Method of manufacturing a compression garment and compression garment

Abstract

A method of manufacturing a compression garment comprising a flat-knitted double-layer fabric comprising at least one elastic yarn, comprising: a) knitting stitches on a row of needles of a front main needle bed and on a row of needles of a back main needle bed, to form a pattern row of the double-layer fabric; b) transferring at least one stitch to a needle that is adjacent to the respective needle onto which the at least one stitch is knitted, such that at least one empty needle and / or at least one needle holding more than one stitch is present within the respective row of needles; and c) knitting a further pattern row by knitting further stitches on the row of needles of the front main needle bed and of the back main needle bed, the further stitches being at least partly intermeshed with the stitches knitted under step a).

Description

METHOD OF MANUFACTURING A COMPRESSION GARMENT AND COMPRESSION GARMENTField of the invention

[0001] The present disclosure relates to a method of manufacturing a compression garment comprising a flat-knitted double-layer fabric comprising at least one elastic yarn. The present disclosure further relates to a flat-knitted fabric for a compression garment and to a compression garment.Background art

[0002] Compression garments are used for the avoidance or treatment of edemas, varicose veins, venous insufficiency, as well as after certain surgical procedures and (burn) injuries. Such compression garments may be, but are not limited to, compression stockings, compression gloves, compression leggings and compression arm sleeves. These garments are primarily produced as knitted fabrics on a flat or circular knitting machine, using at least one elasticated yarn or thread to provide good elastic characteristics.

[0003] Prerequisite for a successful compression therapy is a proper fit of the garment. Garments which fit poorly on the affected body part will reduce adherence of the patient, i.e. reduce the amount of time in which the patient is wearing the garment, and will also not produce the desired compression level in all areas of the affected body part. In particular for strongly affected body parts, body parts which can have a large diameter and / or an uneven surface morphology, it can be difficult to ensure a good, long-lasting fit of the garment. For such body parts, it has, thus, become routine to manufacture customized garments which are specifically adapted to the body part by manufacturing the garments based on measurements of the respective body part.

[0004] In order to give the garment a shape matching a particular body part, the flat-lying knitted fabric is knitted with more stitches per course in areas in which the body part has a larger circumference than in areas with a smaller circumference. Hereto, stitches are commonly added or removed at the edges of each subsequent course in the flat knitted fabric. After making the flat knitted fabric, the longitudinal edges thereof are sewn together to provide the garment with the desired three-dimensional shape. However, the adding and removing stitches at the ends of courses limits the extend with which the compression article can imitate the anatomy of the body part, commonly resulting in an imperfect fit.

[0005] The object of the invention is therefore to provide a method of manufacturing compression garments with an improved fit.Summary of the invention

[0006] According to a first aspect of the present disclosure, a solution is provided through a method of manufacturing a compression garment comprising a flat-knitted double-layer fabric comprising at least one elastic yarn according to claim 1 . In particular, the method comprises the steps of: a) knitting stitches on a row of needles of a front main needle bed and knitting stitches on a row of needles of a back main needle bed, to form a pattern row of the double-layer fabric,wherein the pattern row comprises at least a first knitting row for forming a first layer of the doublelayer fabric and a second knitting row for forming a second layer of the double-layer fabric; b) transferring at least one stitch from within the pattern row, knitted on the row of needles of the front main needle bed and / or transferring at least one stitch from within the pattern row, knitted on the row of needles of the back main needle bed to a needle that is adjacent to the respective needle onto which the at least one stitch is knitted, such that at least one empty needle and / or at least one needle holding more than on stitch is present within the respective row of needles of the front main needle bed or row of needles of the back main needle bed; and c) knitting a further pattern row by knitting further stitches on the row of needles of the front main needle bed and onto the row of needles of the back main needle bed, the further stitches respectively being at least partly intermeshed with the stitches knitted under step a), wherein the further pattern row comprises a further first knitting row to form the first layer of the double-layer fabric and a further second knitting row to form the second layer of the double-layer fabric, with the further stitches comprising a stitch knitted on a respective one of the at least one empty needle and / or at least one needle holding more than one stitch of step b).Further stitches are stitches in the further pattern row, i.e. stitches that are in a row with a different longitudinal location along a wale within the finished fabric from the stitches that are knitted under step a).This particular method of knitting allows for stitches being added and / or removed in the exact location along a course of stiches that corresponds to a change in shape along the circumference of the body part for which the compression garment is intended, i.e. at locations along the course that are not necessarily corresponding to a first or last stitch of the course. The steps a, b and c may be repeated several times, to result in shaped fabric, wherein wales of the fabric are started or terminated at a circumferential position of a body part where a bulge, dimple or other large or small overall shape variation is present. Thus, not only can the shape be adapted to account for joints, but the fabric can also be adjusted for local, patient specific, shape variations, such as for example caused by scars or fatty deposits. This allows for a perfected fit to be achieved for a finished compression garment, wherein compression is evenly distributed along the circumference of a body part for which the garment is made, as the wales of the fabric in the finished compression garment may all run substantially parallel to this central axis. A three-dimensional knitted article using this method therefore has improved effectiveness in addition to an improved fit. Depending on the particular pattern, under step a, the first knitting row may be knitted on the front main needle bed and the second knitting row may be knitted on the back main needle bed, or one or both of the first and second knitting rows may be knitted on both the front and the back needle beds.

[0007] The double-layer fabric may be knitted using a relatively simple double jersey knitting pattern, or according to a more complex knitting pattern such as for example known from W02020207600A1 .

[0008] The stitch knitted on the at least one empty needle and / or knitted on the at least one needle holding more than one stitch under step c) may be part of one of the further first knitting row or further second knitting row. This stitch may thus form part of the first or part of the second layer of the double-layer fabric and be visible from the outside of the finished fabric. While in principle different types of needles can be used for knitting in the context of the claimed method, the method allows for the use of latch needles. Use of a more complex slider needle is possible but not required. The main needle beds mentioned herein can, thus, knit with latch needles.

[0009] A difference between a number of stitches adjacent to one another in the knitting direction, forming the first layer of the double-layer fabric and a number of stitches adjacent to one another in the knitting direction, forming the second layer of the double-layer fabric within a respective pattern row may be 2 or less. The respective pattern row can be the pattern row or a further pattern row. Having a minimum difference in stitches between the knitting rows forming the first and second layers ensures that the lengths thereof match, such that both layers of the fabric match in size and limits the risk of wrinkling of the layer that is worn on the inside. Furthermore, having the knitting rows of the first and second layers having substantially the same length ensures that the stitches at the longitudinal edges of the fabric line up, preventing any unwanted additional tension occurring at seam(s) that hold the finished product together after sowing.

[0010] The transferring under step b) may be performed on both the row of needles of the front main needle bed and the row of needles of the back main needle bed and in parallel, such that the at least one empty needle and / or the at least one needle holding more than on stitch present within the row of needles of the front main needle bed has a position that corresponds to a position of the at least one empty needle and / or the at least one needle holding more than one stitch present within the row of needles of the back main needle bed. Thus, for example, if the sixth needle on the front main needle bed holds more than one stitch, then the sixth needle on the back main needle bed also holds more than one stitch. The resulting fabric then has the wales of each layer starting and / or terminating in the same positions along the knitting row length, further limiting any additional tension occurring within the fabric that may negatively impact the fit and / or comfort of the finished garment.

[0011] The knitting of the further stitch or stitches under step c) may be performed on a respective one of the front main needle bed and back main needle bed, preferably on the same one of the respective front main needle bed and back main needle bed as the stitches knitting of step a) with which the further stitches intermesh. This can be achieved through transferring the stitches to adjacent needles with the use of slider needles.

[0012] However, a more efficient way of transferring the stitches, having the lowest risk of dropping any stitches and needles colliding, is to have the transferring of the at least one stitch under step b) comprise the transferring of the at least one stitch from a needle within the row of needles of the front main needle bed to a selected needle of an additional back needle bed (back transfer bed) and / or the transferring of the at least one stitch from a needle within the row of needles of the back main needle bed to a selected needle of an additional front needle bed (front transfer bed). Depending on the particular knitting machine used, these additional needle beds could also becapable, and used, for knitting all or a part of a further pattern row. When additional needle beds are use for transferring the stitches, latch needles can be used for knitting and transferring.

[0013] The selected needle of the respective additional front needle bed or additional back needle bed may be moved laterally offset with respect to the needle within the row of the respective front main needle bed or back main needle bed, viewed in a knitting direction, before or after transferring. This may be achieved through movement of the additional needle bed along the knitting direction with respect to the main needle bed ahead of a transfer of stitches between said additional and main needle beds, thereby allowing for the at least one stitch to be transferred in a direction that is perpendicular to the knitting direction of the course and sliding from one needle to the next without deformation of the at least one stitch.

[0014] The transferring of at least one stitch forming a part of a respective one of the first or second layer of the double-layer fabric under step b) and the knitting of the further at least one stitch of the further stitches under step c) that intermesh with the transferred at least one stitch may also be performed in direct succession. The second one of the at least one stitch is transferred after the knitting of a first one of the at least one further stitch, intermeshed with the first stitch of the at least one transferred stitch of step b). This allows at least a part of step b) and step c) to be carried out substantially simultaneously, resulting in relatively fast knitting. For example, the knitting machine used to carry out the method could be set up such that the transfer and knitting of stitches is carried out directly after one another during a single movement of the carriage of the knitting machine, rather than during subsequent passings of the carriage.

[0015] The flat-knitted fabric being a double-layer fabric, means that the first and second layer of fabric of which it is comprised are interconnected to some degree over their surfaces. Hereto, an interconnecting stitch may be provided at least every 10 stitches along the first and second knitting rows, interconnecting the first layer and second layer of the double-layer fabric. However, a higher stitch density of interconnecting stitches is preferred, thus the interconnecting stitches may be provided at least every 6 stitches along the first and second knitting rows, of even at least every 4 stitches, and most preferred at least every second stitch. These interconnecting stitches may be included through the use of an additional yarn or the same yarn as used for knitting of the first or second layer.

[0016] Furthermore, an inlay thread may be laid onto the interconnecting stitches, extending between the front main needle bed and the back main needle bed. Inlay threads are frequently used in compression articles to provide the desired compression on the wearer's body part. By inserting these threads before the stitch transfer in step b. the threads can be fixed in the fabric by the transferred stitches. Depending on the particular pattern that is knitted, the inlay thread is laid onto the feeds of the interconnecting stiches and under the legs and head of a split stitch or under interconnecting stiches of the following row. The inlay thread may be an elastic thread, providing or adding to the compressive properties of the garment. The inlay threads can also be hydrophobic threads or have a hydrophobic coating, to prevent the inlay threads from retaining moisture. It is also common to use inlay threads having an elastic core that is covered by a hydrophobic fiber material.

[0017] The first layer of the fabric may consist of, or comprise, a first yarn, while the second layer of the fabric may consist of, or comprise, a second yarn. The first yarn and the second yarn may have different properties, such as for example the first yarn being hydrophobic and the second yarn being hydrophilic, preferably being a moisture transporting yarn. This results in a fabric that transports moisture from the second layer to the first layer. Further, one or both of the first and second yarns may be an elastic yarn.

[0018] To produce a compression garment with a good fit, the method may comprise a final step of joining longitudinal side edges of the flat-knit fabric, which are formed by respective first and last stitches in each knitting row of stitches, to form the compression garment, and step a) may be preceded by obtaining measurement information from a wearer or obtaining measurement information for a pre-designed compression garment for a body part that is to be supported by the compression garment, with the steps a), b) and c) each being carried out such that an amount of stitches in each respective knitting row correspond to the measurement information and a central axis of the flat-knit fabric after joining coincides with a central longitudinal axis of the body part. The finished compression garment, as a result, has stitches added and removed at locations along the length of each knitting row of stitches that substantially correspond to a local radial difference of said body part with respect to the central longitudinal axis thereof, accounting for any localised bumps, dimples and / or lumps. In particular, the body part for which the compression garment is produced may be a human body part. The compression garment may be a sleeve for an arm or leg, a glove, a sock, a tight or a top.

[0019] To make the tailoring of the knitting pattern and programming of the knitting machine a little easier, the first knitting row and the second knitting row may together be subdivided into a predefined plurality of sections, each section comprising a predetermined amount of stitches from both the first and the second knitting row, and wherein the transferring in step b) comprises the transferring of stitches of one or more sections, such that the at least one empty needle and / or at least one needle holding more than one stitch is present at the start or end of a respective section. The sections are maintained over the length of the fabric, as discrete zones that can be individually narrowed or widened through the addition or removal of stitches at their respective edges. Thus, in the finished fabric, each section has a width corresponding to a part of a knitting row length and a height corresponding to the height of the fabric. Preferably, the transferring in step b) is only performed at the beginning or end of a respective section. Thus no stitches are added or removed at any other position within a respective section, other than at the beginning and end thereof. Through the stitches being added or removed at the edges of each section, the width of each section may vary over the length of the fabric. The added or removed stitches at the edges of a respective section are thus part of the section. The finished fabric thus consists of a series of “strips” in the course-direction of the fabric, each extending over the height of the fabric, which is considered to extend in the wale-direction. Having multiple discrete sections makes the tailoring of the pattern and programming of the knitting machine easier, relative to adding and removing stitches at any and all locations along the rows of stitches.

[0020] A predetermined amount of stitches of the first-layer course in a respective section may be equal to a predetermined amount of stitches of the second-layer course in the respective section, so that the edges of each section, in a thickness direction of the fabric, are perpendicular to the course-direction. Thus the part of a knitting row length in each section may be substantially the same for the knitting row of the first layer and the knitting row of the second layer. In this case, both the inner layer and the outer layer in a section in each respective row thereof may thus comprise the same amount of stitches, and having stitches removed or added in the same positions.

[0021] The rows may be subdivided into at least four sections to sufficiently follow the contours of the body part for which the compression garment is intended and achieve desired improvements in compressive force distribution.

[0022] The method may be adapted for manufacturing a medical compression garment. Such medical compression garment is suitable for use in the treatment or prevention of various diseases or conditions which require treatment or prevention with compression therapy. These diseases and conditions include diseases and conditions treated with garments of Compression Class 1 , Compression Class 2, Compression Class 3 or Compression Class 4. Diseases and conditions treated with garments having Compression Class 1 (CCL 1) can be e.g. selected from the group consisting of tired, heavy, aching legs; minor varices without edema; mild swelling of the feet, ankles and legs; onset of pregnancy-related varices; primary or secondary lymphedema in International Society of Lymphology (ISL) stages l-lll; and lipedema. Diseases and conditions treated with garments having Compression Class 2 (CCL 2) can be e.g. selected from the group consisting of tired, heavy, aching legs; moderate to severe varices with and without edema; moderate to severe pregnancy-related varices with and without edema; moderate edema; chronic venous insufficiency (CVI) C3-C5 according to CEAP; venous edema, skin alterations; healed ulcus cruris; venous ulcers; superficial thrombophlebitis I SVT; diseases and conditions resulting from vein surgery; diseases or conditions resulting from sclerotherapy; post-traumatic edema; post-operative edema; primary or secondary lymphedema in ISL stage II; phlebolymphedema; lipedema. Diseases and conditions treated with garments having Compression Class 3 (CCL 3) can e.g. be selected from the group consisting of severe varices with or without edema; severe edema; chronic venous insufficiency (CVI) C3-C6 according to CEAP; venous edema; skin alterations; healed ulcus cruris; ulcus cruris; venous ulcers; post-thrombotic syndrome (PTS); superficial thrombophlebitis I SVT; conditions or diseases after vein surgery; conditions or diseases after sclerotherapy; primary or secondary lymphedema in ISL stage II; risk of rapid edema rebound; and lipedema. The lymphedema can be e.g. lymphedema with or without shape distortions.

[0023] Classification of the garment into these compression classes can be done according to RAL-GZ 387 parts 1 - 3, which respectively cover medical compression hosiery, medical compression arm sleeves and medical compression hosiery systems for the treatment of ulcus cruris, DIN 58133, covering all medical compression hosiery, or equivalent standards such as the AFNOR IFTH (French standard) or BSI (British Standard). The current RAL standard dates from January 2008, with the current DIN standard being dated July 2008. Preferably, the garment is a compression class 1 , 2, 3, or 4 garment, most preferably a compression class 1 , 2 or 3 garment.From the French standards, particularly NF G 30-102 Part B (compression), NF G 07-002 or ISO 2062 (Yarn test - elongation) and NF G 07-316 - Part B (Yarn test - weight) are applicable. For BSI, either BS 6612:1985 (old standard) or BS 661210:2018+A1 :2022 (new standard) are to be used.

[0024] A second aspect of the disclosure relates to a double-layer fabric for a compression garment in accordance with claim 19 or 20. The double-layer fabric may be manufactured in accordance with manufacturing steps of the first aspect. In particular, the double-layer fabric may be a flat-knitted fabric comprising at least one elastic yarn, a first layer consisting of two or more knitting rows and a second layer consisting of two or more knitting rows, wherein a length of a respective knitting row of the two or more knitting rows of the first layer matches a length of a corresponding knitting row of the two or more knitting rows of the second layer, and wherein the amount of stitches of a respective knitting row is increased or reduced at positions within said knitting row, with respect to a preceding knitting row, such that the fabric comprises wale starting positions and wale end positions that are dispersed along a width and length of the fabric. Thus the resulting fabric may have wale starting positions and wale end positions that are not located at the longitudinal side edges of the fabric, but instead, are located at a position that corresponds to a position of a body part for which the fabric is made where a bulge, dimple or other large or small overall shape variation is present. Thus, not only is the shape of the fabric adapted to account for joints, but the fabric may also contain local adjustments for a patients specific shape variations, such as for example caused by scars or fatty deposits.

[0025] A respective one knitting row of the two or more knitting rows of the first layer and a respective one knitting row of the two or more knitting rows of the second layer may be interconnected via three or more interconnecting stitches, to achieve the interlocking of the first and second layers of the double-layer fabric. Preferably, each knitting row of the two or more knitting rows of the first layer is interconnected with a corresponding knitting row of the two or more knitting rows of the second layer.

[0026] As indicated for the first aspect, the dispersion of wale starting positions and wale end positions along the width may be constant along the length of the fabric, such that the fabric comprises at least four sections in a width direction of the fabric. Thus each knitting row of the fabric may be subdivided into at least four sections, or “strips”, with each section having a length corresponding to the length of the fabric, said lengths being determined in a flat-laid position of the fabric. Each of the wale starting positions and wale end positions within the fabric then corresponds to a first or last stitch of a section. Each section may comprise one or more continuous wales centrally located in the width direction of a respective section and flanked by wales of a shorter length, that have a starting and / or end position in a knitting row that is not the first or last knitting row of the fabric.

[0027] A third aspect of the disclosure relates to a compression garment in accordance with claim 23 or 24. In particular, the compression garment may be manufactured according to the method of the first aspect. Additionally or alternatively, the compression garment may comprise the flat-knitted double-layer fabric according to the second aspect, and a joint in which the longitudinal edges ofthe flat-knit double-layer fabric, which are formed by respective first and last stitches in each knitting row of said fabric, are attached to one another such that the compression garment has a tubular shape.Brief description of the drawings

[0028] The present disclosure is further elucidated with reference to the attached drawings, in which:

[0029] Fig. 1 depicts an exemplary schematic of a commonly used, prior art basic pattern for knitting a flat-lying fabric for a compression garment,

[0030] Fig. 2A depicts an exemplary schematic of a pattern for knitting a flat-lying fabric a compression garment according to an embodiment of the present disclosure,

[0031] Fig. 2B depicts an exemplary schematic of the flat-lying fabric manufactured according to the pattern depicted in Fig. 2A,

[0032] Fig. 3A and B respectively depict a schematic of a pattern for knitting a flat-lying, doublelayer fabric for a compression garment according to an embodiment of the present disclosure, and a section of a corresponding knitting process diagram for a flat-bed knitting machine with four needle beds.

[0033] Fig. 4 depicts an example of a compression garment, made of a flat-knitted double-layer fabric.

[0034] The drawings are for illustrative purposes only, and are not to be construed as limiting the inventive idea, which is defined by the appended claims. Corresponding reference numerals in different figures have been used to indicate identical features.Description of embodiments

[0035] Figure 1 depicts an exemplary schematic of a commonly used basic pattern 100 for knitting a fabric for making a compression garment. Knitted fabric is a fabric that is progressively built-up from row after row of intermeshed yarn loops, also referred to as stitches or meshes. The schematic shows a row of knitting needles 10 of a needle bed, knitting direction 20, and the stitches 30, 31 that are to be knitted. The stitches are arranged in knitting rows 21 , 22, which each extend in the horizontal direction, and wales 41 , 42, 43 and knitted on adjacent knitting needles of the row of needles 10, identified by numbers 1 - 33. The knitting rows 21 , 22 are horizontal, and knitted in the direction indicated by a respective arrow of the knitting direction 20, on the right-hand side of each knitting row. Stitches of a further knitting row 22 are intermeshed with stitches of a preceding knitting row 21 , forming the vertically extending wales 41 , 42, 43. The stitches 30, 31 are thus knitted as a horizontal row of stitches 30, 31 , on adjacent needles of the row of needles 10 as indicated by the pattern. As the pattern is so simple, each knitting row 21 , 22 is equal to a pattern row.

[0036] A wale 41 , 42 commences as soon as an empty needle starts to knit. In the depicted pattern of Fig. 1 , the intermeshed needle loops are produced by the same needle from the row of needles 10 knitting at successive knitting cycles, thus the wales 41 ; 42, 43 are each formed by the stitches in a respective vertical column in the pattern 100.

[0037] To account for body shape variation along the length of a body part, the number of stitches in subsequent knitting rows 21 , 22 may be varied. Hereto, stitches at the beginning and / or end of aknitting row may be added 61 , 62, cast-off 71 and / or held and knitted again in a further knitting row. In the schematic of Fig. 1 , the held stitches result in open area’s 51 , 52, which are the result of holding stitches over a predetermined length of the knitting row 91 , 93 and knitting one or more further knitting rows in between the held stitches before knitting some or all of the held stitches in another further knitting row, thus including a predetermined length of the held knitting row 92, 94 in this further knitting row. This results in, an increased wale length for a wale 41 that was knitted continuously throughout the production of all further knitting rows, compared to an adjacent wale 42, 43 that contains a stitch which was held.

[0038] Through all added and cast off stitches being located at the vertical edges 80; 81 , 82; 83 of the pattern, the wales 41 , 42 consist of stitches that are all knitted on the same needle within the row of needles 10.

[0039] After making the flat knitted fabric, the longitudinal edges, corresponding to the longitudinal edges 80, 81 ; 82, 83 of the pattern, thereof are sewn together to provide the garment with the desired three-dimensional shape. However, the adding and removing stitches at the ends of knitting rows 21 , 22 limits the extend with which the compression article can imitate the anatomy of the body part. In particular, through the adding and removing of stitches at the ends of knitting rows, wales on opposing sides of the finished compressive garment are at an angle with respect to the seam holding the longitudinal edges together, due to wales being initiated or terminated at the longitudinal edges of the fabric, such that the wales are at a completely different angle with respect to a central axis of the body part which is encapsulated by the compressive garment. This causes compression to be distributed unevenly to some extend.

[0040] Figs. 2A and 2B respectively depict an example of a schematic pattern 200 for knitting a flat-lying fabric for a compression garment according to an embodiment of the present disclosure, and a schematic of the resulting flat-lying fabric. The schematics only shows a single layer of the fabric, to aid understanding of the principle, but may be assumed a double-layer fabric as claimed.

[0041] Similar to the pattern 100 of Fig. 1 , the pattern 200 of Fig. 2A consists of a series of pattern rows 22 each defining a horizontal row of stitches that are to be produced by adjacent needles in one needle bed. Furthermore, the pattern also has some wales 41 a, 41 b provided with additional length, by holding selected stitches along a predetermined length 91 , 93 of the horizontal row during the knitting of one or more further rows, and knitting some or all of the selected stitches during the knitting of another further row, such that these stitches form a predetermined length 92, 94 of the later horizontal row of stitches. The stitches knitted in the one or more further rows result in additional length 88 of the wales, which results in a local curve, or bulge 390, with respect to the wale direction in the flat-laying fabric 300, as depicted in Fig. 2B, due to the held stitches along the row length 91 ; 93 being knitted again along length 92; 94, which are identified as horizontal joining lines 391 ; 292 in the fabric 300.

[0042] However, contrary to the pattern 100 of Fig. 1 , shape variation along the knitting direction in the pattern 200 of Fig. 2A is achieved through adding (or removing) stitches 62, 63, 64, 65, 66, 67 at selected stitch positions along the pattern row that are not all at the beginning or end of said pattern row. As a result, the commencement (or end) of wales is not limited to the edges 380, 383of the flat-lying fabric 300, but dispersed along the width of the resulting fabric in between existing wales, such that the stitches of a wale 44, 45, 46; 41 a, 41 b of the fabric may be knitted on two or more needles of the row of knitting needles 10. The starting or terminating of a wale within a pattern row results in localized increases, or bulges 362, 363, 364, 365, 367, with respect to the knitting direction of the flat-laying fabric, as depicted in Fig. 2B. Thus, the pattern 200 may be tailored to a particular person’s shape, with the wales of the resulting fabric starting or terminating at a location corresponding to a circumferential position of a body part where a bulge, dimple or other large or small overall shape variation is present, rather than at the longitudinal sides of the fabric 380, 382. This allows for a perfect fit to be achieved, with the wales of the fabric in the finished compression garment all running substantially parallel to a central axis thereof.

[0043] Hereto, knitting according to the pattern 200 comprises knitting a row of stitches having a first length L1 on a row of needles, transferring a predetermined length L2a, L2b of the row of stitches to adjacent needles so that at least one empty needle is present within the row of needles. This is followed by knitting a further row of stitches, that is at least partly intermeshing with the row of stitches having the first length L1 , and comprising at least one additional stitch 62; 63, 64; 65; 66; 67, which is knitted on the at least one empty needle that was obtained within the row of needles. This sequence describes an increase, and similarly, one or more decreases may be achieved, with the difference being that instead of transferring stitches to adjacent needles to obtain at least one empty needle within the row of needles, the stitches are transferred such that at least one needle holding more than one stitch is present within the row of needles.

[0044] To make the tailoring of the knitting pattern and programming of the knitting machine a little easier, pattern 200 is subdivided into four zones 201 , 202, 203, 204, where the adding or removing of stitches is performed at the edges 80, 81 ; 84, 85; 86; 87, 89; 82, 83 of said zones. The predetermined length of the row of stitches that is to be transferred, thus equals to the local width, or row length associated with, of one or more zones. This makes the programming of the knitting machine easier, relative to adding and removing stitches at any and all locations along the rows of stitches. The edges of the zones are identifiable in the finished fabric through wales commencing or ending along vertical axes 384, 386, 388, which vertical axes 384, 386, 388.

[0045] Fig. 3A and 3B respectively depict an alternative schematic of a pattern for knitting a flatlying double-layer fabric for a compression garment according to an embodiment of the present disclosure, and a section of a corresponding knitting process diagram 400 for a flat-bed knitting machine with four needle beds.

[0046] Similar to the schematic of Fig. 2A, the schematic of Fig. 3A is subdivided into four zones 20T, 202’, 203’, 204’, with the two outer-most edges 80’, 82’ marking the longitudinal edges for the resulting fabric, but in Fig. 3A the intermediate edges of adjoining zones are depicted as gaps 84’, 86’, 88’. The section of the corresponding knitting process diagram in Fig. 3B covers a part of pattern row 2T of the schematic of Fig. 3A, where stitches 250, 251 , 252 have been added.

[0047] Within each row of the knitting process diagram 400, demarked by continuous lines on top and bottom thereof, from top to bottom, the first dotted line 431 represents the back additional needle bed, the second dotted line 432 represents the back main needle bed, the third dotted line433 represents the front main needle bed, and the fourth dotted line 434 represents the front additional needle bed. From left to right, the first column 420 of the knitting process diagram 400 indicates the movement direction of the carriage over the needle beds, the second column 416 indicates an offset of the front additional needle bed, the third column 417 indicates an offset of the back main needle bed and the fourth column 418 indicates an offset of the back additional needle bed. All these offsets are with respect to a position of the front main needle bed at the moment the carriage passes over the needle beds. The stitches for a first layer of the double-layer fabric 440 are knitted with a first yarn on the back main needle bed 432 and transferred between the back main needle bed 432 and the front additional needle bed 434, the knitted stitches being indicated with continuously joined lines and the transferred stitches by separated lines. Similarly, the stitches for a second layer of the double layer fabric 441 are knitted with a second yarn using the front main needle bed 433 and transferred between the front main needle bed 433 and the back additional needle bed 431. The pattern row 444 for the first and second layers of the double-layer fabric are broken up into three sections, respectively marking the sections to be knitted on the right and left sides of the indicated additional stitches 250, 251 , 252.

[0048] Although an elastic thread could be included by simply laying the thread on top of the threads that extend between the respective front and back main needle beds, in the present schematic, an elastic thread 445 is woven in between the stitches produced on the front main needle bed. Further, a binding thread 447 is included, interconnecting the first and second layers of the double-layer fabric, by including a binding stitch every 3rdstitch.

[0049] Fig. 4 depicts an example of a compression garment 500, made of a flat-knitted doublelayer fabric according to this disclosure. The depticted garment 500 is a stocking, consisting of a leg-section 501 and a foot-section 502. Although the garment is depicted as a compression stocking, it will occur to the skilled person that the disclosed method of manufacturing and fabric could also be adapted to form other garments such as socks, leggings, and arm or leg sleeves. Such a leg sleeve could correspond to the leg-section 501 of the stocking 500 and such a sock could correspond to the foot-section 502 of the stocking. The fabric of the garment 500 comprises a plurality of wales 510, 512, 513, which are substantially parallel to a central longitudinal axis of the body part A, i.e. parallel to an axis that runs between the centers of rotation of joints. For the toes in the foot, the middle-toe may be used as the average center of rotation. To allow the wales to be substantially parallel to the central longitudinal axis A, stitches are added removed at predetermined locations within the fabric, as described above, causing wales 512, 513 to have a starting position and / or end position along the length of the fabric, i.e. at a position that is not the first or last knitting row of the fabric of the garment 500. To make the programming of the knitting machine easier and the knitting faster, as indicated above, the fabric of the garment 500 is subdivided into four sections, of which two are visible, with the edges of the sections 505, 506, 507 being indicated in the figure. These edges are identifiable within the garment 500 through the starting positions and end positions of wales 512, 513 having formed an identifiable line within the fabric that corresponds to the indicated markings 505, 506, 507. Finally, since the compression garment 500 is made from a flat-knitted double-layer fabric, the garment 500 comprises alongitudinal seam 520, in which the respective longitudinal edges of the fabric are attached to one another. In the depicted example, the seam 520 coincides with the edges of two sections that together form the front of the stocking 507. It will be obvious to the skilled person that alternative positions for the seam may be chosen, depending on particular design and product needs. For example, the seam may be required to be on the back of the article, or at a side that is either facing inward to or away from the body central axis (i.e. facing to or from the torso or opposite leg). Moreover, it will be obvious that instead of a seam, which is a permanent closure, the fabric could be joined completely or partially with an openable closure, such as a zipper or hook and loop material.

[0050] Alternative and equivalent embodiments of the present disclosure are conceivable within the inventive concept, as will be clear to those skilled in the art. For example, a pattern may be provided with a different number of zones, or result in a different manner of intermeshing of the double-layers. The inventive idea is only limited by the appended claims.DefinitionsThe following definitions may be used as guidance for understanding the claims and description: flat-knitted fabric - a fabric that is knit alternately from right to left and left to right without turning.Flat-bed knitting machine - a knitting machine comprising two flat needle beds arranged in an upside-down "V" formation and a carriage. The needle beds can be up to 2.5 metres (8 ft 2 in) wide. The carriage, also known as a Cambox or Head, moves backwards and forwards across these needle beds, working the needles to selectively, knit, tuck or transfer stitches. Hereto, the carriage may hold a plurality of systems for working the needles in the needle beds. double-layer fabric - fabric comprising or consisting of two sheets of fabric that are interlocked, also referred to as interconnected. The sheets are interlocked along the surface areas of the sheets which are adjacent to each other. Such double-layer fabrics can be manufactured e.g. on at least two knitting needle beds of a flat-bed knitting machine, wherein one sheet is knitted on a first needle bed and the second sheet is knitted on a second needle bed. Interlocking between the two sheets is achieved by threads that cross from one sheet to the other, thereby forming a connection. These stitches may be referred to as interlocking stitches or as interconnecting stitches The extent of interlocking between the two sheets can differ. For example, the double-layer fabric may have knitting rows with 1 or more connections per 20 meshes, 2 or more, 5 or more, or 10 or more. In other words, the double-layer fabric may have knitting rows with from 1 to 20 connections per 20 meshes, from 5 to 20, or from 10 to 20.Stitch - a loop of yarn orthread. Stitches are formed on a needle and intermesh with further stitches to, together, form a fabric. Each stitch consists of a head and two legs, each having a foot at their base. When intermeshed with a further stitch, the feet of the stitch are meshed through the head of a stitch formed previously, generally in a preceding knitting row.Knitting row - a predominantly horizontal row of adjacent needle loops identifiable as a row in a finished fabric. A knitting row is generally produced by adjacent needles in one needle bed during a single carriage movement. knitting direction - a predominantly horizontal direction; a direction parallel to a line that extends through the heads of adjacent stitches and crosses both legs of each of said stitches. knitting row length - the measurement of a straight length of yarn knitted in the production of a particular knitting row.Wale - a predominantly vertical column of intermeshed stitches that is generally started when an empty needle starts to knit.Wale direction - predominantly vertical direction; a direction parallel to a line that extends through the heads of intermeshed stitches, in between respective legs of each of said intermeshed stitches.Thus, intermeshed stitches refer to stitches that are in the same stitch wale.pattern row - one or more knitting rows, forming a repeatable pattern. A further pattern row is thus a repeat of the pattern row that precedes. In plain weft knitting fabrics the pattern row is identical to a knitting row, but in more complex fabrics a pattern row may be composed of a plurality of knitting rows. On a flat-bed knitting machine, a pattern row can be knitted in one movement of a carriage with several systems or in several movements of a carriage with one or more systems.Adjacent - immediately next to, i.e. having no other element in between except for an air-gap. Thus, for example, for a needle, an adjacent needle is one directly to the left, right, front or back of this needle. laterally offset - a position that is spaced apart from a previous position when considered along the same line. medical-grade compression garment - a garment, such as for example an arm sleeve or a leg sleeve, sock or stocking that is specifically adapted to provide therapeutical compression for a list of ailments comprising varicose veins, spider veins, deep vein thrombosis, phlebitis, lymphedema, diabetes and lipoedema. The garment meets one or more standards of garment efficacy, such as RAL-GZ 387 / 1 : 2008, RAL-GZ 387 / 2: 2008, RAL-GZ 387 / 3: 2008, DIN 58133: 2008, AFNOR IFTH - NF G 30-102 Part B, AFNOR IFTH - NF G 07-002 or ISO 2062, AFNOR IFTH - NF G 07-316 - Part B, BSI - BS 6612:1985 and BSI - BS 661210:2018+A1 :2022, ensuring that a therapeutic pressure profile is achieved over a limb, when such a garment is worn. A medical-grade arm sleeve may have a pressure profile that starts at 100% pressure at a base measuring point that is intended to sit above the wrist bone of a wearer of said sleeve, and reduces to 40 - 90 % of this pressure at a top of the sleeve, intended to be positioned on the upper half of the upper arm of the wearer. Similarly, a medical grade leg sleeve, sock or stocking, may have a pressure profile that starts at 100% at a base measuring point that is intended to sit at 10 - 13 cm upward of a wearer’s leg, measured from the sole of the foot, and reduces to 50 - 80 % of the original pressure at a location that is intended to sit just below the knee of the wearer, and / or to 20 - 60 % of the original pressure at a location that is intended to sit above the knee. The original pressure may be at least 20 mmHg, or may be at least 30 mmHg. elastic yarn - a yarn that has elastic properties along the length direction thereof. The yarn may be monofilament yarn, multifilament yarn and / or covered yarn.Row of needles - a series of needles adjacent to one another, on which (a part of) a pattern row is knitted. The row of needles may be positioned on one needle bed. main needle bed - a needle bed on which stitches are knitted; the terms “main needle bed” and “knitting needle bed” can be used synonymously. additional needle bed - another needle bed, used for the transferring of stitches, which may or may not be suitable for knitting stitches on; the terms “additional needle bed” and “transfer needle bed” can be used synonymously. The "additional back needle bed" is located in the back of the knitting machine, thus on the same side as the back needle bed, and the “additional front needle bed” islocated in the front of the knitting machine, on the same side as the front needle bed. Depending on the particular knitting machine used, these additional needle beds could be merely suitable for transferring stitches or also be capable of, and used for, knitting all or a part of a further pattern row. central axis of the compression garment - a line that passes through the centroids of cross-sections of the compression garment, wherein the cross-sections are parallel to the knitting direction of the fabric of the garment. central longitudinal axis of a body-part - an axis that runs between the centers of rotation of the joints at opposite ends of the bod-part. The central longitudinal axis is an axis of rotation that is independent from joint flexion or extension. Thus, for example, the longitudinal axis of the forearm runs from the center of the radial head to the center of the distal ulna.

Claims

Claims1 . A method of manufacturing a compression garment comprising a flat-knitted double-layer fabric comprising at least one elastic yarn, the method comprising the steps of: a) knitting stitches on a row of needles of a front main needle bed and knitting stitches on a row of needles of a back main needle bed, to form a pattern row of the double-layer fabric, wherein the pattern row comprises at least a first knitting row for forming a first layer of the doublelayer fabric and a second knitting row for forming a second layer of the double-layer fabric; b) transferring at least one stitch from within the pattern row, knitted on the row of needles of the front main needle bed and / or transferring at least one stitch from within the pattern row, knitted on the row of needles of the back main needle bed to a needle that is adjacent to the respective needle onto which the at least one stitch is knitted, such that at least one empty needle and / or at least one needle holding more than one stitch is present within the respective row of needles of the front main needle bed or row of needles of the back main needle bed; and c) knitting a further pattern row by knitting further stitches on the row of needles of the front main needle bed and knitting further stitches on the row of needles of the back main needle bed, the further stitches being at least partly intermeshed with the stitches knitted under step a), wherein the further pattern row comprises a further first knitting row to form the first layer of the double-layer fabric and a further second knitting row to form the second layer of the double-layer fabric, with the further stitches comprising a stitch knitted on a respective one of the at least one empty needle and / or the at least one needle holding more than one stitch of step b).

2. The method according to claim 1 , wherein the stitch knitted on the at least one empty needle and / or knitted on the at least one needle holding more than one stitch under step c) is part of one of the further first knitting row or further second knitting row.

3. The method according to claim 1 or 2, wherein in step c) the knitting of the further stitches is performed on a respective one of the front main needle bed and back main needle bed, preferably wherein the further stitches that are intermeshed with stitches knitted under step a) are knitted on the same one of the respective front main needle bed and back main needle bed.

4. The method according to any one of the preceding claims, wherein a difference between a number of stitches adjacent to one another in the knitting direction, forming the first layer of the double-layerfabric and a number of stitches adjacent to one another in the knitting direction, forming the second layer of the double-layer fabric within a respective pattern row is 2 or less.

5. The method according to any one of the preceding claims, wherein under step b) the transferring of the at least one stitch is performed on both the row of needles of the front main needle bed and the row of needles of the back main needle bed and in parallel, such that the at least one empty needle and / or the at least one needle holding more than one stitch present within the row of needles of the front main needle bed has a position that corresponds to a position of theat least one empty needle and / or the at least one needle holding more than one stitch present within the row of needles of the back main needle bed, both positions being defined in the knitting direction.

6. The method according to any one of the preceding claims, wherein the transferring of the at least one stitch under step b) comprises the transferring of the at least one stitch from a needle within the row of needles of the front main needle bed to a selected needle of an additional back needle bed and / or the transferring of the at least one stitch from a needle within the row of needles of the back main needle bed to a selected needle of an additional front needle bed.

7. The method according to claim 6, wherein the selected needle of the respective additional front needle bed or additional back needle bed is moved laterally offset with respect to the needle within the row of the respective front main needle bed or back main needle bed, viewed in a knitting direction, before or after the transferring.

8. The method according to any one of the preceding claims, wherein the transferring of at least one stitch forming a part of a respective one of the first or second layer of the double-layer fabric under step b) and the knitting of a further at least one stitch of the further stitches under step c) that intermesh with the transferred at least one stitch are performed in direct succession.

9. The method according to any one of the preceding claims, wherein, in each pattern row, an interconnecting stitch is provided at least every 10 stitches along the first and second knitting rows, interconnecting the first layer and second layer of the double-layer fabric, the interconnecting stitch preferably being provided at least every 6 stitches, more preferred at least every 4 stitches, and most preferred at least every second stitch.

10. The method according to claim 9, wherein an inlay thread is laid onto the interconnecting stitches of a respective pattern row, extending in between the front main needle bed and the back main needle bed, the inlay thread preferably being an elastic thread.

11. The method according to any one of the preceding claims, wherein the first layer of the fabric consists of, or comprises, a first yarn , and wherein the second layer of the fabric consists of, or comprises, a second yarn.

12. The method according to claim 11 , wherein the first yarn and the second yarn have different properties, preferably wherein the first yarn is hydrophobic and the second yarn is hydrophilic.

13. The method according to any one of the preceding claims, comprising a final step of joining longitudinal side edges of the flat-knit fabric, which are formed by respective first and last stitches in each knitting row, to form the compression garment, and wherein step a) is preceded by obtaining measurement information from a wearer or obtaining measurement information for a pre-designed compression garment for a body part that is to be supported by the compression garment, with the steps a), b) and c) each being carried out such that an amount of stitches in each respective knitting row correspond to the measurement information and a central axis of the flat-knit fabric after joining coincides with a central longitudinal axis of the body part, the body part preferably being a human body part.

14. The method according to any one of the preceding claims, wherein the first knitting row and the second knitting row are together subdivided into a predefined plurality of sections, each section comprising a predetermined amount of stitches from both the first and the second knitting row, and wherein the transferring in step b) comprises the transferring of stitches of one or more sections, such that the at least one empty needle and / or at least one needle holding more than one stitch is present at the start or end of a respective section.

15. The method according to claim 14, wherein the transferring in step b) is only performed at the beginning or end of a respective section.

16. The method according to claim 14 or 15, wherein at least four sections are present.

17. The method according to claim 14, 15 or 16, wherein a predetermined amount of stitches of the first knitting row in a respective section is equal to a predetermined amount of stitches of the second knitting row in the respective section.

18. The method according to any one of the preceding claims, the method being adapted for manufacturing a medical compression garment.

19. A double-layer fabric for a compression garment, wherein the fabric is manufactured according to the method steps of any one of claims 1 to 12.

20. A double-layer fabric for a compression garment, the double-layer fabric being a flat-knitted fabric comprising at least one elastic yarn, a first layer consisting of two or more knitting rows and a second layer consisting of two or more knitting rows, wherein a length of a respective knitting row of the two or more knitting rows of the first layer matches a length of a corresponding knitting row of the two or more knitting rows of the second layer, and wherein the amount of stitches of a respective knitting row is increased or reduced at positions within said knitting row, with respect to a preceding knitting row, such that the fabric comprises wale starting positions and wale end positions that are dispersed along a width and length of the fabric.21 . The double-layer fabric according to claim 20, wherein a respective one knitting row of the two or more knitting rows of the first layer and a respective one knitting row of the two or more knitting rows of the second layer are interconnected via three or more interconnecting stitches, preferably wherein each knitting row of the two or more knitting rows of the first layer is interconnected with a corresponding knitting row of the two or more knitting rows of the second layer.

22. The double-layer fabric according to claim 20 or 21 , wherein the dispersion of wale starting positions and wale end positions along the width are constant along the length of the fabric, such that the fabric comprises at least four sections in a width direction of the fabric, such that each knitting row is subdivided into at least four sections, and each section having a length corresponding to the length of the fabric, said lengths being determined in a flat-laid position of the fabric, wherein each wale starting position and wale end position within a knitting row corresponds to a first or last stitch of a section.

23. A compression garment, manufactured according to the method of any one of claims 1 - 18.

24. A compression garment, comprising the flat-knitted double-layer fabric according to any one of claims 19 - 22, and a joint in which the longitudinal edges of the flat-knit double-layer fabric, which are formed by respective first and last stitches in each knitting row of said fabric, are attached to one another such that the compression garment has a tubular shape.

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