CONTAINING FABRIC, GARMENTS COMPRISING SUCH FABRIC, AND RELATED PRODUCTION METHODS

Abstract

A restraining fabric includes at least one stretch portion having a plurality of stitches of at least one ground yarn and at least one elastic yarn. In which, next to at least part of the stretch portion, a restraining portion extends in which first groups of one or more first stitches including the at least one main yarn alternate with second groups of one or more second stitches having a restraining yarn, such that at each of the first stitches a floating length of the restraining yarn extends and at each of the second stitches a floating length of the main yarn extends. The Restraining garments containing the fabric and the method of manufacturing the fabric and garments are also provided for.

Claims

1. A method for manufacturing a knit garment comprising at least one portion of a restraining fabric (1), comprising a sequence of courses, obtained by making, next to at least part of said courses, at least one stretch portion (4) obtained by knitting at least one elastic yarn (5) and by making at least one restraining portion (8) next to at least part of said stretch portion, wherein said restraining portion is obtained by alternatively knitting also a main yarn (3) with a restraining yarn (9) such that first groups (G.sub.1) of one or more first stitches (P.sub.1) are formed and comprise the main yarn, which alternate with second groups (G.sub.2) of one or more second stitches (P.sub.2) comprising the restraining yarn and in that, at the stitches containing the main yarn, floating lengths (10′) of the restraining yarn, and vice versa, at the stitches containing the restraining yarn, floating lengths (10) of the main yarn extend, wherein the restraining fabric (1) is manufactured by a circular machine for knitwear and hosiery having a continuous motion rotating cylinder (24) that can be selectively and rotationally activated in reciprocating motion, which carries a plurality of needles (25) that can be selectively activated between an active position, wherein they intercept at least one yarn to be knitted, and an inactive position, wherein they do not intercept said yarn, the method comprising the steps of: a) at each fabric course, knitting with the needles of the rotating cylinder at least one ground yarn (2) and at least one elastic yarn (5) to form a plurality of courses (R.sub.1, R.sub.2, . . . , R.sub.n) of the fabric, in order to make a stretched portion (4); b) at least at one of said courses (R.sub.1, R.sub.2, . . . , R.sub.n), knitting at least one main yarn (3) with first groups of needles (27) brought to the active position to intercept the main yarn, which alternate with second groups of needles (28) brought to the inactive position to not intercept the main yarn; and knitting the restraining yarn with the second groups of needles (28) brought to the active position to intercept the restraining yarn, which alternate with the first groups of needles (27) brought to the inactive position, to not intercept the restraining yarn; and c) reiterating the step b) for a plurality of subsequent courses in order to make a restraining portion next to at least part of the stretch portion (4); wherein the step a) can be actuated such that groups of needles (27) comprising at least one needle knit said elastic yarn, which alternate with groups of needles (28) comprising at least one needle that do not knit said elastic yarn, wherein step a) is carried out such that, next to at least some subsequent courses (R.sub.1, R.sub.2, . . . , R.sub.n) of the garment, an upper part (14), a first intermediate semi-portion (16) and a lower part (15) of a stretch portion (4) are formed; and wherein a step b′) is provided wherein, at an intermediate plurality of said courses (R1, R2, . . . , Rn), at least the ground yarn is knitted with part of the needles of the rotating cylinder to make a second intermediate semi-portion (17) having the shape of a bag.

2. The method according to claim 1, wherein said garment is an elastic ankle brace (11), an elastic knee brace (13), or a sock with ankle brace (12), and wherein the method further comprises making an elastic edge (20) at ends or an end of said garment.

3. The method according to claim 1, wherein said garment is a sock with ankle brace and wherein the method further comprises making a forefoot portion (22), a toe portion (23) and a possible leg portion (21).

4. The method according to claim 1, wherein, by suitably selecting the cylinder needles, steps b) and c) provide for forming a restraining portion comprising an upper strip (18) and a lower strip (19) both sloped with respect to the direction along which the courses extend, starting respectively from the upper portion (14) and the lower portion (15) towards the first central semi-portion (16), such as to join at the latter and being shaped such as to surround the second intermediate semi-portion (17).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0041] However, the invention will be further depicted in the following in the description made in reference to the accompanying indicative and not limitative drawings, in which:

[0042] FIGS. 1 and 2 schematically show a knit fabric according to the present invention, seen from opposite sides;

[0043] FIGS. 1a and 2a each show a layout of the stitches of the portions of the knit fabric encircled in FIGS. 1 and 2, respectively;

[0044] FIGS. 3a and 3b each show a portion of a course in two different parts of the knit fabric of FIG. 1;

[0045] FIG. 4 shows a perspective view of a garment having the shape of an elastic ankle brace;

[0046] FIGS. 5 and 6 show two different embodiments of a garment having the shape of a sock comprising a portion of elastic ankle brace;

[0047] FIGS. 7 and 8 show a view from the outside and a view from the inside of another embodiment of a garment having the shape of a sock comprising a portion of elastic ankle brace;

[0048] FIGS. 5a and 5b, 6a and 6b, 7a and 7b, 8a and 8b respectively show a view from the front side and a view from the reverse side of part of the garments of FIGS. 5, 6, 7 e 8;

[0049] FIG. 9 shows a perspective view of a garment having the shape of an elastic knee brace; and

[0050] FIG. 10 shows a part of a circular machine for knitwear and hosiery for making the knit fabric and the garments according to the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0051] In FIGS. 1 and 2, a knit fabric according to the present invention is denoted on the whole by the numeral 1.

[0052] The knit fabric comprises a plurality of courses R1, R2, . . . , Rn obtained by knitting at least one ground yarn 2 and at least one main yarn 3 and comprises at least one stretch portion 4 obtained by knitting at least the ground yarn 2 and at least one elastic yarn 5 together, or by knitting the elastic yarn such that in some stitches, termed as elastic stitches 6, it becomes knitted at least with the ground yarn, while in other stitches, termed as float stitches 7, it is not knitted, thus forming lengths of elastic yarn that remain floating.

[0053] Preferably, at each subsequent course R1, R2, . . . , Rn the same sequence of stitches is repeated such that the elastic stitches and the float stitches of a course are aligned to those of the previous and subsequent course, such as to form columns.

[0054] In a preferred solution shown in the figures, in each course of the knit fabric 1 an elastic stitch alternates with a float stitch, with a so-called selection 1:1.

[0055] According to the invention, in at least one part of the stretch portion also a restraining portion 8 is obtained, by also knitting the main yarn 3 and at least one restraining yarn 9.

[0056] In the restraining portion the main yarn 3 and the restraining yarn 9 are knitted alternatively with one another, such that at first groups G1 of one or more first stitches P1 of the main yarn 3, there is a floating length of the restraining yarn 9, and vice versa at second groups G2 of one or more second stitches P2 of the restraining yarn 9, there is a floating length of the main yarn 3.

[0057] The main yarn and the restraining yarn each form a respective sequence of stitches, which comprises at least one plain-knitted stitch followed by at least one float stitch. By the terms “plain-knitted stitch” a stitch is meant wherein the yarn is knitted with the corresponding stitch of the previous course, whereas by “float stitch” a stitch is meant wherein the yarn is not knitted with the corresponding stitch of the previous course, thus originating a length of floating yarn 10, 10′ extending between two subsequent stitches of the same yarn and being visible from a so-called reverse side of the knit fabric.

[0058] Preferably, at least part of the restraining portion is obtained by knitting the main yarn and the restraining yarn such that two stitches P1 of the main yarn are followed by two stitches P2 of the restraining yarn and so on, and that at two stitches P1 of the main yarn, a length of floating restraining yarn 10′ is formed, whereas at two stitches P2 of the restraining yarn a length of floating main yarn 10 is formed. In other words, for each main and restraining yarns, the stitches and the float stitches alternate according to a selection 2:2.

[0059] The float stitches of the main yarn and the restraining yarn are less extensible than the plain-knitted stitches and thus decrease the extensibility of the stretch portion in order to provide the desired restraining effect. By differently alternating stitches and float stitches according to other selections, for example 1:1, 1:3, 2:2, 2:1, 2:4, etc., fabrics having different restraining ability and strength can be obtained. The kind of selection can vary among different courses, or also within the same course.

[0060] As shown in FIGS. 4 to 8, the knit fabric 1 can be part of a garment, such as to provide the garment itself with a restraining effect. Specifically, the garment is an orthopedic type garment having joint bearing and supporting purposes. More in detail, the garment can have the shape of an elastic ankle brace 11, the shape of a stocking or sock with ankle brace 12, i.e. including a portion acting as an elastic ankle brace, or the shape of an elastic knee brace 13, or else the shape of an elastic wrist brace, elastic elbow brace and the like—not shown.

[0061] In other words, the knit fabric can be embedded in a substantially tubular garment and formed in a single piece, i.e. seamless, except from possible finish seams, which has different diameter and/or shape such as to be worn at a user's ankle, knee, wrist, elbow or other joint, thus effecting a restraint of the joint itself such as to allow its usual movements but to prevent wrong twists that could cause traumas, or those the joint can undergo just as a result of a trauma.

[0062] In detail, the elastic ankle brace 11 shown in FIG. 4, the sock with ankle brace 12 of FIGS. 5, 6, 7 and 8 and the elastic knee brace 13 of FIG. 9, comprise an upper part 14 and a lower part 15, joined to one another by a first intermediate semi-portion 16 and a second intermediate semi-portion 17. The second intermediate semi-portion 17 is shaped like a bag to be able to accommodate respectively the user's heel or patella depending on the type of garment.

[0063] At least one portion of the upper part, lower part and first intermediate semi-portion of each garment comprises a portion of knit fabric similar to the afore described one and specifically a stretch portion 4 provided with a restraining portion 8.

[0064] In detail, the restraining portion is shaped such as to follow the conformation of the joint on which it has to be worn, in order to allow the usual movements thereof. Specifically, the restraining portion comprises an upper strip 18 and a lower strip 19 joining to one another at the first intermediate semi-portion. Preferably, such upper and lower strips are shaped such as to extend at least partially sloped with respect to the transverse direction of the upper and lower parts such that when the garment is seen laterally, a sort of V shape is formed inside which there is the second intermediate semi-portion; in other words, the two arms of the V shape surround the second semi-portion. Preferably said two arms are curved inwardly at their free end portions.

[0065] The restraining portion, seen on the whole, forms therefore a sort of coil winding around the limb portion and the joint it is associated with, letting the heel or the patella free, respectively, depending on the type of garment.

[0066] Preferably, thus in the initial courses Ri, the restraining portion only extends along a limited amount of stitches, at one part of the garment itself that can be called rear part in case of elastic ankle brace and sock with ankle brace, since to be worn on a rear portion of the user's leg and on part of the user's foot planum, or front part in case of elastic knee brace, since to be worn on front parts of the leg; in each subsequent course the amount of stitches constituting the restraining portion increases, preferably until having a restraining portion extending at all the stitches of at least one course; in the courses at the first and second semi-portions, the restraining portion only extends at the first semi-portion, such as not to extend at the heel or the patella; and eventually at the lower part, the restraining portion gets gradually narrower, meaning that it comprises a decreasing number of stitches, until comprising an extremely small number, in its final courses Rf.

[0067] Preferably, in order to better follow the shape of the anatomical part on which it has to be worn and to better exert its restraining action, the restraining portion has float stitches and stitches of the main yarn and of the restraining yarn which alternate with one another according to a variable selection, thus it does not stay constant for the whole restraining portion and/or within each course.

[0068] In a preferred solution shown in FIG. 4, at the parts to be worn on the limb portions close to the heel, there could be a sequence of higher number of stitches of each yarn, followed by float stitches of the same yarn, which decrease at the remaining part of the garment, wherein only a small number of stitches alternate with the float stitches.

[0069] FIGS. 5, 6, 7 show three examples of possible embodiments of the sock with ankle brace wherein restraining portions are shown, in which the stitches of the main yarns alternate with the stitches of the restraining yarn according to different selections, better depicted in FIGS. 5a, 6a, and 7a, in order to have different restraining and/or aesthetic effects.

[0070] The main yarn and the restraining yarn can have the same linear density, or different linear densities, preferably the restraining yarn has a larger diameter, even twice the diameter of the main yarn. In fact, this way a strong restraining effect localized in the restraining portion is obtained, whereas the remaining part is lighter, thinner and particularly elastic in order to increase the garment comfort and allow it to be more easily worn.

[0071] The main yarn and the restraining yarn can have different colors so as to highlight the restraining portion with respect to the remaining part of the garment.

[0072] The stretch portion can only extend at the courses in which there is the restraining portion also, or for a larger number of courses, or else still along the whole garment.

[0073] In addition, the garment can have an elastic edge 20 at one or both the ends thereof, just one in case of sock, in order to hold the garment correctly worn.

[0074] Specifically, in reference to the elastic ankle brace of FIG. 4, the upper part is designed to be worn on an ending part of the user's leg, the lower part to be worn on a first part of the user's foot, the first intermediate semi-portion to be worn on the instep and the second intermediate semi-portion is designed like a bag to accommodate the user's heel itself.

[0075] In FIGS. 5, 6 and 7 examples of socks with ankle braces 12 are shown, each one including a portion having a function of ankle brace as the afore described one.

[0076] With respect to the afore described garment, the sock also comprises a possible leg portion 21, a forefoot portion 22 and a toe portion 23 to enclose the toes.

[0077] In this case, the finish elastic edge 20 is combined with the end of the leg portion. The leg, forefoot and toe portions can have any knitting usually present in a sock.

[0078] The elastic knee brace 13, shown in FIG. 8, has a texture similar to that of the elastic ankle brace 11, but has a larger diameter and a shape suitable to be worn on the user's knee.

[0079] Based on the diameter and the number of courses of the garment, it can be also suitable for being associated with an elbow, a wrist, and the like.

[0080] The knit fabric 1 and the garments 11, 12 and 13 are preferably made by a circular machine for knitwear and hosiery having a continuous motion rotating cylinder 24 that can be selectively and rotationally activated in reciprocating motion, which carries a plurality of needles 25 that can be selectively activated between an active position, wherein they intercept at least one yarn to be knitted, and an inactive position, wherein they do not intercept said yarn. The machine is furthermore provided with feeding means usually named as yarn fingers 26, for feeding the needles with at least one ground yarn, at least one main yarn, at least one elastic yarn and at least one restraining yarn.

[0081] The method provides for making a plurality of stitch courses by knitting at least the ground yarn, and the elastic yarn by uniform and/or reciprocating circular motion in order to make a knit fabric, comprising at least one stretch portion 4 and, next to at least part of the courses of the knit fabric, also knitting the main yarn and the restraining yarn, alternatively with the main yarn in order to obtain a fabric portion defined as restraining portion 8, in which the stitches obtained by knitting the main yarn and not knitting the first restraining yarn, alternate with stitches obtained by knitting the restraining yarn and not knitting the main yarn. Thereby lengths of floating restraining yarn 10′ at the stitches comprising the main yarn and lengths of main floating yarn 10 at the stitches comprising the restraining yarn, are formed.

[0082] In detail the method provides the following steps:

a) at each fabric course, knitting at least one ground yarn 2 with the needles of the rotating cylinder and knitting one elastic yarn 5 such that groups of at least one needle knit said elastic yarn, which alternate with groups of at least one needle not knitting said elastic yarn in order to form a plurality of courses R1, R2, . . . , Rn of the fabric;
b) at least at one of said courses R1, R2, . . . , Rn, knitting the main yarn 3 with first groups of needles 27 brought to the active position to intercept the main yarn, which alternate with second groups of needles 28 brought to the inactive position to not intercept the main yarn; and knitting the restraining yarn 9 with the second groups of needles 28 brought to the active position as alternate with the first groups of needles 27 brought to the inactive position;
c) reiterating point b at subsequent courses, in order to make the restraining portion.

[0083] This way the first groups of needles intercepting the main yarn do not intercept the restraining yarn and vice versa the second groups of needles do not intercept the main yarn, but intercept the restraining one.

[0084] This allows a stretched knit fabric to be formed which, at least on one part thereof, also comprises a restraining portion defined by a sequence of stitches of two different yarns, as shown in FIGS. 1 and 1a, in which the stitches P1 of the main yarn are shown, which alternate with the stitches P2 of the restraining yarn, seen from a so-called front side of the fabric. FIGS. 2 and 2a show the aforesaid stitches seen from the other side of the fabric, named reverse; in such figures the floating lengths 10, 10′ of the main yarn and of the restraining yarn are visible.

[0085] Both the first groups of needles 27 and the second groups of needles 28 should each comprise at least one needle. In case the first and second groups of needles comprise two needles, there are two needles knitting the main yarn by swerving the restraining one, which are followed by two needles knitting the restraining needle by swerving the main yarn, in their turn followed by two needles knitting the main yarn by swerving the restraining one and so on according to a selection 2:2.

[0086] However said first and second groups may comprise a larger number of needles and can have different numbers of needles both among them and the different first and second groups of a same course or different courses; thus, the first groups of needles could all be equal and each one comprise the same number of needles and the second groups could all be equal and each one comprise the same number of needles equal or different from that of the first groups, or else be in a different number within the same course, in order to form restraining portions with a shape fitting to the limb shape and having a restraining effect suitable to the body portion on which it is worn.

[0087] Preferably, in adjoining courses, the first groups of needles intercepting the main yarn but not intercepting the restraining yarn, and the second groups of needles not intercepting the main yarn but intercepting the restraining yarn in a course, in the subsequent one can be at least partially offset with respect to the previous one, such that at least some needles of the first groups of needles of the previous course belong to the second groups of needles of the subsequent course and do not intercept the main yarn, but intercept the restraining yarn and at least some needles of the second groups of needles intercept the main yarn, but do not intercept the restraining yarn, and so on to make a restraining portion of the type shown in the figures.

[0088] The afore described fabric can be part of a restraining garment, to be worn on a user's body joint.

[0089] In such a case the method for implementing such a garment also provides the step of:

[0090] at an intermediate plurality of said courses R1, R2, . . . , Rn, knitting at least the ground and the main yarns with part of the needles of the rotating cylinder activated in a reciprocating motion, in order to make a second intermediate semi-portion 17 having the shape of a bag.

[0091] Preferably, by suitably selecting the cylinder needles, the steps required for forming the restraining portion provide for forming a restraining portion comprising an upper strip 18 and a lower strip 19 both sloped with respect to the direction of the courses, respectively starting from the upper portion and the lower portion towards the first central semi-portion, such as to join at the latter.

[0092] Advantageously and in order to be fitted for the shape of the limb it has to be associated with, the starting and final parts of the restraining portion are made with a reduced number of first and second groups of needles.

[0093] Specifically, such steps are carried out as follows:

[0094] at the initial courses Ri of an initial part of the stretch portion, activating a limited number of said first groups of needles 27 and second groups of needles 28, such that said first and second groups of needles only comprise a small part of the needles of the rotating cylinder;

[0095] in the subsequent courses, increasing the number of said first and second groups of needles, until almost all or preferably all of the needles of the rotating cylinder belong to one of said first or second groups of needles;

[0096] decreasing the number of groups of the first and second groups of needles, such that at least part of the needles of the rotating cylinder constituting the second central semi-portion are not comprised;

[0097] in the subsequent courses, increasing the number of said first and second groups of needles, until almost all or preferably all of the needles of the rotating cylinder belong to one of said first or second groups of needles;

[0098] decreasing again the number of said first and second groups of needles; and

[0099] at the final courses Rf of a final part of the stretch portion, activating a limited number of said first groups of needles 27 and second groups of needles 28, such that said first and second groups of needles only comprise a small part of the needles of the rotating cylinder.

[0100] By using different yarns and/or machines for hosiery or knitwear with different diameters or fineness, different types of restraining garments of different measures and sizes can be obtained, such as elastic ankle braces 11, socks with ankle braces 12, elastic knee braces 13 and the like. In fact, garments adapted to be worn on an elbow or wrist can also be obtained.

[0101] The garments obtained are substantially seamless, except for possible finish seams, such as the toe seams, in case the garment is a sock.

[0102] The method can provide the steps, known per se, also required for making one or two elastic finish edges 20 to be combined with the garment or at the ends thereof.

[0103] In case of a garment having the shape of a sock with ankle brace, the method also provides the steps required for forming the toe of the sock 23 and a possible step of sewing the toe itself, to be directly carried out on the circular machine, or with a subsequent operation. In such a garment the restraining portion can only extend at one part of the sock with ankle brace, while the stretch portion 4 can also extend in the remaining parts, such as the forefoot 22 and/or leg 21 portions, if present, and/or the toe portion 23.