed
within second tubular portion 40 to provide electric communication with
conductive yarn 34. Establishing an electrical coupling between conductive bus
28 and conductive yarn 34 may involve soldering or welding at an interface
between conductive bus 28 and conductive yarn 34.
[0072] In a situation where conductive yarn 34 is inlaid within first fabric
panel
24A, conductive bus 28 may electrically coupled to conductive yarn 34 at one
or
more locations 36 on surface 30 of first fabric panel 24A.
[0073] In a situation where conductive yarn 34 is not inlaid within first
fabric
panel 24A, conductive yarn may be disposed within cavity 32 and then
electrically coupled to conductive bus 28 which is also disposed within cavity
32.
Heel
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[0074] A method is provided to form a heel in embodiments of tubular garment
22 having a heel. According to this method, fabric is knit on first knitting
bed 80A
and second knitting bed 80B with unbalanced courses. For example, fabric on
the heel side of tubular garment 22 may be knit with a 3-1, 4-1, 5-1, or other
suitable course ratio. The use of such unbalanced course ratios produces
greater fabric area (more courses) on the heel side of tubular garment 22,
allowing the heel side to bend at the wearer heel or contour around it, while
maintaining consistent fabric density with minimal stretching.
[0075] Importantly, according to this method, layers of fabric on both sides
of
tubular garment 22 (e.g., first fabric panel 24A, second fabric panel 24B, and
third fabric panel 24C) are passed at the same time between first knitting
beds
80A and second knitting beds 80B.
[0076] Embodiments of manufacturing systems employing this method may
avoid friction that is created when holding fabric on one knitting bed while
knitting on the opposite knitting bed, as associated with a conventional
Goring
method. Conveniently, such embodiments may produce multi-tubular garments
with consistent quality of stitch formation.
[0077] This method may be applied to various types of tubular construction,
including construction of angular bends, curvatures or pocket type zones.
[0078] Due to the discrete nature, size and comfort, a tubular shaped garment,
such as a sock, knee brace, elbow sleeve, stocking, legging, and the like are
especially attractive form factors for a smart textile in particular for
applications
involving health and wellness and performance sports, where a sock can be
used to detect and monitor a wide range of health issues, including: tracking
of
gait, pressure sensing, electromyography (EMG), heat stimulation and
electrical
muscle stimulation (EMS) of the calf for improved circulation and bio-
impedance
feedback for sub-skin infection monitoring and other combined features.
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[0079] In some embodiments, at least part of tubular garment 22 may be
formed of other textile forms and/or techniques such as weaving, knitting
(warp,
weft, etc.) or the like. In some embodiments, tubular garment 22 includes any
one of a knitted textile, a woven textile, a cut and sewn textile, a knitted
fabric, a
non-knitted fabric, in any combination and/or permutation thereof. Example
structures and interlacing techniques of textiles formed by knitting and
weaving
are disclosed in U.S. Patent Application No. U515/267,818, entitled
"Conductive
Knit Patch", the entire contents of which are herein incorporated by
reference.
[0080] As used herein, "textile" refers to any material made or formed by
manipulating natural or artificial fibres to interlace to create an organized
network of fibres. Generally, textiles are formed using yarn, where yarn
refers to
a long continuous length of a plurality of fibres that have been interlocked
(i.e.
fitting into each other, as if twined together, or twisted together). Herein,
the
terms fibre and yarn are used interchangeably. Fibres or yarns can be
manipulated to form a textile according to any method that provides an
interlaced organized network of fibres, including but not limited to weaving,
knitting, sew and cut, crocheting, knotting and felting.
[0081] Different sections of a textile can be integrally formed into a layer
to
utilize different structural properties of different types of fibres. For
example, conductive fibres can be manipulated to form networks
of conductive fibres and non-conductive fibres can be manipulated to form
networks of non-conductive fibers. These networks of fibres can comprise
different sections of a textile by integrating the networks of fibres into a
layer of
the textile. The networks of conductive fibres can form one or more conductive
pathways that electrically connect with actuators and sensors embedded in
tubular garment 22, for conveying data and/or power to and/or from these
components.
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[0082] In some embodiments, multiple layers of textile can also be stacked
upon each other to provide a multi-layer textile.
[0083] As used herein, "interlace" refers to fibres (either artificial or
natural)
crossing over and/or under one another in an organized fashion, typically
alternately over and under one another, in a layer. When interlaced, adjacent
fibres touch each other at intersection points (e.g. points where one fibre
crosses over or under another fibre). In one example, first fibres extending
in a
first direction can be interlaced with second fibres extending laterally or
transverse to the fibres extending in the first connection. In another
example, the
second fibres can extend laterally at 90 from the first fibres when
interlaced with
the first fibres. Interlaced fibres extending in a sheet can be referred to as
a
network of fibres.
[0084] As used herein "integrated" or "integrally" refers to combining,
coordinating or otherwise bringing together separate elements so as to provide
a
harmonious, consistent, interrelated whole. In the context of a textile, a
textile
can have various sections comprising networks of fibres with different
structural
properties. For example, a textile can have a section comprising a network
of conductive fibres and a section comprising a network of non-
conductive fibres. Two or more sections comprising networks of fibres are said
to be "integrated" together into a textile (or "integrally formed") when at
least one
fibre of one network is interlaced with at least one fibre of the other
network such
that the two networks form a layer of the textile. Further, when integrated,
two
sections of a textile can also be described as being substantially inseparable
from the textile. Here, "substantially inseparable" refers to the notion that
separation of the sections of the textile from each other results in
disassembly or
destruction of the textile itself.
[0085] The above description is meant to be exemplary only, and one skilled in
the relevant arts will recognize that changes may be made to the embodiments
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described without departing from the scope of the invention disclosed. The
present disclosure may be embodied in other specific forms without departing
from the subject matter of the claims. The present disclosure is intended to
cover and embrace all suitable changes in technology. Modifications which fall
within the scope of the present invention will be apparent to those skilled in
the
art, in light of a review of this disclosure, and such modifications are
intended to
fall within the appended claims. Also, the scope of the claims should not be
limited by the preferred embodiments set forth in the examples, but should be
given the broadest interpretation consistent with the description as a whole.
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