MULTIPURPOSE GARMENT AND METHOD OF MANUFACTURING THE SAME

Abstract

A multipurpose garment manufactured by knitting a first section, the first section including a plurality of single courses; knitting a second section, the second section including a plurality of double courses; knitting a third section, the third section including a plurality of single courses; knitting a fourth section, the fourth section including a plurality of double courses; and knitting a fifth section, the fifth section including a plurality of single courses, wherein transitions between the first section and the second section, the second section and the third section, the third section and the fourth section, and the fourth section and the fifth section are seamless. The multipurpose garment includes sleeve portions being seamlessly knitted to a body portion due to transition stitches connecting the body portion and the sleeve portions.

Claims

1. A method of manufacturing a multipurpose garment comprising the steps of: knitting a first section, the first section including a plurality of single courses; knitting a second section, the second section including a plurality of double courses; knitting a third section, the third section including a plurality of single courses; knitting a fourth section, the fourth section including a plurality of double courses; and knitting a fifth section, the fifth section including a plurality of single courses, wherein transitions between the first section and the second section, the second section and the third section, the third section and the fourth section, and the fourth section and the fifth section are seamless.

2. The method of claim 1 wherein the multipurpose garment includes a body section and at least two sleeve portions.

3. The method of claim 2 wherein the at least two sleeve portions are seamlessly knitted to the body portion.

4. The method of claim 3 wherein the multipurpose garment seamlessly transitions from the body portion to the at least two sleeve portions and from the at least two sleeve portions to the body portion due to transition stitches connecting the body portion and the at least two sleeve portions.

5. The method of claim 4 wherein the transition stitches are split stitches or tuck stitches.

6. The method of claim 1 wherein the plurality of single courses are reverse Jersey stitches.

7. The method of claim 1 wherein the plurality of double courses are Jersey stitches and reverse Jersey stitches.

8. The method of claim 1 wherein the plurality of single courses are mixtures or variations of jersey stitches, tuck stitches or float stitches.

9. The method of claim 8 wherein the plurality of double courses are mixtures or variations of jersey stitches, tuck stitches or float stitches.

10. The method of claim 1 wherein the steps of knitting the second section and the fourth section further comprises the steps of: knitting a first course of a body portion in a first direction; applying a first transition stitch; knitting a first course of a first sleeve section in a second direction; knitting a second course of the body portion in the second direction; applying a second transition stitch; knitting a second course of the first sleeve section in the first direction; and repeating the above steps until the second section and the fourth section of the first sleeve section are a defined number of courses.

11. The method of claim 10 wherein the transition stitch is a split stitch or a tuck stitch.

12. The method of claim 11 wherein the first course of the body portion and the second course of the body portion are reverse Jersey stitches.

13. The method of claim 12 wherein the first course of the first sleeve portion and the second course of the first sleeve portion are Jersey stitches.

14. The method of claim 13 wherein the plurality of single courses are mixtures or variations of jersey stitches, tuck stitches or float stitches.

15. The method of claim 14 wherein the plurality of double courses are mixtures or variations of jersey stitches, tuck stitches or float stitches.

16. The method of claim 1 wherein the steps of knitting the double courses further comprises the steps of: knitting a first course of a sleeve portion in a first direction in a front machine bed; knitting a second course of the sleeve portion in a second direction in a back-machine bed knitting a first course of a body portion in the first direction in the back-machine bed and ending with a first transition stitch; knitting a second course of the body portion on the back-machine bed in a second direction and ending with a second transition stitch; and repeating the above steps until the sleeve portion is a defined number of courses and transition stitches seamlessly connect the body portion and the sleeve portion.

17. A multipurpose garment comprising: a first section including a plurality of single courses; a second section including a plurality of double courses; a third section including a plurality of single courses; a fourth section including a plurality of double courses; and a fifth section including a plurality of single courses, wherein transitions between the first section and the second section, the second section and the third section, the third section and the fourth section, and the fourth section and the fifth section are seamless.

18. The method of claim 17 wherein the multipurpose garment includes a body section and at least two sleeve portions.

19. The method of claim 18 wherein the sleeve portions are seamlessly knitted to the body portion.

20. The method of claim 19 wherein the multipurpose garment seamlessly transitions from the body portion to the sleeve portion and from the sleeve portion to the body portion due to transitions stitches connecting the body portion and the sleeve portion.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The features and advantages of the present disclosure will be more fully understood with reference to the following detailed description when taken in conjunction with the accompanying figures, wherein:

[0031] FIG. 1 shows a prior art design for drape-front cardigan.

[0032] FIG. 2 shows a prior art design for drape-front cardigan in a flattened configuration.

[0033] FIG. 3 shows a multipurpose garment according to embodiments of the invention.

[0034] FIG. 4 shows a front view of a multipurpose garment according to embodiments of the invention, in a different configuration.

[0035] FIG. 5 shows a front view of a multipurpose garment according to embodiments of the invention, in a different configuration.

[0036] FIG. 6 shows a rear view of a multipurpose garment according to embodiments of the invention, in a different configuration.

[0037] FIG. 7 shows a front view of a multipurpose garment according to embodiments of the invention, in a different configuration.

[0038] FIG. 8 shows a front view of a multipurpose garment according to embodiments of the invention, in a different configuration.

[0039] FIG. 9 shows a multipurpose garment in a flattened configuration, according to embodiments of the invention.

[0040] FIG. 10 shows an alternate embodiment of the present invention.

[0041] FIG. 11 shows an alternate embodiment of the present invention in a flattened configuration.

[0042] FIG. 12 shows an exemplary needle for use with embodiments of the invention.

[0043] FIGS. 13a-b show exemplary weft knitting and warp knitting.

[0044] FIG. 14 shows exemplary knitting stitches.

[0045] FIG. 15 shows an exemplary appearance of a Jersey stitch.

[0046] FIG. 16a shows a multipurpose garment in a flattened configuration.

[0047] FIG. 16 b shows a multipurpose garment in a three-dimensional configuration.

[0048] FIG. 17 shows an indication chart for knitting stitches.

[0049] FIG. 18a shows a partial view of a multipurpose garment with double courses and transition stitches.

[0050] FIG. 18b is a flow chart showing steps for forming double course garment sections.

[0051] FIG. 18c shows a partial view of a multipurpose garment with double courses and transition stitches.

[0052] FIG. 18d is a flow chart showing steps for forming double course garment sections.

[0053] FIGS. 19-21 show another embodiment of the disclosed invention as a scarf.

[0054] FIGS. 22-23 show another embodiment of the disclosed invention as a hoodie scarf.

[0055] FIGS. 24-25 show another embodiment of the disclosed invention as a turtle-necked shawl 530

[0056] FIGS. 26-27 show another embodiment of the disclosed invention as a open-neck shawl.

[0057] FIGS. 28-29 show another embodiment of the disclosed invention as a open-neck shawl.

[0058] FIGS. 30-31 show another embodiment of the disclosed invention as an draping, open-neck shawl.

DETAILED DESCRIPTION OF THE INVENTION

[0059] The disclosed technology relates to a method of manufacturing a multipurpose garment in a seamless fashion, saving time and money, and providing a more durable garment.

[0060] In some embodiments, a multimodal garment is described in which sleeve portions are integrated into the body using a tubular knitting-in technique.

[0061] Referring to FIG. 3, an exemplary garment is shown in a position of use. Garment 300 may comprise an elongate body portion 310 formed from one or more pieces of material that is generally rectangular in shape defined by right and left vertical edge portions 320, 330 and top and bottom horizontal edge portions 340 and 350. In alternate embodiments, shapes beyond rectangular may be utilized such as circular and polygonal.

[0062] It will be appreciated by those of skill in the art that a wide variety of sizes and shapes may be used for elongate body portion 310. In a preferred embodiment, a rectangular body portion is contemplated, of a length sufficient to cover the wearer and appropriate to the desired style. It should be noted that in differing embodiments, the rectangular-shaped elongate body portion may be oriented such that the longer edges are aligned with the horizontal plane, or alternatively, that the longer edges are aligned with the vertical plane. In some embodiments, other shapes may be used depending on the application, including polygonal, circular, oval, and elliptical, among others.

[0063] In some embodiments, sleeve portions 360 and 370 may be formed in the garment. A left sleeve portion 370 may be defined along a segment of top horizontal edge portion 340, and a corresponding right sleeve portion 360 may be defined along a segment of top horizontal edge portion 340. In some embodiments, left and right sleeve portions 360, 370 may take the form of mirror opposites of each other. In some embodiments, left and right sleeve portions 360, 370 are designed to accommodate the left and right arms of the wearer, respectively, and extend to a length that may vary with the size of the garment (e.g., S, M, L, XL) or be based upon the average size of a wearer. The left and right sleeve portions 360, 370 may be open-ended to allow the hands of the wearer to protrude. In alternate embodiments, left and right sleeve portions 360, 370 may be closed-ended and capped with an integrated mitten or glove for additional warmth.

[0064] A wide variety of materials may be utilized in garment 300, both in the body portion 310 and sleeve portions 360, 370. In a preferred embodiment, a wool sweater knit may be used. In alternate embodiments, fabrics, such as cotton, linen, silk or other woven fabrics may be utilized.

[0065] As shown in FIG. 3, in use, the arms of the wearer may be inserted through left and right sleeve portions 360, 370 and the garment then may drape.

[0066] Additional stylistic elements may be incorporated into garment 300. For example, decorative adornments such as fringe at right and left vertical edge portions 320, 330 may be incorporated into body portion 310. Additional examples of textures for the body portion 310 and sleeve portions 360, 370 may include jacquard, cable or pointelle textured stitches.

[0067] FIGS. 4-9 show an embodiment of the invention in various stages and configurations of use. FIG. 4 shows an embodiment 400 in a shawl configuration, with the wearer's arms inserted through the sleeve portions and the garment wrapped tightly around the shoulders of the wearer. The garment in this configuration is secured by the wearer's arms, minimizing or eliminating instances of the garment falling off the body of the wearer. Since the wearer is not utilizing their hands to secure the garment, the hands are free for other purposes.

[0068] FIGS. 5-6 show front and rear views of an embodiment in a multi-purpose garment configuration with an open front. The garment is sloped to drape more freely than what is shown in FIG. 4, while remaining secure on the wearer's body with the hands free.

[0069] FIG. 7 shows a further embodiment of the invention in which the garment takes the form of a scarf. Because of the integrated left and right sleeve portions formed with the garment, there are no loose-hanging sleeve portions that would interfere with the scarf configuration, either mechanically or visually.

[0070] Lastly, FIG. 8 shows an embodiment in which the garment is worn as a shawl with one side arm inserted into a sleeve portion and wrapped around the other side to create an asymmetrical configuration. In a preferred embodiment, the garment of FIG. 3, can be utilized in each of these configurations, providing a varied experience for the wearer without requiring distinct garments.

[0071] Referring to FIG. 9, garment 900 of FIG. 3 is shown laid flat. As with the view shown in FIG. 3, FIG. 9 comprises an elongate body portion 910. Body portion 910 may be formed from one or more pieces of material that is generally rectangular in shape defined by top and bottom vertical edge portions 920, 930 and top and bottom horizontal edge portions 940, 950.

[0072] Sleeve portions 960, 970 may be formed in the garment and defined as a tubular knit portion fabricated according to the process described below. Each sleeve portion has an opening 960, 970 that is proximal to the wearer. Corresponding openings 960, 970 are formed opposite the corresponding openings 960, 970 to form a tube through which the arms of the wearer may be inserted.

[0073] In some embodiments, left and right sleeve portions 960, 970 may be formed with garment 900 during manufacturing using a tubular knit-in technique that enables three-dimensional knitting of the complete garment including, for example, tubular knitting to form 960, 970 in the same process as with the main body portion.

[0074] Alternatively, sleeve portions 960, 970 may be laterally linked-on by linking machine or sewn-on by sewing machine leaving openings 960, 970 and corresponding opening 960, 970.

[0075] Various alternate embodiments of the invention are contemplated to fulfill various stylistic or manufacturing requirements.

[0076] For example, referring to FIG. 10, an integrated garment 1000 is shown. Garment 1000 incorporates not only the shawl portion 1010 described above, but also a short portion 1020 that has been knit with the garment as a single unit. Referring to the plan view of FIG. 11, as with the prior embodiments, garment 1100 may comprise an elongate body portion 1110 formed from one or more pieces of material that is generally rectangular in shape defined by top and bottom vertical edge portions 1120, 1120 and top and bottom horizontal edge portions 1130 and 1130. Arm openings 1160, 1170 may be formed in secondary portion 1150.

[0077] In some embodiments, a secondary portion 1150 may be formed in the garment. In a preferred embodiment, secondary portion 1150 may be formed of the same material as body portion 1110 by tubular knit-in technique. Secondary portion 1150 may be attached laterally, linked-on by linking machine or sewn-on by sewing machine on two sides leaving open a top neck portion 1150 and bottom torso portion 1150. Arm openings 1160, 1170 may be provided for receiving the wearer's arms.

[0078] In a preferred embodiment, the entire garment 1100 is formed from a tubular or seamless knitting technique and knit in a single manufacturing step, which can minimize labor and cost, and also provide for a more attractive product. Traditional commercial knitting processes have generally been found to be unsuitable for producing such a garment. However, advances in mechanized knitting technology have made production of the embodiments shown herein possible.

[0079] It has been found that machines such as the Shima Seiki Wholegarment Computerized Flat Knitting Machine (Mach2XS) and the Stoll Knit and Wear series of machines are well-suited for use with the present invention.

[0080] Generally speaking, knitting involves interlacing yarn or thread in a series of connected loops, which are called stitches. Arrays of needles are organized into beds, which slide up or down to carry and transfer the yarn or thread. Needles may be curved or straight, and may contain a latch to hook the yarn. An exemplary latch needle is shown in FIG. 12.

[0081] Cams typically cause the needles in the bed to be raised and lowered. A carriage traverses the needle beds to raise and lower the needles according to the desired pattern. Successive loops in the fabric or garment are pulled through an existing loop and this process is repeated until completion.

[0082] As a needle is raised by a cam, the downward hook passes by the current yarn segment before hooking that yarn segment on the lowering movement. The latch of the needle catches the yarn and holds the yarn in place as another active yarn segment is passed across, pulling the yarn through the prior loop or stitch. The needle then releases the current loop or stitch on the raising movement. The current loops, known as active loops, are held on a needle until another loop can be passed through them to complete the stitch.

[0083] In embodiments that utilize the whole garment machines capable of seamless knitting, these machines are specially configured so that these stitches can be passed from one bed to the other and the beds can be moved in relation to one another. This transfer ability permits the integration of components such as pockets and lateral sleeves into the garment as it is knit.

[0084] In some embodiments, components of the garment (e.g., sleeves) may be formed separately (with the remainder of the garment formed from the tubular or seamless technique) and joined to the main garment using a linking technique.

[0085] Linking is a method of seaming/attaching pieces of a garment together after the pieces have been knitted on a flat-bed knitting machine. It will be appreciated by those of skill in the art that the linking process requires a skilled operator, and is used mainly for fully-fashioned knitted apparel. In the linking process, a slacker course of loops of yarn is created on the linking machine, which connects two pieces of fabric together.

[0086] In another implementation, the disclosed garment can be manufactured using a weft double-bed knitting machine or a weft flat-bed knitting machine known in the art. Weft knitting is a horizontal stitch process that knits using a left to right and right to left motion, e.g., shown in FIG. 13a, as opposed to warp knitting which is a vertical stitch process in a single direction, e.g., shown in FIG. 13b.

[0087] There are numerous stitches that can be knitted using the weft knitting process, e.g., a Jersey stitch, a reverse Jersey Stitch, a tuck stitch, a float stitch, and a split stitch, to name a few. Examples of these stitches are shown in FIG. 14.

[0088] The general appearance of a Jersey stitch is shown in FIG. 15. Jersey stitches are made of a series of horizontal courses stacked upon one another. The Jersey stitch forms a matrix of courses (horizontal rows) and wales (vertical columns).

[0089] By utilizing a weft double-bed knitting machine or a weft flat-bed knitting machine, a disclosed garment 100, as shown in FIG. 16, can be produced in a single knitting process and form a seamless transition from a body portion 110 to sleeve portions 120, 122 (reverse sides 121, 123, respectively). This garment is also more durable than traditional knitting processes.

[0090] During manufacture, the knitting machine can form single courses and double courses as programmed by a user to form the disclosed garment 100. For example, the disclosed garment 100 can be broken into five sections 130-134. The first section 130 can be a single course knit, the second section 131 can be a double course knit, the third section 132 can be a single course knit, the fourth section 133 can be a double course knit and the fifth section 134 can be a single course knit.

[0091] During the knitting process, the first section 130 can be a single course of a reverse Jersey stitch, the second section 131 can be a double course of a Jersey stitch and a reverse Jersey stitch, the third section 132 can be a single course of a reverse Jersey stitch, the fourth section 133 can be a double course of a Jersey stitch and a reverse Jersey stitch and the fifth section 134 can be a single course of a reverse Jersey stitch. Please note that other stitches can be used and are contemplated.

[0092] The knitting machine can begin its process by forming the first section 130 of reverse Jersey stitches in a weft knit that allows the knitting machine to move from left to right and right to left to form the reverse Jersey stitch, shown in FIG. 13a. The first section 130 can be any number of courses chosen for design purposes, e.g., the first section can contain from 1-400 courses.

[0093] The knitting machine can seamlessly transition from the first section 130 to the second section 131. In the second section 131, two courses of different stitches are knitted with one on top of the other, a first course for the body portion 110 and a second course for the first sleeve section 120.

[0094] As shown in FIG. 18b and using FIG. 17 as a guide, the knitting machine can be programmed to form these two courses. FIGS. 16a and 18a are for illustrative purposes and directions of the knit may be changed based on the orientation of the garment within the knitting machine.

[0095] In Step 1, a full course of the body portion 110 is knitted from left to right (line A to line B) and knit reverse jersey stitch in the back-needle bed. In Step 2, the knitting machine (without knitting) moves from right to left to line C (a right side of the sleeve portion 120). The knitting machine applies a first split stitch 140. In Step 3, from that first split stitch 140, a first course of the sleeve portion 120 can be knitted from right to left (line C to line D) using a Jersey stitch in the front needle bed. (The first course of the sleeve portion 120 can have a width (e.g., 1-200 wales) determined by design). Once the first course of the sleeve portion 120 is complete, the knitting machine, in Step 4, without knitting moves from left to right (line D to line B). In Step 5, a second full course of the body portion 110 is knitted from right to left (line B to line A) in the back-needle bed. In Step 6, the knitting machine (without knitting) moves from left to right to line D (a left side of the sleeve portion 121). The knitting machine then applies a second split stitch 141. In Step 7, from that second split stitch 141, a second course of the sleeve portion 120 can be knitted from left to right (line D to Line C) using a Jersey stitch having a length as predetermined by design. Once complete, in Step 8, the knitting machine without knitting moves from right to left (line C to line A). The above steps are repeated until the first sleeve portion with a height determined by design is formed (e.g., 1-200 courses).

[0096] The knitting machine then seamlessly transitions from the second section 131 to the third section 132. The third section can be a series of single course of reverse Jersey stitches with a height determined by design (e.g., 1-800 courses).

[0097] The knitting machine can seamlessly transition from the third section 132 to the fourth section 133. In the fourth section 133, like the second section 131, two courses are to be knitted on top of one another.

[0098] As shown in FIG. 18b and using FIG. 17 as a guide, the knitting machine can be programmed to form these two courses. In Step 1, a full course of the body portion 110 is knitted from left to right (line A to line B) and knit reverse Jersey stitch in the back-needle bed. In Step 2, the knitting machine (without knitting) moves from right to left to line C (a right side of the sleeve portion 122). The knitting machine applies a first split stitch 140. In Step 3, from that first split stitch 140, a first course of the sleeve portion 122 can be knitted from right to left (line C to line D) using a Jersey stitch in the front needle bed. (The first course of the sleeve portion 122 can have a width (e.g., 1-200 wales) determined by design). Once the first course of the sleeve portion 122 is complete, the knitting machine, in Step 4, without knitting moves from left to right (line D to line B). In Step 5, a second full course of the body portion 110 is knitted from right to left (line B to line A) in the back-needle bed. In Step 6, the knitting machine (without knitting) moves from left to right to line D (a left side of the sleeve portion 122). The knitting machine then applies a second split stitch 141. In Step 7, from that second split stitch 141, a second course of the sleeve portion 122 can be knitted from left to right (line D to Line C) using a Jersey stitch having a length as predetermined by design. Once complete, in Step 8, the knitting machine without knitting moves from right to left (line C to line A). The above steps are repeated until the second sleeve portion with a height determined by design is formed (e.g., 1-200 courses).

[0099] The knitting machine then seamlessly transitions from the fourth section 133 to the fifth section 134. The fifth section can be a series of single course of reverse Jersey stitches with a height determined by design (e.g., 1-800 courses).

[0100] During the knitting process these steps are repeated allowing the sleeve portions to be knitted seamlessly. That is, the knitting machine seamlessly transitions from the section 137 to the section 136 and from the section 136 to the section 135. There are no visible seams on Line D and line C due to the split stitches seamlessly connecting the body portion 110 and the sleeve portion 121.

[0101] As shown in FIG. 18d and using FIG. 17 as a guide, knitting machine sequence can be programmed differently. Please see FIGS. 18c and 18d: In step 1, knitting a first course of a sleeve portion (line B to line C) in a first direction in the front machine bed. In step 2, another course of sleeve portion (line C to line D) can be knitted in the second direction in the back-machine bed. In step 3, the knitting a first course of a body portion (line A to line D) in the back-machine bed in a first direction, ending with first split stitch 148. In step 4, the rest of the first course of a body portion is knitted on the back-machine bed (from line B to line C) in a second direction, ending with second split stitch 149. Step 4 is the right side of the sleeve 120 and repeating the above steps until a sleeve section of a defined number of courses is formed.

[0102] During the knitting process these steps are repeated allowing the sleeve portions to be knitted seamlessly. That is, there are no visible seams on Line D and line C due to the transition stitches seamlessly connecting the body portion 110 and the sleeve portion 120.

[0103] FIGS. 19-31 show different configurations of the multipurpose garment formed by the steps discussed above.

[0104] FIGS. 19-21 show an alternate embodiment of the disclosed invention as a scarf with head opening 500. The scarf 500 has a body 501, a first sleeve 502, a second sleeve 503 and an opening 504 for a wearer's head. The scarf 500 can be knitted in a multicolor scheme as shown in FIG. 20. In use, a wearer can use the scarf 510 in multiple fashions as shown in FIG. 21.

[0105] FIGS. 22-23 show another embodiment of the disclosed invention as a hoodie scarf 520. The hoodie scarf 520 has a body 521, a first sleeve 522, a second sleeve 523, an opening 524 for a wearer's head and a hood 525. In use, a wearer can use the hoodie scarf 520 in multiple fashions as shown in FIG. 23.

[0106] FIGS. 24-25 show another embodiment of the disclosed invention as a turtle-necked shawl 530. The turtle-neck shawl 530 has a body 531, a first sleeve 532, a second sleeve 533 and an opening 534 for a wearer's head and a turtle neck 536. In use, a wearer can use the turtle-neck shawl 530 as shown in FIG. 25.

[0107] FIGS. 26-27 show another embodiment of the disclosed invention as an open-neck shawl 540. The open-neck shawl 540 has a body 541, a first sleeve 542, a second sleeve 543 and an opening 544. In use, a wearer can use the open-neck shawl 540 as shown in FIG. 27.

[0108] FIGS. 28-29 show another embodiment of the disclosed invention as an open-neck shawl 550. The open-neck shawl 550 has a body 551, a first sleeve 552, a second sleeve 553, an opening 554 and a hood 555. In use, a wearer can use the open-neck shawl 550 as shown in FIG. 29.

[0109] FIGS. 30-31 show another embodiment of the disclosed invention as a draping, open-neck shawl 560. The open-neck shawl 560 has a body 561, a first sleeve 562, a second sleeve 563 and an opening 564. The body 561 can have three pieces 561a, 561b, 561c. In use, a wearer can use the open-neck shawl 560 as shown in FIG. 31.

[0110] It will be understood that there are numerous modifications of the illustrated embodiments described above which will be readily apparent to one skilled in the art, such as any other combinations of features disclosed herein that are individually disclosed or claimed herein, explicitly including additional combinations of such features. These modifications and/or combinations fall within the art to which this invention relates and are intended to be within the scope of the claims, which follow. It is noted, as is conventional, the use of a singular element in a claim is intended to cover one or more of such an element.