Abstract: A method of forming a garment trim is provided. The method includes folding a peripheral edge of a fabric to a selected position to form a cavity, inserting a binding in the cavity, securing the binding in the cavity and the peripheral edge in the selected position with a seam, and exposing the fabric to at least one condition sufficient to cause the binding to bond to the cavity and to dissipate the seam.

Abstract: A fabric cutting system for cutting a pre-selected pattern from a fabric stock and transferring the cut fabric piece to a workstation. The system includes a cutter assembly for cutting the preselected pattern from the fabric stock. A configurable pickup assembly is located between the cutter assembly and the workstation and adapted to pick-up and transfer the cut fabric piece to the workstation. A hold down table adjacent to the cutter assembly maintains the position of the fabric stock in a determinable relationship to the position of the cutter assembly and the configurable pickup assembly. In the preferred embodiment, the hold down table is vacuum operated and includes a moving mesh belt on which and the fabric stock is moved downstream towards the pickup assembly as the fabric piece is being cut by the cutter assembly. This arrangement results in substantially higher throughput through the fabric cutting system.

Abstract: A hybrid brassiere is provided. The brassiere has a brassiere body having a pair of side wings/back panels made of circular knit fabric and an integrally knitted band. The brassiere also has a pair of breast cups made from one or more fabrics, namely woven, non-woven, warp knitted, and weft knitted fabrics, and an attachment for connecting the pair of breast cups to the brassiere body.

Abstract: A brassiere for supporting a wearer's breasts has breast cups with each of the breast cups connected to a central panel therebetween. The brassiere has a pair of side panels. Each side panel is connected to a different one of the pair of breast cups. The breast cups have a first fabric layer, a second fabric layer and a third fabric layer that is between the first fabric layer and the second fabric layer. The third fabric layer provides breathability and support to the wearer's breasts.

Abstract: A tube brassiere is formed from a circularly knitted garment blank. The blank has an internal dimension, a length, and a pair of breast cup defined therein. The length of the blank encircles a torso of a wearer.

Abstract: A brassiere fastener system having a cushion structure is provided. Preferably, the cushion structure is a pouch with at least one cushion insert therein.

Abstract: A method for circularly knitting an elastomeric yarn into a knitted fabric is provided. The method includes: operating a circular knitting machine at a machine rate, retaining a free end of the elastomeric yarn in a substantially relaxed condition, and taking up the free end into the circular knitting machine while feeding the elastomeric yarn at a first feed rate. The first feed rate maintains the elastomeric yarn in the substantially relaxed condition. The circular knitting machine continues to operate at the machine rate during the taking up of the free end.

Abstract: A circularly knitted garment having a body portion and a shaped band is provided. The body portion has a first area defined therein. The shaped band is also defined in the body portion such that a seamless interface is formed between the body portion and the shaped band.

Abstract: In a first embodiment, a first fabric layer has gelatinous strips, thereby separating the first fabric layer into sections. A second fabric layer is positioned upon the first fabric layer, and an underwire is positioned on the second fabric layer opposite the first fabric layer. The first fabric layer is then folded onto itself to enclose the second fabric layer and the underwire. In a second embodiment, a third, or intermediate, fabric layer is positioned between the first and second fabric layers. In a third embodiment, an underwire is surrounded by a first, non-woven fabric layer. A second, rigid-type fabric having a bladder with a gelatinous material is positioned on the first fabric. The first fabric is wrapped around the underwire, and the bladder is positioned against the body of the wearer.

Abstract: A method for circularly knitting an elastomeric yarn into a knitted fabric is provided. The method includes: operating a circular knitting machine at a machine rate, retaining a free end of the elastomeric yarn in a substantially relaxed condition, and taking up the free end into the circular knitting machine while feeding the elastomeric yarn at a first feed rate. The first feed rate maintains the elastomeric yarn in the substantially relaxed condition. The circular knitting machine continues to operate at the machine rate during the taking up of the free end.

Abstract: A method of dyeing a fabric is provided. The method includes removing folds from the fabric, spraying a dye on a first side of the fabric, and exposing the fabric to a migration and fixation process prior to the dye drying on the first side so that the dye migrates from the first side to a second side of the fabric and reacts with and affixes to a component of the fabric.

Abstract: There is provided a circular knit brassiere having a body portion with a pair of breast cups and a pair of side panels. Each side panel is connected to a different breast cup. The brassiere has different degrees of stretchability in each breast cup and side panel as compared to the center region of the brassiere. Tighter stitches with shorter stitch lengths than in the center region are used in the breast cups, thereby providing support for the breasts. Looser stitches, with longer stitch lengths than in the center region, are used in each side to provide improved flexibility and comfort to the wearer.

Abstract: A method and system for designing circularly knitted garments are provided. The method includes designing a model of the circularly knitted garment, stretching the model from a first size to a second size, and governing the stretching with one or more user definable rules. The system includes a circular knitting machine, a controller for controlling the circular knitting machine with a machine code, a tool for saving a model of the circularly knitted garment as a first output, and a conversion program for converting the first output into the machine code. The tool has a stretching function for changing a size of the first output using one or more user selected rules.

Abstract: An apparatus and method for closing the toe of a hosiery blank includes a hosiery toe closing machine including a sewing head having a sewing needle and a toe seam width guide. The toe seam width guide has a maximum thread guide width greater than 5 mm, preferably in the range of 6-10 mm. When the sewing needle pulls a thread around the maximum thread guide width of the toe seam width guide, the hosiery toe is closed with a wide, visible seam. The hosiery toe closing machine can include a first sewing head having a maximum thread guide width of 5 mm, for sewing a first, narrow seam, and a second sewing head having a maximum thread guide width greater than 5 mm, allowing a second seam that is wider than the first seam to be sewn over the first seam. The toe seam width guides are adjustably attached to the sewing heads for adjusting the effective thread guide width in the respective sewing heads and thereby provide corresponding adjustments to the relative widths of the first and second seams.

Abstract: The present invention relates to a method of manufacturing a single knit tubular blank, and the resultant blank and products. The method provides two circular knit brassieres each having first and second layers, thereby minimizing the steps in the process of manufacturing.

Abstract: A stitchless garment and a method of making the stitchless garment are provided. The method is used in connection with manufacturing a circular knit garment using a first garment component and a second garment component. The method includes the steps of providing the first garment component and providing the second garment component so that the second garment component overlaps the first garment component to define a connection. A bonding tape is provided at the connection. Heat is applied to the first garment component and the second garment component. The method also includes the step of applying pressure to the bonding tape to adhere the first garment component to the second garment component to provide a stitchless garment.

Abstract: A circular knit bra is provided. The bra has a pair of breast cups, a central gore disposed between the breast cups, and a pair of side panels. Each of the breast cups has at least two different areas of stretchability. Each different area of stretchability has a different stitch density.

Abstract: A shoulder strap pad assembly is provided that includes: a top cover, a bottom cover, and a cushion filler. The bottom cover is laminated to the top cover to form an enclosure in which the cushion filler is secured. The top cover has a top fabric layer, a first adhesive web layer positioned below the top fabric layer and a first base layer positioned below the first adhesive layer on a side opposite that of the top fabric layer. The bottom cover has a second base layer, a second adhesive web layer positioned above the second base layer. The cushion filler has a cushion layer, a third adhesive web layer positioned above the cushion layer, a fourth adhesive web layer positioned below the cushion layer, and a third base layer positioned below the fourth adhesive web layer. In a preferred embodiment, the pad assembly is attached to a piece of fabric to form a channel in which a brassiere shoulder strap is positioned.

Abstract: An automated process is provided that includes loading a blank on a carrier and moving one of the carrier or the blank to more than one of a number of stations. The carrier has at least a portion with a desired shape that provides the blank with a stretched condition. Each station performs an operation on the blank while the blank is mounted on the carrier.