Compression garment and method

Abstract

A compression garment, for example, a sock, formed of a knitted fabric that includes an elastomer compression inlay yarn introduced into a predetermined first selection of needles on a first knitting machine finger position and first and second pattern yarns introduced into a predetermined second selection of needles on second and third knitting machine finger positions, the first selection of needles and the second selection of needles collectively defining a predetermined pattern. When the predetermined second selection of needles is raised to take on the first and second pattern yarns, the elastomer compression inlay yarn deflects predetermined ones of the second selection of needles radially inwardly to define an annular space into which the pattern yarns are dropped in an offset relation to the elastomer compression inlay yarn. The first and second pattern yarns are plated to respective outer and inner surfaces of the fabric, and the elastomer compression yarn are inlaid to the inner surface of the fabric.

Claims

1. A compression garment formed of a circular-knitted fabric, comprising: (a) first and second plated pattern yarns collectively defining a predetermined pattern; (b) an elastomer inlay compression yarn inlaid with the first and second plated pattern yarns to define an inner surface of the circular-knitted fabric; (c) the elastomer inlay compression yarn and the first and second plated pattern yarns collectively defining respective inner and outer surfaces of the circular-knitted fabric; (d) the first and second plated pattern yarns defining stitches formed by radially deflected needles deflected in an enhanced yarn-receiving stitch position by the inlay yarn; and (e) the elastomer inlay compression yarn and the first and second plated pattern yarns collectively defining an inner garment surface that is characterized by an absence of loose threads, cut threads and loops.

2. A compression garment according to claim 1, wherein the compression garment is a compression hosiery product.

3. A compression garment according to claim 1, wherein the elastomer inlay compression yarn is spandex covered with at least one yarn selected from the group of yarns consisting of nylon, polyester, polypropylene, cotton, rayon, wool and silk.

4. A compression garment according to claim 1, wherein the first plated pattern yarn has a composition that takes on a dye differently than the second plated pattern yarn takes on dye, resulting in a pattern that is distinguished by a different color appearance of the yarns.

5. A compression garment according to claim 1, wherein at least one of the first and second plated pattern yarns is cotton.

6. A compression garment according to claim 4, wherein the elastomer inlay compression yarn is spandex double covered with textured nylon yarn.

7. A compression garment according to claim 5, wherein the cotton plated pattern yarn is a 30/1 cotton yarn.

8. A compression garment according to claim 1, wherein the elastomer inlay compression yarns are 300 denier spandex yarn double covered with 1/20/7 textured nylon yarn and the elastomer pattern are 20 denier spandex yarn double covered with 1/40/13 textured nylon yarn.

9. A compression garment according to claim 2, wherein the garment is a hosiery product including a knitted heel pocket.

10. A compression garment according to claim 2, wherein the garment is a hosiery product comprising an over-the-calf sock having an integrally-formed cuff, leg, heel, foot and toe.

11. A compression garment according to claim 10, wherein the cuff is non-patterned, the leg includes a color-contrast pattern, the heel is non-patterned, the foot is mesh patterned and the toe is non-patterned.

12. A compression garment according to claim 11, wherein the leg includes a color contrast pattern comprised of a plurality of mutually-intersecting diagonal knitted stitch lines collectively defining a repeating diamond pattern.

13. A compression garment according to claim 12, wherein the leg includes a color contrast pattern formed comprising a plurality of mutually-intersecting diagonal knitted stitches.

14. A compression garment according to claim 1, wherein the yarns of the compression garment include 1st, 2nd, 3rd and 4th feed yarns comprising: 1st Feed: 300 denier spandex yarn double covered with 1/20/7 textured nylon yarn (Finger #9); 2nd Feed: Pattern Yarn: 30/1 Cotton yarn (Finger #1) Plating Yarn: 20 denier spandex yarn double covered with 1/40/13 textured nylon yarn (Finger #8); 3rd Feed: 300 denier spandex yarn double covered with 1/20/7 textured nylon yarn (Finger #9); and 4th Feed: Pattern Yarn: 30/1 Cotton yarn (Finger #1) Plating Yarn: 20 denier spandex yarn double covered with 1/40/13 textured nylon yarn (Finger #8).

15. A compression garment formed of a knitted fabric, the fabric including: (a) an elastomer inlay compression yarn positioned in a predetermined first selection of needles on a first knitting machine finger position; (b) first and second plated pattern yarns positioned in a predetermined second selection of needles on second and third knitting machine finger positions, the first selection of needles and the second selection of needles collectively defining a predetermined pattern; (c) the predetermined second selection of needles being positioned and adapted to take on the first and second pattern yarns; (d) the elastomer inlay compression yarn being adapted to deflect predetermined ones of the second selection of needles radially inwardly, the predetermined ones of the second selection of needles defining an annular space into which the pattern yarns are positioned in an offset relation to the elastomer compression inlay yarn; (e) the first and second plated pattern yarns positioned in a plated relationship to respective outer and inner surfaces of the fabric; and (f) the elastomer inlay compression yarn positioned in an inlaid position to the inner surface of the fabric.

16. A compression garment according to claim 15, wherein the compression garment is a compression hosiery product.

17. A compression garment according to claim 15, wherein the elastomer inlay compression yarn is spandex covered with at least one yarn selected from the group of yarns consisting of nylon, polyester, polypropylene, cotton, rayon, wool and silk.

18. A compression garment according to claim 15, wherein the yarns of the compression garment include 1st, 2nd, 3rd and 4th feed yarns comprising: 1st Feed: 300 denier spandex yarn double covered with 1/20/7 textured nylon yarn (Finger #9); 2nd Feed: Pattern Yarn: 30/1 Cotton yarn (Finger #1) Plating Yarn: 20 denier spandex yarn double covered with 1/40/13 textured nylon yarn (Finger #8); 3rd Feed: 300 denier spandex yarn double covered with 1/20/7 textured nylon yarn (Finger #9); and 4th Feed: Pattern Yarn: 30/1 Cotton yarn (Finger #1) Plating Yarn: 20 denier spandex yarn double covered with 1/40/13 textured nylon yarn (Finger #8).

19. A compression garment according to claim 15, wherein the second plated pattern yarn is positioned in a plated relationship to the inner surface of the fabric and the elastomer inlay compression yarn is positioned in an inlaid condition to the inner surface of the fabric and collectively define an inner garment surface that is smooth, uniform and characterized by an absence of loose threads, cut thread ends and loops.

20. A compression garment formed of a circular-knitted fabric, comprising: (a) first and second plated pattern yarns collectively defining a predetermined pattern entirely defined by needle selections that extends continuously around a circumference of the compression garment; (b) an elastomer inlay compression yarn inlaid with the first and second plated pattern yarns to define an inner surface of the circular-knitted fabric; (c) the elastomer inlay compression yarn and the first and second plated pattern yarns collectively defining respective inner and outer surfaces of the circular-knitted fabric; (d) the first and second plated pattern yarns defining stitches formed by radially deflected needles residing in an enhanced yarn-receiving stitch position; and (e) the elastomer inlay compression yarn and the first and second plated pattern yarns collectively defining an inner garment surface that is characterized by an absence of loose threads, cut threads and loops.

21. A compression garment according to claim 20, wherein the compression garment is a compression hosiery product.

22. A compression garment according to claim 20, wherein the yarns of the compression garment include 1st, 2nd, 3rd and 4th feed yarns comprising: 1st Feed: 300 denier spandex yarn double covered with 1/20/7 textured nylon yarn (Finger #9); 2nd Feed: Pattern Yarn: 30/1 Cotton yarn (Finger #1) Plating Yarn: 20 denier spandex yarn double covered with 1/40/13 textured nylon yarn (Finger #8); 3rd Feed: 300 denier spandex yarn double covered with 1/20/7 textured nylon yarn (Finger #9); and 4th Feed: Pattern Yarn: 30/1 Cotton yarn (Finger #1) Plating Yarn: 20 denier spandex yarn double covered with 1/40/13 textured nylon yarn (Finger #8).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The present invention is best understood when the following detailed description of the invention is read with reference to the accompanying drawings and photographic images, in which:

(2) FIG. 1 is an image of a portion of the inner surface of a compression sock knitted according to prior art methods;

(3) FIG. 2 is a compression sock knitted according to the method of the invention;

(4) FIG. 3 is an image of the inner surface of the compression sock of FIG. 2;

(5) FIGS. 4-11 are sequential views of a design screen showing creation of a compression hosiery pattern using plating techniques; and

(6) FIG. 12 is a partial detailed view of the exterior surface of the sock shown in FIG. 2.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT AND BEST MODE

(7) Referring now to the drawings, the image shown in FIG. 1 is of the interior of a conventional prior art compression sock 10 that is designed to give the outward appearance of a typical patterned sock, such as an argyle pattern. As can be seen, the interior surface 12 of the prior art sock 10 is a tangled mass of loose threads, cut thread ends and loops 14. As described above, these artifacts of the prior art knitting process are particularly objectionable when used by wearers who have compromised lower extremity circulation and the loose threads, cut thread ends and loops 14 can cause discomfort and indentations on the surface of the skin of the lower leg. It is also possible that a toe of the wearer can catch in one of the loops when donning the sock.

(8) As shown in FIG. 2, a compression sock 20 according to an embodiment of the invention includes a cuff 22, leg 24, heel 26, foot 28 and toe 30, respectively. The sock 20 has the outward appearance of a conventional non-compression, patterned hosiery product. This type of product is often desired by individuals who are required to wear compression hosiery products but wish to avoid the heavy, thick appearance of many compression hosiery products. The sock 20 may have characteristics as do conventional socks. For example, the heel 26 may be formed by reciprocation, may be heelless, or may include a non-reciprocated heel pocket. Similarly, the cuff 22 and/or the foot 28 may be patterned or non-patterned.

(9) As shown in FIG. 3, the interior surface 32 of the sock 20 is smooth, even and without any raised or loose threads or loops. This desirable effect is achieved by implementing a new process of plating selected yarns that provide a fully conventional outward appearance while providing medically efficacious compression without the loose threads and loops found in prior art hosiery products. Note that a patterned product does not necessarily imply a distinct color separation between yarns. The pattern may be formed of the same or similar color yarns, in which case the pattern may be indistinct or visible as distinct textures or visible stitch variations.

(10) Design software, such as Photon G616D is used to create the input for a 4-feed compression knitting machine, such as a Merz CC4.

(11) As shown in FIG. 4, the design screen template starts with a grid of 320×556 pixels. According to FIG. 5, using the graphics software pen, odd numbered pixels on a row from top to bottom are selected by, for example, identifying them by a distinct color, such as white. When this step is completed, the template is resized by deleting the odd numbered rows marked in white, leaving a finished template that is 320 pixels wide and 278 pixels deep. See FIG. 6. This template is used for the No. 2 yarn feed on the knitting machine.

(12) As shown in FIG. 7, using the graphics software pen, even numbered pixels on a row from top to bottom are selected by, for example, identifying them by a distinct color such as white. When this step is completed, the template is resized by deleting the even numbered rows marked in white, leaving a finished template that is 320 pixels wide and 278 pixels deep. See FIG. 8. This template is used for the No. 4 yarn feed on the knitting machine.

(13) Referring to FIG. 9, a 320×278 pixel screen is used to flood fill a predetermined pattern, for example, the argyle pattern shown in FIGS. 2 and 12, with a 1×1 mesh pattern indicated by different colors, with horizontal row No. 1 as the starting line indicating the pattern. The remaining pixels are flood filled with the background. See FIG. 10. This template is used for the No. 2 yarn feed. The drop down menu shown in FIG. 9 indicates that numerous mesh patterns can be created that can then be selected to flood fill the different segments of the 320×278 pixel screen shown in FIG. 11. By comparing FIGS. 10 and 11 it will be noted that the pattern designs are offset vertically and horizontally by one stitch in each direction.

(14) With the pixel screen of FIG. 9, starting with horizontal row No. 2, the argyle pattern is flood filled with a 1×1 pattern. The remainder of the pixels are flood-filled with a 1×1 mesh pattern. This template is used for the No. 4-feed.

(15) The knitting machine used for construction of the sock 20 is a 4-feed machine with a 1×1 rib selection starting on the 2.sup.nd needle for the 1.sup.st feed, which is an inlay feed, and a 1×1 rib selection starting on the 1.sup.st needle for the 3.sup.rd feed, which is also an inlay feed.

(16) An exemplary body yarn construction used to achieve the effects described in this application is as follows:

(17) 1.sup.st Feed:

(18) 300 denier spandex yarn double covered with 1/20/7 textured nylon yarn (Finger #9);

(19) 2.sup.nd Feed:

(20) Pattern Yarn: 30/1 Cotton yarn (Finger #1)

(21) Plating Yarn: 20 denier spandex yarn double covered with 1/40/13 textured nylon yarn (Finger #8);

(22) 3.sup.rd Feed:

(23) 300 denier spandex yarn double covered with 1/20/7 textured nylon yarn (Finger #9); and

(24) 4.sup.th Feed:

(25) Pattern Yarn: 30/1 Cotton yarn (Finger #1)

(26) Plating Yarn: 20 denier spandex yarn double covered with 1/40/13 textured nylon yarn (Finger #8).

(27) According to the above, the cotton yarn is threaded through pattern fingers #1 or #2 on the 2.sup.nd and 4.sup.th feeds, while the double covered nylon is threaded in fingers #7 or #8 on the 2.sup.nd and 4.sup.th feeds. This provides the maximum separation for both of these yarns. The pattern fingers, #1 or #2 on the 2.sup.nd and 4.sup.th feeds are set in the highest and deepest positions possible, but are still able to deliver the yarn to the hooks of the needles in a consistent manner without damaging the needles. Fingers #7 or #8 on the 2.sup.nd and 4.sup.th feeds are set in a much lower position. This setup gives additional separation of the two yarns. The elastomer compression yarn 40 may be a spandex covered with at least one yarn selected from the group of yarns consisting of synthetic or bio-based yarns, such as nylon, polyester, polypropylene, cotton, rayon, wool and silk.

(28) As best shown in FIG. 12, yarn 40 is an inner plating yarn, a 20 denier spandex yarn double covered with 1/40/13 textured nylon yarn that knits on all needles and 50 percent is present on the outer surface and 50 percent on the inner surface (not shown). The inlay yarn cannot be seen on the exterior surface of the sock 20. The yarn 42 is a 30/1 Cotton yarn that only knits on the needles that are selected “up” by the pattern. The cotton yarn 42 is present on the outer surface relative to the inner surface at an approximate ratio of 3 to 1. The plating of both yarn 40 and yarn 42 takes place only in the leg 24 and foot 28 on the 2.sup.nd and 4.sup.th feeds.

(29) The plating thus includes two yarns being knitted on the same feeds, 2.sup.nd and 4.sup.th, such that the cotton yarn 42 is plated to the outside of the sock 20 and the spandex/nylon yarn 40 is plated to the inside of the sock 20, without miss-plating. The pattern is created by controlling the needles on the 2.sup.nd and 4.sup.th feeds that are actually selected “up” to take on the cotton yarn 42.

(30) More specifically, the elastomer compression inlay yarn 40 is introduced to every other needle at tuck height. When the remaining needles are raised to take on the pattern yarns 42, the presence of the inlay yarn 40 deflects the pattern needles inwards, causing every other needle to slightly pull towards the center of the cylinder of the knitting machine. This slight offset, which resembles a “saw tooth” pattern when viewed from above, provides a channel for the pattern yarns 42 to drop into, assuring that they will lay in the proper position. This permits the pattern yarns 42 to be introduced in a controlled manner, avoiding a more random yarn path that could lead to miss-plating. Note also that the inlay yarn 40 can be floated across several needles in an alternative embodiment to form yet another pattern effect.

(31) According to one embodiment, the sock 20 includes a color contrast diamond-shaped pattern 46 knitted into the leg 24 to form a plurality of mutually-intersecting diagonal knitted stitch lines 48 defined by inner plating yarns 48 and collectively defining the repeating diamond-shaped pattern 46.

(32) According to a further embodiment, two distinct and different stitch patterns 50 and 52 are knitted into each pattern 46 to provide a further decorative effect. The diamond-shaped pattern 46 may be symmetrical or asymmetrical, or may be a different geometric shape altogether.

(33) It is known that various natural and synthetic fibers and yarns take on dye differently. These differences may be the result of the basic constituent natural or synthetic materials, physical characteristics of the yarns, treatments applied to the fibers and/or yarns or a combination of these factors. The factors may result in differential coloring or shading. Accordingly, embodiments of the invention can be created using yarns having differential dye take-up characteristics that result in a pattern that is distinguished by a different color and/or shade appearance of one or the other of the pattern yarns in relation to the elastomer compression yarn.

(34) While the disclosure of the invention has been illustrated by explaining the construction of a lower leg and foot garment, i.e., a “sock”, the invention is not limited to a sock but is applicable to any knitted compression fabric and garments such as panties, tights, leggings, panty hose, anklets, sleeved upper body articles and the like.

(35) A compression hosiery product and method for producing a compression hosiery product according to the invention have been described with reference to specific embodiments and examples. Various details of the invention maybe changed without departing from the scope of the invention. Furthermore, the foregoing description of the preferred embodiments of the invention and best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation, the invention being defined by the claims.