Head covering

Abstract

A head covering, such as a hijab and method of forming a head covering, in which a shaping portion 120 of the head covering includes two seams 122, 124 formed integrally with one another by a circular

Description

23 06 25 TECHNICAL FIELD This invention relates to head coverings such as hijabs, and methods for forming such head coverings using a circular knitting machine. 5 BACKGROUND Head coverings such as hijabs come in many forms. In particular, the term hijab often specifically refers to a cloth wrapped around the head and neck, covering the hair but leaving the face visible. Known hijabs or other head coverings suitable for wearing while exercising, training, playing 10 sports, or otherwise taking part in athletic activities are typically constructed of individual panels of lightweight, breathable material which are sewn together to provide the desired three-dimensional arrangement. The panels are cut to shape and sewn together, with multiple seems across the garment to hold separate elements together. SUMMARY OF THE INVENTION 15 In general terms, the present invention provides a head covering (in particular, a hijab) and method of forming a head covering in which a shaping portion of the head covering includes two seams formed integrally with one another by a circular knitting machine, to thereby provide the desired shape of typical head coverings. The seams extend diagonally across a series of rows of stitches. 20 An aspect of the invention provides a method for forming a head covering according to the appended claims. A problem with the prior art approach of cutting and sewing individual panels is that it relies on human effort and is thus also subject to human error. As such, there may be issues with the consistency of sewing between garments, as well as limitations on the speed with which 25 garments can be manufactured. The present invention serves to solve these problems by providing a method of manufacturing a head covering using a circular knitting machine. Such circular knitting machines are also known as seamless knitting machines, because they produce fabric in a tubular form that is continuous (or seamless) in the circumferential direction. The method of 30 the present invention allows the majority of the head covering to be constructed in an automated fashion, with improved product quality, consistency and speed. A key aspect of the circular knitting process is that certain needles are held (i.e. stop knitting), while others continue to knit through a defined tapered fold zone. When the held needles reach a point in the pattern outside of the tapered fold zone, they begin to knit again, thereby joining seam edges of the tapered fold zone to create seams and provide a curved shape to the overall garment. There are two or more tapers in preferred arrangements of the tapered fold zone, which allow the garment to shape around the head. The needles are preferably latch needles, or latch-hook needles, of the type suitable for use 5 with a circular knitting machine. The segment of the circle is defined by an arc of the circle subtended by a chord of the circle. Each of the subset of needles is within the segment if it is bounded by the segment, i.e. bounded by the arc and chord of the segment. The segment may comprise a major segment or a minor segment. 10 The knitting position of the needles is a position in which they are capable of knitting stitches. In the knitting position each needle may move in an up-and down motion, such that a hooked portion of the needle latches onto a yarn (or thread) fed into the circular knitting machine, to thereby knit a new row of a knitted fabric. The hold position of the needles is a position in which each held needle does not knit. That is, each held needle is 15 not able to latch onto the yarn (or thread) being fed into the circular knitting machine. Optionally, the headband sequence, shaping sequence, and base sequence are knitted via a continuous knit process so as to be formed integrally. The method may include operating the circular knitting machine according to a circular knit process. The circular knit process may comprise feeding multiple yarns, or threads, into the circular knitting machine. Such CO20 processing, apparatus and methods are suitable to provide a seamless tubular knitted head covering. The headband sequence, shaping sequence, and base sequence are preferably each continuous, or seamless, in the circumferential direction. As an alternative or addition to the steps of the first aspect comprising knitting the shaping 25 series of stitches using a subset of the series of needles within a segment of the circle, the method may include, for each row of stitches of the shaping sequence, knitting the shaping series of stitches using a subset of the series of needles corresponding to a tapered fold zone of the shaping sequence of rows of stiches, wherein successively through the rows of stitches: of the shaping sequence the tapered fold zone progressively widens from a first 30 width to a second width, then progressively narrows from the second width to the first width, then progressively widens to a third width, then progressively narrows from the third width to the first width, the method including the steps of: arranging a plurality of needles of the subset of needles in the held position; and 23 06 25 maintaining each of the plurality of needles in the held position, until a row of stitches is reached in which that needle is not within the tapered fold zone. The method includes arranging in the knitting position remaining needles of the subset of needles other than the plurality of needles. The method preferably includes maintaining the 5 remaining needles in the knitting position continuously through all of the rows of stitches of the shaping sequence. The remaining needles of the subset of needles are successively alternated with the plurality of needles of the subset of needles. That is, preferably within the subset of needles, each needle in the held position is successively alternated with each needle in the knitting 10 position. This arrangement provides a particularly neat and robust garment. In particularly preferred arrangements, the method of the first aspect provides, to each of left and right sides of the shaping sequence, a first seam and a second seam, wherein: the first seam comprises a first seam edge and a second seam edge formed integrally with one another, the first seam edge extending diagonally across a first series of 15 rows of stitches of the shaping sequence and the second seam edge extending diagonally across a second series of rows of stitches of the shaping sequence, the first seam edge and second seam edge meeting at a point between the first series and second series; and the second seam comprises a third seam edge and a fourth seam edge formed integrally with one another, the third seam edge extending diagonally across a third series 20 of rows of stitches of the shaping sequence and the fourth seam edge extending diagonally across a fourth series of rows of stitches of the shaping sequence, the third seam edge and fourth seam edge meeting at a point between the third series and fourth series. In some embodiments the method further includes, successively through the rows of stitches, again progressively increasing a size of the segment to increase a number of 25 needles in the subset of needles, then progressively decreasing the size of the segment to decrease a number of needles in the subset of needles. This arrangement may provide a third seam, wherein: the third seam comprises a fifth seam edge and a sixth seam edge formed integrally with one another, the fifth seam edge extending diagonally across a fifth series of rows of 30 stitches of the shaping sequence and the sixth seam edge extending diagonally across a sixth series of rows of stitches of the shaping sequence, the fifth seam edge and sixth seam edge meeting at a point between the fifth series and sixth series. The method preferably commences with knitting of the headband portion. The method preferably provides a folded band structure for improved strength and fit of the head covering around a wearer's face. Thus, the method may include using the circular knitting machine to form the headband portion by knitting the rows of stitches of the headband sequence to form a band, and subsequently successively arranging alternating needles of the series of needles in the held position and the knitting position and then knitting a folding 5 row of stitches to thereby fold the band. A ruching effect produced by the circular knitting machine can be used to help provide anchor points for a drawstring. Thus, the method may include knitting one or more drawstring guide portions of the head covering by moving one or more adjacent needles of the series of needles from the knitting position to the held position, maintaining the one or 10 more adjacent needles in the held position continuously through all of a plurality of rows of stitches, and subsequently moving the one or more adjacent needles to the knitting position. The method may further include passing a drawstring between a knitted fabric of the head covering and the one or more drawstring guide portions. Other post-knitting modifications are also possible. For example, holes may be punched, or 15 otherwise cut, in the knitted fabric of the head covering for a drawstring to pass therethrough. LO Also disclosed is a head covering knitted using the method of the first aspect. In preferred arrangements the first seam comprises a first seam edge and a second seam edge formed integrally with one another, the first seam edge extending diagonally across a CO20 first series of rows of stitches of the shaping sequence and the second seam edge extending diagonally across a second series of rows of stitches of the shaping sequence, the first seam edge and second seam edge meeting at a point between the first series and second series; and the second seam comprises a third seam edge and a fourth seam edge formed integrally with one another, the third seam edge extending diagonally across a third series 25 of rows of stitches of the shaping sequence and the fourth seam edge extending diagonally across a fourth series of rows of stitches of the shaping sequence, the third seam edge and fourth seam edge meeting at a point between the third series and fourth series. By forming the seam edges integrally with one another using a circular knitting machine, the head covering can be produced particularly quickly and efficiently, with excellent 30 consistency. The particular shape of the first and second seams, defined by the shapes of the seam edges, are preferably achieved using the method of the first aspect. Preferably, the head covering is formed using a circular knitting machine comprising a series of needles arranged in a circle and movable between a knitting position and a held position. In preferred arrangements, the second seam edge of the first seam and the third seam 35 edge of the second seam meet at a point between the second series and the third series. 23 06 25 The shaping portion preferably further includes: a first tapered folded flap portion comprising successive rows of stitches of the shaping sequence extending between the first seam edge and the second seam edge; and a second tapered folded flap portion comprising successive rows of stitches of the shaping sequence extending between the third seam edge 5 and the fourth seam edge. The first and second tapered folded flap portions may each be cut away from the head covering in a post-processing step. In some embodiments, a series of over-stitches may be applied to the first and second seams in a further post-processing step. In preferred embodiments: each of the successive rows of stitches of the first tapered 10 folded flap portion comprises a first series of shaping stitches, whereby through each of the successive rows of stitches a width of the first series of shaping stitches progressively increases and then progressively decreases; and each of the successive rows of stitches of the second tapered folded flap portion comprises a second series of shaping stitches, whereby through each of the successive rows of stitches a width of the second series of 15 shaping stitches progressively increases and then progressively decreases. The first series of shaping stitches together thus provide the tapered fold zone of the shaping sequence. The shaping portion may comprise, to each of left and right sides thereof, a third seam; and the third seam may comprise a fifth seam edge and a sixth seam edge formed integrally with one another, the fifth seam edge extending diagonally across a fifth series of rows of stitches of the shaping sequence and the sixth seam edge extending diagonally across a sixth series of rows of stitches of the shaping sequence, the fifth seam edge and sixth seam edge meeting at a point between the fifth series and sixth series. Preferably, the headband portion, shaping portion and base portion are formed integrally as a unitary body. Preferably the head covering is continuous in the circumferential direction. 25 The unitary construction is provided by forming the head covering using a circular knitting machine. Within this specification, reference to 'thread' refers to a textile cord comprising multiple yarns plied together to form a long, thin strand. In particular, the present thread may comprise a plurality of individual threads plied together, with each individual thread 30 comprising a plurality of yarns. Optionally, a composition of the thread in the head covering comprises nylon, polyester and elastane. Reference within the specification to 'elastane' encompasses a yarn, cord or thread comprising a polyamide, polyurea and / or a polymer blend configured to provide a construction that stretches and recovers / returns to its pretensioned state. Reference within the specification to 'thread' may be interchangeable with 35 'knit'. Optionally, each of the yarns that form the thread, may be formed, in turn, from fibres or filaments and in particular a plurality of fibres or filaments. Optionally, each of the yarns may be formed from monofilaments. Throughout the description and claims of this specification, the words "comprise" and "contain" and variations of the words, for example "comprising" and "comprises", mean "including but not limited to", and do not exclude other components, integers or steps. Moreover the singular encompasses the plural unless the context otherwise requires: in 5 particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise. Preferred features of each aspect of the invention may be as described in connection with any of the other aspects. Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding 10 paragraphs, in the claims and / or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and / or features of any embodiment can be combined in any way and / or combination, unless such features are incompatible. 23 06 25 10 01 25 BRIEF DESCRIPTION OF THE DRAWINGS One or more embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 illustrates a first knitting pattern suitable for use in embodiments of the invention; 5 Figure 2 illustrates a second knitting pattern suitable for use in embodiments of the invention; Figure 3 illustrates a third knitting pattern suitable for use in embodiments of the invention; Figure 4 shows a side view of a head covering according to an embodiment of the invention in an as-worn configuration; 10 Figure 5 shows a second side view of the head covering of Figure 4; Figure 6 shows a side view of the head covering of Figures 4 and 5 in a flattened configuration; Figure 7 shows a detail view of a drawstring feature of the head covering of Figures 4 to 7; and 15 Figure 8 shows an illustrative representation of a series of needles of a circular knitting machine arranged in a circle. DETAILED DESCRIPTION In general terms, the invention provides a head covering 100 as illustrated in Figures 4 to 7, produced by a circular knitting machine using a pattern 200, 300, 400 having the 20 features illustrated in Figures 1 to 3. Figure 8 provides a schematic not-to-scale representation of a series of needles 500 of a circular knitting machine arranged in a circle. Circular knitting machines knit together fabric yarns, or threads, to create a fabric tube that is continuous, or seamless, in the circumferential direction. Such machines comprise a series of latch-hook needles arranged in a ring, the shape and size of the ring of needles 25 controlling the shape and size of the fabric tube. The needles can each be moved between a knitting position, in which they move in a reciprocating motion to knit together fabric yarns, and a hold position, in which they do not knit. Circular knitting machines can knit using multiple different knitting stitch types, so that different visual patterns and functional effects can be achieved in the fabric tube that is produced. Example fabric finishes that can be 30 produced include single or double jersey, mesh knit, rib knit or jacquard knit. Suitable circular knitting machines for knitting the head covering 100 include single directional or bidirectional circular knitting machines produced by Santoni™. 10 01 25 The head covering 100 comprises a headband 110, a shaping portion 120, and a base portion 130 formed integrally with one another. The head covering 100 has a generally tube-shaped configuration, with the headband 110 defining a first opening, the base portion 130 comprising a straight tube-shaped region defining a second opening, and the shaping 5 portion 120 defining a curved tube-shaped region therebetween. The head covering 100 is formed from a knit fabric produced on a circular knitting machine, as described further below. The headband 110 comprises a ring-shaped band comprising a ribbed knit fabric including elastane. The headband 110 encircles a wearer's face in use, and has a generally looser knit 10 upper region 112 (generally comprising the portion of the headband 110 that passes from ear to ear across a wearer's forehead) and a generally tighter knit lower region 114 (generally comprising the portion of the headband 110 that passes from ear to ear around a wearer's lower jaw). The ribbed knit fabric ensures that the headband 100 fits snuggly around a wearer's face. Moreover, the lower region 114 provides a closely-conforming fit 15 around the curves and angles of a wearer's lower face, while the (more stretchable) upper region 112 provides for a comfortable close fit across a wearer's forehead or brow. The base portion 130 has a lower hemmed edge 132 that is shaped to rise to two curved peaks to provide shaped regions 134 over a wearer's shoulders, and fall to two curved troughs to provide front 136 and rear 138 bib portions to the front and rear of a wearer's torso. The shaping portion 120 extends between the base portion 130 and headband 110. As can be best seen from Figures 4 to 6, the shaping portion 120 has left and right pairs of folded seams, each pair comprising a first folded seam 122 and a second folded seam 124. Each of the first 122 and second 124 folded seams comprises a tapered folded flap of fabric that 25 projects inwardly so that all that is visible from an outer view of the head covering 100 is a neat seam. Together, the first 122 and second 124 folded seams serve to provide a curved shape to the shaping portion 120. The first folded seam 122 extends from a position near a base of the lower region 114 of the headband 110 at a first angle to the headband 110. Similarly, the 30 second folded seam 124 extends from a similar position near a base of the lower region 114 of the headband 110 at a second angle to the headband 110, the second angle being larger than the first angle. In preferred embodiments, as illustrated, at least the first angle is an acute angle. The first 122 and second 124 folded seams are formed using the circular knitting machine, 35 as described further below. In some embodiments, the folded flaps of fabric are subsequently removed by a cutting process. In such embodiments, as illustrated in Figures 10 01 25 4 to 6, the seams may then be over-stitched with a flatlock stitch using a sewing machine, to add reinforcement and improve durability of the head covering 100. An elasticated drawstring 140 is fixed at a first end to a first side location 142 adjacent a right side of the headband 110 and at a second end to a second side location 144 adjacent a 5 left side of the headband 110. The first 142 and second 144 side locations may be adjacent the respective joins between the looser knit upper region 112 and the tighter knit lower region 114, so that they are generally aligned with a wearer's ears. The left and right portions of the drawstring 140 are each threaded through a fabric channel (not illustrated) mounted on an inside face of the head covering 110, and each emerges through one of a 10 first pair of eyelets 146 towards a rear region of the head covering 110 towards the nape of a wearer's neck. The left and right portions of the drawstring 140 then each pass through a respective one of a pair of ruched drawstring guides 148 which are formed integrally with the base portion 130, as described further below. Each ruched drawstring guide 148 comprises two loops of 15 knitted fabric that together form a channel sized to receive the drawstring 140. A fastening toggle 150 receives the left and right portions of the drawstring 140. The fastening toggle 150 is biased towards a clamping configuration in which the fastening toggle 150 is held securely in a position along the drawstring 140 selected by a wearer. The wearer can press a button, or other actuating feature, to arrange the fastening toggle 150 in a sliding configuration in which the fastening toggle 150 can be readily moved along the drawstring 140 to a desired position. Thus, the drawstring 140 can be loosened to permit donning and doffing of the head covering 100, and tightened to ensure a close fit of the head covering 100 during use. The free loop 152 of the drawstring 140 passes through a second pair of eyelets 154 so that 25 the free loop 152 is adjacent an inner face of the head covering 100. This arrangement minimises risk of the drawstring 140 becoming caught on sports equipment or other hazards during use of the head covering 100. Figure 1 illustrates a knitting pattern 200 suitable for following to knit a head covering 100 similar to that illustrated in Figures 4 to 6 using a circular knitting machine. The pattern 200 30 is shown in a two-dimensional form, but the skilled reader will understand that, in the resulting fabric tube, the left 202 and right 204 edges of the pattern 200 are joined together in a seamless fashion. The mid-line 206 of the pattern 200 corresponds to the mid-line of the front of the head covering 100 (from tighter knit lower region 114 of the headband 110 to front bib portion 136), while the left 202 and right 204 edges together correspond to the 35 mid-line of the rear of the head covering 100 (from looser knit upper region 112 of the headband 110 to rear bib portion 138). 10.01 25 The pattern 200 is followed from the first row of stitches 210 at the top of the pattern to the last row of stitches 212 at the bottom of the pattern. The pattern 200 starts with a headband sequence 220 of rows of stitches forming a headband portion that provides the headband 110 of the head covering 100. Each of the 5 rows of the headband sequence is formed from rib knit stitches, including a series of first rib knit stitches 222 to provide the generally tighter knit lower region 114 of the headband 110, and a series of second rib knit stitches 224 to provide the generally looser knit upper region 112 of the headband 110. Suitable stitch types include a three by one rib stitch. Directly beneath the headband sequence 220 of rows of stitches forming the headband 10 portion is a folding row of stitches 226, which is formed by arranging all of the needles 500 of the circular knitting machine so that alternating needles are in the held position. That is, the needles are arranged in an alternating pattern of hold position, knitting position, hold position, knitting position, and so on. This arrangement has the effect of causing the first row of stitches 210 to be integrated with the folding row of stitches 226, so that the 15 headband portion is folded to form the headband 110. Beneath the folding row of stitches 226, and formed integrally with the headband sequence 220, is a shaping sequence 230 of rows of stitches forming the shaping portion 120 of the head covering 100. The shaping sequence includes a garment zone 232 and a tapered fold zone 234. The garment zone 232 provides the outwardly visible part of the shaping portion 120 of the head covering 100, whereas the tapered fold zone 234 provides the first 122 and second 124 folded seams of the shaping portion 120 and the internally-projecting tapered folded flaps. Each row of stitches of the shaping sequence 230 comprises a knit series of plain knit stitches in the garment zone 232 and a shaping series of stitches in the tapered fold zone 234. Suitable stitch types for the garment zone 232 include a single jersey plain 25 knit stitch, or double jersey plain knit stitch. The width of the tapered fold zone 234 increases and decreases progressively through the shaping sequence 230, in order to provide the shape of the shaping portion 120 of the head covering 100. The tapered fold zone 234 has an initial first width, then progressively widens to a second width to define a first seam edge 236, then progressively narrows to the first 30 width to define a second seam edge 238, then progressively widens to a third width to define a third seam edge 240, then progressively narrows to the third width to define a fourth seam edge 242. There is a sharp point at each transition point, resulting in two mirrored pairs of sharp peaks extending laterally from the mid-line 206 of the pattern 200. The third width and second width may be equal in some embodiments. 35 This particular shape, in combination with the particular arrangement of needles 500, results in the tapered folded flaps of the first 122 and second 124 folded seams. Each first 10 01 25 folded seam 122 is created by integral knitting of the first seam edge 236 and the second seam edge 238, as described further below. Similarly, each second folded seam 124 is created by integral knitting of the third seam edge 240 and the fourth seam edge 242. The tapered fold zone 234 is knitted by a subset of needles from the series of needles 500. 5 Successively through the rows of stitches of the shaping sequence, the number of needles within the subset progressively increases, then decreases, then increases, then decreases, in correspondence with the progressive widening and narrowing of the tapered fold zone 234. This is perhaps best understood from Figure 8, which illustrates a smaller first segment 510 of a circle encompassing the subset of needles 530, and a larger second segment 520 10 of the circle encompassing the subset of needles 530; it can be clearly seen that there are more needles in the subset of needles 530 when it is defined by a larger segment, and there are fewer needles in the subset of needles 530 when it is defined by a smaller segment. For example, the smaller first segment 510 may correspond to the number of needles in the subset 530 required to knit the initial first width of the tapered fold zone 234, and the larger 15 second segment 520 may correspond to the number of needles in the subset 530 required to knit the second width of the tapered fold zone. For each row of stitches of the shaping sequence 230, alternating ones of the subset of needles 530 is arranged in the held position, while the remaining needles of the subset 530 are arranged in the knitting position. Those held needles are then maintained in the held position continuously until the pattern reaches a row where that needle falls outside of subset of needles 530, and therefore falls outside of the tapered fold zone 234. This arrangement results in the integral knitting of each first seam edge 236 and second seam edge 238 to form the first folded seams 122, and the integral knitting of each third seam edge 240 and fourth seam edge 242 to form the second folded seams 124. 25 Directly beneath, and formed integrally with, the shaping sequence 230 is a base sequence 250 of rows of stitches forming the base portion 130 of the head covering 100. Suitable stitch types for the base sequence 250 include a single jersey plain knit stitch, or double jersey plain knit stitch. In preferred arrangements, the stitch type of the base sequence 250 is the same as the stitch type of the garment zone 232 of the shaping sequence 230. 30 Figure 2 illustrates an alternative knitting pattern 300 suitable for following to knit a head covering 100 similar to that illustrated in Figures 4 to 6 using a circular knitting machine. The pattern 300 of Figure 2 is identical to the pattern 200 of Figure 1 with the exception that the tapered fold zone 234' of the shaping sequence 230 has a modified shape to produce not only the first folded seam 122 and second folded seam 124 shown in Figures 4 35 to 6, but also a third folded seam (not shown) extending from a position near a base of the 10.01 25 lower region 114 of the headband 110 at a third angle to the headband 110 that is different to the first and second angles described above. All description of the features of the pattern 200 applies equally to the pattern 300, and therefore the discussion below will be limited to the differences only. 5 The width of the tapered fold zone 234' increases and decreases progressively through the shaping sequence 230, in order to provide the shape of the shaping portion 120 of the head covering 100. The tapered fold zone 234' has an initial first width, then progressively widens to a second width to define a first seam edge 236', then progressively narrows to the first width to define a second seam edge 238', then progressively widens to a third width to 10 define a third seam edge 240', then progressively narrows to the third width to define a fourth seam edge 242', then progressively widens to define a fifth seam edge 244, then finally progressively narrows to define a sixth seam edge 246. There is a sharp point at each transition point, resulting in two mirrored pairs of sharp peaks extending laterally from the mid-line 206 of the pattern 200. The third width and second width may be equal in some 15 embodiments. This particular shape, in combination with the particular arrangement of needles 500 described above in relation to the pattern 200 of Figure 1, results in the tapered folded flaps of the first 122, second 124 and third folded seams. Each first folded seam 122 is created by integral knitting of the first seam edge 236' and the second seam edge 238'. Similarly, each second folded seam 124 is created by integral knitting of the third seam edge 240' and the fourth seam edge 242'. Finally, each third folded seam is created by integral knitting of the fifth seam edge 244 and the sixth seam edge 246. For each row of stitches of the shaping sequence 230, alternating ones of the subset of needles 530 is arranged in the held position, while the remaining needles of the subset 530 25 are arranged in the knitting position. Those held needles are then maintained in the held position continuously until the pattern reaches a row where that needle falls outside of subset of needles 530, and therefore falls outside of the tapered fold zone 234'. This arrangement results in the integral knitting of each first seam edge 236' and second seam edge 238' to form the first folded seams 122, the integral knitting of each third seam 30 edge 240' and fourth seam edge 242' to form the second folded seams 124, and the integral knitting of each fifth seam edge 244 and sixth seam edge 246 to form the third folded seams. Figure 3 illustrates an alternative knitting pattern 400 suitable for following to knit a head covering 100 similar to that illustrated in Figures 4 to 6 using a circular knitting machine. The pattern 400 of Figure 3 is identical to the pattern 200 of Figure 1 with the addition of a number of additional features, as described below. All description of the features of the pattern 200 applies equally to the pattern 400, and therefore the discussion below will be limited to the differences only. 5 The shaping sequence 230 comprises the garment zone 232 and the tapered fold zone 234. The garment zone 232 is divided into three decorative sub-zones 232a, 232b 232c, each of which has a different stitch type to thereby produce an attractive visual effect. The garment zone 232 also includes two small square-shaped sub-zones 232d adjacent the headband 110 with a decorative stitch type to further enhance the visual effect. 10 The base sequence 250 of the pattern 400 includes the left and right ruched drawstring guides 148 formed integrally with the base portion 130 of the head covering 110. Each ruched drawstring guide 148 is formed by arranging two adjacent consecutive groups of two or more of the series of needles 500 in the held position, maintaining them in the held position for a plurality of rows of stitches, and then returning them to the knitting position. 15 This arrangement results in a pair of adjacent bridged regions of knitted fabric defining a channel through which the drawstring 140 can pass. LO The skilled reader will understand that any of the features described above in relation to any embodiment or aspect of the invention may be applied to other embodiments or aspects of the invention, or combined with features of other embodiments of aspects of the ___20 invention.

Claims

23 06 251. A method for forming a head covering using a circular knitting machine comprising a series of needles arranged in a circle, the needles each being movable between a knitting5 position and a held position, the method including using the circular knitting machine to knit via a continuous process:a headband sequence of rows of stitches forming a headband portion of the head covering;a shaping sequence of rows of stiches forming a shaping portion of the head10 covering, each of the rows of stiches of the shaping sequence having a shaping series of stitches; anda base sequence of rows of stitches forming a base portion of the head covering,wherein the method includes, for each row of stitches of the shaping sequence, knitting the shaping series of stitches using a subset of the series of needles within a segment of the circle, including the steps of:arranging a plurality of needles of the subset of needles in the held position;arranging remaining needles of the subset of needles other than the plurality of needles in the knitting position, wherein the remaining needles of the subset of needles are successively alternated with the plurality of needles of the subset of20 needles; andsuccessively through the rows of stitches:(a) progressively increasing a size of the segment to increase a number of needles in the subset of needles, then progressively decreasing the size of the segment to decrease a number of needles in the subset of needles, to form a first25 seam, then;(b) progressively increasing the size of the segment to increase a number of needles in the subset of needles, and then progressively decreasing the size of the segment to decrease a number of needles in the subset of needles, to form a second seam; and30 maintaining each of the plurality of needles in the held position, until a row ofstitches is reached in which that needle is not within the segment.

2. A method according to claim 1, including maintaining the remaining needles in the knitting position continuously through all of the rows of stitches of the shaping sequence.

3. A method according to any preceding claim, wherein the method further includes, successively through the rows of stitches, again progressively increasing a size of the5 segment to increase a number of needles in the subset of needles, then progressively decreasing the size of the segment to decrease a number of needles in the subset of needles.

4. A method according to any preceding claim, including using the circular knitting machine to form the headband portion by knitting the rows of stitches of the headband10 sequence to form a band, and subsequently successively arranging alternating needles of the series of needles in the held position and the knitting position and then knitting a folding row of stitches to thereby fold the band.

5. A method according to any preceding claim, wherein the method includes knitting one or more drawstring guide portions of the head covering by moving one or more15 adjacent needles of the series of needles from the knitting position to the held position, maintaining the one or more adjacent needles in the held position continuously through all of a plurality of rows of stitches, and subsequently moving the one or more adjacent needles to the knitting position.23 06 25

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