Seamless knitting process for three-layer nursing bras woven in one piece

Abstract

This invention discloses a seamless knitting process for a three-layer nursing bra, manufactured in a single knitting operation. The bra of this invention mainly consists of an outer cup, an inner cup, and a band. It employs a one-time seamless knitting technique. The outer cup is composed of an outer layer fabric (d) and a middle layer fabric (a), while the inner cup is composed of an inner layer fabric (b). Through a two-step seamless knitting process, the middle layer fabric (a) is seamlessly connected to the inner layer fabric (b) via a tying line. The middle layer fabric (a) and the inner layer fabric (b) are also seamlessly connected to the band fabric (c) via tying lines. Each of the inner and outer cups has two symmetrical cups on top. The middle part of the inner cup has a horizontal mesh for use with a breast pump. The shoulder straps are equipped with an automatic adjuster to adjust the length of the straps for attaching a breast pump. This invention improves the production efficiency of the three-layer nursing bra, avoids inconsistent sizes during the cutting process of the three layers of fabric, and reduces sewing stitches.

Description

Technical Field

[0001] This invention relates to the field of seamless knitted underwear, specifically to a seamless knitting process for a three-layer nursing bra that is knitted in one piece. Background Technology

[0002] Most nursing bras on the market consist of an inner cup and an outer cup. The inner cup supports the breasts around their perimeter, while the outer cup covers the entire breast. The inner cup is made of a single layer of fabric with an opening for breastfeeding. The outer cup consists of two layers of fabric, with an opening on the inner side. When a breast pad is placed between the two layers, it prevents milk leakage. When no breast pad is placed, the two layers of fabric in the outer cup prevent nipple exposure and protect the wearer's privacy.

[0003] However, nursing bras made of three layers of fabric require extensive cutting, splicing, and sewing processes. Inconsistent cutting and sewing techniques, along with low splicing precision, not only affect the bra's aesthetics but also its production quality and wearing comfort. Furthermore, the cutting and sewing processes increase the difficulty and time required for bra design and production, consuming more manpower and resources.

[0004] Seamless knitted bras are made using a one-piece forming technology. Knitted on a specialized circular knitting machine, the overall structure of the bra fabric is essentially formed in one piece. After knitting, minimal trimming, hemming, shoulder strap attachment, and finishing are required to create the final product. This necessitates the design of a new knitting process, utilizing the start-up and tie-knitting technique within seamless knitting technology to weave the three layers of fabric for nursing bras in a single piece. This eliminates seams at the back panels, cup and underband connections, improving the overall aesthetics and comfort of the nursing bra while saving time and costs associated with bra sewing.

[0005] Currently, nursing bras on the market that allow for handless breast pumping have an opening design to support the pump. To prevent the opening from coming undone, the opening is often made of several pieces of fabric sewn together. This requires cutting, rolling, hemming, and sewing of the opening, making the production process complex and time-consuming. When there is a lot of milk in the bottle, you still need to hold the bottle with your hand. Summary of the Invention

[0006] This invention addresses the shortcomings of existing technologies by providing a detachable, one-piece seamless knitting process for three-layer fabrics, enabling seamless knitted nursing bras with different weave structures and techniques in the three-layer fabrics. The outer fabric d, the middle fabric a, the inner fabric b, and the undergarment fabric c are seamlessly connected. The middle fabric is seamlessly connected to the inner fabric via a tie line, and the middle and inner fabrics are seamlessly connected to the undergarment fabric via tie lines.

[0007] The process includes the following steps:

[0008] Step 1: The starting point is the bottom edge of fabric a. Several rows of yarns are placed on the needle pad. The single-piece half needle extends out of the half disc and is then retracted after the binding thread is placed on it. The circular knitting machine has a total of N loop forming systems. In each loop forming system, the A-type yarn is used for the face yarn knitting with nylon or polyester yarn, and the B-type yarn is used for the base yarn knitting with nylon / spandex covered yarn, etc. Fabric a is woven into a greige fabric.

[0009] Step II, N-way loop forming system weaves fabric b: When reaching the mesh position, the C and D-way loop forming systems start stitching, and the remaining loop forming systems continue weaving fabric b, completing the mesh structure weaving; the C and D-way loop forming systems stop stitching, and the N-way loop forming system continues weaving the greige fabric of fabric b, completing the greige fabric weaving, the half needle extends out of the half disc again, transfers the binding loop to the lower edge of fabric b and then retracts into the half disc, forming the binding structure;

[0010] Step III: Place several rows of yarn on the needle pad, extend the single-piece half needle out of the half disc, and after placing the binding thread on it, retract it back into the half disc. The E and F loop forming systems use the G yarn feeder, remove the yarn from the A and B yarn feeders, and use coarse spandex yarn for the G yarn feeder. The rest of the loop forming system remains unchanged. Complete the knitting of the lower fabric c. Extend the half needle out of the half disc again, transfer the binding thread loop to the lower edge of fabric c, and retract it back into the half disc to form the binding structure.

[0011] Steps IV, E, and F: The loop-forming system removes yarn from the G-type yarn feeder and restores the A and B-type yarn feeders for weaving. The rest of the loop-forming system remains unchanged, and the knitting needles continue to weave the fabric d until the end, thus completing the weaving of a one-piece cylindrical fabric.

[0012] Compared with the prior art, the present invention has the following advantages:

[0013] The seamless knitting process of this invention can knit nursing bras in one three-dimensional form, which has the advantages of low production cost and short process flow. It reduces manual cutting and sewing processes, improves the production efficiency of fabrics, and saves raw material waste. It can realize the breast pump without hands through the mesh of the inner fabric and the automatic adjuster, so that the bra can quickly breastfeed. Attached Figure Description

[0014] Figure 1 A side flow diagram of the process for one-piece seamless circular knitting machine knitting;

[0015] Figure 2 The cylindrical greige fabrics of fabrics a and b are shown in the weaving process, and the images are front and back views of the weaving process.

[0016] Figure 3The cylindrical greige fabric of fabric c is shown in the weaving process, and the images are front and back views of the weaving process.

[0017] Figure 4 The image shows a one-piece cylindrical fabric completed by weaving fabrics a, b, c, and d, with views of the weaving process from the front and back.

[0018] Figure 5 Image showing the appearance of the inner fabric of a seamless three-layer nursing bra;

[0019] Figure 6 This is a design diagram of the inner fabric after removing the outer and middle layers of the seamless three-layer nursing bra.

[0020] Figure 7 A perspective view of the operation method of using a breast pump device to perform handless breast pumping for a seamless three-layer nursing bra. Detailed Implementation

[0021] The present invention will be further described below with reference to the accompanying drawings and embodiments. The contents mentioned in the embodiments are not intended to limit the present invention. The present invention is not limited to the knitting of seamless three-layer nursing bras, but can also be used to knit any seamless three-layer top or bottom garment in one knitting process.

[0022] like Figures 1-6 As shown, the seamless three-layer nursing bra involved in this embodiment is woven using a Santoni SM8-TOP2 seamless circular knitting machine, with a total of 8 loop-forming systems (N = 8). The No. 5 yarn feeder (i.e., yarn feeder ①) of each loop-forming system uses nylon or other yarns for the face yarn, with a fineness range of 20D to 200D (common fineness is 70D); the No. 2 yarn feeder (i.e., yarn feeder ②) uses nylon / spandex covered yarns or other yarns for the base yarn, with a fineness range of 20D / 20D to 150D / 150D (common nylon fineness is 30D, common spandex fineness is 20D). The selection of face and base yarns is not limited to the yarns used in this example; all three-layer nursing bras woven using the seamless knitting process of this invention are within the scope of protection of this invention.

[0023] This embodiment describes a seamless, three-layer nursing bra woven using this process, comprising an outer fabric, a middle fabric, an inner fabric, a band fabric, shoulder straps, hooks and loops, clasps, and an automatic adjuster. The outer, middle, and inner fabrics are woven together seamlessly in a single process. The middle fabric is seamlessly connected to the inner fabric via a binding seam, and the middle and inner fabrics are also seamlessly connected to the band fabric via binding seams. The specific process flow is as follows:

[0024] like Figure 1 and Figure 2 As shown, Figure 1(1) The fabric woven is the middle layer fabric a, the front side of which is a1 and the back side is a2. After all the needles e are padded with yarn, the single-piece half needles f extend out of the half disc, and after the binding thread is padded, they retract into the half disc to knit the finished fabric a. The finished fabric a cup area 2 uses plain knit or tuck stitch weaving, etc.; the back part 5 of the bra uses rib knit (1+1 rib knit), etc., to give it better elasticity and tightness; the middle part 9 of the cup of the middle layer fabric a uses rib knit (1+1 rib knit), etc., to make the bra cup more three-dimensional.

[0025] At point 3, where the middle layer fabric a connects to the inner layer fabric b, the eight-way loop-forming system weaves fabric b until it reaches the mesh area. Loop-forming systems 7 and 8 (7 for A, 8 for B) then begin stitching, while the remaining six loop-forming systems continue weaving fabric b. Once the mesh structure is complete, loop-forming systems 7 and 8 cease stitching, and the eight-way loop-forming system continues weaving the greige fabric b until it is finished. Figure 1 (2) is the inner layer fabric b, with the front side of the process being b1 and the back side being b2. For example... Figure 1 As shown in (2) to (3), the half needle extends out of the half disc again, transfers the knotting loop to the lower edge of fabric b, and then retracts into the half disc to form a knotting structure.

[0026] like Figure 2 As shown, 1 represents the weaving direction, 4 the binding line, 10 the middle layer cup area, 5 the back band of the bra, 6 the mesh in the middle of the inner layer fabric b, 7 the inner center gore, and 8 the hanging stitch technique on both sides of the mesh in the middle of the inner layer cup. The finished fabric b, the cup area, uses plain knit or tuck stitch weaving; the back band 5 uses rib knit (1+1 rib knit), giving it good elasticity and tightness; the bra cup has a mesh 6 in the middle, and hanging stitch technique 8 on both sides of the mesh 6, making the mesh more durable and less prone to fraying; the hanging stitch technique in the middle of the cup enhances the three-dimensional effect of the bra cup, highlighting the bra's curves.

[0027] like Figure 1 and Figure 3 As shown, Figure 1In steps (4) to (5), c1 and c2 represent the front and back sides of the lower fabric c, respectively. Several rows of yarn are placed on the needle pad, and the single-piece half needle extends out of the half disc, and after the binding thread is placed, it retracts back into the half disc. The 2nd and 6th loop forming system (C is 2, D is 6) uses a No. 3 yarn feeder (i.e., yarn feeder ③). Yarns from yarn feeders 2 and 5 are removed, and yarn feeder 3 uses coarse spandex yarn, with a fineness range of 50D to 500D (common fineness is 210D). The other six loop forming systems remain unchanged, and the lower fabric c is woven. The half needle extends out of the half disc again, and the binding thread loop 4 is transferred to the lower edge of the fabric c and then retracted back into the half disc to form a binding structure. The woven fabric c uses a rib structure (1+1 rib structure), which gives it good elasticity and tightness.

[0028] like Figure 1 and Figure 4 As shown, Figure 1 In (6), d1 and d2 represent the front and back sides of the outer fabric d process, respectively. For example... Figure 1 As shown in (6)~(7), the 2nd and 6th loop forming systems unload the yarn from the No. 3 yarn feeder and restore the No. 2nd and 5th yarn feeders for weaving. The remaining six loop forming systems remain unchanged, and the knitting needles continue to weave the fabric d until the end. The knitting needles then unload the yarn, and the one-piece cylindrical fabric weaving is completed and falls off. Figure 4 As shown, 5 represents the back panel of the outer fabric d bra, and 13 represents the bra cup of the outer fabric d bra. The finished fabric d cup area uses plain knit or tuck stitch weaving, etc.; the back panel 5 of the bra uses rib knit (1+1 rib knit), etc., and the middle part 12 of the outer fabric d cup uses rib knit (1+1 rib knit), etc., to make the bra cup more three-dimensional.

[0029] Weaving process Figure 1 In this method, the starting point is the bottom edge of the middle layer fabric, and the weaving direction gradually moves away from the bottom edge, unlike the traditional method where the starting point is the top edge of the inner or outer layer fabric. (See the weaving process flow diagram, such as...) Figure 1 As shown), a single-piece half-needle is used twice above the knitting needles to connect the middle layer fabric and the inner layer fabric with a binding thread. The middle layer fabric and the inner layer fabric are seamlessly connected to the lower circumference fabric through the binding thread.

[0030] like Figure 4 As shown, the bra fabric is simply cut, cutting the top seam between the middle layer and the inner layer of the bra, and then cutting the left and right sides, aligning with the middle cutting line; as shown... Figure 2As shown, the arcs 11 on both sides of the middle layer fabric where the breast pads are inserted need to be cut; the outer layer fabric and the middle layer fabric are uniformly overlocked and rolled to form the outer cup, and the arcs on both sides of the middle layer fabric can be used to remove or replace the breast pads; the inner layer fabric is rolled separately to form the inner cup; the shoulder straps are covered and sewn with detachable buckles, and hooks and loops are covered and sewn on both sides of the back of the outer layer fabric, the middle layer fabric and the inner layer fabric. After shaping, the finished nursing bra is obtained.

[0031] like Figure 5 , Figure 6 and Figure 7 As shown, the outer fabric and the middle fabric are sewn together by a piping process to form the outer cup, which can be removed by a buckle; the holes on both sides of the middle fabric can be used to insert or replace breast pads; the breast pump can be used to pump milk without hands through the mesh in the middle of the inner fabric cup and the automatic adjuster on the shoulder strap.

[0032] This application embodiment adds a new structure to the opening and designs a new structure on the shoulder strap. The front end of the shoulder strap has two buckles of different heights and an adjustment buckle. The upper buckle is connected to the outer cup, and the lower buckle is connected to the inner cup. By opening the upper buckle, the outer cup can be opened to expose the inner fabric. The seamless bra directly designs the opening in the inner fabric through a knitting process, forming it in one piece, saving production costs and time. A special knitting process is added to both sides of the opening structure to reinforce the opening. The shoulder strap is designed with a detachable automatic adjuster made of edible silicone material to adjust the length of the strap for hanging the breast pump and maintaining the stability of the handless breast pumping process.

[0033] This embodiment of the nursing bra also employs a special knitting technique in several selectable areas:

[0034] The outer fabric includes the cups, back band, and the center of the cups. The cups (13) are made of plain knit or tuck stitch, etc.; the back band (5) and the center of the cups (12) are made of rib knit (such as 1+1 rib knit). It conforms to the ergonomics of young women and accentuates the curves of a woman's bust.

[0035] The middle layer fabric includes the cups, back band, and the center of the cups. The rounded sides 11 of the middle layer fabric can be used to remove or replace the breast pads. The cups 2 use plain knit or tuck stitch weave, etc. The back band 5 and the center of the cups 9 use rib knit (such as 1+1 rib knit). It conforms to the ergonomics of young women and enhances the curves of the female breasts.

[0036] The inner fabric includes the cups, mesh, back band, center gore, and the center part of the cups. The inner fabric cups 10 use plain weave or tuck weave, etc.; the back band 5 uses rib weave (such as 1+1 rib weave), etc.; the mesh sides 8 use a hanging needle technique to make the mesh more robust and prevent it from fraying; the center gore 7 uses rib weave (such as 1+1 rib weave), etc., and the center part of the cups 8 uses a hanging needle technique to enhance the three-dimensional effect of the female breasts.

[0037] The shoulder straps are made with covert stitching, and detachable buckles 17 are sewn onto the shoulder straps. Hooks 14 are also covert stitched onto the back sides of the outer, middle, and inner layers of fabric. The shoulder straps are equipped with detachable automatic adjusters 15 made of edible silicone material, which can adjust the length of the straps and are used to hold the breast pump 18, allowing for handless breast pumping. The shoulder straps 16 are bound with elastic bands to prevent them from slipping. The width of the shoulder straps 16, the top edges of the outer, middle, and inner layers of fabric is 1cm, making the bra lightweight and breathable.

[0038] The specific embodiments of the present invention have been described above in conjunction with the accompanying drawings. However, these descriptions should not be construed as limiting the scope of the present invention. The scope of protection of the present invention is defined by the appended claims. Any modifications based on the claims of the present invention are within the scope of protection of the present invention.

Claims

1. A seamless knitting process for a three-layer nursing bra, formed in a single weaving process, employing three layers of fabric, wherein fabric a is the middle layer of the bra, fabric b is the inner layer of the bra, fabric c is the underband fabric, and fabric d is the outer layer of the bra; characterized in that: The outer fabric, middle fabric, inner fabric, and lower circumference fabric are woven together seamlessly in one operation. The middle fabric is seamlessly connected to the inner fabric via a binding thread, and the middle fabric and inner fabric are seamlessly connected to the lower circumference fabric via binding threads. A cylindrical fabric is woven using a circular knitting machine, as detailed below: Step 1: The starting point is the bottom edge of fabric a. Several rows of yarns are placed on the needle pad. The single-piece half needle extends out of the half disc and is then retracted into the half disc after being padded with binding thread. The circular knitting machine has a total of N loop forming systems. The yarn nozzle ① of each loop forming system is made of nylon or polyester for the face yarn, and the yarn nozzle ② is made of nylon / spandex covered yarn for the base yarn. The greige fabric of fabric a is woven. Step II, N-way loop forming system weaves fabric b: When the mesh position is reached, the A and B-way loop forming systems start the needle, and the remaining loop forming systems continue to weave fabric b. The mesh structure weaving is completed. The loop forming systems A and B do not start stitching, while the loop forming system N continues to weave fabric b. Once fabric b is woven, the half needle extends out of the half disc again, transfers the knotting loop to the bottom edge of fabric b, and then retracts back into the half disc to form the knotting structure. Step III: Place several rows of yarn on the needle pad, extend the single-piece half needle out of the half disc, and after placing the binding thread on it, retract it back into the half disc. The loop forming system of routes C and D uses yarn feeder ③. Unwind yarn feeders ① and ②. Yarn feeder ③ uses coarse spandex yarn. The rest of the loop forming system remains unchanged. Complete the knitting of the lower fabric c. Extend the half needle out of the half disc again, transfer the binding thread loop to the lower edge of fabric c, and retract it back into the half disc to form the binding structure. Steps IV, C, and D: The loop-forming system removes yarn from nozzle ③ and restores nozzles ① and ② for weaving. The rest of the loop-forming system remains unchanged, and the knitting needles continue to weave fabric d until the end, completing the weaving of a one-piece cylindrical fabric.

2. The process according to claim 1, characterized in that: Fabric a is the middle layer fabric, and fabric b is the inner layer fabric; fabric a and fabric b are connected at the top.

3. The process according to claim 1, characterized in that: The starting point of the cylindrical greige fabric is the bottom edge of fabric a, and the weaving direction is away from the bottom edge.

4. The process according to claim 1, characterized in that: The inner layer fabric is woven into a mesh in the middle of the cups on both sides. The mesh is made with a hanging needle process to prevent the mesh from coming loose. The mesh area is used for the milk pumping device to pump milk.

5. The process according to any one of claims 1 to 4, characterized in that: During the weaving process of the cylindrical greige fabric, two starting and tying operations are used. The fabric is woven on a Santoni SM8-TOP2 seamless circular knitting machine.

6. A three-layer nursing bra, woven using the process described in any one of claims 1 to 5.

7. A three-layer nursing bra according to claim 6, characterized in that: After the aforementioned three-layer seamless knitting process for nursing bras, it also includes: Cut the bra fabric by cutting the top edge of the bra's middle layer fabric and then cutting the left and right sides, then the middle cutting line. The outer layer fabric and the middle layer fabric of the bra are uniformly overlocked and rolled to form the outer cup; The inner layer of the bra fabric is individually edged to form the inner cup; The shoulder straps are covered with a bandage and detachable buckles are sewn onto them. The nursing bra is finished by attaching hooks and loops to the back sides of the outer layer fabric, middle layer fabric, and inner layer fabric of the bra and shaping them.

8. A three-layer nursing bra according to claim 7, characterized in that: The bra's middle layer fabric is cut with rounded edges on both sides to accommodate the breast pads; these rounded edges can be used to remove or replace the breast pads.

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