Performance sports garments formed from single layer double-faced performance warp knit fabric and method of making same

Abstract

Performance sports garments formed containing an integrally formed stretch warp knit fabric structure formed from a single layer fabric having definitive two-sided qualities. 1373-008

Description

CROSS-REFERENCE TO RELATED APPLICATION(S)

This nonprovisional utility patent application claims the benefit of one or more prior filed copending nonprovisional applications; a reference to each such prior application is identified as the relationship of the applications and application number (series code/serial number): The present application is a Continuation-In-Part of application 10/720,947, which is incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

(1) Field of the Invention

The present invention relates generally to textile fabrics and, more particularly, to a double-faced warp knit fabric for performance garment applications.

(2) Description of the Prior Art

Prior art includes reversible garments having different inside and outside parts of the garment, typically provided by two fabrics joined together at seams, i.e., woven or knitted fabrics that are later joined together, wherein the two fabrics have a differing qualities, such as color, design or pattern, or texture. Examples include: U.S. Pat. No. 6,647,551 issued Nov. 18, 2003 to Palumbo for Reversible garment; U.S. Pat. No. 5,561,860 issued Oct. 08, 1996 to Nguyen-Senderwicz for Reversible two-toned and/or two-textured shirt/sweater with extended sleeves; U.S. Pat. No. 5,204,995 issued Apr. 27, 1993 to Knapp for Fashionable reversible pants; U.S. Pat. No. 4,310,929 issued Jan. 19, 1982 to Finlay for Reversible running shorts; U.S. Pat. No. 4,296,498 issued Oct. 27 1981 to Vinson for Reversible garment; U.S. Pat. No. 4,414,691 issued Nov. 15, 1983 to Estruch for Reversible bathing garment; U.S. Pat. No. 6,128,783 issued Oct. 10, 2000 to Blauer, et al. for Reversible sweater with opposing sides that optionally present either customary appearance or enhanced visibility; U.S. Pat. No. 4,481,683 issued Nov. 13, 1984 to Estruch for Reversible uni-sex garment;

Notably, typically the prior art reversible garments are characterized by their two distinct fabrics, one forming an inside and the other forming the outside, which are intended to be reversed inside/outside for different effect.

In another form of prior art, U.S. patent application Ser. No. 20040048540 published Mar. 11, 2004 for inventor Dailly for Fabric for garment and resulting garment provides a two-sided knit fabric having two layers that are assembled closely together by a knitting process with incorporation of an elastic thread. In particular, the fabric combines sweat- repellent and thermally insulating characteristics via these superposed layers including hollow synthetic fibers.

Thus, there remains a need for a garment formed from a single layer double-faced warp knit fabric having different qualities on the face and back sides, and wherein the garment is formed from a single fabric.

SUMMARY OF THE INVENTION

The present invention provides garment embodiments utilizing single layer double-faced warp knit fabrics having different qualities on the face and back sides of the fabric that correspond to different inside and outside surfaces of the garment, wherein the sides are aesthetically enhanced fabrics with advantageous performance properties. The garment embodiments may also include other suitable and appropriate warp knit or weft knit fabrics in combination with the said single layer double-faced warp knit of the present invention in any proportion according to the garment design. The present invention also provides methods for producing such fabrics.

In an aspect the present invention a garment formed from a single layer fabric having a definitive two-sided, and even more desirably, two distinctive and different colors on each side as a result.

More specifically an embodiment of the present invention provides a garment having a definitive two-sided single layer warp knit fabric structure with a first technical back side forming the inside of the garment including a textured micro-denier multifilament synthetic yarn such as nylon or polyester, preferably polyester, and a base structure comprised of spandex elastomeric yarn, and a second technical face side forming the outside of the garment including a fully dyeable synthetic either continuous multifilament or a spun staple length yarn such as nylon or polyester, preferably nylon, and a second technical back side forming the inside of the garment including a textured micro-denier multifilament synthetic yarn such as nylon or polyester, preferably polyester, and a base structure comprised of spandex elastomeric yarn.

Any of the conventional yarn types known in the art may be utilized to produce a warp knit fabric for use with the performance garments of the present invention, including, but not limited to natural and synthetic yarns produced from spandex, nylon, polyester, viscose, cotton and/or blends thereof. In a preferred embodiment of the present invention the technical back-side of the single layer warp knit fabric is comprised of a substantially resilient and thermo-settable continuous filament synthetic yarn. The synthetic yarn may comprise a textured multifilament yarn, a flat non-textured multifilament yarn, or a spun staple yarn wherein the synthetic yarn comprises polyester or nylon. In the case of a flat non-textured multifilament yarn, a higher reflectance surface can be produced thereby imparting a metallic look effect, particularly when the yarn is either solution dyed, yarn dyed, or fabric piece dyed in the into silver or gold metallic looking colors.

A particularly desirable combination is achieved when any fashionable color such as Navy or Red, for example, is dyed only on the yarn visible in the technical face side of the fabric, which corresponds to the outside of the garment, while a contrasting and different color such as silver is dyed on the yarn visible on the technical back side of the fabric, which corresponds to the inside of the garment, resulting in a silver backed fabric having any color on the reverse face of the garment product. The garment may also include other types of warp knit or weft knit fabric constructions that enhance the garment in function and/or aesthetics.

A feature of the present invention is that an embodiment of the present invention provides a garment formed from a single layer double faced or distinctly two-sided warp knit fabric wherein the first and second distinct and different yarn layers together in a tightly spaced relationship parallel to each other.

Another feature of the present invention is that an embodiment of the present invention provides a multi-directional stretch performance fabric utilizing synthetic polymer spandex elastomeric yarn.

A further feature of the present invention is that a performance sports garment embodiment of the present invention provides for a sueded or brushed technical back fabric surface, corresponding to the inside of the garment, for maximizing wearer comfort.

Embodiments of the present invention provide methods of making performance garments using single layer warp knitted double faced fabrics that may have a luster range from a full dull luster face, any intermediate luster such as semi-dull or semi-bright, or a bright or high luster face, a Printed face, Embossed face, or Specialty Yarn faced fabric consisting of a first distinct and opaque outer technical face fabric surface, a second distinct inner technical back fabric surface that may be either fully dull or highly bright in luster, and that will facilitate the manufacturing of performance sports garments in a minimal number of manufacturing steps.

These and other aspects of the present invention will become apparent to those skilled in the art after a reading of the following description of the preferred embodiment when considered with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of a sleeveless garment constructed according to the present invention.

FIG. 2 is a front view of an alternative, short-sleeved garment constructed according to the present invention.

FIG. 3 is a front view of another alternative, long-sleeved garment constructed according to the present invention.

FIG. 4 shows a front view of yet another alternative garment constructed according to the present invention.

FIG. 5 shows a front view of another alternative garment according to the present invention.

FIG. 6 illustrates a front view of another alternative garment according to the present invention.

FIG. 7 illustrates a front view of another alternative garment according to the present invention.

FIG. 8 shows a front view of another alternative garment according to the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

In the following description, like reference characters designate like or corresponding parts throughout the several views. Also in the following description, it is to be understood that such terms as “forward,” “rearward,” “front,” “back,” “right,” “left,” “upwardly,” “downwardly,” and the like are words of convenience and are not to be construed as limiting terms.

Referring now to the drawings in general, the illustrations are for the purpose of describing preferred embodiments of the invention and are not intended to limit the invention thereto. The various FIGS. 1-8 all show particular embodiments for performance sports garments according to the present invention, each with some garment pattern difference, intended to illustrate but not limit the range of garment types to which the present invention applies. All of the garments set forth herein are formed using a knitted fabric according to the prior filed parent application 10/720,947, of which this application is a Continuation-In-Part, which is incorporated herein by reference in its entirety regarding the fabric construction, and may be used in combination with other warp knit or weft knit fabrications according to each unique garment design embodiment.

As seen in FIG. 1, a knitted sleeveless shirt is constructed according to the present invention is shown. FIG. 1 shows a first fabric surface 10 and a second fabric surface 12, wherein the first fabric surface corresponds to the inside of the garment and the second fabric surface corresponds to the outside of the garment, when the garment is worn in its intended orientation. Similarly, all figures show first (10) and second (12) fabric surfaces corresponding to the inside and outside of the garment, respectively.

Similarly, FIGS. 2 and 3 illustrate alternative patterns for making a knitted shirt constructed according to alternative embodiments of the present invention. FIG. 2 shows a short-sleeved shirt embodiment, while FIG. 3 shows a long-sleeved shirt embodiment.

FIG. 4 illustrates a knitted pants embodiment, once again with inside and outsides of the garment indicated. FIGS. 7 and 8 show short knitted pants constructions, including sports performance underwear in FIG. 7.

FIGS. 5 and 6 show tank top embodiments, with FIG. 6 having narrower straps and an alternative construction. Importantly, in more delicate apparel garments, such as illustrated in FIG. 6 or even in underwear garments as in FIG. 7, it is not possible to utilize the reversible garment constructions according to any of the various prior art, since combining more than one fabric via seaming or other connection would render the garment too bulky to be worn as close-fitting, lightweight sports performance apparel.

The design examples set forth in the FIGS. 1-8 in the foregoing description are not necessarily optimized but illustrative of what can be done for a system and method and indicative of the preferred embodiment at the time of the invention.

The preferred embodiments of the present invention include garments formed from a two-sided single layer stretch warp knit fabric having a first (face) side and a second (technical back) side identified as such for the purposes of the following description; it will be appreciated that the fabric could be reversible, in which case the first and second side labeling may be used to more generally identify and distinguish the fabric's opposite sides, faces, or surfaces, depending on the application, design, and function of the fabric.

The present invention provides for performance garments formed from a single layer double-faced or distinctly two-sided warp knit fabric that has first and second knit parallel yarn layers forming each of a first side and a second side of the fabric that are integrally knitted and joined together by a series of knit courses forming a resultant single thickness fabric which discretely secures the first and second distinct and different yarn layers together in a tightly spaced relationship parallel to each other.

A preferred embodiment of the present invention provides a sports performance garment that is formed of a warp knitted single-layer performance fabric that has optimized comfort features on the inside of the garment, which corresponding to the second side of the fabric, with at least one different quality on the,outside of the garment, which corresponds to the first side of the fabric as illustrated in the various embodiments shown in FIGS. 1-8.

The outer surface yarn, which is used on the surface of the second side (12) of the fabric, which corresponds to the outside of the garment, will also be the visible ingredient in the fabric therefore will be dyed into fashion colors as desired for the appropriate end use for performance wear garment applications. The fabric inner surface backside, which contacts the skin of the wearer, will thus be hidden from view but provide appropriate features for the comfort of the garment wearer.

Thus, the first and second sides of the fabric used for the garments according to the present invention advantageously provides for each side having at least one different quality from the other side, wherein said quality is either quantitatively and/or qualitatively distinguishable between the first and second sides. By way of example and not limitation, said at least one different quality preferably includes color, shade, fiber type(duplicate) fiber type, pattern, texture, chemical finish, mechanical finish or additional processing, luster or brightness, opacity, reflectivity, and/or wherein the side differences affect fabric performance such as the functional features of wicking, breathability or permeability, water-resistance, stain resistance, comfort, heat transfer, insulation or cooling, flame retardant, and combinations thereof.

In the case of color differences, the first and second sides may have different colors or different shades of the same color, which may be achieved by solution dyeing, yarn dyeing, fabric piece dyeing, and the like. Additionally or alternatively, the first and second sides may have differences such as one of the sides having a metallic color, look or finish, realized by fiber type, finish, coating, and combinations thereof.

The first and second sides of the fabric and garment may have different fiber types in terms of the material or substance itself, or in terms of the form of the material, such as multifilament, textured multifilament, spun staple, and the like, and combinations thereof, which provide for a difference of at least one quality between the inside and outside of the garment.

Another difference between the first (10) and second (12) sides of the fabric, and subsequently the inner and outer surfaces of the performance garment in which the fabric is utilized, according to the present invention, includes the pattern on each side. Pattern differences include printed, embossed, embroidery, specialty yarn, and knitting differences on either side; any variation in pattern from one side to the other that is distinguishable is considered to fall within the scope of the present invention, i.e., the difference need not be highly pronounced, but noticeable by a qualitative and/or quantitative measure.

The texture may also vary between the first and second sides. The two-sided single layer stretch warp knit fabric is preferably formed using a knitting technique that provides for a quality unique to each side. The textural differences may be provided by finish-enhanced means, including but not limited to brushed, chemically treated, sueded, sanded, and the like, and combinations thereof, as well as being optionally provided in part due to the yarn differences, as set forth hereinabove.

Another difference between the first (10) and second (12) sides of the fabric and performance garment according to the present invention is luster and/or brightness or opacity may be one of the at least one distinguishing quality from the first to second sides of the two-sided single layer stretch warp knit fabric, which correspond to inside and outside of the garment formed therewith, respectively, according to the present invention.

Another distinction between sides occurs where the side differences affect fabric performance, i.e., the differences between the sides produce a functional quality in the fabric overall, such as stain resistance and wearer comfort, more specifically the ability of the inner fabric structure inside the performance garment to efficiently and rapidly move and transport moisture away from the body of the wearer and transfer it to the outer garment surface layer by means of a hydrophobic highly wickable ingredient such as microdenier textured polyester yarn against the body integrally knitted to and connected with the outer fabric face of the garment that in turn releases the moisture through evaporation.

The present invention provides embodiments such as underwear garments formed from single layer double-faced warp knit fabrics having different qualities on the face and back sides that are aesthetically enhanced fabrics with advantageous performance properties, such as comfort-enhanced inside properties to benefit the garment wearer.

More specifically, one embodiment of the present invention provides a distinctive inside/outside sports performance garment formed from a definitive two-sided single layer warp knit fabric structure with a first technical face side, corresponding to the garment outside, comprised of a fully dyeable synthetic either continuous multifilament or a spun staple length yarn such as nylon or polyester, preferably nylon, and a second technical back side, corresponding to the garment inside, comprised of a textured micro-denier multifilament synthetic yarn such as nylon or polyester, preferably polyester, and a base structure of the fabric comprised of spandex elastomeric yarn. A range of fabric weights would be suitable for the garment embodiments according to the present invention, preferably, between about four to about twelve oz/yd².

Any of the conventional yarn types known in the art may be utilized to produce a garment according to the present invention formed from a warp knit fabric of the present invention, including, but not limited to natural and synthetic yarns produced from spandex, nylon, polyester, viscose, cotton and/or blends thereof. In a preferred embodiment of the present invention a garment is formed from a two-sided single layer warp knit fabric wherein the technical back-side of the single layer warp knit fabric is comprised of a substantially resilient and thermo-settable continuous filament synthetic yarn. The synthetic yarn may comprise a textured multifilament yarn, a flat non-textured multifilament yarn, or a spun staple yarn wherein the synthetic yarn comprises polyester or nylon. In the case of a flat non-textured multifilament yarn, a higher reflectance surface can be produced thereby imparting a metallic look effect, particularly when the yarn is either solution dyed, yarn dyed, or fabric piece dyed in the into silver or gold metallic looking colors. A similar look may be accomplished when using a preferred textured multi-filament micro-denier polyester yarn which optimizes moisture wicking action when against and in direct contact with the skin of the garment wearer.

Yet another embodiment of the present invention provides a sports performance garment utilizing a multi-directional stretch performance fabric. More particularly, in one embodiment, the multi-directional stretch performance fabric utilizes a synthetic polymer spandex elastomeric yarn such as Lycra produced by the DuPont Company of Wilmington, De. The inclusion of spandex yarn into the fabric structure is integral to the successful execution of separation of the two distinct yarn systems into technical face and technical back. Alternatively, a non-spandex stretch yarn, such as a stretch polyester or extra-stretch polyester, or similar yarn having stretch properties may be used, depending upon the application for the fabric, including but not limited to additional processing steps and/or use of the fabric, including cleaning and care or fabric maintenance, either alone or in its use as an article, such as a garment or accessory.

Another embodiment of the present invention provides for a sueded or brushed technical back fabric surface for maximizing wearer comfort and increasing the thermal retention properties of the fabric and garment.

Embodiments of the fabric set forth hereinabove may be advantageously utilized in articles of manufacture. Accordingly, the present invention includes articles of manufacture comprising a fabric of the present invention as set forth hereinabove, by way of example for performance garments of the present invention include a short sleeved shirt, a long sleeved shirt, a tank top, and the like.

The present invention provides a method for forming a two-sided garment including the steps of: providing a two-sided single layer stretch warp knit fabric comprising a first side and a second side that are integrally formed, such that the first and second sides of the fabric have at least one different quality from the other side, cutting the fabric into garment components using a pattern, and attaching predetermined components to form the garment by sewing them at seams, wherein the garment has an inside and an outside corresponding to the first and second sides of the fabric, respectively such that the inside and the outside of the garment having at least one different quality from each other.

Methods of making garments using the single layer, warp knitted, double faced fabrics as set forth hereinabove include methods for making fabrics that may have a range in texture and luster from a full dull luster face, any intermediate luster such as semi-dull or semi bright, to a bright or high luster face, a printed face, embossed face, or specialty yarn-faced fabric having a first distinct and opaque outer technical face fabric surface, a second distinct inner technical back fabric surface that may also be in a range from fully dull to highly bright in luster, and that will facilitate the manufacturing of the garments in a minimal number of manufacturing steps.

Further steps of processing the fabric to be utilized in the performance garment may be performed to create at least one different quality between the first and second sides of the fabric, such as, by way of example and not limitation: napping, brushing, sueding, chemical treating, finishing, printing, embossing, and combinations thereof.

Certain modifications and improvements will occur to those skilled in the art upon a reading of the foregoing description. All modifications and improvements have been deleted herein for the sake of conciseness and readability but are properly within the scope of the following claims.

Claims

1. A performance garment using a multi-directional stretch performance fabric comprising:

A two-sided single layer stretch warp knit fabric further comprising a first side and a second side that are integrally formed during knitting wherein each side has at least one different quality from the other side, wherein the two-sided single layer stretch warp knit fabric is processed to form a performance garment having an inside and outside corresponding to the first side and the second side of the fabric, respectively.

2. The performance garment of claim 1, wherein the processing includes cutting into components, configuring, and attaching the components to form the performance wear garment, utilizing a two-sided single layer warp knit as a main component and may be in combination with other warp knit or weft knit fabrics, according to the garment design.

3. The garment of claim 1, wherein the performance garment is used in applications including sports, and fitness activities, as well as everyday leisure wear, casual wear, or generally non-sporting, non-physically exertive attire.

4. The garment of claim 1, wherein the fabric includes a spandex yarn component.

5. A method for forming a garment comprising the steps of:

providing a two-sided single layer stretch warp knit fabric comprising a first side and a second side that are integrally formed, such that the first and second sides of the fabric have at least one different quality from the other side,

cutting the fabric into garment components using a pattern;

attaching predetermined components to form the garment by either conventional sewing technology, ultrasonic welding, adhesive seaming, or any such method of fabricating a garment by joining them at seams, wherein the garment has an inside and an outside corresponding to the first and second sides of the fabric, respectively such that the inside and the outside of the garment having at least one different quality from each other.