Panty-hose articles with ultra-high molecular weight polyethylene and methods of making same

Abstract

An article of pantyhose includes a first tubular member having an underpants portion and a first tubular leg portion, the first tubular leg portion having a first main sub-portion and a first transition sub-portion. The main sub-portion extends from the thigh region of the tubular leg portion to its foot end, and the transition sub-portion extends between the panty portion and the main sub-portion. The primary sub-portion is formed from a first knitted fabric having a first ultra high molecular weight polyethylene (UHMWPE) fiber and a first companion fiber. The transition sub-portion is formed from a second knitted fabric having a second UHMWPE fiber and a second companion fiber, the first knitted fabric being different from the second knitted fabric. The second tubular member has similar pant portions and tubular leg portions. A method for manufacturing a panty-hose article includes forming the first tubular member, forming the second tubular member, cutting the first and second pant portions, engaging longitudinal edges of the pant portions to form a pant tube, and joining the longitudinal edges to a crotch.

Description

[0001] Related Applications

[0002] This PCT application claims priority to U.S. Provisional Application No. 63 / 341,160 filed on May 12, 2022 and Canadian Patent Application No. 3,185,681 filed on December 23, 2022, which are incorporated herein in their entirety. Technical Field

[0003] The present disclosure generally relates to a pantyhose article having ultra-high molecular weight polyethylene (UHMWPE) and a method of making the same, and more particularly, to a pantyhose article having a plurality of different knitted fabrics, including at least two knitted fabrics having UHMWPE. Background Art

[0004] Traditional knitted fabrics used to make hosiery products (such as pantyhose, stockings, socks and tights) include nylon and spandex fibers (e.g., spandex TM Leica TM However, these fabrics tend to tear or rip when subjected to friction. It has been observed that transparent hosiery products (e.g., 30 denier and below) made using these fibers are very fragile. They can be easily torn by hands, feet, or hanging nails, and are therefore generally considered disposable. Therefore, there remains a need for commercially viable transparent (low denier) elastic knitted fabrics that are not easily torn.

[0005] Ultra-high molecular weight polyethylene (UHMWPE) fibers are considered to be ideal reinforcing components due to their high impact strength, low density, low elongation at break, resistance to corrosive chemicals, low moisture absorption, and low coefficient of friction. Knitted fabrics comprising a combination of UHMWPE fibers with elastic fibers such as spandex, nylon, or polyester have shown enhanced tear resistance. However, UHMWPE fibers are very expensive and the quality varies greatly between different suppliers and between different batches. Lower quality UHMWPE fibers may result in defects such as yarn loops or barring, which compromises the quality of the hosiery and makes it unsalable and waste.

[0006] Therefore, there remains a need for a commercially viable knitted fabric for use in making hosiery articles that allows for the use of lower amounts and / or lower grades of UHMWPE fibers, but at the same time has adequate tear resistance and durability. Summary of the invention

[0007] According to one aspect, a pantyhose article is provided that includes a first tubular member, the first tubular member including a first panty portion and a first tubular leg portion, the first panty portion extending from a waist end of the pantyhose article to a bottom end of the first panty portion, the first tubular leg portion defining a first leg cavity and extending from a top end thereof to a first foot end of the first tubular leg portion, the top end of the first leg cavity corresponding to the bottom end of the first panty portion, the first tubular leg portion including a first main sub-portion and a first transition sub-portion, the first main sub-portion extending from a first thigh region of the first tubular leg portion to the first foot end, and the first transition sub-portion extending from a top end of the first tubular leg portion to the first thigh region of the first tubular leg portion, the first main sub-portion being formed of a first knitted fabric including first ultra-high molecular weight polyethylene (UHMWPE) fibers and at least one first companion fiber, and the first transition sub-portion being formed of a second knitted fabric including second UHMWPE fibers and at least one second companion fiber, and the first knitted fabric being different from the second knitted fabric.

[0008] According to another aspect, a method for manufacturing a pantyhose article is provided. The method includes forming a first tubular member having a first panty portion and a first tubular leg portion, the first panty portion extending from a waist end of the pantyhose article to a bottom end of the first panty portion, the first tubular leg portion defining a first leg cavity and extending from a top end thereof to a first foot end of the first tubular leg portion, the top end of the first leg cavity corresponding to the bottom end of the first panty portion, the first tubular leg portion including a first main sub-portion and a first transition sub-portion, the first main sub-portion extending from a first thigh region of the first tubular leg portion to the first foot end, and the first transition sub-portion extending from a top end of the first tubular leg portion to the first thigh region of the first tubular leg and extending circumferentially around the first tubular leg portion, the first main sub-portion being formed of a first knitted fabric comprising first ultra-high molecular weight polyethylene (UHMWPE) fibers and at least one first companion fiber, and the first transition sub-portion being formed of a second knitted fabric comprising second UHMWPE fibers and at least one second companion fiber, and the first knitted fabric being different from the second knitted fabric. The method also includes forming a second tubular member, the second tubular member having a second panty portion and a second tubular leg portion, the second panty portion extending from the top end of the pantyhose article to the bottom end of the second panty portion aligned with the bottom end of the first panty portion, the second tubular leg portion defining a second leg cavity and extending from its top end to the second foot end of the second tubular leg portion, the top end of the second leg cavity corresponding to the bottom end of the second panty portion, the second tubular leg portion including a second main sub-portion and a second transition sub-portion, the second main sub-portion extending from the second thigh region of the second tubular leg portion to the second foot end, and the second transition sub-portion extending from the top end of the second tubular leg portion to the second thigh region of the second tubular leg portion and extending circumferentially around the second tubular leg portion, the second main sub-portion being formed by a first knitted fabric comprising a first UHMWPE fiber and at least one first accompanying fiber, and the second transition sub-portion being formed by a second knitted fabric comprising a second UHMWPE fiber and at least one second accompanying fiber. The method also includes cutting the first panty portion along its longitudinal direction to form a first longitudinal edge therein, and cutting the second panty portion along its longitudinal direction to form a second longitudinal edge therein, joining the first longitudinal edge of the first panty portion with the second longitudinal edge of the second panty portion to form a panty tube defining a panty cavity for accommodating the wearer's lower body, the panty cavity being fluidly connected to the first leg cavity of the first tubular leg portion, and the panty cavity being fluidly connected to the second leg cavity of the second tubular leg portion, and joining the longitudinal edge of the first panty portion with the first edge of the crotch, and joining the longitudinal edge of the second panty portion with the second edge of the crotch. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The present disclosure can be best understood from the following detailed description when read in conjunction with the accompanying drawings. It is emphasized that, according to convention, the various features of the drawings are not necessarily drawn to scale. On the contrary, the sizes and spatial relationships of the various features may be arbitrarily enlarged or reduced for clarity. Throughout the specification and drawings, the same reference numerals represent the same features.

[0010] Figure 1 is a front view of a pantyhose article according to an exemplary embodiment when placed on a quality control device;

[0011] Figure 2 is a top perspective view of the interior of a pantyhose article according to one embodiment when placed on a quality control device;

[0012] Figure 3 is a bottom view of a crotch region of a pantyhose article according to one embodiment when placed on a quality control device;

[0013] Figure 4 is a front perspective view of a pantyhose article according to an exemplary embodiment when being worn;

[0014] Figure 5 is a side perspective view of a pantyhose article according to an exemplary embodiment when being worn;

[0015] Figure 6 is a rear perspective view of a pantyhose article according to an exemplary embodiment when worn;

[0016] Figure 7 is a bottom view of a pantyhose article according to an exemplary embodiment when worn; and

[0017] Figure 8 is a top view of a pantyhose article according to an exemplary embodiment when being worn. DETAILED DESCRIPTION

[0018] In the following description, certain specific details are set forth to provide a thorough understanding of various embodiments. However, those skilled in the art will appreciate that the present invention can be implemented without these details. In other cases, well-known structures are not shown or described in detail to avoid unnecessarily obscuring the description of the embodiments. Unless the context otherwise requires, throughout the specification and subsequent claims, the words "include / comprise" and their variants, such as "include / comprises" and "include / comprising" should be interpreted as open, inclusive meanings, i.e., "including, but not limited to". In addition, the titles provided herein are merely for convenience and do not explain the scope or meaning of the claimed invention.

[0019] Reference to "one embodiment" or "an embodiment" throughout the specification means that the specific features, structures or characteristics described in conjunction with the embodiment are included in at least one embodiment. Therefore, the phrases "in one embodiment" or "in an embodiment" appearing throughout the specification do not necessarily all refer to the same embodiment. In addition, specific features, structures or characteristics can be combined in one or more embodiments in any suitable manner. In addition, as used in this specification and the appended claims, the singular forms "a", "an" and "the" include plural references unless the reference content is clearly specified in addition. It should also be noted that the term "or" is generally used in its sense including "and / or" unless its meaning is clearly indicated in addition. In addition, as used in this specification and the appended claims, the term "about" has the meaning that one of ordinary skill in the art would reasonably give it when used in conjunction with a stated value or range, namely, to indicate slightly above or slightly below the stated value or range, within ±20% of the stated value; ±19% of the stated value; ±18% of the stated value; ±17% of the stated value; ±16% of the stated value; ±15% of the stated value; ±14% of the stated value; ±13% of the stated value; ±12% of the stated value; ±11% of the stated value; ±10% of the stated value; ±9% of the stated value; ±8% of the stated value; ±7% of the stated value; ±6% of the stated value; ±5% of the stated value; ±4% of the stated value; ±3% of the stated value; ±2% of the stated value; or ±1% of the stated value.

[0020] definition

[0021] As used herein, unless the context dictates otherwise, the following terms have the meanings specified below.

[0022] The term "UHMWPE" refers to ultra-high molecular weight polyethylene, also known as high modulus polyethylene (HMPE), or high performance polyethylene (HPPE).

[0023] The term "colored UHMWPE" refers to UHMWPE that has been colored (eg, made non-white) by a non-additive coloring process.

[0024] As used herein, the term "fiber" refers to a single source base material composed of one or more filaments. It has an elongated body with a length dimension much greater than the lateral dimensions of width and thickness.

[0025] As used herein, the term "filament" refers to a single fibril of a material, which may be a fiber by itself or may be combined with other filaments to produce a multifilament fiber. A single fiber may be formed from only one filament or from a plurality of filaments.

[0026] As used herein, the term "microfilament" refers to filaments having a denier of 5 denier or less.

[0027] The term "denier" as used herein refers to a unit of weight that indicates the fineness of a fiber filament. It can be measured as the mass in grams per 9,000 meters of fiber. A lower denier indicates a finer fiber, and a higher denier indicates a thicker or heavier fiber.

[0028] The term "decitex" or "dtex" as used herein refers to an alternative weight unit for expressing the fineness of fiber filaments. It can be measured as a mass expressed in grams per 10,000 meters.

[0029] The term "tensile strength" as used herein relates to the durability of a garment and is measured by the maximum stress a material can withstand before breaking while being stretched or pulled. It is measured as force per unit area and can be expressed in grams-force (gf) and centinewton (cN) / dtex.

[0030] As used herein, the term "elongation" refers to the degree of stretching of individual fibers and composite fibers that results in the elasticity of the final embodiments of the present disclosure. Elongation is measured as a percentage relative to the initial length.

[0031] As used herein, the term "natural fibers" refers to a class of fibers that can be obtained from materials of natural origin.

[0032] As used herein, the term "synthetic fiber" is used to refer to a class of fibers that are man-made. Synthetic fibers include, for example, polymeric materials synthesized by polymerization of monomers, fibers obtained by regeneration of natural fibers (for example, after dissolving in a solvent), and glass fibers.

[0033] As used herein, the term "stretch fiber" refers to a type of fiber that can be stretched to at least about 130% of its original dimensions without breaking when a force is applied.

[0034] As used herein, the term "non-stretch fibers" refers to fibers that are substantially inelastic and that exhibit little or no elongation.

[0035] As used herein, the term "high performance fibers" refers to a class of fibers having high tenacity values ​​greater than, for example, greater than 10 g / denier, making them suitable for applications requiring high abrasion and / or cut resistance. Typically, high performance fibers have a high degree of molecular orientation and crystallinity in the final fiber structure.

[0036] As used herein, the term "elastomeric fibers" refers to fibers having an elongation at break exceeding 100%, and which, when stretched and released, quickly and positively retract to substantially their original length.

[0037] As used herein, the term "thermoplastic fibers" refers to a class of fibers obtained from plastic or deformable polymers which melt into a liquid when heated and freeze into a brittle glassy state when sufficiently cooled.

[0038] As used herein, the term "abrasion resistant fibers" refers to a type of fiber that inhibits the wear of materials with which they come into contact.

[0039] As used herein, the term "knit" refers to a fabric produced by combining one or more fibers on a flat knitting machine or a circular knitting machine.

[0040] As used herein, the term "gauge" refers to the number of needles on a knitting machine. High-gauge knitting machines (e.g., 32 gauge and above) are required to produce transparent hosiery, such as transparent tights, stockings, and pantyhose, while low-gauge knitting machines (e.g., 18 to 32 gauge) are used to produce heavier garments, such as leggings, tights, socks, shirts, and other athletic apparel. Gauge is also used to refer to the knitted fabric produced by the machine: in other words, a knitted fabric made on a 32 gauge machine is a 32 gauge knitted fabric.

[0041] The term "plating" as used herein refers to the technique of knitting two fibers together in two different layers. While in the same stitch, one fiber stays on the back side, i.e. behind the front fiber.

[0042] As used herein, the term "serving" refers to a process in which two fibers are spun together to produce a composite fiber.

[0043] As used herein, the term "non-additive" refers to a coloring (usually dyeing) process that does not increase the overall denier of the fiber.

[0044] "Tensile properties" are properties measured when a material is subjected to a tensile force, and properties measured when the tensile force is removed. Examples of tensile properties include, but are not limited to, tensile strength at break, percent elongation at break, elastic modulus, toughness or tensile energy at break, permanent set, tensile load at a specific elongation, etc. The tensile properties of polymer fibers can be determined, for example, by standard test methods (such as ASTM D2256 / D2256M-21, "Standard Test Method for Tensile Properties of Yarns by the Single Ply Method").

[0045] As used herein, the term "barre" is defined as an unintentional, repeating visual pattern of continuous stripes or stripes generally parallel to the courses of a circular knitted fabric.

[0046] UHMWPE fiber

[0047] Various aspects described herein relate to UHMWPE fibers for use in making knitted fabrics and methods for forming the knitted fabrics.

[0048] In some embodiments, the UHMWPE fibers have high impact strength, low density, low elongation at break, resistance to corrosive chemicals, low moisture absorption, and / or a low coefficient of friction. In other aspects, the material is self-lubricating and highly wear and odor resistant.

[0049] In some embodiments, the UHMWPE fibers have a weight average molecular weight (M) of at least about 200,000. w In some embodiments, the UHMWPE fibers have a weight average molecular weight (M) of about 300,000 to about 7,000,000, about 700,000 to about 5,000,000, or about 900,000 to about 4,000,000. w The molecular weight distribution of the UHMWPE fiber, that is, the weight average molecular weight (M w ) and number average molecular weight (M n ) is about 5.0 or less, about 4.0 or less, or about 3.0 or less.

[0050] In some embodiments, the UHMWPE fiber is a monofilament. In some other embodiments, the UHMWPE fiber comprises a plurality of microfilaments. In some embodiments, each microfilament in the UHMWPE has a denier of about 5 or less, about 4 or less, about 3 or less, about 2.5 or less, about 2 or less, about 1.5 or less, about 1 or less, or about 0.5 or less.

[0051] The UHMWPE fiber may include any suitable number of microfilaments. In some embodiments, the UHMWPE fiber comprises 2 to 400 microfilaments, 10 to 300 microfilaments, 10 to 50 microfilaments, 5 to 25 microfilaments, or 20 to 200 microfilaments. In some embodiments, the UHMWPE fiber comprises 5, 7, 10, 15, 20, 25, 30, 35, 40, 45, or 50 microfilaments.

[0052] The UHMWPE fibers may have any denier suitable for pantyhose. In some embodiments, the UHMWPE fibers have a denier of about 10 to about 250. In some embodiments, the UHMWPE fibers have a denier of about 10 to about 60, and in some embodiments, the UHMWPE fibers have a denier of about 10, about 15, about 20, about 25, about 30, about 40, about 50, about 60, about 70, about 75, about 80, about 90, about 100, about 110, about 120, about 125, about 130, about 140, about 150. In some embodiments, the UHMWPE fibers have a denier of 50 or less.

[0053] In some embodiments, the UHMWPE fiber is a high-strength fiber. In some embodiments, the UHMWPE fiber has a tensile strength (i.e., tenacity) of at least 20 cN / dtex, at least 25 cN / dtex, at least about 30 cN / dtex, at least about 35 cN / dtex, at least about 40 cN / dtex, at least about 45 cN / dtex, at least about 50 cN / dtex, or at least about 60 cN / dtex. In some embodiments, the UHMWPE fiber has a tensile strength of about 26 cN / dtex, about 28 cN / dtex, about 30 cN / dtex, about 32 cN / dtex, about 36 cN / dtex, about 40 cN / dtex, about 45 cN / dtex, or about 50 cN / dtex.

[0054] In some embodiments, the UHMWPE fiber has a modulus of about 1000 cN / dtex or more, about 1100 cN / dtex or more, about 1200 cN / dtex or more, about 1300 cN / dtex or more, about 1400 cN / dtex or more, about 1500 cN / dtex or more, about 1600 cN / dtex or more. In some embodiments, the UHMWPE fiber has a modulus of about 1400 cN / dtex, about 1420 cN / dtex, about 1450 cN / dtex, about 1500 cN / dtex, or about 1360 cN / dtex.

[0055] In some embodiments, the UHMWPE fibers allow an elongation of no greater than about 10%, no greater than about 8%, no greater than about 5%, no greater than about 4%, no greater than about 3.5%, no greater than about 3%, no greater than about 2.5%, no greater than about 2%, or no greater than about 1.5%.

[0056] In some embodiments, the UHMWPE fiber has a breaking force of about 10 N or more, about 11 N or more, about 12 N or more, about 13 N or more, about 14 N or more, about 15 N or more, about 16 N or more, about 18 N or more, or about 20 N or more. In some embodiments, the UHMWPE fiber has a work of rupture of at least about 100 N·mm, at least about 110 N·mm, at least about 120 N·mm, at least about 130 N·mm, at least about 140 N·mm, at least about 150 N·mm, at least about 160 N·mm, or at least about 170 N·mm.

[0057] In some embodiments, the UHMWPE fiber is a colored UHMWPE fiber comprising a dye. In some embodiments, the dye has a color selected from black, blue, gray, red, blue, brown, yellow, green, orange, and nude.

[0058] In some embodiments, the UHMEPE fiber includes a plurality of untwisted microfilaments. In some other embodiments, in order to keep the filaments together and increase strength and reduce pilling, the UHMWPE fiber is twisted. In some embodiments, the UHMWPE fiber has a twist per inch (TPI) of 1 to 30, 1 to 20, 1 to 10, 1 to 5, 4 to 25, 6 to 20 or 8 to 16, and in some embodiments, the TPI of the UHMWPE fiber is 1. In some embodiments, the TPI of the UHMWPE fiber is 2, and in some embodiments, the TPI of the UHMWPE fiber is 3. In some embodiments, the TPI of the UHMWPE fiber is 4. In some embodiments, the TPI of the UHMWPE fiber is 5. In some embodiments, the TPI of the UHMWPE fiber is 6. In some embodiments, the TPI of the UHMWPE fiber is 8. In some embodiments, the TPI of the UHMWPE fiber is 10. In some embodiments, the UHMWPE fiber has a TPI of 12. In some embodiments, the UHMWPE fiber has a TPI of 15. In some embodiments, the UHMWPE fiber has a TPI of 16. In some embodiments, the UHMWPE fiber has a TPI of 18. In some embodiments, the UHMWPE fiber has a TPI of 20. In some embodiments, the UHMWPE fiber has a TPI of 25. In some embodiments, the UHMWPE fiber has a TPI of 30.

[0059] In various aspects, the UHMWPE fibers described herein may be prepared according to the methods described in U.S. Published Application US20220056620.

[0060] In some embodiments, the UHMWPE fiber has a color variation along the length of the UHMWPE fiber. In some embodiments, the color variation along the length of the UHMWPE fiber is less than ±2.5%, less than ±3%, less than ±3.5%, less than ±4%, less than ±5%, less than ±6%, less than ±7%, less than ±8%, or less than ±9%, or less than ±10%.

[0061] The use of UHMWPE fibers brings benefits to knitted fabrics, such as cooling effects, light weight, moisture wicking and / or antibacterial. The tensile properties of the UHMWPE fibers also enhance the resistance of knitted fabrics to tearing, snagging or other wear or damage. In some embodiments, the denier of the UHMWPE fibers varies along their length. In some embodiments, the denier of the UHMWPE fibers along their length varies by less than ±2.5%, less than ±3%, less than ±3.5%, less than ±4%, less than ±5%, less than ±6%, less than ±7%, less than ±8%, or less than ±9%, or less than ±10%. In some embodiments, the diameter of the UHMWPE fibers along the length of the UHMWPE fibers varies by less than ±2.5%, less than ±3%, less than ±3.5%, less than ±4%, less than ±5%, less than ±6%, less than ±7%, less than ±8%, or less than ±9%, or less than ±10%. In some embodiments, the UHMWPE fibers have a cross-sectional shape that is substantially similar to a circle. In some embodiments, the UHMWPE fiber has a cross-sectional shape that is substantially similar to an oval. In some embodiments, the UHMWPE fiber has a cross-sectional shape that is substantially similar to a stadium. In some embodiments, the UHMWPE fiber has a cross-sectional shape that is substantially similar to an ellipse. In some embodiments, the cross-sectional shape of the UHMWPE fiber remains substantially unchanged along its length.

[0062] Based on the total amount of fibers in the knitted fabric, the content of UHMWPE fibers in the knitted fabric may be in the range of about 10 wt % to about 90 wt %. In some embodiments, the content of UHMWPE fibers in the knitted fabric is in the range of about 15 wt % to about 80 wt %, about 20 wt % to about 80 wt %, about 30 wt % to about 70 wt %, or about 40 wt % to about 60 wt %.

[0063] In some embodiments, the knitted fabric comprises a plurality of UHMWPE fibers. Each of the UHMWPE fibers comprises a plurality of microfilaments, each of the microfilaments having a denier of 5 or less. Each of the UHMWPE fibers may comprise 50 or less microfilaments.

[0064] The companion fiber is selected to enhance the properties of the knitted fabric (e.g., but not limited to, comfort, durability, dyeability / printability, and / or stretchability). In some embodiments, the companion fiber comprises a single fiber. In some other embodiments, the companion fiber comprises a plurality of fibers.

[0065] The companion fiber may be a synthetic fiber, a natural fiber, a stretched fiber, a non-stretched fiber, a high performance fiber, an elastomeric fiber, a thermoplastic fiber, or an abrasion resistant fiber, or a combination of any of the foregoing.

[0066] In some embodiments, the companion fiber comprises a synthetic fiber. Examples of organic synthetic fibers include those made from the following polymers: polyolefins, such as polyethylene, polypropylene, high molecular weight polypropylene, UHMWPE, polybutylene, etc.; polyamides, such as nylon; polyesters, such as polyethylene terephthalate, polyethylene naphthalate, poly(ethylene succinate), polymethyl methacrylate; 1,2-polybutadiene; and copolymers of these polymers.

[0067] In some embodiments, the companion fibers include natural fibers. Examples of natural fibers include cotton, silk, wool, and the like.

[0068] In some embodiments, the companion fiber comprises a draw fiber.Examples of draw fibers include those made from polyurethane, polyolefins (such as low molecular weight polyethylene or polypropylene), and the like.

[0069] In some embodiments, the companion fiber comprises a non-stretch fiber.Examples of non-stretch fibers include those made of or comprising polyester, cotton, nylon, rayon, and / or wool.

[0070] In some embodiments, the companion fiber comprises a high performance fiber. Examples of high performance fibers include high molecular weight polypropylene, aromatic polyamide, high molecular weight polyvinyl alcohol, high molecular weight polyacrylonitrile, and liquid crystal polyester.

[0071] In some embodiments, the companion fiber comprises an elastomeric fiber.Examples of elastomeric fibers include spandex (also known as elastane), lastol fibers, polyurethanes, and polyetheresters.

[0072] In some embodiments, the companion fiber comprises a thermoplastic fiber.Examples of thermoplastic fibers include those made from polyamides, polyimides, polyurethanes, polyolefins, polystyrenes, aromatic polyesters, polycarbonates, polyketones, polyureas, polyvinyl resins, polyacrylates, and polymethacrylates.

[0073] In some embodiments, the companion fiber comprises an abrasion resistant fiber.Examples of abrasion resistant fibers include those made from nylon, polyester, and polyamide.

[0074] The companion fiber can include any suitable number of microfilaments. In some embodiments, the companion fiber includes 2 to 400 microfilaments, 10 to 300 microfilaments, 10 to 200 microfilaments, 10 to 150 microfilaments, 10 to 100 microfilaments, 10 to 50 microfilaments, 5 to 50 microfilaments, or 20 to 200 microfilaments.

[0075] The companion fiber can have any denier suitable for pantyhose. In some embodiments, the companion fiber has a denier ranging from about 2 to about 100, about 5 to about 100, about 10 to about 100, or about 15 to about 100. In some embodiments, the companion fiber has a denier of about 5, about 10, about 13, about 15, about 17, about 20, about 25, about 30, about 50, about 60, about 70, about 80, or about 90. In the case where the knitted fabric includes multiple companion fibers, the multiple companion fibers can have the same or different deniers as each other.

[0076] In some embodiments, the companion fibers allow for an elongation greater than 100%. In some embodiments, the companion fibers have an elongation of about 130% or greater, about 200% or greater, about 300% or greater, or about 400% or greater.

[0077] In some embodiments, the companion fiber is a colored fiber containing a dye. In some embodiments, the companion fiber has a color of black, blue, gray, red, blue, brown, yellow, green, orange or nude. In some embodiments, the companion fiber is white. In some embodiments, the companion fiber has the same color as the UHMWPE fiber. In some other embodiments, the companion fiber has a different color from the UHMWPE fiber. The knitted fabric has high dimensional stability. In some embodiments, the dimensional stability of the knitted fabric in each of the length direction and the width direction is about ± 6%, about ± 4%, about ± 2%, about ± 1% or about ± 0.5%.

[0078] In some embodiments, the knitted fabric has a denier of about 150 or less, about 120 or less, about 100 or less, about 80 or less, about 60 or less, about 50 or less, about 40 or less, or about 30 or less. For example, the knitted fabric has a denier between 10 and 200, between 20 and 100, between 20 and 50, between 10 and 40, or between 20 and 40.

[0079] Process for making pantyhose articles comprising UHMWPE

[0080] On the other hand, a method for manufacturing the above-mentioned knitted fabric is provided. The knitted fabric disclosed in the present application is produced by weaving the UHMWPE fiber and the accompanying fiber using a knitting machine. The appropriate needle gauge of the knitting machine is selected according to the type of pantyhose product. The needle gauge number of the knitting machine can affect the stretchability and basis weight of the resulting knitted fabric. The needle gauge range of the knitted fabric can be 10 to 40. In some other embodiments, the needle gauge range of the knitted fabric is 28 to 32, which is suitable for producing knitted fabrics for pantyhose or transparent stockings. In some embodiments, the knitted fabric can have a needle gauge of at least 32.

[0081] In some embodiments, a knitting machine of the single-knit type is used. The circular cylinder size of the knitting machine is selected according to the final use of the knitted fabric. In some embodiments, the knitting machine has a circular cylinder of about 3 inches to about 14 inches, about 10 inches to about 14 inches, or about 3 inches to about 7 inches that is suitable for producing knitted fabric for pantyhose. In some embodiments, a circular cylinder is not used.

[0082] When weaving the fabric disclosed in the present application, as common sense, the technician can use a conventional knitting machine. The knitting machine can have any desired number of feeders, depending on the number of fiber types to be woven and the knitting speed to be adopted. Typically, the knitting machine has 2, 4 or 8 feeders, with 4 or 8 feeders being the most common. In some embodiments, the knitting machine can use more than 8 feeders. In some embodiments, the knitting machine can use more than 16 feeders. In one embodiment disclosed in the present application, the garment is manufactured using a four-feeder hosiery machine. When weaving the garment disclosed in the present application, each feeder can use fibers ranging from 10 denier to 50 denier. Depending on the weight of the pantyhose produced and the required degree of transparency, the total denier of the fibers of the knitted garment can be any desired. In some embodiments, all feeders are used. In some embodiments, only 1 feeder is used. In some embodiments, only 2 feeders are used. In some embodiments, only 3 feeders are used. In some embodiments, all yarn feeders use the same UHMWPE fibers with the same properties and variations of the same properties. In some embodiments, all yarn feeders use the same UHMWPE fibers with the same properties and variations of different properties. In some embodiments, all yarn feeders use different kinds of UHMWPE fibers with different properties and variations of different properties. In some embodiments, all yarn feeders use different kinds of UHMWPE fibers with different properties but variations of the same properties.

[0083] In some embodiments, the knitting machine may be equipped with a tensioner to maintain a constant tension on each feed fiber. In some embodiments, the tension is constant along the length of each feed fiber. In some embodiments, the tension is constant along the length of each feed fiber. In some embodiments, the tension along the length of the feed UHMWPE fiber varies by less than ±2.5%, less than ±3%, less than ±3.5%, less than ±4%, less than ±5%, less than ±6%, less than ±7%, less than ±8%, or less than ±9%, or less than ±10%. In some embodiments, the tension of the UHMWPE fiber varies between different yarn feeders by less than ±2.5%, less than ±3%, less than ±3.5%, less than ±4%, less than ±5%, less than ±6%, less than ±7%, less than ±8%, or less than ±9%, or less than ±10%.

[0084] In order to effectively achieve stretch in the final knitted fabric without losing the strength properties provided by the UHMWPE fibers, the weaving of the UHMWPE fibers and companion fibers includes plating or serving of the UHMWPE fibers and companion fibers.

[0085] In some embodiments, in order to effectively achieve stretching in the final knitted fabric without losing the strength properties provided by the UHMWPE fiber, the UHMWPE fiber and the companion fiber are woven to form a plated knitted fabric. When knitting the plated knitted fabric, UHMWPE fibers are required on each course of the knitted fabric, and the companion fiber can appear on each course or every other course. In some embodiments, the plated knitted fabric includes UHMWPE fibers on each course and companion fibers on at least every other course, and has a denier of no more than 30. In some embodiments, the plated knitted fabric includes UHMWPE fibers on each course and companion fibers on at least every other course, and has a denier of no more than 40. In some embodiments, the plated knitted fabric includes UHMWPE fibers on each course and companion fibers on at least every other course, and has a denier of no more than 50. In some embodiments, the plated knitted fabric includes UHMWPE fibers on each course and companion fibers on at least every other course, and has a denier of no more than 60. In some embodiments, the plated knitted fabric includes UHMWPE fibers on each course and companion fibers on at least every other course, and has a denier of about 20, about 25, about 30, about 35, about 40, about 45, about 55, or about 65. After the knitting process is completed, one side of the knitted fabric more prominently exposes the UHMWPE fibers, while the other side exposes the companion fibers.

[0086] In some other embodiments, in order to effectively achieve stretching in the final knitted fabric without losing the strength properties provided by the UHMWPE fiber, the UHMWPE fiber and the companion fiber are twisted to form a composite fiber. This twisting forms a combined composite fiber. In some embodiments, the UHMWPE fiber and the companion fiber are twisted with a twist between 100 and 4500 twists / meter (TPM). To ensure greater stretchability of the final product, as well as an increase in the durability of the final knitted fabric, a higher number of twists per meter may be required because a higher twist results in a larger surface area of ​​the companion fiber reinforced with the UHMWPE fiber. In some embodiments, the TPM of the UHMWPE fiber and the accompanying fiber is 100, the TPM of the UHMWPE fiber and the accompanying fiber is 500, the TPM of the UHMWPE fiber and the accompanying fiber is 1000, the TPM of the UHMWPE fiber and the accompanying fiber is 1500, the TPM of the UHMWPE fiber and the accompanying fiber is 2000, the TPM of the UHMWPE fiber and the accompanying fiber is 2500, the TPM of the UHMWPE fiber and the accompanying fiber is 3000, the TPM of the UHMWPE fiber and the accompanying fiber is 3500, the TPM of the UHMWPE fiber and the accompanying fiber is 4000, and the TPM of the UHMWPE fiber and the accompanying fiber is 4500. In some embodiments, the TPM of the UHMWPE fiber and the accompanying fiber is between 2 and 100. In some embodiments, the UHMWPE fiber and companion fibers have a twist per inch (TPI) of 3, 5 TPI, 10 TPI, 15 TPI, 20 TPI, 25 TPI, 30 TPI, 40 TPI, or 50 TPI.

[0087] In some embodiments, UHMWPE fiber and nylon coated spandex fiber are used as companion fibers to make knitted fabrics. Both the UHMWPE fiber and the companion fiber can be twisted or straight. In some embodiments, the denier of the nylon is in the range of 1 to 20. In some embodiments, the denier of the nylon is in the range of 5 to 20. In some embodiments, the nylon is a multifilament fiber including 5 to 16 microfilaments. In some embodiments, the nylon coated spandex fiber is formed by coating a monofilament spandex fiber with a denier of 17 with a nylon fiber including 5 to 20 microfilaments and a denier in the range of 1 to 20. In some embodiments, the knitted fabric has alternating rows between UHMWPE fiber and nylon coated spandex fiber, wherein the spandex fiber is a monofilament fiber with a denier of 40 and the nylon fiber is a multifilament fiber including 7 microfilaments and a denier of 20. In some embodiments, the denier of the resulting knitted fabric is in the range of 15 to 60. In some embodiments, the resulting knitted fabric has a denier of about 40.

[0088] In some embodiments, the knitted fabric is made of UHMWPE fiber and nylon fiber. The nylon fiber is a multifilament fiber including 40 microfilaments and having a denier of 40.

[0089] Pantyhose products containing UHMWPE

[0090] In one aspect, the present application discloses a pantyhose article. Figure 1 , which is a front view of a pantyhose article 1 according to an exemplary embodiment when placed on a quality control device. The quality control device generally has two panel members spaced apart from each other, each panel member receiving a respective leg member of the pantyhose article under quality control test. The leg members stretched on the panel members allow for a visual inspection of the quality of the leg members of the pantyhose article. The shaft member of the pantyhose article is also stretched between the panel members of the quality control device, thereby also allowing for a visual inspection of the quality of the shaft member of the pantyhose. Figure 4 , 5 , 6, 7 and 8 respectively show a front view, a side view, a rear view, a bottom view and a top view of a pantyhose article 1 according to an exemplary embodiment when worn. When worn, the knitted fabric of the pantyhose article 1 stretches with the contours of the wearer.

[0091] The pantyhose article 1 comprises a first tubular member 8 and a second tubular member 16, and a crotch portion 24, which are suitably joined together to form the pantyhose article 1. The first tubular member 8 extends from a waist end 40 of the pantyhose article 1 to a foot end 48 of the first tubular member 8.

[0092] exist Figure 1 , 4 , 5, 6, 7 and 8, the first tubular member 8 corresponds to the right side of the pantyhose article 1, but it is worth noting that the actual side (left or right) will depend on the wearing direction of the pantyhose article 1. In various embodiments, the pantyhose article 1 is non-directional, so the first tubular member 8 can be worn on the left leg or the right leg interchangeably. Similarly, according to these embodiments, the second tubular member 16 can be worn on the left leg or the right leg interchangeably.

[0093] The first tubular member 8 includes a plurality of portions corresponding to different knitted fabrics of the first tubular member 8. The first tubular member 8 includes a first panty portion 56 extending from the waist end 40 of the pantyhose article 1 to a bottom end 64 of the first panty portion 56. The first panty portion 56 may include at least one waistband 44 at the waist end 40 to ensure a tight fit when the pantyhose article 1 is worn.

[0094] according to Figure 1 , 4 , 5, 6, 7 and 8, the bottom end 64 of the first underpants portion 56 corresponds substantially to the crotch region along the longitudinal direction 72 of the pantyhose article 1.

[0095] In another embodiment, the bottom end 64 of the first panty portion 56 is located lower (ie, closer to the foot end 48) than the crotch region of the pantyhose article 1 in the longitudinal direction 72.

[0096] The first tubular member 8 also includes a first tubular leg portion 80 extending from its top end 88 to the first foot end 48 of the first tubular member 8. The top end 88 of the first tubular leg portion 80 corresponds to the bottom end 64 of the first panty portion 56. The first tubular leg portion 80 of the first tubular member 56 defines a first leg cavity 92 ( Figure 2 , 8 ).

[0097] According to one embodiment, the first foot end 48 of the first tubular member 8 may be closed, for example ending in a closed sock form, such as Figure 1 , 4 , 5 and 6. In another embodiment, the first foot end 48 of the first tubular member 8 may have an opening, such as a footless pantyhose, so that when the pantyhose article 1 is worn, the first foot end 48 is located near the ankle of the wearer. In yet another embodiment, the first foot end 48 of the first tubular member 8 may be partially open, such as having a buckle member (e.g., a footrest, a toe strap), which is used to keep the first tubular member 8 in place when worn, but at the same time at least partially expose the wearer's foot.

[0098] The pantyhose article 1 further comprises a second tubular member 16 extending from a waist end 40 of the pantyhose article 1 to a foot end 104 of the second tubular member 16 .

[0099] The second tubular member 16 includes a plurality of portions corresponding to different knitted fabrics of the second tubular member 16. The second tubular member 16 includes a second panty portion 112 extending from the waist end 40 of the pantyhose article 1 to a bottom end 120 of the second panty portion 112. The bottom end 120 of the second panty portion 112 may be substantially aligned with the bottom end 64 of the first panty portion 56. The second panty portion 112 may also include at least one waistband to ensure a snug fit when the pantyhose article 1 is worn. The waistband may be equivalent to the waistband 44 of the first tubular member 8.

[0100] according to Figure 1 , 4, 5 and 6, the bottom end 120 of the second panty portion 112 along the longitudinal direction 72 of the pantyhose article 1 is substantially equivalent to the crotch area of ​​the pantyhose article 1. In another embodiment, the bottom end 120 of the second panty portion 112 along the longitudinal direction 72 is located at a lower position (i.e., closer to the foot end 104) than the crotch area of ​​the pantyhose article 1.

[0101] The second tubular member 16 further includes a second tubular leg portion 128 extending from a top end 136 thereof to the second foot end 104 of the second tubular member 16. The top end 136 of the second tubular leg portion 128 corresponds to the bottom end 120 of the second panty portion 112. The second tubular leg portion 128 of the second tubular member 16 defines a second leg cavity 138 ( Figure 2 , 8 ).

[0102] According to one embodiment, the second foot end 104 of the second tubular member 16 may be closed, for example ending in a closed sock form, such as Figure 1 , 4 , 5 and 6. In another embodiment, the second foot end 104 of the second tubular member 16 may have an opening, such as footless pantyhose, so that when the pantyhose article 1 is worn, the second foot end 104 is located near the ankle of the wearer. In yet another embodiment, the second foot end 104 of the second tubular member 16 may be partially open, such as having a buckle member (e.g., a footrest, a toe strap), which is used to keep the second tubular member 16 in place when worn, but at the same time at least partially expose the wearer's foot.

[0103] According to one embodiment, and as Figure 1 , 4 , 5 and 6, the first tubular leg portion 80 of the first tubular member 8 includes a first main sub-portion 140 and a first transition sub-portion 148. The first main sub-portion 140 extends from the first thigh region 156 of the first tubular leg portion 80 of the pantyhose article 1 to the first foot end 48 of the first tubular member 8. The first transition sub-portion 148 extends between the bottom end 64 of the first panty portion 56 and the upper end of the first main sub-portion 140. More specifically, the first transition sub-portion 148 extends from the top end 88 of the first tubular leg portion 80 to the first thigh region 156 of the first tubular leg portion 80. It is worth noting that the top end of the first transition sub-portion 148 is equivalent to the top end 88 of the first tubular leg portion 80, which is also equivalent to the bottom end 64 of the first panty portion 56.

[0104] According to one embodiment, and as Figure 1 , 4, 5 and 6, the configuration of the second tubular leg portion 128 of the second tubular member 16 is consistent with the configuration of the first tubular leg portion 80. The second tubular leg portion 128 of the second tubular member 16 includes a second main sub-portion 160 and a second transition sub-portion 164. The second main sub-portion 160 extends from the second thigh region 168 of the second tubular portion 128 to the second foot end 104 of the second tubular member 16 of the pantyhose article 1. The second transition sub-portion 164 extends between the bottom end 120 of the second panty portion 112 and the upper end of the second main sub-portion 160. More specifically, the second transition sub-portion 164 extends from the top end 136 of the second tubular leg portion 128 to the second thigh region 168 of the second tubular leg portion 128. It is worth noting that the top end of the second transition sub-portion 164 is equivalent to the top end 136 of the second tubular leg portion 128, which is also equivalent to the bottom end 120 of the second panty portion 112.

[0105] The longitudinal edge 172 of the first panty portion 56 is joined to the corresponding longitudinal edge 180 of the second panty portion 112 to form a panty tube 188 defining a panty cavity 196. Figure 2 ). The edges 172 and 180 may be joined by sewing.

[0106] Figure 2 is a top perspective view of the interior of a pantyhose article 1 according to one embodiment when it is placed on a quality control device. Figure 8 1 is a top view of a pantyhose article 1 as if it were worn according to one embodiment (the pantyhose article 1 is shown in a stretched state as if it were worn, but for greater clarity, the wearer's body is not shown). The panty cavity 196 is in fluid communication with the first leg cavity 92 defined by the first tubular leg portion 80, and is also in fluid communication with the second leg cavity 138 defined by the second tubular leg portion 128.

[0107] When the pantyhose article 1 is worn, the panty cavity 196 accommodates the wearer's lower body. The first leg cavity 92 receives the wearer's first leg (eg, right leg), and the second leg cavity 138 receives the wearer's second leg (eg, left leg).

[0108] The lower area of ​​the longitudinal edge 172 of the first panty portion 56 (i.e., the area closer to the bottom end 64 of the first panty portion 56) is also joined to the corresponding lower area of ​​the longitudinal edge 180 of the second panty portion 112 (i.e., the area closer to the bottom end 120 of the second panty portion 112) through the crotch portion 24, for example, by sewing. In this way, at least one edge of the bottom end 64 of the first panty portion 56 is joined to the crotch portion 24, for example, by sewing, and at least one edge of the bottom end 120 of the second panty 112 is also joined to the crotch portion 24, for example, by sewing.

[0109] Now refer to Figure 3 , which shows a bottom view of the crotch region of a pantyhose article 1 according to one embodiment when placed on a quality control device. Figure 7 2 is a bottom view of a pantyhose article according to one embodiment when being worn. The first bottom edge 204 of the first panty portion 56 is directly joined (e.g., directly sewn) to the first edge 212 of the first end of the crotch portion 24, the second bottom edge 220 of the first panty portion 56 is directly joined (e.g., directly sewn) to the first edge 228 of the second end of the crotch portion 24, the first bottom edge 236 of the second panty portion 112 is directly joined (e.g., directly sewn) to the second edge 244 of the first end of the crotch portion 24, and the second bottom edge 252 of the second panty portion 112 is directly joined (e.g., directly sewn) to the second edge 262 of the second end of the crotch portion 24.

[0110] according to Figures 1 to 8 In the embodiment shown, the bottoms 64 and 120 of the first panty portion 56 and the second panty portion 112 substantially correspond to the crotch region of the pantyhose article 1, the first transition sub-portion 148 is directly joined to the crotch portion 24, and the second transition sub-portion 164 is also directly joined to the crotch portion 24. Figure 3As shown most clearly in FIG. 1 , the middle region 268 of the first edge of the crotch portion 24 (equivalent to the edge portion between the first edge 212 at the first end and the first edge 228 at the second end of the crotch portion 24) is directly joined (e.g., directly sewn) to a portion of the edge 276 of the first transition sub-portion 148. The joined portion may be located at the top edge 88 of the first transition sub-portion 148. In addition, the middle region 284 of the second edge of the crotch portion 24 (equivalent to the edge portion between the second edge 244 at the first end and the second edge 260 at the second end of the crotch portion 24) is directly joined (e.g., directly sewn) to a portion of the edge 292 of the second transition sub-portion 164. The joined portion may be located at the top edge 136 of the second transition sub-portion 164. Thus, the first panty portion 56, the second panty portion 112, the crotch portion 24, the first transition sub-portion 148, and the second transition sub-portion 164 are appropriately joined to close (i.e., ensure that there is no opening or gap) the crotch area of ​​the pantyhose article 1 and enclose the panty cavity 196.

[0111] According to an alternative embodiment, in which the bottom end 64 of the first panty portion 56 and the bottom end 120 of the second panty portion 112 are both located in the longitudinal direction 72 below the crotch region of the pantyhose article 1, the first side of the crotch portion 24 is directly joined (e.g., directly sewn) to the corresponding area of ​​the longitudinal edge 172 of the first panty portion 56, and the second side of the crotch portion 24 is directly joined (e.g., directly sewn) to the corresponding area of ​​the longitudinal edge 180 of the second panty portion 112 to close (i.e., ensure that there is no opening or gap) the crotch region of the pantyhose article 1 and enclose a panty cavity 196. According to this alternative embodiment, the top edges 88, 136 of the first and second leg portions 80 and 128 are not directly joined (e.g., directly sewn) to the crotch portion 24.

[0112] according to Figures 1 to 8 In the embodiment shown, the thigh region 156 of the main sub-portion 140 (which corresponds to the bottom end of the first transition sub-portion 148) is located in the mid-thigh region of the first tubular leg member 80, which corresponds to the mid-thigh of the wearer's first leg when the pantyhose article 1 is worn. Therefore, the transition sub-portion 148 extends from the crotch region of the pantyhose article 1 to the mid-thigh region of the first tubular leg member 8. The second transition sub-portion 164 also extends along the corresponding region of the second tubular leg member 16.

[0113] According to another embodiment, the thigh region 156 of the main sub-portion 140 is located in the upper thigh region of the first tubular leg portion 80, which corresponds to the upper thigh region of the wearer's first leg when the pantyhose article 1 is worn. Thus, the transition sub-portion 148 extends from the crotch region of the pantyhose article 1 to the upper thigh region of the first tubular leg member 8. The second transition sub-portion 164 also extends along the corresponding region of the second tubular leg member 16.

[0114] According to yet another embodiment, the thigh region 156 of the main sub-portion 140 is located in the lower thigh region (i.e., near the knee region) of the first tubular leg portion 80, which corresponds to the lower thigh region of the wearer's first leg when the pantyhose article 1 is worn. Thus, the transition sub-portion 148 extends from the crotch region of the pantyhose article 1 to the lower thigh region of the first tubular leg member 8. The second transition sub-portion 164 also extends along the corresponding region of the second tubular leg member 16.

[0115] According to another embodiment, the bottom end 64 of the first panty portion 56 (corresponding to the top end 88 of the first tubular leg portion 80, and also corresponding to the top end of the first transition sub-portion 148) is located in the longitudinal direction 72 below the crotch region of the pantyhose article 1; and the thigh region 156 of the main sub-portion 140 (for example, the thigh region of the first tubular member 8) is located in the middle thigh region of the first tubular leg 80, which corresponds to the bottom end of the first transition sub-portion 148, and when the pantyhose article 1 is worn, this region corresponds to the middle thigh of the wearer's first leg. Therefore, the transition sub-portion 148 extends from below the crotch region of the pantyhose article 1 to the middle thigh region of the first tubular leg portion 80. The second panty portion 112 and the second transition sub-portion 164 also extend along the corresponding regions of the second tubular leg member 16.

[0116] According to another embodiment, the bottom end 64 of the first panty portion 56 (corresponding to the top end 88 of the first tubular leg 80, and also corresponding to the top end of the first transition sub-portion 148) is located in the longitudinal direction 72 below the crotch region of the pantyhose article 1; and the thigh region 156 of the main sub-portion 140 (for example, the thigh region of the first tubular member 8) is located in the lower thigh region of the first tubular leg 80 (i.e., near the knee region), and the thigh region 156 corresponds to the bottom end of the first transition sub-portion 148, and when the pantyhose article 1 is worn, this region corresponds to the lower thigh region of the wearer's first leg. Therefore, the transition sub-portion 148 extends from below the crotch region of the pantyhose article 1 to the lower thigh region of the first tubular leg 80. The second panty portion 112 and the second transition sub-portion 164 also extend along the corresponding regions of the second tubular leg member 16.

[0117] It is worth noting that in each of the embodiments described herein, wherein the first and second leg portions 80 and 128 each include a transition sub-portion 148 and 164, the transition sub-portion 148, 164 always extends between the bottom end 64, 120 of the respective panty portion 56, 112 and the respective thigh region 156, 168 of the tubular leg portion 80, 128. The length and position of the transition sub-portion 148, 164 vary depending on whether the top end of the transition sub-portion 148, 164 is located in the crotch region of the pantyhose article 1 and the position of the thigh region 156, 168 of the tubular leg portion 80, 128.

[0118] According to one embodiment, and as shown in the accompanying drawings, the first main subsection 140 of the first tubular leg portion 80 is formed by a first knitted fabric including a first UHMWPE fiber and at least one first companion fiber. The first transition subsection 148 of the first tubular leg portion 80 is formed by a second knitted fabric including a second UHMWPE fiber and at least one second companion fiber. The first knitted fabric of the first main subsection 140 of the first tubular leg portion 80 is different from the second knitted fabric of the first transition subsection 148 of the first tubular leg portion 80.

[0119] According to one embodiment, the first knitted fabric of the first main sub-portion 140 is different from the second knitted fabric of the first transition sub-portion 148 in that the knitting pattern of the first knitted fabric is different from the knitting pattern of the second knitted fabric. The knitting pattern mentioned here, with respect to the first knitted fabric and the second knitted fabric, refers to how the UHMWPE fibers and at least one companion fiber are engaged with each other inside the knitted fabric in a given knitted fabric. The difference in the knitting pattern may include, but is not limited to, how the UHMWPE fibers and at least one companion fiber are looped, hooked with each other, and / or which UHMWPE fiber(s) and / or which companion fiber(s) appear in the horizontal row of the knitted fabric.

[0120] According to an exemplary embodiment, the first knitted fabric of the first main subsection 140 is different from the second knitted fabric of the first transition subsection 148 in that the first UHMWPE fiber in the first knitted fabric is different from the second UHMWPE fiber in the second knitted fabric. The first and second UHMWPE fibers may differ in one or more of color, denier, tensile strength, modulus, twist per turn, or whether they are coated.

[0121] According to one embodiment, the first knitted fabric of the first main sub-portion 140 is different from the second knitted fabric of the second transitional sub-portion 148 in that at least one first companion fiber in the first knitted fabric is different from at least one second companion fiber in the second knitted fabric. The set of at least one first companion fiber may include at least one companion fiber that is not in the set of at least one second companion fiber, and vice versa. The at least one second companion fiber may include at least one first companion fiber, but may also include at least one additional at least one second companion fiber that is not in the set of at least one first companion fiber, and vice versa. In one embodiment, the set of at least one second companion fiber includes all of the set of at least one first companion fiber, and also includes at least one additional at least one second companion fiber that is not in the set of at least one first companion fiber. Any first fiber and any second fiber may differ in one or more aspects of fiber type, fiber material, fiber structure, fiber construction, color, denier, tensile strength, modulus, and whether it is coated.

[0122] In one embodiment, the second knitted fabric of the first transition sub-portion 148 is reinforced compared to the first knitted fabric of the first main sub-portion 140. For example, the second knitted fabric of the first transition sub-portion 148 uses the same UHMWPE fiber as the first UHMWPE fiber of the first main sub-portion 140, and the second knitted fabric of the first transition sub-portion 148 also includes at least one companion fiber that is the same as the at least one first companion fiber of the first main sub-portion 140; however, the second knitted fabric of the first transition sub-portion 148 also includes at least one additional companion fiber, which is woven into the second knitted fabric, thereby providing an additional reinforcement effect for the second knitted fabric of the first transition sub-portion 148 relative to the first knitted fabric of the first main sub-portion 140.

[0123] The second knitted fabric of the first transition sub-portion 148 may have stronger sewing resistance than the first knitted fabric of the first main sub-portion 140 of the first tubular leg portion 80. The stronger sewing durability mentioned here refers to the durability of the second knitted fabric when it is pierced by a sewing needle in a sewing operation during the assembly process, or refers to the second knitted fabric having stronger tear resistance when one or more threads sewn to the second knitted fabric apply tension to it during the sewing operation.

[0124] Compared with the first knitted fabric of the first main sub-portion 140 of the first tubular leg portion 80, the second knitted fabric of the first transition sub-portion 148 has stronger anti-unraveling performance when being torn or cut. The anti-unraveling performance refers to the ability to prevent the tear or cut from continuing to spread along the longitudinal direction 72 of the tubular leg member 1 after the initial tear or cut occurs.

[0125] According to one embodiment, the second knitted fabric of the first transition sub-portion 148 comprises a mesh knitted fabric. The mesh knitted fabric refers to a knitted fabric in which the yarn does not form a loop in each given number of rows of yarn for knitting the mesh knitted fabric. For example, the mesh knitted fabric may be a 1×1 knitted fabric, i.e., the yarn forms a loop in one row and does not form a loop in the second row. The mesh knitted fabric may also be a 3×1 knitted fabric, i.e., the yarn forms a loop in three rows and does not form a loop in the fourth row. The mesh knitted fabric may also be a 5×1 knitted fabric, i.e., the yarn forms a loop in five rows and does not form a loop in the sixth row. In a preferred embodiment, the mesh knitted fabric may be a 7×1 knitted fabric, i.e., the yarn forms a loop in seven rows and does not form a loop in the eighth row. It has been observed that the mesh knitted fabric has an anti-loosening property, i.e., when the second knitted fabric is cut or torn, the loosening caused by cutting or tearing will continue until a position where no loop is formed due to the mesh knitting is encountered. The missing of a given loop will prevent the spread of unthreading. By making the missing of loops in the mesh knitted fabric occur frequently enough, the mesh knitted fabric can prevent unthreading when the second knitted fabric is torn or cut.

[0126] According to an exemplary embodiment, the mesh knitted fabric of the second knitted fabric of the first transition sub-portion 148 is configured so that the position of the skipped stitches (i.e., one row of unlooped loops) in any given row of the second knitted fabric is staggered relative to the position of the skipped stitches in the next row of mesh knitting immediately following. This non-aligned arrangement of the positions of the skipped stitches in different rows of the mesh knitted fabric improves the anti-stripping performance by ensuring that the stray stitches of the tubular leg member at any given angular position will eventually encounter the position of a skipped stitch.

[0127] According to an exemplary embodiment, the second knitted fabric of the first transition sub-portion 148 includes a combination of a plain knitted fabric and a mesh knitted fabric. Plain knitted fabrics are also commonly referred to as single-sided knitted fabrics. The plain knitted fabric of the second knitted fabric can be woven from a second UHMWPE and a companion fiber of the second knitted fabric, wherein the second UHMWPE is the same as the first UHMWPE of the first knitted fabric of the first main sub-portion 140, and the companion fiber of the second knitted fabric is the same as the first companion fiber of the first knitted fabric. The mesh knitted fabric of the second knitted fabric can be woven from at least one additional companion fiber in the second knitted fabric, and according to the configuration of the mesh knitted fabric, the at least one additional companion fiber is woven in the plain knitted fabric to form the mesh knitted fabric. For example, when knitting the plain knitted fabric, the at least one additional companion fiber of the second knitted fabric is appropriately looped with the loops of the plain knitted fabric according to the configuration of the mesh knitted fabric, and according to the configuration of the mesh knitted fabric, the at least one additional companion fiber of the second knitted fabric is appropriately skipped (i.e., does not form a loop) at the position where the plain knitted fabric is looped. More specifically, in the n×1 mesh knitted fabric of the additional companion fiber of the second knitted fabric, in every n rows of the plain knitted fabric formed of UHMWPE and the second companion fiber, the additional companion fiber is also looped together with the yarn of the plain knitted fabric, while in n+1 rows of the plain knitted fabric, the plain knitted fabric yarn is looped but the additional companion fiber is not looped.

[0128] According to an exemplary embodiment, the mesh knitted fabric is woven into the second knitted fabric to provide resistance to unthreading that propagates toward the foot end 48 along the longitudinal direction 72. That is, the mesh knitted fabric is able to resist unthreading that starts from a position near the top end 40 of the first tubular leg member 8 (for example, caused by cutting or tearing) and propagates toward the foot end 48, thereby limiting the unthreading from continuing to develop downward toward the foot end 48 when encountering the mesh knitted fabric.

[0129] The second transition sub-portion 164 of the second tubular leg portion 128 can be made of the same second knitted fabric as the first transition sub-portion 148 of the first tubular leg portion 80, the second knitted fabric comprising at least one second UHMWPE fiber and at least one accompanying stretched fiber. Thus, the second knitted fabric of the second transition sub-portion 164 is different from the first knitted fabric of the second main sub-portion 160 according to various approaches described herein.

[0130] According to one embodiment, the first panty portion 56 of the first tubular member 8 is made of a knitted fabric without (e.g., free of) UHMWPE. Therefore, the first panty portion 56 can be made of a knitted fabric with one or more stretched fibers without UHMWPE. It is observed that the most expensive material in the pantyhose article 1 is the UHMWPE fiber. It is also observed that the first panty portion 56 is typically worn under one or more layers of other clothing and is not directly in contact with external objects that may cause tearing, damage or pilling. Therefore, there is no need to reinforce the first panty portion 56 with a knitted fabric containing UHMWPE to improve its tear resistance. Accordingly, it is further observed that the first panty portion 56 is a suitable area in the pantyhose article 1 where UHMWPE can be omitted without significantly reducing its performance. However, as described elsewhere in this document, other parts of the pantyhose article 1 may require additional adjustments to accommodate the situation where the first panty portion 56 is made of a knitted fabric without UHMWPE. The second panty portion 112 of the second tubular member 16 may also be made of a knitted fabric that does not contain UHMWPE in the same manner as the first panty portion 56. The first panty portion 56 and the second panty portion 112 may be made of the same knitted fabric.

[0131] The first tubular member 8 is formed or woven in a continuous knitting operation. More specifically, the first panty portion 56, the first transition sub-portion 148 and the first main sub-portion 140 are formed in the same continuous knitting operation. The continuous knitting operation refers to a continuous operation performed by a knitting machine (such as a circular knitting machine) so that the various parts of the first tubular member 8 (e.g., the first panty portion 56, the first transition sub-portion 148 and the first main sub-portion 140) obtained by the continuous knitting operation are woven successively or integrally. In such a continuous knitting operation, after knitting a given portion of the first tubular member 8 (e.g., the first panty portion 56), the next portion of the first tubular member 8 (e.g., the first transition sub-portion 148) will continue to be woven from the last interface of the fibers of the just completed given portion (e.g., the last loop of the knitted fabric forming the first panty portion 56). The knitting is continued by switching from the fibers and knitting pattern of the just completed given portion to the fibers and knitting pattern suitable for the next portion of the first tubular member 8. It should be understood that at any stage of the weaving operation, the continuous weaving operation of the first tubular member 8 will not produce the first underpants portion 56, the first transition subportion 140 and the first main subportion 148 as independent and separate parts that need to be subsequently joined together in any manner (for example, by sewing these parts together).

[0132] It has been observed that the interface between different knitted fabrics in the first tubular member 8 may create a weak point in the first tubular member 8. This weak point may cause defects, such as tears or breaks, to appear at the interface and propagate within the pantyhose article 1. These defects may occur due to repeated stresses applied to the pantyhose article 1 when the wearer puts on the pantyhose article 1, such as repeated pulling and stretching in the longitudinal direction 72. In addition, this transition between different knitted fabrics may also cause discomfort when wearing the pantyhose article 1.

[0133] The continuous weaving of the first panty portion 56 and the second knitted fabric of the first transition sub-portion 148 reduces tearing at the transition between the two portions, which corresponds to the bottom end 64 of the first panty portion 56. The second knitted fabric of the first transition sub-portion 148 is also used to improve durability and reduce tearing along the transition at the bottom end 64. According to one embodiment, one of the one or more stretch fibers used to weave the first panty portion 56 is also present in the second knitted fabric of the first transition sub-portion 148, which ensures the continuity of the knitted fabric at the transition between the panty portion 56 and the first transition sub-portion 148, thereby also reducing the possibility of tearing. This transition can also improve comfort.

[0134] The continuous weaving of the first transition sub-portion 148 and the main sub-portion 140 reduces tearing at the transition between the two portions, which corresponds to the first thigh region 156 of the tubular leg portion 80. The second knitted fabric of the first transition sub-portion 148 and the first knitted fabric of the first main sub-portion 140 are used to improve the durability of the first thigh region 156 at the transition and reduce tearing. According to one embodiment, the combination of UHMWPE and accompanying fibers in the first knitted fabric of the first main sub-portion 140 is also present in the second knitted fabric of the first transition sub-portion 148, which ensures the continuity of the knitted fabric at the transition between the first transition sub-portion 148 and the main sub-portion 140, thereby also reducing the possibility of tearing. This transition can also improve comfort.

[0135] It should be understood that the inclusion of the first transition sub-portion 148 in the first tubular leg member 8 results in two knitted fabric transitions: the first transition is located between the first panty portion 56 and the first transition sub-portion 148 at the bottom end 64 of the first panty portion 56, and the second transition is located between the first transition sub-portion 148 and the first main sub-portion 140 at the thigh region 156. Therefore, a tensile force applied along the longitudinal direction 72 of the first tubular member 8 (e.g., when the wearer puts on the pantyhose 1) will be distributed between the first transition and the second transition. Compared to a first tubular member 8 having only one transition (e.g., a single transition from the panty portion 56 directly to the first main sub-portion 140), this distribution of tensile force can reduce the likelihood of tearing.

[0136] As described above, the second knitted fabric of the first transition subsection 148 can be optionally selected so that there is continuity between the knitted fabric of the first panty portion 56 and the second knitted fabric of the first transition subsection 140, and this continuity is achieved by the two knitted fabrics having common fibers in their respective knit structures. In addition, the second knitted fabric of the first transition subsection 148 can be optionally selected so that there is continuity between the knitted fabric of the first transition subsection 148 and the first knitted fabric of the first main subsection 140, and this continuity is achieved by the two knitted fabrics having at least one common fiber in their respective knit structures. It has been observed that because the knitted fabric of the first panty portion 56 is relatively thin (e.g., less than 200 total denier), it can be worn discreetly under tight clothing, but the low denier of the first panty portion 56 directly transitioned to the first knitted fabric of the main subsection 140 is prone to tearing. The addition of the first transition subsection 148 as an intermediate fabric between the first panty portion 56 and the first fabric of the main subsection 140 solves this drawback that would otherwise occur in a tubular member comprising essentially only the first panty portion and the main subsection.

[0137] According to one embodiment, the first panty portion 56 is made of a knitted fabric having a total denier of about 20 to 250. It will be appreciated that the knitted fabric of the first panty portion 56 has a denier low enough so that it can be worn next to the body under tight clothing, such as a tight dress or a hip skirt. According to one embodiment, the first panty portion 56 is primarily made of a knitted fabric of nylon fibers having a denier of about 20 to 100 and nylon-coated spandex fibers having a denier of about 20 to 120. In one embodiment, the nylon fibers are two strands of 40-denier nylon fibers, and the nylon-coated spandex fibers are composed of two 20-denier spandex fibers coated with 40-denier nylon.

[0138] It is noteworthy that when the first main sub-portion 140 is worn on the leg, it is generally exposed to environmental factors that may cause tearing and / or breakage. The first knitted fabric of the first main sub-portion 140 is intentionally designed to have at least tear resistance and pilling resistance. Since the first main sub-portion 140 is exposed and visible, the first knitted fabric is also intentionally designed to have desired aesthetic properties. According to an exemplary embodiment, the first UHMWPE fiber in the first knitted fabric of the first main sub-portion 140 includes a first UHMWPE fiber having a denier of approximately 10 to 60, and the first companion fiber has a denier of approximately 10 to 100. According to various exemplary embodiments described herein, the first UHMWPE fiber and the first companion fiber can be woven into a plated knitted fabric with different appearances.

[0139] In an exemplary embodiment, if the first main sub-portion 140 is required to present a transparent appearance, the denier of the first UHMWPE fiber in the first knitted fabric should be between about 25 and about 35, and the first companion fiber mainly includes a stretch fiber with a denier between about 10 and about 20. According to an exemplary embodiment, the denier of the first UHMWPE fiber is about 30, and the stretch fiber is a nylon-coated spandex fiber of about 15 denier.

[0140] According to an exemplary embodiment, when the first main sub-portion 140 is to present a translucent appearance, the denier of the first UHMWPE fiber in the first knitted fabric should be between about 25 and about 35, while the first companion fiber includes a total denier of about 40 to about 80. According to an exemplary embodiment, the denier of the first UHMWPE fiber is about 30, and the companion fiber includes one or more nylon-coated spandex fibers with a total denier of about 50.

[0141] According to an exemplary embodiment, when the first main sub-portion 140 is to present an ultra-thin and transparent appearance, the denier of the first UHMWPE fiber in the first knitted fabric should be between about 10 and about 20, and the first companion fiber includes a total denier of about 5 to about 15. According to an exemplary embodiment, the denier of the first UHMWPE fiber is about 15, and the first companion fiber is a coated spandex fiber of about 9 denier.

[0142] According to an exemplary embodiment, when the first main sub-portion 140 is to present a translucent appearance, the denier of the first UHMWPE fiber in the first knitted fabric should be between about 25 and about 50, while the first companion fiber includes a total denier of about 60 to about 150. According to an exemplary embodiment, the denier of the first UHMWPE fiber is about 30, and the first companion fiber is a coated spandex fiber of about 75 denier.

[0143] According to an exemplary embodiment, the second knitted fabric of the first transition sub-portion 148 is woven from a second UHMWPE fiber with a denier of about 10 to about 60, and the total denier of the second companion fiber is about 50 to about 150. According to an exemplary embodiment of a second knitted fabric, the second knitted fabric is to be combined with the first main sub-portion 140 with a transparent appearance, and the second UHMWPE fiber in the second knitted fabric also has a denier of about 25 to about 35, preferably about 30 denier, and the UHMWPE fiber is woven together with the second companion fiber, and the second companion fiber basically includes a stretched fiber with a denier of about 10 to about 20, preferably a coated spandex fiber of about 15 denier. The second UHMWPE fiber and the second companion fiber can be woven into a plated knitted fabric. It is worth noting that this UHMWPE fiber and this companion fiber are present both in the first knitted fabric of the main sub-portion 140 and in the first transition sub-portion 148. As described elsewhere herein, the second knitted fabric of the first transition sub-portion 148 also includes a mesh knitted fabric. The mesh knitted fabric may be woven with additional accompanying fibers, including nylon-coated Lycra fibers having a denier of about 40 to about 120, preferably two 20-denier spandex fibers coated with 40-denier nylon. It is noteworthy that such additional accompanying fibers in the second knitted fabric of the first transition sub-portion 148 are also present in the knitted fabric of the first panty portion 56.

[0144] According to one embodiment, and Figure 1 , 4 , 5, 6, 7 and 8, the first tubular member 8 is made in a non-directional manner about its longitudinal axis 212. That is, before being assembled with the crotch portion 24 and the second tubular member 16, the first tubular member 8 is the same at any angular position about its longitudinal axis 212. The first panty portion 56 extends circumferentially about the longitudinal axis 212, and thus can be cut at any angular position about the longitudinal axis 212 to form its longitudinal edge 172 for engagement with the corresponding edge 180 of the second panty portion 112. The second tubular member 16 can also be made in a similar non-directional manner about its own axis.

[0145] The first transition sub-portion 148 also extends circumferentially around the longitudinal axis 212 and the first tubular leg portion 80. According to one embodiment, in which the edge of the first transition sub-portion 148 is directly joined to the edge of the crotch portion 24, the engagement between the edge 228 of the first transition sub-portion 148 and the edge of the crotch portion 24 can be performed at any angular position of the tubular leg portion 80 around the longitudinal axis 212 (as long as the angular position is common to the first main sub-portion 140 and the first transition sub-portion 148). That is, the engagement does not have to be performed at the precise angular region / position of the circumferential edge 228 of the first transition sub-portion 148 that is predetermined after the first tubular leg portion 80 is made. The second transition sub-portion 164 can also extend circumferentially around the second tubular leg portion 128 around its own axis.

[0146] In addition, the cutting of the first panty portion 56 is performed from the top edge 40 to the bottom edge 64 in the longitudinal direction 72 and may extend slightly to the first transition sub-portion 148. Such a cutting may otherwise cause a thread break on the first tubular member 8, but due to the presence of a reinforcing knitted fabric (e.g., a mesh knitted fabric) in the first transition sub-portion 148, the thread break is limited from continuing to propagate toward the foot end 48 of the first tubular member 8. In addition, because the first transition sub-portion 148 extends circumferentially around the first tubular member 8, the cutting can be performed at any angular position around the axis 212, and the reinforcing knitted fabric of the first transition sub-portion 148 will limit the continued propagation of the thread break. The second transition sub-portion 164 extends circumferentially around the corresponding axis of the second tubular leg portion 128, providing a similar limitation on the propagation of a thread break that may result when cutting the second panty portion 112 to form the longitudinal edge 180.

[0147] According to various embodiments described herein, the first and second transition sub-portions 148, 164 of the first and second leg portions 80 and 128, respectively, extend between the bottom ends of the respective panty portions 56, 112 and the thigh regions 156, 168 of the tubular leg portions 80, 128, respectively. Due to this positioning, when the pantyhose article 1 is worn, the first and second transition sub-portions 148, 164 will be located in the thigh region of each leg of the wearer. In addition, since the first transition sub-portion 148 and the second transition sub-portion 164 extend circumferentially around their respective leg portions 80, 128, when the pantyhose article 1 is worn, the first inner thigh region at the height of the wearer's first leg will be covered by the first corresponding angular region of the first transition sub-portion 148, and the second inner thigh region at the height of the wearer's second leg will be covered by the second corresponding angular region of the second transition sub-portion 164. It is noteworthy that when the pantyhose article 1 is worn, the first corresponding angle area of ​​the first transition subsection 148 will face the second corresponding angle area of ​​the second transition subsection 164 (because the inner thigh area of ​​the first leg will face the inner thigh area of ​​the second leg). It has been observed that friction between the wearer's first and second inner thigh areas is a common cause of wear or damage to leg clothing. Further observations have found that positioning the first transition subsection 148 and the second transition subsection 164 at the thigh height of the corresponding first and second tubular leg portions can better prevent wear or damage to the pantyhose article 1 due to inner thigh friction. It is noteworthy that the second knitted fabric of the first and second transition subsections 148, 164 is a knitted fabric including UHMWPE fibers and at least one accompanying fiber, and the addition of the UHMWPE fibers provides additional protection against wear or damage to the knitted fabric due to its higher durability.

[0148] According to a method for making a pantyhose article 1 according to an embodiment, a first tubular member 8 is first made. As described herein, the first tubular member 8 is made in a continuous knitting operation, such as using a circular knitting machine. Similarly, a second tubular member 16 is also made. As described herein, the second tubular member 16 is also made in a continuous knitting operation, such as using a circular knitting machine.

[0149] After forming the first tubular member 8 and the second tubular member 16, the tubular members 8, 16 are appropriately cut and joined to form the pantyhose article 1. The first tubular member 8 is manufactured in a non-directional manner, wherein the first panty portion 56 extends circumferentially around the longitudinal axis 212 and the first transition sub-portion 148 also extends circumferentially around the longitudinal axis 212 (the second tubular member 16 also has these same characteristics), so that the pantyhose article 1 can be assembled in a substantially automatic process. The automatic assembly process here refers to one or more machine-performed cutting, alignment and / or joining (e.g., stitching) without manual human intervention. After the knitting machine has knitted the first tubular member 8 and the second tubular member 16, the tubular members 8 and 16 are appropriately loaded onto the automatic assembly machine. Since the first tubular member 8 is non-directional and has a first panty portion 56 extending circumferentially around the longitudinal axis 212, the panty portion 56 can be cut in the longitudinal direction 72 at any angular position of the first tubular member 8 to form its longitudinal edge 172. Cuts may be made in a similar manner on the second tubular member 16 to form the longitudinal edges 180 .

[0150] In addition, according to one embodiment, in which the edge of the first transition sub-portion 148 is directly joined to the edge of the crotch portion 24, since the first transition sub-portion 148 extends circumferentially around the longitudinal axis 212, any area of ​​the edge 228 of the top edge of the transition sub-portion 140 is suitable for sewing with the crotch portion 24. The edge 228 of the transition sub-portion 140 (corresponding to the angular position when the panty portion 56 is cut on the first tubular member 8) is joined (e.g., sewn) with the crotch portion 24. In the second transition sub-portion 164, it can be joined (e.g., stitched) with the crotch portion 24 in a similar manner.

[0151] The longitudinal edge 172 of the first panty portion 56 is further joined (e.g., sewn) to the longitudinal edge 180 of the second panty portion 112 to form a panty tube 188. The edges of the panty portions 56, 112 are further sewn to the corresponding edges of the crotch portion 24 to close any gaps and enclose a panty cavity 196.

[0152] It is noteworthy that, depending on the configuration and functionality of the assembly machine, the steps of automatically assembling the pantyhose article 1 may be performed in a different order than described above. In addition, one or more steps may be completed in a single operation, such as sewing multiple edges together in a single sewing operation.

[0153] As described elsewhere herein, the first tubular member 8 and the second tubular member 16 are formed by a continuous knitting operation on a circular knitting machine. According to some exemplary embodiments, the tubular leg members 8 and 16 are formed by continuously feeding fibers from the same number of yarn feeders of the knitting machine throughout the continuous knitting operation, i.e., throughout the knitting of the panty portions 56 and 112, the transitional sub-portions 148 and 164, and the main sub-portions 140 and 160. In one embodiment, the tubular leg members 8 and 16 are knitted using two yarn feeders of the knitting machine throughout the full continuous knitting operation.

[0154] It is observed that the first and second main sub-portions 140, 160 and the first and second transition sub-portions 148, 164, each formed of a knitted fabric containing UHMWPE, require fewer feeders (i.e., 2 or fewer feeders) to be knitted due to the complexity introduced by the properties of UHMWPE. It is also observed that the panty portion 56, 112 without UHMWPE can be knitted with more feeders of the knitting machine (i.e., more than 2 feeders, such as 4 or more feeders). It is further observed that when switching from 4 or more feeders (corresponding to the knitted fabric of the panty portion 56, 112) to 2 or fewer feeders (corresponding to the knitted fabric of the transition sub-portion 148, 164 and the main sub-portion 140, 160), a weak point is introduced in the tubular leg member 8, 16 at this transition location. The weak point may appear as a hole in the tubular leg member 8, 16 at this transition location. However, it has also been observed that by knitting the tubular leg members 8, 16 by continuously feeding fibres from the same number of feeders of the knitting machine throughout the continuous knitting operation, this weak point can be eliminated, thereby improving the strength / durability of the knitted fabric.

[0155] Although examples of embodiments are provided above, it should be understood that certain features and / or functions of these embodiments may be modified without departing from the spirit and principles of the described embodiments. Therefore, the above description is intended to be illustrative rather than limiting, and those skilled in the art will appreciate that other variations and modifications may be made without departing from the scope of the invention as defined in the appended claims.

Claims

1. A pantyhose product, comprising: A first tubular member having: a first panty portion extending from a waist end of the pantyhose article to a bottom end of the first panty portion; A first tubular leg portion defines a first leg cavity and extends from its top end to a first foot end of the first tubular leg portion, the top end corresponding to the bottom end of the first panty portion, the first tubular leg portion comprising a first main sub-portion and a first transition sub-portion, the first main sub-portion extending from a first thigh region of the first tubular leg portion to the first foot end, and the first transition sub-portion extending from the top end of the first tubular leg portion to the first thigh region of the first tubular leg portion, the first main sub-portion being formed by a first knitted fabric comprising a first ultra-high molecular weight polyethylene (UHMWPE) fiber and at least one first accompanying fiber, and the first transition sub-portion being formed by a second knitted fabric comprising a second UHMWPE fiber and at least one second accompanying fiber, the first knitted fabric being different from the second knitted fabric.

2. The pantyhose article of claim 1, further comprising a crotch portion; wherein an edge of the first transition subsection is joined to the crotch portion.

3. The pantyhose article of claim 2, wherein the second knitted fabric of the first transition sub-portion has a stronger sewing resistance than the first knitted fabric of the first main sub-portion of the first tubular leg portion.

4. The pantyhose article according to claim 2 or 3, wherein the second knitted fabric of the first transition sub-portion has a stronger resistance to unraveling when being torn or cut than the first knitted fabric of the first main sub-portion of the first tubular leg portion.

5. The pantyhose article according to any one of claims 2 to 4, wherein the second knitted fabric of the first transition sub-portion comprises a mesh knitted fabric.

6. The pantyhose article of any one of claims 1 to 5, wherein the first transition sub-portion extends circumferentially around the first tubular leg portion.

7. The pantyhose article according to any one of claims 1 to 6, wherein the first panty portion, the first transition subportion and the first main subportion are integrally knitted.

8. The pantyhose article according to any one of claims 1 to 7, wherein the first panty portion, the first transition sub-portion and the first main sub-portion are knitted in a continuous knitting operation.

9. The pantyhose article of claim 8, wherein continuous knitting of the second knit fabric of the first panty portion and the first transition subportion reduces tearing along a transition between the first panty portion and the first transition subportion.

10. The pantyhose article of claim 9, wherein continuous knitting of the second knitted fabric of the first transition subsection and the first knitted fabric of the main subsection reduces tearing along a transition between the first transition subsection and the first main subsection.

11. The pantyhose article as claimed in any one of claims 8 to 10, wherein the first panty portion, the first transition sub-portion and the first main sub-portion are formed in the continuous knitting operation using the same number of yarn feeders of a circular knitting machine throughout the continuous knitting operation.

12. The pantyhose article of claim 11, wherein the same number of yarn feeders is 2 yarn feeders or less.

13. The pantyhose article according to any one of claims 1 to 12, wherein the first panty portion is formed from a knitted fabric that does not contain UHMWPE.

14. The pantyhose article according to any one of claims 1 to 13, wherein the knitted fabric of the first panty portion and the second knitted fabric of the first transition sub-portion have at least one common fiber.

15. The pantyhose article according to any one of claims 1 to 14, wherein the first knitted fabric of the first main subsection and the second knitted fabric of the first transition subsection have at least one common fiber.

16. The pantyhose article of claim 15, wherein the first UHMWPE fiber and the at least one first companion fiber are knitted together in a plated knit in the first knit of the first main subsection; wherein the second UHMWPE fiber of the second knitted fabric of the first transition sub-portion is the same as the first UHMWPE fiber of the first knitted fabric; wherein at least one of said second companion fibers of said second knitted fabric of said first transition subsection is identical to at least one of said first companion fibers of said first knitted fabric; wherein the second UHMWPE fiber and the at least one second companion fiber are knitted together in the second knitted fabric of the first transition subsection, the at least one second companion fiber being identical to the at least one first companion fiber; The second knitted fabric of the first transition sub-portion further comprises at least one additional companion fiber.

17. The pantyhose article of claim 16, wherein the additional companion fibers are knitted as a mesh knit within the second knit of the first transition subsection.

18. The pantyhose article according to claim 16 or 17, wherein the at least one additional companion fiber of the second knitted fabric of the first transition sub-portion is present in the knitted fabric of the first panty portion.

19. The pantyhose article according to any one of claims 1 to 18, wherein: The first UHMWPE fiber of the first knitted fabric has a denier of about 25 to about 35, and the at least one first companion fiber includes at least one drawn fiber having a total denier of about 10 to about 20.

20. The pantyhose article according to claim 19, wherein the second UHMWPE fiber of the first transition subsection has a denier of about 25 to about 35, and the at least one second companion fiber comprises at least one stretch fiber having a total denier of about 10 to about 20 knitted together with the second UHMWPE fiber; and Wherein the at least one second companion fiber further comprises an additional companion fiber reinforcing the second knitted fabric of the first transition sub-portion.

21. The pantyhose article of any one of claims 1 to 20, wherein the first panty portion is formed from a knit fabric having a total denier of about 20 to about 250.

22. The pantyhose article of any one of claims 1 to 21, further comprising a second tubular member having: a second panty portion extending from a waist end of the pantyhose article to a bottom end of the second panty portion aligned with a bottom end of the first panty portion; a second tubular leg portion defining a second leg cavity and extending from a top end thereof to a second foot end of the second tubular leg portion, the top end corresponding to a bottom end of the second panty portion, the second tubular leg portion comprising a second main sub-portion and a second transition sub-portion, the second main sub-portion extending from a second thigh region of the second tubular leg portion to the second foot end, and the second transition sub-portion extending from the top end of the second tubular leg portion to the second thigh region of the second tubular leg portion, the second main sub-portion being formed by a first knitted fabric comprising first UHMWPE fibers and at least one first companion fiber, and the second transition sub-portion being formed by a second knitted fabric comprising the second UHMWPE fibers and the at least one second companion fiber; The longitudinal edges of the first panty part are joined to the corresponding longitudinal edges of the second panty part to form a panty tube defining a panty cavity for accommodating the wearer's lower body, the panty cavity being fluidically connected to the first leg cavity of the first tubular leg part, and the panty cavity being fluidically connected to the second leg cavity of the second tubular leg part.

23. The pantyhose article according to claim 22, wherein the first transition subportion formed by the second knitted fabric having the second UHMWPE fiber and the second transition subportion formed by the second knitted fabric having the second UHMWPE fiber provide protection against wear of the first transition subportion and the second transition subportion caused by friction against the inner thigh of a person wearing the pantyhose article.

24. A method for making a pantyhose article, the method comprising: A first tubular member is formed, the first tubular member having: a first panty portion extending from a waist end of the pantyhose article to a bottom end of the first panty portion; a first tubular leg portion defining a first leg cavity and extending from a top end thereof to a first foot end of the first tubular leg portion, the top end corresponding to a bottom end of the first panty portion, the first tubular leg portion comprising a first main sub-portion and a first transition sub-portion, the first main sub-portion extending from a first thigh region of the first tubular leg portion to the first foot end, and the first transition sub-portion extending from the top end of the first tubular leg portion to the first thigh region of the first tubular leg portion, the first main sub-portion being formed of a first knitted fabric comprising first ultra-high molecular weight polyethylene (UHMWPE) fibers and at least one first companion fiber, and the first transition sub-portion being formed of a second knitted fabric comprising second UHMWPE fibers and at least one second companion fiber, the first knitted fabric being different from the second knitted fabric; A second tubular member is formed, the second tubular member having: a second panty portion extending from a waist end of the pantyhose article to a bottom end of the second panty portion aligned with a bottom end of the first panty portion; a second tubular leg portion defining a second leg cavity and extending from a top end thereof to a second foot end of the second tubular leg portion, the top end corresponding to a bottom end of the second panty portion, the second tubular leg portion comprising a second main sub-portion and a second transition sub-portion, the second main sub-portion extending from a second thigh region of the second tubular leg portion to the second foot end, and the second transition sub-portion extending from the top end of the second tubular leg portion to the second thigh region of the second tubular leg portion and extending circumferentially around the second tubular leg portion, the second main sub-portion being formed by a first knitted fabric comprising first UHMWPE fibers and at least one first companion fiber, and the second transition sub-portion being formed by a second knitted fabric comprising the second UHMWPE fibers and the at least one second companion fiber; cutting the first panty portion along a longitudinal direction thereof to form a first longitudinal edge therein, and cutting the second panty portion along a longitudinal direction thereof to form a second longitudinal edge therein; joining the first longitudinal edge of the first panty portion with the second longitudinal edge of the second panty portion to form a panty tube defining a panty cavity for receiving the lower torso of a wearer, the panty cavity being in fluid communication with the first leg cavity of the first tubular leg portion, and the panty cavity being in fluid communication with the second leg cavity of the second tubular leg portion; as well as The longitudinal edge of the first panty portion is joined to a first edge of a crotch, and the longitudinal edge of the second panty portion is joined to a second edge of the crotch.

25. The method of claim 24, wherein the first panty portion, the first transition subportion, and the first main subportion are formed in a continuous knitting operation.

26. The method of claim 25, wherein the first panty portion, the first transition subportion, and the first main subportion are formed in the continuous knitting operation using the same number of yarn feeders of a circular knitting machine throughout the continuous knitting operation.

27. The method of claim 26, wherein the same number of yarn feeders is 2 yarn feeders or less.

28. The method of any one of claims 24 to 27, further comprising joining an angled region of an edge of the first transition subsection to the first edge of the crotch portion, and joining an angled region of an edge of the second transition subsection to the second edge of the crotch portion.

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