(12)
`
`United States Patent
`Browder, Jr.
`
`(10) Patent N0.:
`(45) Date of Patent:
`
`US 6,276,175 B1
`Aug. 21, 2001
`
`US006276175B1
`
`(54) SEAMLESS TORSO CONTROLLING
`GARMENT AND METHOD OF MAKING
`SAME
`
`_
`(75) Inventor‘
`
`%rglE?Jn§)Br0Wden
`"
`’
`(73) Assigneei Sara'Lee Corporatiom winston'salem
`
`NC (Us)
`
`( * ) Notice:
`
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U'S'C' 154(k)) by 0 days'
`
`(21) Appl. N0.: 09/301,854
`(22) Filed:
`Apr. 29, 1999
`
`IIlt. Cl-7 ............................... ..
`(52) US. Cl. ........................................ .. 66/171; 2/409
`(58) Field of Search ............................ .. 66/171, 175, 176,
`66/ 177; 2/401, 409; 450/156
`
`(56)
`
`References Cited
`US‘ PATENT DOCUMENTS
`
`2/1969 Knohl .
`3,425,246
`9/ 1975 Sackman -
`3,906,754
`4,663,946 * 5/1987 Wright ................................. .. 66/177
`5,479,791
`1/1996 Osborne.
`5,572,888
`11/1996 Browder, Jr. et al. .
`5,590,548
`1/1997 Osborne .
`5,592,836
`1/1997 Schuster et a1. .
`5,737,213 * Z1998 giginfj ............................... .. 66/171
`
`5,787,732 * 8/1998 Perron et a1. . . . . . . .
`. . . . .. 66/177
`5,850,745 * 12/1998 Albright ............................... .. 66/176
`_
`_
`* cued by examlner
`Primary Examiner—Andy Falik
`(74) Attorney, Agent,
`or Firm—Ohlandt, Greeley,
`Ruggiero, & Perle, LL
`(57)
`ABSTRACT
`
`blank for use in the manufacture of under
`A Circular
`garments and the garments so manufactured comprising a
`tubular knit body having an elastomeric yarn on selected
`courses, Wherein said tubular body contains at least one area
`of control that has a stitch pattern increasing its modulus by
`about 8%, to provide a balance of comfort and control. The
`stitch pattern is preferably a 1 by 1 alternating tuck.
`
`2,736,036
`
`2/1956 Sinigagliesi .
`
`18 Claims, 6 Drawing Sheets
`
`15
`
`mil"
`1"!"
`Q
`||||||||||
`nwnvvvo'o'oo
`0.0.0.0...0000000
`
`0o 00¢
`“20:
`30%‘
`I O
`
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`

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`U.S. Patent
`
`Aug. 21, 2001
`
`Sheet 1 6f 6
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`US 6,276,175 B1
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`11w .0 .0 .0 O
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`Q 22
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`000000000000
`0 000000
`00¢...‘
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`00000 0
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`FI.1
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`FIG. 2
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`U.S. Patent
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`Aug. 21, 2001
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`Sheet 2 6f 6
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`US 6,276,175 B1
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`FIG.
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`.3
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`FIG.
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`U.S. Patent
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`Aug. 21, 2001
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`Sheet 3 6f 6
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`US 6,276,175 B1
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`lIi!HlllllHlllllllllllll] Ill llllllllHllllllllllllllllll
`f
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`III\IIIIIII
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`\
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`U.S. Patent
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`Aug. 21, 2001
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`Sheet 4 6f 6
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`US 6,276,175 B1
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`000
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`00000
`oouowonoo
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`Q00 1
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`FIG. 7
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`FIG.
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`8
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`U.S. Patent
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`Aug. 21, 2001
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`Sheet 5 6f 6
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`US 6,276,175 B1
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`“0&3” 0000000000
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`00w000
`0000000
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`3 2
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`ll
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`FIG. 10
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`FIG. 12
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`U.S. Patent
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`Aug. 21, 2001
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`Sheet 6 6f 6
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`US 6,276,175 B1
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`XGXCDXGXGXGXGX
`CDXCDXCDXOXGXCDXG
`XOXOXGXGXGXGX
`@XCDXGXOXGXCDXQ
`
`FIG. 13
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`US 6,276,175 B1
`
`1
`SEAMLESS TORSO CONTROLLING
`GARMENT AND METHOD OF MAKING
`SAME
`
`BACKGROUND OF THE INVENTION
`1. Field of the Invention
`The present invention relates generally to a control gar
`ment and a method for providing additional control to
`selected portions of a garment. More particularly, the present
`invention relates to seamless garments provided With addi
`tional control through the use of elastomeric yarn and
`purpose-speci?c knitting techniques, and methods for pro
`viding such control.
`Consumers desire an undergarment that provides control
`or support in speci?c areas of the body, such as hips and
`Waist, and is not bulky or unsightly.
`2. Description of the Prior Art
`Previously knoWn techniques used for adding support to
`an undergarment include that disclosed in US. Pat. No.
`2,736,036 to Sinigagliesi. This patent provides a seamless
`undergarment knitted as a single piece of tubular knitted
`fabric, but containing a strengthening patch.
`US. Pat. No. 3,425,246 to Knohl provides a knitted
`brassiere having eXtra courses of elastic yarn knitted into the
`breast cups to shape the cups by providing fullness therein.
`US. Pat. No. 3,906,754 to Sackman provides an under
`garment having a plurality of integrally knitted panels. Each
`panel eXtends circumferentially around the garment. Certain
`of the courses of each panel are knitted of elastomeric yarn
`to impart an elastic character to the area.
`Amore recent technique for imparting support to selected
`area of garments is shoWn in US. Pat. No. 5,479,791 to
`Osborne. This patent provides a brassiere having a support
`area betWeen the pair of breast cups in Which the courses
`vary betWeen simple knits, such as plain knit, and Welt knit,
`such as miss-stitch.
`US. Pat. No. 5,572,888 to BroWder, Jr. et al. provides a
`seamless undergarment knit from a ?rst yarn. A control area
`is formed by knitting in a second, heavier yarn on designated
`courses along With the ?rst yarn. A predetermined con?gu
`ration of plain jersey stitch loops and tuck loops are utiliZed
`in the control area to achieve the characteristics of a foun
`dation garment.
`US. Pat. No. 5,590,548 to Osborne provides a circularly
`knit legged panty having knit-in shaping panels. The panels
`are formed by modifying the knit structure in selected areas
`to form regions having a greater resistance, particularly
`courseWise resistance, to stretch than the remainder of the
`tubular body. The patent provides that greater resistance to
`stretch can be accomplished by using conventional knitting
`structures, such as ?oating in an elastic yarn or tucking a
`yarn in selected alternating courses.
`US. Pat. No. 5,592,836 to Schuster et al. provides a
`brassiere having at least tWo support panels formed by
`tucking speci?c stitches for a predetermined number of
`courses and extending generally WaleWise, thus, giving
`greater resistance to courseWise stretch. Preferably, each
`support panel is described as preferably located on the
`outside edge of a breast cup and roughly in the form of a “C”
`partially encircling the breast cup.
`US. Pat. No. 5,605,060 to Osborne provides a circularly
`knit body suit in Which the middle torso portion is knit With
`a predetermined cross-stretch that is less than that of the
`breast supporting section of the garment.
`HoWever, a perpetual need eXists for improved seamless
`undergarment provided With control areas shaped speci?
`
`2
`cally to affect certain areas of the body, such as the hips,
`Waist, and even under a Woman’s breasts. All such control
`areas need to be formed integrally With the garment so as to
`appear as an aesthetic, non-bulging feature and, thus, no
`different than the remainder of the integral garment.
`
`BRIEF SUMMARY OF THE INVENTION
`
`10
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`15
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`20
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`25
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`30
`
`It is the object of the present invention to provide an
`improved seamless garment having areas of additional con
`trol that are shaped to affect speci?cally chosen areas of the
`body.
`It is another object of the present invention to provide
`such a garment that has a control area formed by an
`alternating tuck stitch pattern in the undergarment.
`It is yet another object of the present invention to provide
`such a garment in Which the tuck stitch pattern is a 1 by 1
`(1x1) alternating tuck stitch.
`It is a further object of the present invention to provide
`such a garment as an undergarment.
`It is still a further object of the present invention to
`provide a method of manufacturing the blank and the
`garment of the type set forth herein.
`In accordance With the present invention, a circular knit
`ting machine knits a single tubular blank including a tubular
`knit body. The tubular knit body contains an elastomeric
`yarn added along designated courses. The tension of the
`elastomeric yarn is constant throughout the entire garment.
`HoWever, in the area of the garment Where increased control
`is desired, a 1x1 alternating tuck stitch pattern is used. The
`1><1 tuck stitch tightens the fabric and increases the modulus
`of the elastomeric yarn. Thus, the stitch pattern decreases the
`amount of stretch in the fabric.
`
`35
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`FIG. 1 is a frontal vieW of a brief that uses the present
`invention;
`FIG. 2 is a rear vieW of the brief of FIG. 1;
`FIG. 3 is a frontal vieW of a high Waist brief that uses the
`present invention;
`FIG. 4 is a rear vieW of the high Waist brief of FIG. 3;
`FIG. 5 is a frontal vieW of a half-slip that uses the present
`invention;
`FIG. 6 is a rear vieW of the half-slip of FIG. 5;
`FIG. 7 is a frontal vieW of a thigh-slimmer that uses the
`present invention;
`FIG. 8 is a rear vieW of the thigh-slimmer of FIG. 7;
`FIG. 9 is a bottom vieW of the thigh-slimmer of FIG. 7,
`but With the legs expanded;
`FIG. 10 is body-slip that uses the present invention;
`FIG. 11 is a maternity brief that uses the present inven
`tion;
`FIG. 12 is a brassiere that uses the present invention; and
`FIG. 13 is a graphic depiction of the 1x1 alternating tuck
`stitch pattern.
`
`DETAILED DESCRIPTION OF THE
`INVENTION
`Referring to the draWings and, in particular FIGS. 1 and
`2, there is illustrated a brief according to the present inven
`tion generally represented by reference numeral 10. Brief
`10, as With all the embodiments of the present invention, is
`formed as a unitary, seamless knit, tubular garment blank or
`body 15 having a Waistband 20 formed as a turned Welt.
`
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`US 6,276,175 B1
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`3
`The fabric, Which forms the turned Welt, is knit on circular
`needles and dial bits in a Well-knoWn manner. Knitting
`machines for producing a fabric in the form of a turned Welt
`are Widely used in the industry, and their construction and
`mode of operation are Well knoWn. Alternatively, Waistband
`20 may be an attached piece of elastic banding. As stated
`beloW, Waistband or torso-band 20 is made of a combination
`of nylon covered spandex and nylon. Most preferably,
`torso-band 20 is made of about 265 to about 420 denier
`nylon covered spandex and nylon. Such a high denier
`spandex is preferred in order to make certain that brassiere
`130 stays in place on the Wearer’s body.
`Brief 10 is preferably integrally knit to the turned Welt.
`The tubular knit body 15 has a front portion 16, a rear
`portion 17, and side portions 18. Additionally, the under
`garment or brief 10 can have binding or trim that aestheti
`cally ?nishes and more comfortably de?nes the leg openings
`21 and 23.
`Preferably, the undergarment of all embodiments of the
`present invention, including brief 10, have body 15 made of
`either nylon micro?ber in the about 40 to about 120 denier
`range or about 40/1’s to about 60/ 1’s cotton yarn. Such yarns
`provide softness, comfort, and desired Wicking properties.
`The knit construction may be any combination of conven
`tional knit, stitches.
`The body 15 of brief 10, as With the bodies of all
`embodiments of the present invention, includes an elasto
`meric yarn, such as spandex. Preferably, the elastomeric
`yarn is knit throughout the garment at an even tension. More
`preferably, the tension of the elastomeric yarn is about 5 to
`about 7 grams throughout the garment. The elastomeric yarn
`is preferably spandex, and most preferably about 70 denier
`spandex.
`Control area 25 is an area of the undergarment, in this
`example brief 10, Where increased control is desired.
`Increased control in control area 25 is accomplished by
`tightening the fabric of body 15 of brief 10 by using a 1 by
`1 (1x1) alternating tuck stitch pattern. Thus, the 1x1 alter
`nating tuck stitch pattern increases the modulus of the fabric.
`By increasing the modulus of the fabric, the fabric stretches
`less and controls more. Preferably, the modulus of the fabric
`is increased betWeen about 6% and about 10%, more pref
`erably about 8%. Increasing the modulus by about 8%
`provides a desirable compromise betWeen control and com
`fort.
`Control area 25 of brief 10 is apron shaped, covering only
`the stomach area and the area of the hips, then gradually
`transitioning over the rear portion, ultimately becoming a
`relatively narroW, horiZontal band integral to Welt 20. The
`border betWeen control area 25 and crotch portion 27 may be
`of any functional and aesthetically pleasing shape.
`FIGS. 3 and 4 illustrate a high Waist brief 30 according to
`the present invention. High Waist brief 30 is knit using the
`same method as that for the brief 10. HoWever, control area
`35 of high Waist brief 30 is extended over the abdomen and
`ends beloW the Wearer’s breasts. Thus, the entire abdominal
`area, and an area, preferably all, of the hips are covered.
`Control area 35 is relatively smaller over rear portion 37 of
`high Waist brief 30 With a rounded transition area extending
`from front portion 36 of the high Waist brief and over the rear
`portion. The border betWeen control area 35 and crotch
`portion 38 may be of any functional and aesthetically
`pleasing shape.
`FIGS. 5 and 6 shoW a half-slip 50 according to the present
`invention. Half-slip 50 is knit using the same method as that
`of the embodiments of FIGS. 1 through 4, but absent the leg
`
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`openings. Control area 65 of half-slip 50 is shaped similarly
`to control area 25 of brief 10 and high Waist brief 30. On the
`front portion 61 of half-slip 50, the border betWeen control
`area 65 and skirt portion 62 is angled. HoWever, the border
`betWeen control area 65 and skirt portion 62 may be of any
`aesthetic or functional shape. It is preferable that half-slip 50
`has a ?rst Waistband 52 at the Waist of the half-slip and a
`second bond 54 at the loWer end of the half-slip. The
`Waistband 52 is a turned Welt Waistband that is integrally
`formed With half-slip 50. LikeWise, band 54 is also a turned
`Welt integrally formed With half-slip 50. As With Waistband
`20 shoWn in FIGS. 1 and 2, ?rst Waistband 52, as Well as
`band 54, are preferably a combination of nylon covered
`spandex and nylon, With the most preferred being about 265
`to about 420 denier nylon covered spandex and nylon.
`FIGS. 7 and 8 shoW a thigh-slimmer 70 according to the
`present invention. The thigh-slimmer 70 is knit using the
`same method as the undergarments of FIGS. 1 through 6.
`Control area 85 is shaped similarly to control area 65 in
`FIGS. 5 and 6. Optionally, control areas may be placed on
`leg portions 81 and 82. In addition, leg portions 81 and 82
`are seamlessly knit to front portion 80. The thigh-slimmer 70
`can have binding or trim that aesthetically ?nishes and more
`comfortably de?nes leg openings 86 and 87. In an alterna
`tive embodiment shoWn in FIG. 9, thigh-slimmer 70 may
`include a seamed gusset panel 75 to improve ?t and comfort.
`The gusset panel 75 is made of the same material as the body
`of thigh-slimmer 70, but preferably also includes a cotton
`liner 78. The gusset panel 75 is seWn to thigh-slimmer 70
`also seW lines 76 so that cotton line 78 is either rapped about
`the gusset panel, or positioned betWeen the gusset panel and
`the underside of thigh-slimmer 70.
`In FIG. 10, there is illustrated a body-slip 90 according to
`the present invention. Body-slip 90 is knit by the method
`used for the undergarments of FIGS. 1 through 8. Control
`area 105 is apron shaped, but extends over the abdomen and
`ends beloW the Wearer’s breasts. The borders of control area
`105 are shaped to folloW the shape of the Wearer. Thus, the
`abdominal area, and the area of the hips are covered. Front
`portion 106 has an upper border 103 of control area 105 that
`may be scalloped to folloW the breast line and a loWer border
`104 of control area 105 that is scalloped to alloW less
`restricted movement of the Wearer’s legs. Control area 25b
`is relatively smaller over rear portion 107 of body slip 90
`With a rounded transition area extending from the front
`portion 106 and over the rear portion 107. On the front
`portion of body slip 90, the border betWeen control area 105
`and skirt portion 107 is angled. HoWever, the border
`betWeen control area 105 and skirt portion 107 may be of
`any functional or aesthetically pleasing shape.
`FIG. 11 shoWs a maternity brief 110 according to the
`present invention. Maternity brief 110 is knit using the
`method described in reference to brief 10 and high Waist
`brief 11. HoWever, control area 125 extends over rear
`portion 121 and also extends onto front portion 122 covering
`the Wearer’s groin. The portion covering stomach area 123
`is speci?cally knitted Without any control area to alloW the
`portion covering the stomach to expand as needed. Thus,
`control area 125 controls the Wearer’s buttocks and hips,
`While simultaneously lifting the Wearer’s stomach area.
`Referring to FIG. 12, there is provided a brassiere 130
`having an upper torso part 141. Brassiere 130 is produced
`from a seamless blank that is formed by a conventional high
`speed circular knitting machine. Upper torso part 141 is
`integrally joined to turned Welt or torso-band 147 in a
`seamless manner.
`Upper torso part 141 preferably has formed therein breast
`cups 142 and 143. Upper torso part 141 may also have a ?rst
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`US 6,276,175 B1
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`5
`or right strap or strap portion 148, and a second or left strap
`or strap portion 149, Which may be integrally knit.
`Turned Welt or torso-band 147 is preferably an elasto
`meric yarn or material. As stated before, more preferably
`torso-band 147 is made of a combination of nylon covered
`spandex and nylon. Most preferably, torso-band 147 is made
`of about 265 to about 420 denier nylon covered spandex and
`nylon to make certain that brassiere 130 stays in place on the
`Wearer’s body.
`Upper torso part 141 is, as With the body 15 of brief 10
`and the bodies of the other undergarments of the present
`invention, preferably made of ?at nylon ground yarn and a
`cotton and/or nylon yarn. Flat yarn is used because it has no
`stretch. The fabric also includes an elastomeric yarn, such as
`spandex. The combination of yarns forms a pattern that is in
`the range of 60/1’s to 40/1’s cotton count or about 40 to
`about 120 denier, preferably about 80 to about 120. The ?at
`nylon ground yarn is about 20 to about 40 denier, preferably
`about 20 denier.
`Brassiere 130 is formed mostly With simple knit
`constructions, such as plain, tuck, pearl and combinations
`thereof. Welt knit stitches may suitably be used to provide
`special features at various locations. HoWever, in the areas
`of brassiere 130 Where increased control is desired, a 1x1
`alternating tuck stitch pattern is used. Such areas are shoWn
`generally as 145 and 146. As stated before, the 1x1 alter
`nating tuck stitch pattern tightens the fabric of brassiere 130
`and, thus, increases the modulus of the fabric. By increasing
`the modulus of the fabric, the fabric stretches less and
`controls more. Preferably, the modulus of the fabric is
`increased betWeen about 6% and about 10%, more prefer
`ably about 8%. Increasing the modulus by about 8% pro
`vides a desirable compromise betWeen control and comfort.
`In the example illustrated as FIG. 12, control areas
`145,146 are narroW bands located underneath breast cups
`142,143 and extending courseWise in the area of transition
`betWeen upper torso portion 141 and torso-band 147. In this
`Way, control areas 145,146 take the place of traditional
`underWires. HoWever, control areas may also be located in
`other areas of the brassiere, such as betWeen the cups or on
`the outside edge of the cups. Additionally, control areas for
`brassiere 130 need not be shaped as narroW bands. If the
`purpose of the brassiere 130 is to pull the breast together, an
`hourglass-shaped control area betWeen the breast cups could
`be employed.
`The present invention having thus been described With
`particular reference to the preferred forms thereof, it Will be
`obvious that various changes and modi?cations may be
`made therein Without departing from the spirit and scope of
`the present invention as de?ned in the appended claims.
`What We claim is:
`1. A circular knit blank for use in the manufacture of
`undergarments comprising a tubular knit fabric having a ?rst
`stitch pattern and a second stitch pattern With each stitch
`pattern having an elastomeric yarn knitted therein, said
`second stitch pattern being a tightening and alternating tuck
`stitch pattern that forms at least one area of control that
`increases the modulus of said tubular knit fabric.
`2. The circular knit blank according to claim 1 Wherein
`said area of control provides control for a user’s hips.
`3. The circular knit blank according to claim 1, Wherein
`said stitch pattern is a 1x1 alternating tuck stitch pattern.
`4. A loWer torso garment comprising a tubular knit fabric
`having a ?rst stitch pattern and a second stitch pattern With
`each stitch pattern having an elastomeric yarn knitted
`therein, said second stitch pattern being a tightening and
`
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`alternating tuck stitch pattern that forms at least one area of
`control that increases the modulus of said tubular knit fabric.
`5. The loWer torso garment according to claim 4, Wherein
`said loWer torso garment is a brief having said at least one
`area of control substantially covering only a user’s stomach
`and hip areas.
`6. The loWer torso garment according to claim 4, Wherein
`said loWer torso garment is a high Waist brief having said at
`least one area of control substantially covering only a user’s
`abdominal and hip areas.
`7. The loWer torso garment according to claim 4, Wherein
`said loWer torso garment is a half-slip having said at least
`one area of control substantially covering only a user’s
`stomach and hip areas.
`8. The loWer torso garment according to claim 4, Wherein
`said loWer torso garment is a legged brief having said at least
`one area of control substantially covering only a user’s
`stomach and hip areas.
`9. The loWer torso garment according to claim 4, Wherein
`said loWer torso garment is a body slip having said at least
`one area of control substantially covering only a user’s
`abdominal and hip areas.
`10. The loWer torso garment according to claim 4,
`Wherein said loWer torso garment is a maternity brief having
`said at least one area of control substantially covering a
`user’s buttocks, hips, and groin areas, Wherein said at least
`one area of control aids in controlling the stomach area
`Without reducing the ability of the portion of said maternity
`brief covering the stomach area to expand as needed.
`11. Abrassiere comprising a tubular knit fabric having a
`?rst stitch pattern and a second stitch pattern With each stitch
`pattern having an elastomeric yarn knitted therein, said
`second stitch pattern being a tightening and alternating tuck
`stitch pattern forming at least one area of control that
`increases the modulus of said tubular knit fabric.
`12. The brassiere according to claim 11, Wherein said at
`least one area of control is tWo areas of control, Wherein each
`of said tWo areas of control is located underneath a respec
`tive breast cup of said brassiere.
`13. A method of making a loWer torso garment compris
`ing:
`knitting a Welt portion and a tubular knit body, said
`tubular knit body made of a fabric having a ?rst stitch
`pattern and a second stitch pattern With each stitch
`pattern having an elastomeric yarn knitted therein, said
`second stitch pattern being a tightening and alternating
`tuck stitch pattern forming at least one area of control
`that increases the modulus of said fabric;
`knitting an extended portion integrally to said tubular knit
`body, said extended portion having a distal edge; and
`attaching said distal edge to said tubular knit body to form
`leg openings.
`14. The method of making a loWer torso garment accord
`ing to claim 13, Wherein said modulus is increased by about
`8%.
`15. The method of making a loWer torso garment accord
`ing to claim 13, Wherein said stitch pattern is a 1x1 alter
`nating tuck stitch pattern.
`16. A method of making a brassiere comprising:
`knitting a Welt portion and a tubular knit body, said
`tubular knit body made of a fabric With a ?rst stitch
`pattern and a second stitch pattern With each stitch
`pattern having an elastomeric yarn knitted therein, said
`second stitch pattern being a tightening and alternating
`tuck stitch pattern forming at least one area of control
`that increases the modulus of said elastomeric fabric;
`and
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`US 6,276,175 B1
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`7
`knitting to said tubular knit body extended portions that
`When attached together form shoulder straps.
`17. The method of making a loWer torso garment accord-
`ing to claim 16, Wherein said modulus is increased by about
`8%.
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`8
`18. The method of making a loWer torso garment accord
`ing to claim 16, Wherein said stitch pattern is a 1x1 alter
`nating tuck stitch pattern.
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`Target Corporation
`EX. 1004 - Page 11
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