Seamless circular woven fabric, method of making same and forming machine using same, and articles comprising strips or tapes made therefrom

Abstract

A seamless circular woven fabric (10) comprising elastic yarns is provided. The fabric (10) has a continuous circular weave throughout its length. The circular woven fabric (10) further comprises a cured cushioning filler (12) inside and bonded to the circular woven fabric (10). The manufacturing method comprises weaving yarns to produce a continuous length of circular woven fabric (10), and injecting a curable cushioning filler in a pre-cured state into the interior of the circular woven fabric (10). The method forms a machine assembly using a circular knitted fabric including a circular knitting machine and an injector.

Description

[0001] The present invention relates to a seamless circular woven fabric, a brassiere including shoulder straps made from such seamless circular woven fabric, a method of forming a seamless circular woven fabric, and a seamless circular woven fabric forming machine assembly.

[0002] The shoulder straps of a bra are often formed from strips of elastic material with adhesive edge material that is uncomfortable and noticeable. These materials are relatively hard against the wearer's skin. Conventional shoulder straps tend to dig into the wearer's skin, especially when the wearer wears the bra for most of the day. It is also known to use similar strips of material for ear loops, which can be used to position a mask on the wearer's face. Again, the relatively hard ear loop elastic material tends to dig into the wearer's face, which is not only uncomfortable, but can also leave marks on the skin. The same is true for the underband of a bra (the portion that extends around the wearer's back) and a stretchable waistband (e.g., for briefs, panties, shorts, or trousers / tights).

[0003] According to a first aspect of the present invention, there is provided a seamless circular woven fabric comprising an elastic yarn, the fabric having a continuous circular weave throughout its length, the circular woven fabric further comprising a cured cushioning filler within and bonded to the circular woven fabric.

[0004] Seamless circular knitted fabrics in the context of the present invention are understood to be seamless tubular fabrics. This is different from joining two pieces of fabric or two edges of the same fabric together to produce a tubular fabric, which will not be seamless due to the joints.

[0005] A fabric having a continuous circular weave running through its length refers to a circular weave pattern that flows continuously over the entire length of the fabric. Depending on the desired application of the fabric, the fabric can be cut into any size to form a circular weave fabric of discrete lengths. Therefore, the user is not limited by the preset length of the tubular fabric that a circular weave machine (e.g., a circular weave sock machine) usually produces. In addition, such typical circular weave machines tend to release a completed single piece of fabric (e.g., the heel and toe of a sock have been woven) at a preset length, so that a single piece of fabric is not considered to have a continuous circular weave running through its length.

[0006] At the same time, seamless circular woven fabrics with cured cushioning fillers provide additional comfort to circular woven fabrics that can be used as wearable garments or accessories or as part of wearable garments or accessories. Cured cushioning fillers within and bonded to a continuous fabric means that the filler is integral with the fabric and therefore provides solid and consistent comfort across the entire length of the fabric. Specifically, the filler is added during the manufacturing process of the circular woven fabric, which is why the filler is present in the continuous length of the circular woven fabric and bonded to it (as opposed to after it is added to the fabric as a separate component). "Cured" cushioning fillers are understood to mean that they are made of a material that was previously in a non-cured (e.g., soft or liquid) state before it cured. As explained in more detail later, this means that the cushioning filler can be added to a circular woven fabric and cured during the weaving process.

[0007] Preferably, the cured cushioning filler is a thermoplastic or thermosetting polymer. Optionally, the cured cushioning filler is a two-component silicone gel.

[0008] Any such arrangement allows the cushioning filler to be in a pre-cured state during the manufacture of the circular woven fabric, which allows the cushioning filler to flow into and fill the hollow cavities of the circular woven fabric as the circular woven fabric is manufactured. It also permits the shape of the fabric (with the pre-cured cushioning filler therein) to be molded into a specific shape, as described in more detail later.

[0009] The seamless circular woven fabric may have cut ends to define discrete lengths of circular woven fabric.

[0010] By fabric with cut ends, it is understood that the fabric as a whole is cut, i.e., the yarns passing through the circumference of the fabric are cut, so as to form discrete lengths of continuous circular woven fabric which may be any desired length. This is in contrast to a single piece of fabric which is released from a machine by cutting the yarn fed into the machine. Such a single piece of fabric will be finished woven by the machine at a preset length before being released, so that the single piece of fabric is not considered to have cut ends.

[0011] Optionally, the seamless circular woven fabric has more than one filled portion filled with a cured cushioning filler, wherein each filled portion is separated by an unfilled portion where no cured cushioning filler is present.

[0012] Such arrangement of adjacent filled and unfilled portions of the circular woven fabric allows for easy cutting of the continuous length of circular woven fabric at the unfilled portion to form discrete lengths of fabric. In addition, such cutting will result in discrete lengths of fabric having unfilled ends, which makes it easier to attach the circular woven fabric to another fabric or garment.

[0013] Preferably, the seamless circular woven fabric may have a minimum width of 2 mm, optionally 6 mm, optionally 8 mm. The seamless circular woven fabric may have a maximum width of 20 mm, optionally 30 mm, optionally 50 mm.

[0014] Such minimum widths permit the circular knit fabric to be suitable for use as ear loops (eg, 2 mm minimum) or bra shoulder straps (eg, 6 mm or 8 mm minimum).

[0015] According to a second aspect of the invention there is provided a brassiere comprising a main body portion for positioning about the torso of a wearer and a shoulder strap secured to the main body portion at each end, the shoulder strap being manufactured from a seamless circular knit fabric as defined above.

[0016] According to a third aspect of the present invention there is provided a brassiere comprising a lower band portion for positioning about the torso of a wearer, the lower band portion being manufactured from a seamless circular knit fabric as defined above.

[0017] According to a fourth aspect of the present invention there is provided a lower body garment comprising a stretchable waistband for positioning about the waist of a wearer and a lower body portion extending from the waistband, the waistband being manufactured from a seamless circular knit fabric as defined above.

[0018] It should be understood that the lower body portion may extend from the waistband downwardly to the entire length of the wearer's legs (e.g., trousers or leggings) or to only a portion of the length of the wearer's legs (e.g., shorts, boxer shorts, skirts, capri pants or leggings) or to only the wearer's hips (e.g., underwear, briefs).

[0019] According to a fifth aspect of the invention there is provided a mask comprising a face covering portion for positioning over the nose and mouth of a wearer and a head strap secured to the face covering portion at each end, the head strap being manufactured from a seamless circular woven fabric as defined above.

[0020] It should be understood that a "head strap" may be a strap that goes all the way around the wearer's head or a strap that may go around the wearer's ears (ie, two ear loops).

[0021] Using a seamless circular woven fabric as described above as a bra shoulder strap, bra underband, waistband or mask head strap provides optimal comfort to the wearer firstly because there are no joins in the straps / bands that could irritate or dig into the wearer's skin, and secondly because the cushioning padding provides additional softness and comfort to the wearer.

[0022] According to a sixth aspect of the present invention, there is provided a method of forming a seamless circular woven fabric, the method comprising:

[0023] Feeding the elastic yarn into the circular knitting machine head,

[0024] The yarn is woven by bending the yarn into loops and intermeshing the yarn loops in a seamless manner in a horizontal direction to produce a continuous length of circular woven fabric,

[0025] A curable cushioning filler in a pre-cured state is injected into the interior of the circular knit fabric while the fabric is being knitted.

[0026] The advantages set out above in relation to the features of the first aspect of the invention apply mutatis mutandis to the fourth aspect of the invention.

[0027] It should be understood that injecting the curable cushioning filler in a pre-cured state into the interior of the circular woven fabric while the fabric is being woven means injecting the pre-cured filler into the hollow cavity formed by the circular woven fabric.

[0028] Preferably, the step of injecting the curable cushioning filler comprises injecting a thermoplastic or thermosetting polymer.

[0029] Optionally, the step of injecting a curable cushioning filler comprises injecting a two-component silicone gel.

[0030] In one embodiment, the method includes curing the cushioning filler while the continuous length of round woven fabric is being manufactured.

[0031] By curing the cushioning filler as the continuous length of circular woven fabric is being manufactured, the cured cushioning filler is formed during the same weaving process as the circular woven fabric is formed, thereby reducing the required processing steps. In addition, the curing step produces a cured cushioning filler that forms part of the circular woven fabric (i.e., is bonded to the circular woven fabric), thereby providing continuous and consistent cushioning over the entire length of the circular woven fabric.

[0032] Optionally, the method includes sequentially filling and de-filling the circular woven fabric with the curable cushioning filler in a pre-cured state to form adjacent filled and unfilled portions of the circular woven fabric.

[0033] The method may include passing a continuous length of circular woven fabric having curable cushioning fill through an adjustment mechanism to adjust the shape of the fabric.

[0034] Such steps utilize the moldable properties of the pre-cured cushioning fill to produce a circular woven fabric having a desired shape.

[0035] The method may include feeding yarn from a yarn platform upwardly toward a circular knitting machine head and producing a continuous length of circular knitted fabric in a space created between the circular knitting head and the yarn platform.

[0036] Such an arrangement provides space for circular knitted fabrics to be produced in a continuous manner without limiting the length of the fabric produced. In addition, creating space between the yarn platform and the circular knitting machine head allows additional processing steps to be easily performed during the knitting process because such additional mechanisms (e.g., adjustment mechanisms) can operate in this space between the yarn platform and the circular knitting machine head. In addition to the foregoing, it also allows the injection of pre-cured cushioning filler to occur directly at the machine head without being hindered by other parts of the machine. This is important to prevent premature curing of the cushioning filler, which may otherwise occur if the cushioning filler travels a longer distance to the machine head.

[0037] The method may include pulling a continuous length of circular woven fabric in the direction in which the circular woven fabric is being produced.

[0038] Such a pulling step (eg, performed by a removal mechanism) helps specify the needles per inch (CPI) or fabric.

[0039] Preferably, the method further comprises cutting the continuous length of circular woven fabric into discrete lengths of circular woven fabric.

[0040] Cutting the continuous length of circular woven fabric allows for the creation of discrete lengths of continuous circular woven fabric that can be any desired length.

[0041] The method may comprise producing a continuous length of circular woven fabric having a minimum width of 2 mm, optionally 6 mm, optionally 8 mm. The method may comprise producing a continuous length of circular woven fabric having a maximum width of 20 mm, optionally 30 mm, optionally 50 mm.

[0042] According to a seventh aspect of the present invention, there is provided a seamless circular woven fabric forming machine assembly comprising:

[0043] a circular knitting machine head configured to bend the elastic yarn into loops and to cause the yarn loops to intermesh horizontally in a seamless manner to produce a continuous length of circular knitted fabric,

[0044] a yarn feeder configured to feed yarn into the circular knitting machine head,

[0045] An injector is configured to inject a curable cushioning filler in a pre-cured state into the interior of the circular knitted fabric while the circular knitted fabric is being knitted.

[0046] The advantages set out above in connection with the features of the first and fourth aspects of the invention apply mutatis mutandis to the fifth aspect of the invention.

[0047] The syringe may be configured to inject thermoplastic or thermosetting polymers.

[0048] The syringe may be configured to inject a two-component silicone gel.

[0049] Optionally, the injector is configured to sequentially fill and stop filling the circular braided fabric with the curable cushioning filler in a pre-cured state to form adjacent filled and unfilled portions of the circular braided fabric.

[0050] Optionally, the machine assembly includes a curing mechanism configured to apply a curing action to the continuous circular woven fabric to effect curing of the pre-cured cushioning filler.

[0051] Preferably, the machine assembly includes an adjustment mechanism configured to receive a continuous circular woven fabric having pre-cured cushioning fill and configured to adjust the shape of the fabric as the fabric passes through the adjustment mechanism.

[0052] The machine assembly may include a yarn platform from which yarn is fed upwardly toward a circular knitting machine head, wherein a continuous circular knitted fabric is produced in a space created between the circular knitting head and the yarn platform.

[0053] The machine assembly may include a take-up mechanism configured to pull the continuous length of circular woven fabric in the direction in which the circular woven fabric is being produced.

[0054] Optionally, the machine assembly includes a cutting mechanism configured to cut the continuous length of circular woven fabric into discrete lengths of fabric.

[0055] The circular knitting machine head may be configured to produce a continuous length of circular knitted fabric having a minimum width of 2 mm, optionally 6 mm, optionally 8 mm.

[0056] The circular knitting machine head may be configured to produce a continuous length of circular knitted fabric having a maximum width of 20 mm, optionally 30 mm, optionally 50 mm.

[0057] Preferred embodiments of the present invention will now be described by way of non-limiting examples with reference to the accompanying drawings, in which:

[0058] Figure 1a A seamless circular woven fabric according to a first embodiment of the present invention is shown;

[0059] Figure 1b A seamless circular woven fabric according to a second embodiment of the present invention is shown;

[0060] Figure 2a and Figure 2b A seamless circular woven fabric forming machine assembly according to a third embodiment of the present invention is shown;

[0061] Figure 3a Shown from Figure 2a and Figure 2b a needle bed of a machine head of the machine assembly shown;

[0062] Figure 3b Shows Figure 3a The operating direction of the needle bed is shown;

[0063] Figure 4 Shows Figure 2a and Figure 2b the injector portion of the machine assembly as shown; and

[0064] Figure 5 Shows Figure 2a and Figure 2b The conditioning and curing portion of the machine assembly is shown.

[0065] A seamless circular (or also referred to as tubular) woven fabric according to one embodiment of the present invention is Figure 1a and Figure 1b It is shown in FIG. 1 and is denoted by reference numeral 10 .

[0066] Due to the inclusion of elastic yarns, circular knit fabric 10 has a degree of stretch.Circular knit fabric 10 has a continuous circular weave throughout its length, which will be discussed in more detail below.

[0067] The circular woven fabric 10 further includes a cured cushion filler 12 inside the circular woven fabric 10. That is, the cured cushion filler 12 fills the hollow cavity 14 of the circular woven fabric 10. The cured cushion filler 12 is bonded to the circular woven fabric 10.

[0068] In the illustrated embodiment, the cured cushioning filler is a thermoplastic elastomer (TPE) and more specifically may be a thermoplastic polyurethane (TPU).

[0069] In other embodiments, the cured cushioning filler 12 may be replaced by any suitable thermoplastic or thermosetting polymer. The cured cushioning may be a two-component silicone gel. The silicone gel may be a silicone gel known as RTV 2K GEL TP 3841 sold by GE Bayer Silicones GmbH & Co. KG. TMOr a silicone gel of the type "SILOPREN" gel TP 3904. The cured cushioning filler may alternatively be a curable foam or a polymer gel. The cured cushioning filler may alternatively be a bio-based polymer, a biodegradable synthetic polymer or a naturally occurring biodegradable / non-degradable polymer.

[0070] The circular woven fabric 10 has a cut end 16 that defines discrete lengths of circular woven fabric. The circular woven fabric 10 leaves the weaving machine as a continuous length of circular woven fabric 10 that can then be cut into desired lengths. This is in contrast to finishing the circular woven fabric as a single piece of fabric of a preset length.

[0071] In this embodiment, the cured cushion filler 12 fills the length of the round woven fabric 10 in a continuous manner, so that even when the round woven fabric is cut, the cured cushion filler 12 fills right up to the cut end 16 .

[0072] In the embodiment shown, the width of the circular knitted fabric 10 is about 8 mm. This width can alternatively be as narrow as 2 mm (e.g., ear loops), or as wide as 50 mm (e.g., waistbands). The continuous length of circular knitted fabric 10 produced can vary, but can be at least 40 mm. The following production table indicates exemplary widths of circular knitted fabrics 10 and the expected end uses of fabrics having such widths. The table also summarizes examples of hourly production and speeds of circular knitting machines that can be used (which will be discussed in more detail later).

[0073]

[0074] Production Table 1

[0075] Finished circular woven fabric widths can have the following tolerances:

[0076] ο2mm–6mm accurate

[0077] ο8mm to 18mm: + / -0.5mm

[0078] ο20mm to 30mm: + / -1mm

[0079] The circular knit fabric can be formed from a single elastic yarn. The elastic yarn can be nylon. For example, the elastic yarn can be 2 / 78 / 24 / 0 nylon 66 ("2 / 78 / 24 / 0" is a common way to indicate the properties of a yarn, i.e., 2-ply, 78 denier, 24 filaments, 0 twist per meter (TPM)).

[0080] A circular knitted fabric may be formed from more than one yarn. Two or all of the yarns may be the same type of yarn, or they may be different yarns. The yarns may have different properties. For example, the yarn may be any single covered yarn.

[0081] Figure 1b A circular woven fabric 10' according to a second embodiment of the invention is shown. The circular woven fabric 10' of the second embodiment shares the same features as the circular woven fabric 10 of the first embodiment, and similar features are indicated by the same reference numerals.

[0082] like Figure 1b As shown, the circular woven fabric 10' in this embodiment includes a first filling portion 18a and a second filling portion 18b, which are filled with a solidified cushioning filler 12. The first filling portion 18a and the second filling portion 18b are separated by an unfilled portion 20, which does not contain any solidified cushioning filler 12.

[0083] although Figure 1b Only two filled portions 18 a , 18 b are shown in FIG. 1 , but it should be understood that there may be any number of filled portions 18 a , 18 b separated by unfilled portions 20 .

[0084] The unfilled portion 20 is significantly shorter in length than the filled portions 18a, 18b. In other embodiments, the lengths of the filled portions 18a, 18b and the unfilled portion 20 may be similar or identical to one another. In further embodiments, the length of each portion 18a, 18b, 20 may be different (i.e., the first filled portion 18a may have a different length than the second filled portion 18b).

[0085] Furthermore, each of the first filling portion 18 a and the second filling portion 18 b may be filled with a different type of solidified buffer filler 12 .

[0086] Unfilled portion 20 presents sections that can be easily cut (ie, at line 22) to form discrete lengths of circular woven fabric 10', each of which has an unfilled cut end.

[0087] Seamless circular woven fabric forming machine components in Figures 2a to 5 1 and indicated by reference numeral 100 .

[0088] The machine assembly 100 has a circular knitting machine head 102 secured to a knitting head platform 104. The machine assembly 100 also includes a yarn feeder 106 configured to feed yarn 107 into the circular knitting head machine 102.

[0089] The machine assembly 100 further comprises a yarn platform 108 from which the yarn 107 is supplied. Specifically, the yarn platform 108 comprises a spool holder 110 (in this example in the form of a hook 110) on which a yarn spool 112 is positioned when in use. In the example shown, there are four hooks 110 and therefore four yarn spools 112 are positioned on the yarn platform 108. The yarn spools 112 stand upright relative to the yarn platform 108. It can be seen that the yarn hooks 110 are positioned around the center of the yarn platform 108.

[0090] The knitting head platform 104 and the yarn platform 108 are spaced apart from each other such that a gap 114 is created between the circular knitting machine head 102 and the yarn platform 108. Furthermore, the knitting head platform 104 is positioned higher than the yarn platform 108. In other words, there is a space 114 between where the yarn 107 is being supplied and where the yarn 107 is being fed into the machine, and the yarn 107 is fed to the feeder 106 in an upward manner.

[0091] In the illustrated embodiment, the braiding head platform 104 is positioned directly above the yarn platform 108. In addition, the braiding head platform 104 and the yarn platform 108 are aligned centrally with each other. Both platforms 108, 104 are circular platforms that share a central axis C. In other embodiments, the platforms 108, 104 may take any shape and / or may not be in line with each other.

[0092] The space 114 (ie, the distance between the yarn platform 108 and the knitting head platform 104) may be approximately 40 cm.

[0093] The machine assembly 100 includes support members 116 that secure the platforms 104, 108 to each other and spatially locate them relative to each other. In the illustrated embodiment, there are four support members 116 equally spaced about the center of each platform 104, 108. The support members 116 may take any suitable form.

[0094] The machine assembly 100 includes a yarn guide 118 that guides the yarn 107 from the yarn platform 108 toward the yarn feeder 106. The yarn guide 116 helps maintain a desired tension in the yarn 107.

[0095] In the illustrated embodiment, there are four yarn guides 118 secured to the knitting head platform 104. Each yarn guide 116 is equally spaced from one another around the center of the knitting head platform 104. Each yarn guide 118 is positioned in line with the hook 110 and receives yarn 107 from a yarn spool 112 on the hook 110 directly below the respective yarn guide 118. There is a single yarn feeder 106 and the yarn guides 118 feed the yarn 107 into the single yarn feeder 106.

[0096] In the illustrated embodiment, the yarn 107 from two of the yarn spools 112 is fed directly from the yarn spools 112 through the corresponding yarn guides 118 to the yarn feeder 106. At the same time, the yarn 107 from the remaining two of the yarn spools 112 is fed from the yarn spools 112 through the corresponding yarn guides 118, and then fed to the yarn feeder 106 via the adjacent yarn guides 118. Figure 2b This is more clearly shown in FIG. 1 , where the direct yarn paths YD from two of the yarn spools 112a are shown and the indirect yarn paths YI from the remaining two yarn spools 112b are shown.

[0097] Steering Figure 3a and Figure 3b , the circular knitting machine head 102 is configured to bend the yarn 107 into loops 120 and to intermesh the yarn loops 120 in a seamless manner in a horizontal direction D to produce a continuous length of circular knitted fabric.

[0098] The circular knitting machine head 102 includes a needle bed 122 that holds a plurality of needles 124 (e.g., Figure 3a 124 is a needle bed 122, which is a plurality of needles 124 arranged in a circle. The needles 124 are arranged in a circle with a hook 125 at one end. The needles 124 are held at a specific distance relative to each other, which is determined by the needle bed 122. The needle bed 122 also guides the needles 124 during the knitting process. To achieve this control, the needle bed 122 includes a needle slot 126 (also called a needle track), in which the corresponding needle 124 is located, and the slot 126 is used to guide each needle 124 during knitting.

[0099] As in Figure 3b As can be seen in the figure, the needles 124 move up and down in sequence in a horizontal (when looking directly at the machine head 102) direction of travel D, with each needle 124 moving upward to capture (via its hook 125) a yarn 107 fed into the circular knitting machine head 102, and then pulling this yarn 107 downward and through a yarn loop 120 that has been created in the fabric.

[0100] The number of slots 126 in the circular knitting machine head 102 determines the knitting gauge. The gauge can be 12 to 16.

[0101] The diameter of the circular knitting machine head 102 affects the width of the produced circular knitted fabric 10. The type of yarn 107 used is also a factor in the final width of the fabric 10.

[0102] Steering Figure 4 The machine assembly 100 further includes an injector 128 configured to inject a curable cushioning filler 129 in a pre-cured state into the interior of the circular woven fabric 10 while the circular woven fabric 10 is being woven.

[0103] The injector 128 includes an extrusion machine 130 and a nozzle 132. In this embodiment, the extrusion machine 130 extrude the TPE, and the nozzle 132 is an inkjet type nozzle that inserts the TPE in a pre-cured state into the circular knitted fabric 10.

[0104] As can be seen, the nozzle 132 is directed towards the hollow cavity 14 of the circular woven fabric 10 at the end where the fabric 10 is being formed.

[0105] In some embodiments, the injector 128 may be configured to sequentially fill and stop filling the circular woven fabric with the curable cushion filler 129 in a pre-cured state to form adjacent filled and unfilled portions of the circular woven fabric. Figure 1b Such filled and unfilled portions are described in more detail.

[0106] Steering Figure 5 , the machine assembly 100 further includes an adjustment mechanism 134. The adjustment mechanism 134 shown in this embodiment is a conical cavity 136 that receives the continuous round woven fabric 10 with pre-cured cushioning filler inside at its wider end 138. The fabric 10 passes through the narrower end 140 of the conical cavity 136, which molds the shape of the pre-cured cushioning filler and thus the shape of the round woven fabric 10. For example, the conical cavity 136 can be a rectangular shape at its narrow end 140, and thus squeezes the fabric 10 into a flat, thin shape. Other shapes that the adjustment mechanism 134 can produce include ovals, circles, and rectangles.

[0107] Also like Figure 5 As shown, the machine assembly 100 further includes a curing mechanism 142. The curing mechanism 142 is located directly below the adjusting mechanism 134 so as to cure the cushioning filler after it is molded into a desired shape by the adjusting mechanism 142, thereby setting the desired shape of the circular knitted fabric 10.

[0108] In this embodiment, the curing mechanism 142 is an air cooler 144 that blows cold air through the circular woven fabric 10 to cure the TPE cushioning filler. In other embodiments, curing can be accomplished by cold or hot air, water, or by adding another material that initiates curing. In addition, the curing mechanism 142 can be a combination of such curing methods.

[0109] Although not shown in this embodiment, the machine assembly 100 may also include a removal mechanism configured to pull the circular woven fabric 10 downward in the direction of travel (i.e., in the direction in which the circular woven fabric is being produced). The machine assembly 100 may also include a cutting mechanism to cut the continuous length of circular woven fabric into desired discrete lengths.

[0110] Exemplary raw materials and machine settings for producing the circular woven fabric 10 of the present invention are summarized below.

[0111] Example 1.

[0112] Intended Use: Bra straps

[0113] Raw material information:

[0114]

[0115] Raw materials 1

[0116] Machine Settings

[0117] Loom speed: 700RPM

[0118] Loom weft: 3.6

[0119] Unfinished width: 11mm

[0120] Number of tapes: 10

[0121] Unfinished stretch: 90 at 3.5Kg Finished weft (needle count): 33

[0122] Finished weight (1M): 5.1g

[0123] Machine head diameter: 17mm

[0124] Number of needles: 34

[0125] Needle specification: 16

[0126] Needle size: 16

Claims

1. A seamless circular woven fabric comprising elastic yarn, said fabric having a continuous circular weave throughout its length, said circular woven fabric further comprising a cured cushioning filler within and bonded to said circular woven fabric.

2. The seamless circular woven fabric of claim 1, wherein the cured cushioning filler is a thermoplastic or thermosetting polymer.

3. A seamless circular woven fabric according to claim 1 or claim 2, wherein the cured cushioning filler is a two-component silicone gel.

4. A seamless circular woven fabric according to any preceding claim having cut ends to define discrete lengths of circular woven fabric.

5. A seamless circular woven fabric according to any preceding claim, having more than one filled portion filled with the cured cushioning filler, wherein each filled portion is separated by an unfilled portion, the cured cushioning filler being absent from the unfilled portion.

6. A seamless circular woven fabric according to any preceding claim having a minimum width of 2mm, optionally 6mm, optionally 8mm.

7. A seamless circular woven fabric according to any preceding claim having a maximum width of 20mm, optionally 30mm, optionally 50mm.

8. A bra comprising a main body portion for positioning about the torso of a wearer and shoulder straps secured at each end to the main body portion, the shoulder straps being manufactured from a seamless circular knit fabric according to any one of claims 1 to 7.

9. A brassiere comprising a lower belt portion for positioning about a wearer's torso, the lower belt portion being manufactured from a seamless circular knit fabric according to any one of claims 1 to 7.

10. A lower body garment comprising a stretchable waistband for positioning about a wearer's waist and a lower body portion extending from the waistband, the waistband being made from a seamless circular knit fabric according to any one of claims 1 to 7.

11. A face mask comprising a face covering portion for positioning over the nose and mouth of a wearer and a head strap secured at each end to the face covering portion, the head strap being manufactured from a seamless circular knit fabric according to any one of claims 1 to 7.

12. A method of forming a seamless circular woven fabric, the method comprising: Feeding the elastic yarn into the circular knitting machine head, Weaving the yarn by bending the yarn into loops and intermeshing the yarn loops in a seamless manner in a horizontal direction to produce a continuous length of circular woven fabric, A curable cushioning filler in a pre-cured state is injected into the interior of the circular knit fabric while the fabric is being knitted.

13. The method of claim 12, wherein the step of injecting a curable cushioning filler comprises injecting a thermoplastic or thermosetting polymer.

14. A method according to claim 12 or claim 13, wherein the step of injecting a curable cushioning filler comprises injecting a two-component silicone gel.

15. A method according to any one of claims 12 to 14, comprising curing the cushioning filler whilst the continuous length of round woven fabric is being produced.

16. A method according to any one of claims 12 to 15, comprising sequentially filling and stopping filling the circular woven fabric with the curable cushioning filler in a pre-cured state to form adjacent filled and unfilled portions of the circular woven fabric.

17. A method according to any one of claims 12 to 16, comprising passing the continuous length of circular woven fabric with curable cushioning fill through an adjustment mechanism to adjust the shape of the fabric.

18. A method according to any one of claims 12 to 16, comprising feeding the yarn upwardly towards the circular knitting machine head from a yarn platform and producing the continuous length of circular knitted fabric in a space created between the circular knitting head and the yarn platform.

19. A method according to any one of claims 12 to 18, comprising pulling the continuous length of circular woven fabric in the direction in which the circular woven fabric is being produced.

20. The method of any one of claims 12 to 19, further comprising cutting the continuous length of circular woven fabric into discrete lengths of circular woven fabric.

21. A method according to any one of claims 12 to 20 comprising producing a continuous length of circular woven fabric having a minimum width of 2mm, optionally 6mm, optionally 8mm.

22. A method according to any one of claims 12 to 21 comprising producing a continuous length of circular woven fabric having a maximum width of 20mm, optionally 30mm, optionally 50mm.

23. A seamless circular knitted fabric forming machine assembly comprising: a circular knitting machine head configured to bend the elastic yarn into loops and to cause the yarn loops to intermesh horizontally in a seamless manner to produce a continuous length of circular knitted fabric, a yarn feeder configured to feed yarn into the circular knitting machine head, An injector is configured to inject a curable cushioning filler in a pre-cured state into the interior of the circular knitted fabric while the circular knitted fabric is being knitted.

24. The seamless circular woven fabric forming machine assembly of claim 23, wherein the injector is configured to inject a thermoplastic or thermosetting polymer.

25. A seamless circular knitted textile forming machine assembly according to claim 23 or 24, wherein the injector is configured to inject a two-component silicone gel.

26. A seamless circular woven fabric forming machine assembly according to any one of claims 23 to 25, wherein the injector is configured to sequentially fill and stop filling the circular woven fabric using the curable buffer filler in a pre-cured state to form adjacent filled and unfilled portions of the circular woven fabric.

27. The seamless circular woven fabric forming machine assembly of any one of claims 23 to 26, further comprising a curing mechanism configured to apply a curing action to the continuous circular woven fabric to effect curing of the pre-cured cushioning filler.

28. A seamless circular woven fabric forming machine assembly according to any one of claims 23 to 27, further comprising an adjustment mechanism configured to receive the continuous circular woven fabric with pre-cured cushioning filler and configured to adjust the shape of the fabric as the fabric passes through the adjustment mechanism.

29. A seamless circular woven fabric forming machine assembly according to any one of claims 23 to 28, comprising a yarn platform from which yarn is fed upwardly toward the circular woven machine head, wherein the continuous circular woven fabric is produced in a space created between the circular woven head and the yarn platform.

30. The seamless circular woven fabric forming machine assembly of any one of claims 23 to 29, further comprising a removal mechanism configured to pull the continuous length of circular woven fabric in the direction in which the circular woven fabric is being produced.

31. The seamless circular woven fabric forming machine assembly of any one of claims 23 to 30, further comprising a cutting mechanism configured to cut the continuous length of circular woven fabric into discrete lengths of fabric.

32. A seamless circular woven fabric machine assembly according to any one of claims 23 to 31 , wherein the circular woven fabric machine head is configured to produce a continuous length of circular woven fabric having a minimum width of 2 mm, optionally 6 mm, optionally 8 mm.

33. A seamless circular woven fabric forming machine assembly according to any one of claims 23 to 32, wherein the circular woven fabric machine head is configured to produce a continuous length of circular woven fabric having a maximum width of 20mm, optionally 30mm, optionally 50mm.

Images