Two-ply blank and a method of manufacturing a circularly knitted two-ply blank
View Patent ↗A circularly knitted garment and a method of making a circularly knitted garment are provided. The garment has a cylindrical layer of fabric having an inner layer having a first free-end and a first edge, an outer layer having a second free-end and a second edge and a junction to join the first edge to the second edge. The second free-end is connected to the first free-end and the second edge is connected to the first edge during the knitting process to form a completed two-ply garment. The method provides turning the second series of courses outside of the first series of courses while the second series of courses is joined by held loops to the first series of courses at a junction. The method further includes knitting a second free-end to a first-free end using held loops from the second series of courses to form a completed two-ply garment.
1. A circularly knitted garment comprising:
a first series of courses having a first free-end, a third end, and having a first end and
a second series of courses having a second free-end, a fourth end, and having a second end
wherein said first end and said second end form a connection, and wherein said second end is integrally connected to said first end and said second free-end is integrally connected to said first free-end to form a two-ply garment without the first and second courses needing to be turned outside one another.
2. The garment according to claim 1 , wherein said connection is a welt.
3. The garment according to claim 1 , wherein said third free end and said fourth end are turned welts.
4. The garment according to claim 1 , wherein said first series of courses and said second series of courses are knitted using a stitch that requires a plurality of held loops and said second series of courses is connected to said first series of courses by transferring said plurality of held loops.
5. The garment according to claim 1 , wherein said garment is a brassiere.
6. The garment according to claim 1 , wherein said garment is selected from the groups consisting of a brassiere, a pair of panty hose, a stocking, a leotard, a swimsuit, a pair of underwear and a pair of panties.
7. A circularly knitted two-ply garment comprising:
a first series of courses having a first free-end, a first front side, a first pair of breast cups, said first pair of breast cups having a first periphery, and a first back side having a welt; and
a second series of courses having a second free-end, a second front side, a second pair of breast cups, said second pair of breast cups having a second periphery, and a second back side having said welt;
wherein said first series is integrally connected to said second series at said welt, said second periphery is integrally connected to said first periphery and said second free-end is integrally connected to said first free-end to form a two-ply garment.
8. A circularly knitted garment comprising:
a first layer of fabric having a first free-end and a second end; and
a second layer of fabric having a second free-end and a third end, said second layer connected to said second end by a junction at said third end and by a plurality of integrally formed loops extending from said second free-end to form a completed two-ply garment.
9. The garment according to claim 8 , wherein each of said plurality of loops comprise a single strand of thread.
10. The garment according to claim 8 , wherein each of said plurality of loops comprise multiple strands of thread.
11. The garment according to claim 8 , wherein said junction has a first end and a second end that are connected.
12. The garment according to claim 8 , wherein said first layer and said second layer and said junction are knit using a using a rib stitch.
13. The garment according to claim 8 , wherein the garment is selected from the group consisting of a brassiere, a pair of panty hose, a stocking, a leotard, a swimsuit, a pair of underwear and a pair of panties.
14. The garment according to claim 8 , wherein the garment is a brassiere.
15. A circular knit garment comprising:
a first series of courses having a first-free end comprising an inner layer;
a second series of courses having a second free-end comprising an outer layer;
a junction connecting said first series to said second series; and
a plurality of integrally formed loops connecting said second free-end to said first free-end to form a completed garment.
16. The garment according to claim 15 , wherein said first series of courses has a first front side and said second series of courses has a second front side and said first series of courses has a first back side and said second series of courses has a second back side.
17. The garment according to claim 15 , wherein said first front side comprises a first pair of breast cups knitted therein comprising a first lower arcuate border and said second front side comprises a second pair of breast cups knitted therein comprising a second lower arcuate border integrally connected to said first border.
18. The garment according to claim 17 , wherein said first lower arcuate border comprises a first medial portion and first lateral portions and said second lower arcuate border comprises a second medial portion and second lateral portions.
19. The garment according to claim 18 , wherein said first front side further comprises a first central gore proximate said first medial portion and first support panels proximate said first lateral portion and said second front side further comprises a second central gore proximate said second medial portion and first support panels proximate said second lateral portions.
20. The garment according to claim 15 , wherein said inner layer is knitted using a wicking yarn.
21. The garment according to claim 15 , wherein said outer layer is selecting from the group consisting of natural fiber, spandex, synthetic continuous multifilament flat or textured polymer yarn, staple yarn, and any combination thereof.
22. The garment according to claim 15 , wherein the garment is selected from the group consisting of a brassiere, a pair of panty hose, a stocking, a leotard, a swimsuit, a pair of underwear and a pair of panties.
23. A method of making a garment blank comprising:
knitting a generally cylindrical first series of courses having a first free-end;
knitting a generally cylindrical second series of courses having a second free-end;
knitting a junction to seamlessly connect said first series to said second series;
turning said second series outside of said first series about said junction; and
knitting said second free end to said first free end at a plurality of locations using threads from said second series of courses to form a completed two-ply garment.
24. The method according to claim 23 , further comprising knitting said first series of courses and said second series of courses on a first side to form a first pair of breast cups and a second pair of breast cups, respectively, that overlay each other in registration when said second series is turned outside of said first series.
25. The method according to claim 24 , further comprising knitting a portion of said second pair of breast cups to said first pair of breast cups before said garment is completed.
26. The method according to claim 24 , wherein said step of knitting said second free-end to said first free-end comprises transferring held loops from said second free-end to said first free-end.
27. The method according to claim 23 , wherein said step of knitting said junction comprises knitting a turned welt.
28. The method according to claim 23 , wherein after said step of turning said second series outside of said first series further comprises knitting a portion of said junction to itself.
29. A method according to claim 23 , wherein said steps of knitting said first series of courses, said second series of courses and said junction further comprise knitting a turned welt.
30. The garment according to claim 23 , wherein said garment is selected from the group consisting of a brassiere, a pair of panty hose, a stocking, a leotard, a swimsuit, a pair of underwear and a pair of panties.
31. The garment according to claim 8 , wherein said junction is a welt.