Pantyhose articles having ultra-high molecular weight polyethylene and methods for their manufacture - Patents.com

Abstract

The pantyhose article includes a first tubular member having a panty portion and a first tubular leg portion having a first main subportion and a first transition subportion. The main subportion extends from the thigh region of the tubular member to a first foot end, and the transition subportion extends between the panty portion and to the main subportion. The main subportion is formed from a first knit having a first ultra-high molecular weight polyethylene (UHMWPE) fiber and a first companion fiber. The transition subportion is formed from a second knit having a second UHMWPE fiber and a second companion fiber, the first knit being different from the second knit. The second tubular member has a similar panty portion and tubular leg portion. A method for manufacturing a pantyhose article includes forming a first tubular member, forming a second tubular member, cutting the first and second panty portions, joining longitudinal edges of the panty portions to form a panty tubular portion, and joining the longitudinal edges to a gusset.

Description

[Technical field]

[0001] Related Applications This Patent Cooperation Treaty application claims the benefit of priority to U.S. Provisional Application No. 63 / 341,160, filed May 12, 2022, and Canadian Patent Application No. 3,185,681, filed December 23, 2022, which provisional applications and applications are incorporated by reference herein in their entireties.

[0002] Technical Field The present disclosure relates generally to pantyhose articles having ultra-high molecular weight polyethylene (UHMWPE) and methods for the manufacture thereof, and more specifically to pantyhose articles having a plurality of different knits, including at least two knits having UHMWPE. [Background technology]

[0003] background Traditional knit fabrics for the manufacture of hosiery products (such as pantyhose, stockings, socks, and tights) include nylon combined with elastane (e.g., Spandex™'s Lycra™). However, these fabrics have a tendency to tear or rip when subjected to abrasive forces. Sheer hosiery products (e.g., 30 denier and below) made with these fibers have been observed to be very weak. They can easily tear from hands, feet, or hangnails, and are generally considered disposable. Thus, a need remains for commercially viable sheer (low denier) pliable knits that do not tear easily.

[0004] Ultra-high molecular weight polyethylene (UHWMPE) fibers are considered an ideal reinforcing component due to their high impact strength, low density, low elongation at break, resistance to aggressive chemicals, low moisture absorption, and low coefficient of friction. Knits incorporating UHMWPE fibers in combination with stretch fibers such as Spandex, nylon, or polyester have shown increased tear resistance. However, UHMWPE fibers are very expensive, and their quality varies considerably from supplier to supplier and batch to batch. Low quality UHMWPE fibers can result in defects such as yarn rings or barres, which result in defective hosiery that cannot be used in inventory and thus becomes waste.

[0005] Thus, a need remains for a commercially viable knit for making hosiery that allows for the utilization of lower amounts and / or lower grades of UHMWPE fiber while maintaining desirable tear resistance and durability. Summary of the Invention

[0006] Abstract According to one aspect, a pantyhose article is provided that includes a first tubular member, the first tubular member including a first panty portion and a first tubular leg portion, the first panty portion extending from a waist end of the pantyhose article to a bottom end of the first panty portion, the first tubular leg portion defining a first leg cavity and extending from an upper end thereof corresponding to the bottom end of the first panty portion to a first foot end of the first tubular leg portion, the first tubular leg portion including a first main subportion and a first transition subportion, the first main subportion extending from a first thigh region of the first tubular leg portion to a first leg region of the first tubular leg portion. from the upper end of the first tubular leg portion to a first foot end, a first transition subsection extending from an upper end of the first tubular leg portion to a first thigh region of the first tubular leg portion, the first main subsection formed from a first knit including a first ultra-high molecular weight polyethylene (UHMWPE) fiber and at least one first companion fiber, and the first transition subsection formed from a second knit including a second UHMWPE fiber and at least one second companion fiber, the first knit being different from the second knit.

[0007] According to another aspect, a method for manufacturing a pantyhose article is provided, the method comprising forming a first tubular member having a first panty portion extending from a waist end of the pantyhose article to a bottom end of the first panty portion, and a first tubular leg portion defining a first leg cavity and extending from an upper end thereof corresponding to the bottom end of the first panty portion to a first foot end of the first tubular leg portion, the first tubular leg portion including a first main subportion and a first transition subportion, the first main subportion extending from a first thigh region of the first tubular leg portion to the first foot end. , the first transition sub-section extends from an upper end of the first tubular leg portion to a first thigh region of the first tubular leg portion and extends circumferentially about the first tubular leg portion, the first main sub-section being formed from a first knit including a first ultra-high molecular weight polyethylene (UHMWPE) fiber and at least one first companion fiber, and the first transition sub-section being formed from a second knit including a second UHMWPE fiber and at least one second companion fiber, the first knit being different from the second knit. The method also includes forming a second tubular member having a second panty portion extending from a top end of the panty hose article to a bottom end of the second panty portion aligned with a bottom end of the first panty portion, and a second tubular leg portion defining a second leg cavity and extending from its top end corresponding to the bottom end of the second panty portion to a second foot end of the second tubular leg portion, the second tubular leg portion including a second main subportion and a second transition subportion. The second main subsection extends from the second thigh region to the second foot end, and the second transition subsection extends from the upper end of the second tubular leg portion to the second thigh region of the second tubular leg portion and extends circumferentially about the second tubular leg portion, the second main subsection being formed from a first knit including a first UHMWPE fiber and at least one first companion fiber, and the second transition subsection being formed from a second knit including a second UHMWPE fiber and at least one second companion fiber.The method further includes cutting the first panty portion along its length to form a first longitudinal edge therein; and cutting the second panty portion along its length to form a second longitudinal edge therein; joining the first longitudinal edge of the first panty portion to the second longitudinal edge of the second panty portion to form a tubular panty portion defining a panty cavity for receiving a wearer's lower torso, where the panty cavity is in fluid communication with the first leg cavity of the first tubular leg portion and the panty cavity is in fluid communication with the second leg cavity of the second tubular leg portion; and joining the longitudinal edge of the first panty portion to the first edge of the gusset; and joining the longitudinal edge of the second panty portion to the second edge of the gusset.

[0008] The present disclosure is best understood from the following detailed description when read in conjunction with the accompanying drawings. It is emphasized that, according to common practice, the various features of the drawings are not necessarily drawn to scale. To the contrary, dimensions and spatial relationships of the various features may be arbitrarily expanded or reduced for clarity. Like reference numerals refer to like features throughout the specification and drawings. [Brief description of the drawings]

[0009] [Figure 1] FIG. 1 is a front view of an article of pantyhose according to one exemplary embodiment as it is placed on a quality control apparatus; [Diagram 2] FIG. 2 is a top perspective view of the inside of a pantyhose article according to one embodiment when placed on a quality control apparatus; [Diagram 3] FIG. 3 is a bottom view of the crotch area of ​​a pantyhose article according to one embodiment when placed on a quality control apparatus; [Figure 4] FIG. 4 is a front view of a pantyhose article according to an example embodiment when worn; [Diagram 5] FIG. 5 is a side view of a pantyhose article according to an example embodiment when worn; [Figure 6] FIG. 6 is a rear view of a pantyhose article according to an example embodiment when worn; [Figure 7] FIG. 7 is a bottom view of a pantyhose article according to an example embodiment when worn; [Figure 8] FIG. 8 is a top view of a pantyhose article according to an example embodiment as it would appear when worn. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] Detailed Description In the following description, certain specific details are described to provide a thorough understanding of various embodiments. However, one skilled in the art will understand that the present invention may be practiced without these details. In other instances, well-known structures have not been shown or described in detail to avoid unnecessarily obscuring the description of the embodiments. Unless the context otherwise requires, throughout the specification and the claims that follow, the word "comprise" and variations thereof, such as "comprises," "comprising," "includes," and "including," should be interpreted in an open, inclusive sense, i.e., "including but not limited to." Moreover, the headings provided herein are merely for convenience and do not interpret the scope or meaning of the claimed invention.

[0011] Throughout this specification, reference to "one embodiment" or "an embodiment" means that the particular feature, structure, or characteristic described in connection with that embodiment is included in at least one embodiment. Thus, the appearances of the phrases "in one embodiment" or "in an embodiment" in various places throughout this specification do not necessarily all refer to the same embodiment. Moreover, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. Also, as used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Also, the term "or" is generally used in its sense to include "and / or" unless the context clearly dictates otherwise. Additionally, as used herein and in the appended claims, the term "about," when used in conjunction with a stated numerical value or range, has the meaning reasonably ascribed to that term by one of ordinary skill in the art, i.e., to represent a value or range that is somewhat more or somewhat less than the stated value or range, up to within a range of ±20% of the stated value; ±19% of the stated value; ±18% of the stated value; ±17% of the stated value; ±16% of the stated value; ±15% of the stated value; ±14% of the stated value; ±13% of the stated value; ±12% of the stated value; ±11% of the stated value; ±10% of the stated value; ±9% of the stated value; ±8% of the stated value; ±7% of the stated value; ±6% of the stated value; ±5% of the stated value; ±4% of the stated value; ±3% of the stated value; ±2% of the stated value; or ±1% of the stated value.

[0012] definition As used herein, and unless the context clearly dictates otherwise, the following terms have the meanings specified below.

[0013] The term "UHMWPE" is an abbreviation for ultra-high molecular weight polyethylene, also known as high modulus polyethylene (HMPE) or high performance polyethylene (HPPE).

[0014] The term "pigmented UHMWPE" means UHMWPE that has been colored (eg, made non-white) by a non-additive coloring process.

[0015] The term "fiber" as used herein refers to a single-origin base material made of one or more filaments. It has an elongated body, the length dimension of which is much greater than the transverse dimensions of width and thickness.

[0016] The term "filament," as used herein, refers to a single original fiber of material that may be a fiber by itself or may be combined with other filaments to form a multifilament fiber. A single fiber may be formed from just one filament or may be formed from multiple filaments.

[0017] The term "microfilament" as used herein refers to filaments having a denier of 5 or less.

[0018] The term "denier" as used herein refers to a unit of weight indicating the fineness of a fiber filament. It may be measured in mass in grams per 9,000 meters of fiber. A lower denier number indicates a finer fiber and a higher denier number indicates a thicker or heavier fiber.

[0019] The term "dtex" as used herein refers to an alternative unit of weight that indicates the fineness of a fiber filament. It can be measured in mass in grams per 10,000 meters.

[0020] The term "tensile strength" as used herein relates to the durability of a garment and is measured by the maximum stress that a material can withstand while being stretched or pulled before breaking. It is measured as force per unit area and can be expressed in units of grams-force (gf) and centiNewtons (cN) per dtex.

[0021] The term "elongation" as used herein refers to the extension of individual fibers and composite fibers that result in the elastic properties of the final embodiment of the present disclosure. Elongation is measured as a percentage of the starting length.

[0022] The term "natural fibers" as used herein refers to a class of fibers that can be obtained from naturally occurring materials.

[0023] The term "synthetic fibers" as used herein refers to a class of fibers created by mankind. Synthetic fibers include, for example, polymeric materials synthesized by polymerization of monomers, fibers obtained by regeneration of natural fibers (e.g., after degradation in solvents), and glass fibers.

[0024] The term "elastic fiber," as used herein, refers to a class of fibers that, upon the application of a force, can be stretched to an elongated state of at least about 130% of its original dimension without breaking.

[0025] The term "inelastic fibers" refers to a class of fibers that are substantially inelastic and exhibit little or no elongation.

[0026] The term "high performance fibers" as used herein refers to a class of fibers that have higher values ​​of tenacity, e.g., greater than 10 g / denier, making them suitable for applications where high abrasion and / or cut resistance is important. Typically, high performance fibers have a very high degree of molecular orientation and crystallinity in the final fiber structure.

[0027] The term "elastomeric fiber," as used herein, refers to a fiber that has a break elongation of greater than 100% and that, when stretched and released, rapidly and forcibly retracts substantially to its original length.

[0028] The term "thermoplastic fibers," as used herein, refers to a class of fibers derived from polymers that are plastic or deformable and that melt into a liquid state when heated and undergo a non-elastic, brittle, glassy state when cooled sufficiently.

[0029] The term "abrasion resistant fiber," as used herein, refers to a class of fiber that inhibits abrasion of the material to which it is most closely adjacent.

[0030] The term "knit" as used herein refers to a fabric made by combining one or more fibers on a flat or circular knitting machine.

[0031] The term "gauge" as used herein refers to the number of needles on a knitting machine. High gauge knitting machines (32 gauge and above) are needed to make sheer hosiery such as sheer tights, stockings and trouser socks, while low gauge knitting machines, (18-32 gauge) are used to make heavier garments such as leggings, bodysuits, socks, shirts and other activewear. Gauge is also used to refer to machine-made knits: in other words, a knit made on a 32 gauge machine is a 32 gauge knit.

[0032] The term "plating" as used herein refers to the technique of interweaving two fibers in two distinct layers, where one fiber remains on the back behind the front fiber, despite being knitted in the same stitch.

[0033] The term "serving," as used herein, refers to the process of spinning two fibers together to produce a composite fiber.

[0034] The term "non-additive" as used herein refers to a method of coloring, typically a dyeing method, that does not increase the overall denier of the fiber.

[0035] "Tensile properties" are properties measured when a material is subjected to a stretching force and also when the stretching force is removed. Examples of tensile properties include, but are not limited to, tensile strength at break, elongation to break, modulus of elasticity, tenacity or tensile energy to break, permanent set, tensile load at a specified elongation, etc. Tensile properties of polymeric fibers can be determined by standard test methods such as, for example, ASTM D2256 / D2256M-21 "Tensile Properties of Yarns by the Single-Strand Method."

[0036] The term "horizontal stripes", as used herein, is defined as the unintentional repeating appearance of bars or stripes parallel to the courses, usually of a circular knitted fabric.

[0037] UHMWPE fiber Various aspects described herein include UHMWPE fibers for preparing knitted fabrics and methods for forming the same.

[0038] In some embodiments, the UHMWPE fibers have high impact strength, low density, low elongation at break, resistance to aggressive chemicals, low moisture absorption, and / or low coefficient of friction. In other aspects, the material is self-lubricating and highly abrasion and odor resistant.

[0039] In some embodiments, the UHMWPE fibers have a weight average molecular weight (M w In some embodiments, the UHMWPE fiber has a weight average molecular weight (M) ranging from about 300,000 to about 7,000,000, from about 700,000 to about 5,000,000, or from about 900,000 to about 4,000,000. w ) The number average molecular weight (M n ) to the weight average molecular weight (M w The molecular weight distribution of the UHMWPE fibers, which is the ratio of (molecular weight to molecular weight) to (molecular weight) is about 5.0 or less, about 4.0 or less, or about 3.0 or less.

[0040] In some embodiments, the UHMWPE fiber is a monofilament. In some other embodiments, the UHMWPE fiber comprises a plurality of microfilaments. In some embodiments, each of the microfilaments in the UHMWPE has a denier of about 5 or less, about 4 or less, about 3 or less, about 2.5 or less, about 2 or less, about 1.5 or less, about 1 or less, or about 0.5 or less.

[0041] The UHMWPE fiber may include any suitable number of microfilaments. In some embodiments, the UHMWPE fiber includes 2-400 microfilaments, 10-300 microfilaments, 10-50 microfilaments, 5-50 microfilaments, 5-25 microfilaments, or 20-200 microfilaments. In some embodiments, the UHMWPE fiber includes 5, 7, 10, 15, 20, 25, 30, 35, 40, 45, or 50 microfilaments.

[0042] The UHMWPE fibers may be of any denier suitable for pantyhose. In some embodiments, the UHMWPE fibers have a denier ranging from about 10 to about 250. In some embodiments, the UHMWPE fibers have a denier ranging from about 10 to about 60. In some embodiments, the UHMWPE fibers have a denier of about 10, about 15, about 20, about 25, about 30, about 40, about 50, about 60, about 70, about 75, about 80, about 90, about 100, about 110, about 120, about 125, about 130, about 140, about 150. In some embodiments, the UHMWPE fibers have a denier of 50 or less.

[0043] In some embodiments, the UHMWPE fibers are high strength fibers. In some embodiments, the UHMWPE fibers have a tensile strength (i.e., tenacity) of at least 20 cN / dtex, at least 25 cN / dtex, at least about 30 cN / dtex, at least about 35 cN / dtex, at least about 40 cN / dtex, at least about 45 cN / dtex, at least about 50 cN / dtex, or at least about 60 cN / dtex. In some embodiments, the UHMWPE fibers have a tensile strength of about 26 cN / dtex, about 28 cN / dtex, about 30 cN / dtex, about 32 cN / dtex, about 36 cN / dtex, about 40 cN / dtex, about 45 cN / dtex, or about 50 cN / dtex.

[0044] In some embodiments, the UHMWPE fibers have a modulus of about 1000 cN / dtex or more, about 1100 cN / dtex or more, about 1200 cN / dtex or more, about 1300 cN / dtex or more, about 1400 cN / dtex or more, about 1500 cN / dtex or more, about 1600 cN / dtex or more. In some embodiments, the UHMWPE fibers have a modulus of about 1400 cN / dtex, about 1420 cN / dtex, about 1450 cN / dtex, about 1500 cN / dtex, or about 1360 cN / dtex.

[0045] In some embodiments, the UHMWPE fibers permit elongation of about 10% or less, about 8% or less, about 5% or less, about 4% or less, about 3.5% or less, about 3% or less, about 2.5% or less, about 2% or less, or about 1.5% or less.

[0046] In some embodiments, the UHMWPE fibers have a breaking force of about 10 N or greater, about 11 N or greater, about 12 N or greater, about 13 N or greater, about 14 N or greater, about 15 N or greater, about 16 N or greater, about 18 N or greater, or about 20 N or greater.

[0047] In some embodiments, the UHMWPE fibers have a breaking work of at least about 100 N·mm, at least about 110 N·mm, at least about 120 N·mm, at least about 130 N·mm, at least about 140 N·mm, at least about 150 N·mm, at least about 160 N·mm, or at least about 170 N·mm.

[0048] In some embodiments, the UHMWPE fiber is a colored UHMWPE fiber that includes a dye. In some embodiments, the dye has a color selected from black, blue, gray, red, blue, brown, yellow, green, orange, and flesh color.

[0049] In some embodiments, the UHMEPE fiber comprises a plurality of microfilaments that are not twisted together. In some other embodiments, the UHMWPE fiber is twisted together to keep the filaments together and to increase strength and reduce pilling. In some embodiments, the UHMWPE fiber has a twists per inch (TPI) of 1-30, 1-20, 1-10, 1-5, 4-25, 6-20, or 8-16. In some embodiments, the UHMWPE fiber has a TPI of 1. In some embodiments, the UHMWPE fiber has a TPI of 2. In some embodiments, the UHMWPE fiber has a TPI of 3. In some embodiments, the UHMWPE fiber has a TPI of 4. In some embodiments, the UHMWPE fiber has a TPI of 5. In some embodiments, the UHMWPE fiber has a TPI of 6. In some embodiments, the UHMWPE fiber has a TPI of 8. In some embodiments, the UHMWPE fiber has a TPI of 10. In some embodiments, the UHMWPE fibers have a TPI of 12. In some embodiments, the UHMWPE fibers have a TPI of 15. In some embodiments, the UHMWPE fibers have a TPI of 16. In some embodiments, the UHMWPE fibers have a TPI of 18. In some embodiments, the UHMWPE fibers have a TPI of 20. In some embodiments, the UHMWPE fibers have a TPI of 25. In some embodiments, the UHMWPE fibers have a TPI of 30.

[0050] In various aspects, the UHMWPE fibers described herein can be produced according to the methods described in U.S. Publication No. US20220056620.

[0051] In some embodiments, the UHMWPE fiber has a color variation along the length of the UHMWPE fiber. In some embodiments, the color variation along the length of the UHMWPE fiber is less than ±2.5%, less than ±3%, less than ±3.5%, less than ±4%, less than ±5%, less than ±6%, less than ±7%, less than ±8%, or less than ±9%, or less than ±10%.

[0052] The use of UHMWPE fibers provides benefits to the knit, such as cooling effect, light weight, moisture wicking, and / or antimicrobial. The tensile properties of UHMWPE fibers also provide increased resistance to tearing, snagging, or other wear or defects. In some embodiments, the UHMWPE fibers have a denier variation along the length of the UHMWPE fiber. In some embodiments, the denier variation along the length of the UHMWPE fiber is less than ±2.5%, less than ±3%, less than ±3.5%, less than ±4%, less than ±5%, less than ±6%, less than ±7%, less than ±8%, or less than ±9%, or less than ±10%. In some embodiments, the UHMWPE fibers have a variation in diameter along the length of the UHMWPE fiber that is less than ±2.5%, less than ±3%, less than ±3.5%, less than ±4%, less than ±5%, less than ±6%, less than ±7%, less than ±8%, or less than ±9%, or less than ±10%. In some embodiments, the UHMWPE fibers have a substantially circular cross-sectional shape. In some embodiments, the UHMWPE fibers have a substantially oval cross-sectional shape. In some embodiments, the UHMWPE fibers have a substantially stadium cross-sectional shape. In some embodiments, the UHMWPE fibers have a substantially oval cross-sectional shape. In some embodiments, the UHMWPE fibers have a cross-sectional shape that remains substantially constant along the length of the fiber.

[0053] The amount of UHMWPE fiber in the knit can range from about 10% to about 90% by weight, based on the total amount of fiber in the knit. In some embodiments, the amount of UHMWPE fiber in the knit ranges from about 15% to about 80% by weight, from about 20% to about 80% by weight, from about 30% to about 70% by weight, or from about 40% to about 60% by weight.

[0054] In some embodiments, the knit comprises a plurality of UHMWPE fibers, each of which includes a plurality of microfilaments, each of which has a denier of 5 or less. Each of the UHMWPE fibers may include 50 or less microfilaments.

[0055] The companion fiber is selected to enhance the properties of the knit, such as, but not limited to, the comfort, durability, dyeability / printability, and / or stretchability of the knit. In some embodiments, the companion fiber comprises a single fiber. In some other embodiments, the companion fiber comprises multiple fibers.

[0056] The companion fibers may be synthetic fibers, natural fibers, stretch fibers, non-stretch fibers, high performance fibers, elastomeric fibers, thermoplastic fibers, or abrasion resistant fibers, or combinations of any of the foregoing fibers.

[0057] In some embodiments, the companion fiber comprises a synthetic fiber. Examples of organic synthetic fibers include those made from: polyolefins such as polyethylene, polypropylene, high molecular weight polypropylene, UHMWPE, polybutylene, etc.; polyamides such as nylon; polyesters such as polyethylene terephthalate, polyethylene naphthalate, poly(ethylene succinate), polymethyl methacrylate, etc.; 1,2-polybutadiene; and copolymers of these polymers.

[0058] In some embodiments, the companion fiber comprises a natural fiber. Examples of natural fibers include cotton, silk, wool, and the like.

[0059] In some embodiments, the companion fiber comprises an elastic fiber. Examples of elastic fibers include those made from polyurethane, polyolefins such as low molecular weight polyethylene or polypropylene, and the like.

[0060] In some embodiments, the companion fiber comprises a non-elastic fiber. Examples of non-elastic fibers include those made from or including polyester, cotton, nylon, rayon, and / or wool.

[0061] In some embodiments, the companion fiber comprises a high performance fiber. Examples of high performance fibers include high molecular weight polypropylene, aramid, high molecular weight polyvinyl alcohol, high molecular weight polyacrylonitrile, and liquid crystalline polyester.

[0062] In some embodiments, the companion fiber comprises an elastomeric fiber. Examples of elastomeric fibers include spandex (also known as elastane), lastol, polyurethane, and polyetherester.

[0063] In some embodiments, the companion fiber comprises a thermoplastic fiber. Examples of thermoplastic fibers include those made from polyamides, polyimides, polyurethanes, polyolefins, polystyrenes, aromatic polyesters, polycarbonates, polyketones, polyureas, polyvinyls, polyacrylates, and polymethacrylates.

[0064] In some embodiments, the companion fiber comprises an abrasion resistant fiber. Examples of abrasion resistant fibers include those made from nylon, polyester, and polyamide.

[0065] A companion fiber may include any suitable number of microfilaments, hi some embodiments, the companion fiber includes 2-400 microfilaments, 10-300 microfilaments, 10-200 microfilaments, 10-150 microfilaments, 10-100 microfilaments, 10-50 microfilaments, 5-50 microfilaments, or 20-200 microfilaments.

[0066] The companion fiber may be of any denier suitable for pantyhose. In some embodiments, the companion fiber has a denier ranging from about 2 to about 100, about 5 to about 100, about 10 to about 100, or about 15 to about 100. In some embodiments, the companion fiber has a denier of about 5, about 10, about 13, about 15, about 17, about 20, about 25, about 30, about 50, about 60, about 70, about 80, or about 90. In cases where the knit includes multiple companion fibers, the multiple companion fibers may have the same denier or different denier from one another.

[0067] In some embodiments, the companion fiber allows for an elongation of greater than 100%. In some embodiments, the companion fiber has an elongation of about 130% or more, about 200% or more, about 300% or more, or about 400% or more.

[0068] In some embodiments, the companion fiber is a colored fiber that includes a pigment. In some embodiments, the companion fiber has a black, blue, gray, red, blue, brown, yellow, green, orange, or flesh color. In some embodiments, the companion fiber is white. In some embodiments, the companion fiber has the same color as the UHMWPE fiber. In some other embodiments, the companion fiber has a different color than the UHMWPE fiber.

[0069] The knit has high dimensional stability, hi some embodiments, the dimensional stability of the knit in each of the length and width directions is about ±6%, about ±4%, about ±2%, about ±1%, or about ±0.5%.

[0070] In some embodiments, the knit has a denier of about 150 or less, about 120 or less, about 100 or less, about 80 or less, about 60 or less, about 50 or less, about 40 or less, or about 30 or less. For example, the knit has a denier of 10-200, 20-100, 20-50, 10-40, or 20-40.

[0071] Method for manufacturing a pantyhose article comprising UHMWPE In another aspect, a method for manufacturing the knit is provided. The knit of the present disclosure is manufactured by knitting UHMWPE fibers and companion fibers using a knitting machine. The appropriate gauge of the knitting machine is selected according to the type of pantyhose. The gauge number of the knitting machine can affect the stretchability and basis weight of the resulting knit. The knit may have a gauge in the range of 10 to 40. In some other embodiments, the knit has a gauge in the range of 28 to 32, which is suitable for manufacturing knits for pantyhose or sheer hosiery. In some embodiments, the knit may have a gauge of at least 32.

[0072] In some embodiments, a single knit type knitting machine is used. The cylinder size of the knitting machine is selected according to the final use of the knit. In some embodiments, the knitting machine has a cylinder having a size of about 3 inches to about 14 inches, about 10 to about 14 inches, or about 3 inches to about 7 inches, suitable for producing knits for pantyhose. In some embodiments, no cylinder is used.

[0073] In knitting the fabric of the present disclosure, a conventional knitting machine can be used as a basis. The knitting machine can have any desired number of feeds depending on the number required to cover the number of fiber types being knitted and the speed at which knitting will be performed. Typically, the knitting machine has 2, 4, or 8 feeds, the most common being 4 or 8 feeds. In some embodiments, the knitting machine can be used with more than 8 feeds. In some embodiments, the knitting machine can be used with more than 16 feeds. In one embodiment of the present disclosure, the garment is made using a 4-feed hosiery knitting machine. In knitting the garment of the present disclosure, each feed can use fibers having a denier in the range of 10-50 denier. The total denier of the fibers that make up the garment can be any desired depending on the weight of the pantyhose to be produced and the level of sheerness desired. In some embodiments, all of the feeds are used. In some embodiments, only one feed is used. In some embodiments, only two feeds are used. In some embodiments, only three feeds are used. In some embodiments, the same UHMWPE fibers with the same properties and the same property variance are used in all feeds. In some embodiments, the same UHMWPE fibers with the same properties and different property variance are used in all feeds. In some embodiments, different UHMWPE fibers with different properties and different property variance are used in all feeds. In some embodiments, different UHMWPE fibers with different properties and the same property variance are used in all feeds.

[0074] In some embodiments, the braider may include a tensioner to maintain a constant tension on each of the fiber feeds. In some embodiments, the tension is constant along the length of each individual fiber feed. In some embodiments, the tension is constant along the length of each individual fiber feed. In some embodiments, the variation in tension along the length of the UHMWPE fiber feed is less than ±2.5%, less than ±3%, less than ±3.5%, less than ±4%, less than ±5%, less than ±6%, less than ±7%, less than ±8%, or less than ±9%, or less than ±10%. In some embodiments, the variation in tension between different UHMWPE fiber feeds is less than ±2.5%, less than ±3%, less than ±3.5%, less than ±4%, less than ±5%, less than ±6%, less than ±7%, less than ±8%, or less than ±9%, or less than ±10%.

[0075] To effectively achieve stretch in the final knit without compromising the strength properties provided by the UHMWPE fiber, knitting of the UHMWPE fiber and companion fiber involves plating or serving of the UHMWPE fiber and companion fiber.

[0076] In some embodiments, to effectively achieve stretchability in the final knit without compromising the strength properties provided by the UHMWPE fiber, the UHMWPE fiber and the companion fiber are knitted to form a plating knit structure. In knitting the plating knit, the UHMWPE fiber is required in every course of the knit, and the companion fiber can be present in every course or every other course. In some embodiments, the plating knit includes UHMWPE fiber in each course and companion fiber in at least every other course, and has a denier not greater than 30. In some embodiments, the plating knit includes UHMWPE fiber in each course and companion fiber in at least every other course, and has a denier not greater than 40. In some embodiments, the plating knit includes UHMWPE fiber in each course and companion fiber in at least every other course, and has a denier not greater than 50. In some embodiments, the plating knit comprises UHMWPE fibers in each course and companion fibers in at least every other course, and has a denier not exceeding 60. In some embodiments, the plating knit comprises UHMWPE fibers in each course and companion fibers in at least every other course, and has a denier of about 20, about 25, about 30, about 35, about 40, about 45, about 55, about 55, or about 65. After the knitting process, one side of the knit has more prominently exposed UHMWPE fibers and the companion fibers are exposed on the other side.

[0077] In some other embodiments, the UHMWPE fiber and the companion fiber are twisted together to form a composite fiber to effectively achieve stretchability in the final knit without compromising the strength properties provided by the UHMWPE fiber. This twisting forms a served composite fiber. In some embodiments, the UHMWPE fiber and the companion fiber are twisted together at 100 to 4500 twists per meter (TPM). A higher twist per meter may be desirable because it ensures that the companion fiber has a larger surface area that is reinforced by the UHMWPE fiber, resulting in a higher stretchability in the final product and a higher durability in the final knit. In some embodiments, the UHMWPE fiber and companion fiber have a TPM of 100, the UHMWPE fiber and companion fiber have a TPM of 500, the UHMWPE fiber and companion fiber have a TPM of 1000, the UHMWPE fiber and companion fiber have a TPM of 1500, the UHMWPE fiber and companion fiber have a TPM of 2000, the UHMWPE fiber and companion fiber have a TPM of 2500, the UHMWPE fiber and companion fiber have a TPM of 3000, the UHMWPE fiber and companion fiber have a TPM of 3500, the UHMWPE fiber and companion fiber have a TPM of 4000, and the UHMWPE fiber and companion fiber have a TPM of 4500. In some embodiments, the UHMWPE fibers and companion fibers have a TPM of 2 to 100. In some embodiments, the UHMWPE fibers and companion fibers have a twists per inch (TPI) of 3, a TPI of 5, a TPI of 10, a TPI of 15, a TPI of 20, a TPI of 25, a TPI of 30, a TPI of 40, or a TPI of 50.

[0078] In some embodiments, the knit is made with UHMWPE fibers and nylon-coated spandex fibers as companion fibers. Both the UHMWPE fibers and the companion fibers may be textured or flat. In some embodiments, the nylon has a denier in the range of 1 to 20. In some embodiments, the nylon has a denier in the range of 5 to 20. In some embodiments, the nylon is a multifilament fiber containing 5 to 16 microfilaments. In some embodiments, the nylon-coated spandex fiber is formed by coating a monofilament spandex fiber having a denier of 17 with a nylon fiber containing 5 to 20 microfilaments and having a denier in the range of 1 to 20. In some embodiments, the knit has alternating courses of UHMWPE fibers and nylon-coated spandex fibers, where the spandex fiber is a monofilament fiber having a denier of 40 and the nylon fiber is a multifilament fiber containing 7 microfilaments and having a denier of 20. In some embodiments, the resulting knit has a denier ranging from 15 to 60. In some embodiments, the resulting knit has a denier of about 40.

[0079] In some embodiments, the knit is made using UHMWPE fibers and nylon fibers. The nylon fibers are multifilament fibers containing 40 microfilaments and having a denier of 40.

[0080] Pantyhose articles comprising UHMWPE In one aspect, the present disclosure provides a pantyhose article. Referring to FIG. 1, a front view of a pantyhose article 1 according to an example embodiment is shown when placed on a quality control apparatus. The quality control apparatus typically has two panel members spaced apart from each other, each panel member receiving a respective leg member of the pantyhose article under quality control testing. The leg members are stretched over the panel members, allowing visual inspection of the quality of the leg members of the pantyhose article. The body member of the pantyhose article is also stretched between the panel members of the quality control apparatus, which also allows visual inspection of the quality of the body member of the pantyhose.

[0081] 4, 5, 6, 7 and 8 respectively show a front view, a side view, a back view, a bottom view and a top view of a pantyhose article 1 according to an example embodiment when worn. When worn, the pantyhose article 1 stretches to conform to the contours of the wearer.

[0082] The pantyhose article 1 includes first and second tubular members 8 and 16 and a gusset 24 that are suitably joined together to form the pantyhose article 1.

[0083] The first tubular member 8 extends from a waist end 40 of the pantyhose article 1 to a foot end 48 of the first tubular member 8 .

[0084] 1, 4, 5, 6, 7 and 8, the first tubular member 8 corresponds to the right side of the pantyhose article 1, although it will be understood that the actual side (left or right) will depend on the orientation in which the pantyhose article 1 is worn. In various embodiments, the pantyhose article 1 is non-directional in that the first tubular member 8 may be worn interchangeably on the left or right leg. Similarly, according to such embodiments, the second tubular member 16 may be worn interchangeably on the left or right leg.

[0085] The first tubular member 8 includes a plurality of portions corresponding to different knits of the first tubular member 8. The first tubular member 8 includes a first panty portion 56 that extends from the waist end 40 of the pantyhose article 1 to a bottom end 64 of the first panty portion 56. The first panty portion 56 can include at least one waistband 44 at the waist end 40 to ensure a snug fit when the pantyhose article 1 is worn.

[0086] According to the embodiment shown in FIGS. 1, 4, 5, 6, 7 and 8, the bottom end 64 of the first panty portion 56 substantially corresponds to the crotch region of the pantyhose article 1 along its longitudinal direction 72.

[0087] In another embodiment, the bottom end 64 of the first panty portion 56 is disposed along the longitudinal direction 72 lower than the crotch region of the pantyhose article 1 (ie, closer towards the foot end 48).

[0088] The first tubular member 8 also includes a first tubular leg portion 80 that extends from its upper end 88 to the first foot end 48 of the first tubular member 8. The upper end 88 of the first tubular leg portion 80 corresponds to the bottom end 64 of the first panty portion 56. The first tubular leg portion 80 of the first tubular member 56 defines a first leg cavity 92 (FIGS. 2, 8).

[0089] According to one embodiment, the first foot end 48 of the first tubular member 8 can be closed like the end of a closed sock, as shown in Figures 1, 4, 5 and 6. In another embodiment, the first foot end 48 of the first tubular member 8 can have an opening like a footless pantyhose, such that the first foot end 48 is positioned adjacent the wearer's ankle when the pantyhose article 1 is worn. In yet another embodiment, the first foot end 48 of the first tubular member 8 can be partially open (e.g., having a loop member (e.g., stirrup, toe strap) to secure the first tubular member 8 when worn, while leaving the wearer's foot at least partially exposed).

[0090] The pantyhose article 1 also includes a second tubular member 16 that extends from the waist end 40 of the pantyhose article 1 to a foot end 104 of the second tubular member 16 .

[0091] The second tubular member 16 includes a plurality of portions corresponding to different knits of the second tubular member 16. The second tubular member 16 includes a second panty portion 112, which extends from the waist end 40 of the pantyhose article 1 to a bottom end 120 of the second panty portion 112. The bottom end 120 of the second panty portion 112 may be substantially aligned with the bottom end 64 of the first panty portion 56. To ensure a snug fit when the pantyhose article 1 is worn, the second panty portion 112 may also include at least one waistband. The waistband may be the same as the waistband 44 of the first tubular member 8.

[0092] 1, 4, 5 and 6, the bottom end 120 of the second panty portion 112 substantially corresponds along its longitudinal direction 72 to the crotch region of the pantyhose article 1. In another embodiment, the bottom end 120 of the first panty portion 112 is disposed along the longitudinal direction 72 lower (i.e., closer towards the foot end 104) than the crotch region of the pantyhose article 1.

[0093] The second tubular member 16 also includes a second tubular leg portion 128 that extends from its upper end 136 to the second foot end 104 of the second tubular member 16. The upper end 136 of the second tubular leg portion 128 corresponds to the bottom end 120 of the second panty portion 112. The second tubular leg portion 128 of the second tubular member 16 defines a second leg cavity 138 (FIGS. 2, 8).

[0094] According to one embodiment, the second foot end 104 of the second tubular member 16 can be closed like the end of a closed sock, as shown in Figures 1, 4, 5 and 6. In another embodiment, the second foot end 104 of the second tubular member 16 can have an opening like a legless pantyhose, such that the second foot end 104 is positioned adjacent the wearer's ankle when the pantyhose article 1 is worn. In yet another embodiment, the second foot end 104 of the second tubular member 16 can be partially open (e.g., having a loop member (e.g., stirrup, toe strap) to secure the second tubular member 16 when worn, while leaving the wearer's foot at least partially exposed).

[0095] According to one embodiment, and as shown in Figs. 1, 4, 5 and 6, the first tubular leg portion 80 of the first tubular member 8 includes a first main sub-portion 140 and a first transition sub-portion 148. The first main sub-portion 140 extends from a first thigh region 156 of the first tubular leg portion 80 to a first foot end 48 of the first tubular member 8 of the pantyhose article 1. The first transition sub-portion 148 extends between the bottom end 64 of the first panty portion 56 and an upper end of the first main sub-portion 140. More specifically, the first transition sub-portion 148 extends from an upper end 88 of the first tubular leg portion 80 to the first thigh region 156 of the first tubular leg portion 80. It will be appreciated that the upper end of the first transition sub-portion 148 corresponds to the upper end 88 of the first tubular leg portion 80 , which also corresponds to the bottom end 64 of the first panty portion 56 .

[0096] According to one embodiment, and as shown in Figures 1, 4, 5 and 6, the second tubular leg portion 128 of the second tubular member 16 has a configuration corresponding to that of the first tubular leg portion 80. The second tubular leg portion 128 of the second tubular member 16 includes a second main sub-portion 160 and a second transition sub-portion 164. The second main sub-portion 160 extends from a second thigh region 168 of the second tubular leg portion 128 to the second foot end 104 of the second tubular member 16 of the pantyhose article 1. The second transition sub-portion 164 extends between the bottom end 120 of the second panty portion 112 and the top end of the second main sub-portion 160. More specifically, the second transition sub-section 164 extends from the upper end 136 of the second tubular leg portion 128 to a first thigh region 168 of the second tubular leg portion 128. It will be appreciated that the upper end of the second transition sub-section 164 corresponds to the upper end 136 of the second tubular leg portion 128, which also corresponds to the bottom end 120 of the second panty portion 112.

[0097] The longitudinal edges 172 of the first panty portion 56 are joined to the longitudinal edges 180 of the respective second panty portions 112 to form a panty sleeve 188, which defines a panty cavity 196 (FIG. 2). The edges 172 and 180 may be joined by sewing.

[0098] Fig. 2 is a top perspective view of the inside of a pantyhose article 1 according to one embodiment as it is placed on a quality control apparatus. Fig. 8 is a top view of a pantyhose article 1 according to one embodiment as it is placed on a quality control apparatus (the pantyhose article 1 is shown in an extended state as it would be worn, but for greater clarity, the wearer's body is not shown). The panty cavity 196 is in fluid communication with the first leg cavity 92 defined by the first tubular leg portion 80 and also in fluid communication with the second leg cavity 138 defined by the second tubular leg portion 128.

[0099] When the pantyhose article 1 is worn, the panty cavity 196 receives the wearer's lower torso. The first leg cavity 92 receives a first leg (e.g., the right leg) of the wearer, and the second leg cavity 138 receives a second leg (e.g., the left leg) of the wearer.

[0100] A lower region of the longitudinal edge 172 of the first panty part 56 (i.e., the region closer to the bottom end 64 of the first panty part 56) is further joined, e.g., by sewing, to a corresponding lower region of the longitudinal edge 180 of the second panty part 112 (i.e., the region closer to the bottom end 120 of the second panty part 112) via the gusset 24. In this way, at least one edge of the bottom end 64 of the first panty part 56 is joined, e.g., by sewing, to the gusset 24, and at least one edge of the bottom end 120 of the second panty part 112 is also joined, e.g., by sewing, to the gusset 24.

[0101] Reference is now made to Figure 3, which shows a bottom view of the crotch area of ​​a pantyhose article 1 according to one embodiment when placed on a quality control apparatus, and Figure 7 shows a bottom view of a pantyhose article according to one embodiment when worn. A first bottom edge 204 of the first panty portion 56 is directly joined (e.g., directly sewn) to a first edge 212 at a first end of the gusset 24, a second bottom edge 220 of the first panty portion 56 is directly joined (e.g., directly sewn) to a first edge 228 at a second end of the gusset 24, a first bottom edge 236 of the second panty portion 112 is directly joined (e.g., directly sewn) to a second edge 244 at a first end of the gusset 24, and a second bottom edge 252 of the second panty portion 112 is directly joined (e.g., directly sewn) to a second edge 262 at a second end of the gusset 24.

[0102] According to the embodiment shown in Figures 1-8 in which the bottom ends 64 and 120 of the first and second panty sections 56, 112 substantially correspond to the crotch region of the pantyhose article 1, the first transition subsection 148 is directly joined to the gusset 24, and the second transition subsection 164 is also directly joined to the gusset 24. As best shown in Figure 3, an intermediate region 268 of the first edge of the gusset 24 (corresponding to the portion of the edge disposed between the first edge 212 at the first end and the first edge 228 at the second end of the gusset 24) is directly joined (e.g., directly sewn) to a portion of the edge 276 of the first transition subsection 148. The joined portion may be at the top edge 88 of the first transition subsection 148. Furthermore, an intermediate region 284 of the second edge of the gusset 24 (corresponding to a portion of the edge disposed between the second edge 244 at the first end and the second edge 260 at the second end of the gusset 24) is directly joined (e.g., directly sewn) to a portion of the edge 292 of the second transition sub-portion 164. The joined portion may be at the upper edge 136 of the second transition sub-portion 164. Thus, the first panty portion 56, the second panty portion 112, the gusset 24, the first transition sub-portion 148 and the second transition sub-portion 164 are suitably joined to close the crotch region of the pantyhose article 1 (i.e., ensure that there are no openings or gaps) and enclose the panty cavity 196.

[0103] According to an alternative embodiment in which the bottom end 64 of the first panty portion 56 and the bottom end 120 of the second panty portion 112 are both disposed along the longitudinal direction 72 below the crotch region of the pantyhose article 1, a first side of the gusset 24 is directly joined (e.g., directly sewn) to a corresponding region of the longitudinal edge 172 of the first panty portion 56, and a second side of the gusset 24 is directly joined (e.g., directly sewn) to a corresponding region of the longitudinal edge 180 of the second panty portion 112 to close (i.e., ensure that there are no openings or gaps) the crotch region of the pantyhose article 1 and enclose the panty cavity 196. According to the alternative embodiment, the top edges 88, 136 of the first and second leg portions 80 and 128 are not directly joined (e.g., directly sewn) to the gusset 24.

[0104] 1-8, the thigh region 156 of the main sub-portion 140, which corresponds to the bottom end of the first transition sub-portion 148, is disposed in the mid-thigh region of the first tubular leg member 80, which corresponds to the mid-thigh region of the wearer's first leg when the pantyhose article 1 is worn. Thus, the transition sub-portion 148 extends from the crotch region of the pantyhose article 1 to the mid-thigh region of the first tubular leg member 8. The second transition sub-portion 164 also extends along the corresponding region of the second tubular leg member 16.

[0105] According to another embodiment, the thigh region 156 of the main sub-portion 140 is disposed in the upper thigh region of the first tubular leg member 80, which corresponds to the upper thigh region of the wearer's first leg when the pantyhose article 1 is worn. Thus, the transition sub-portion 148 extends from the crotch region of the pantyhose article 1 to the upper thigh region of the first tubular leg member 8. The second transition sub-portion 164 also extends along a corresponding region of the second tubular leg member 16.

[0106] According to yet another example, the thigh region 156 of the main sub-portion 140 is disposed in the crus region of the first tubular leg portion 80 (i.e., adjacent the knee region), which corresponds to the crus region of the wearer's first leg when the pantyhose article 1 is worn. Thus, the transition sub-portion 148 extends from the crotch region of the pantyhose article 1 to the crus region of the first tubular leg member 8. The second transition sub-portion 164 also extends along a corresponding region of the second tubular leg member 16.

[0107] According to yet another embodiment, the top end 88 of the first tubular leg portion 80 and also the bottom end 64 of the first panty portion 56 corresponding to the top end of the first transition sub-portion 148 are disposed along the longitudinal direction 72 below the crotch region of the pantyhose article 1, and the thigh region 156 of the main sub-portion 140 (e.g., the thigh region of the first tubular member 8) corresponding to the bottom end of the first transition sub-portion 148 is disposed in the mid-thigh region of the first tubular leg portion 80, which corresponds to the mid-thigh region of the first leg of the wearer when the pantyhose article 1 is worn. Thus, the transition sub-portion 148 extends from below the crotch region of the pantyhose article 1 to the mid-thigh region of the first tubular leg portion 80. The second panty portion 112 and the second transition sub-portion 164 also extend along the corresponding region of the second tubular leg member 16.

[0108] According to yet another embodiment, the top end 88 of the first tubular leg portion 80 and also the bottom end 64 of the first panty portion 56 corresponding to the top end of the first transition sub-portion 148 are disposed along the longitudinal direction 72 below the crotch region of the pantyhose article 1, and the thigh region 156 of the main sub-portion 140 (e.g., the thigh region of the first tubular member 8) corresponding to the bottom end of the first transition sub-portion 148 is disposed in the lower leg region of the first tubular leg portion 80 (i.e., adjacent to the knee region), which corresponds to the lower leg region of the wearer's first leg when the pantyhose article 1 is worn. Thus, the transition sub-portion 148 extends from below the crotch region of the pantyhose article 1 to the lower leg region of the first tubular leg portion 80. The second panty portion 112 and the second transition sub-portion 164 also extend along the corresponding region of the second tubular leg member 16.

[0109] It will be understood that in each of the embodiments described herein in which the first and second leg portions 80 and 128 include respective transition sub-portions 148 and 164, the transition sub-portions 148, 164 always extend between the bottom ends 64, 120 of the respective panty portions 56, 112 and the respective thigh regions 156, 168 of the tubular leg portions 80, 128. The length and location of the transition sub-portions 148, 164 will vary depending on whether or not the top ends of the transition sub-portions 148, 164 are located in the crotch region of the pantyhose article 1 and where the thigh regions 156 and 168 of the tubular leg portions 80, 128 are located.

[0110] According to one embodiment, and as shown in the drawings, the first main subsection 140 of the first tubular leg 80 is formed from a first knit including a first UHMWPE fiber and at least one first companion fiber. The first transition subsection 148 of the first tubular leg 80 is formed from a second knit including a second UHMWPE fiber and at least one second companion fiber. The first knit of the first main subsection 140 of the first tubular leg 80 is different from the second knit of the first transition subsection 148 of the first tubular leg 80.

[0111] According to one embodiment, the first knit of the first main subsection 140 differs from the second knit 148 of the first transition subsection in that the knitting pattern of the first knit differs from the knitting pattern of the second knit. Knitting pattern, as it relates to the first and second knits, refers to how the UHMWPE fiber and at least one companion fiber in a given knit interfere with each other within the knit. Differences in knitting patterns can include, but are not limited to, how the UHMWPE fiber and at least one companion fiber loop around or hook around each other, and / or which UHMWPE fiber(s) and / or companion fiber(s) are present on the course of the knit.

[0112] According to one example embodiment, a first knit of the first main subsection 140 differs from a second knit of the first transition subsection 148 in that a first UHMWPE fiber of the first knit differs from a second UHMWPE fiber of the second knit. The first and second UHMWPE fibers may differ in one or more of their color, denier, tensile strength, tensile stress, twists per turn, or coated / uncoated.

[0113] According to one embodiment, a first knit of the first main subsection 140 differs from a second knit of the second transition subsection 148 in that at least one first companion fiber of the first knit differs from at least one second companion fiber of the second knit. The set of at least one first companion fiber can include at least one companion fiber that is not found in the set of at least one second companion fiber, or vice versa. The set of at least one second companion fiber can include at least one of the first companion fibers, but can also include at least one additional second companion fiber that is not found in the set of at least one first companion fiber, or vice versa. In one embodiment, the at least one second set of companion fibers includes all of the at least one first set of companion fibers, but also includes at least one additional second companion fiber not found in the at least one first set of companion fibers. Any of the first and second fibers may differ in one or more of their fiber type, fiber material, fiber construction, fiber construction, color, denier, tensile strength, tensile stress, coated / uncoated, and the like.

[0114] In one embodiment, the second knit of the first transition subsection 148 is reinforced compared to the first knit of the first main subsection 140. For example, the second knit of the first transition subsection 148 has the same UHMWPE fiber as the first UHMWPE fiber of the first main subsection 140, and the second knit of the first transition subsection 148 also includes at least one companion fiber that is the same as the at least one first companion fiber of the first main subsection 140, but the second knit of the first transition subsection 148 includes at least one additional companion fiber that is woven within the second knit to provide additional reinforcement to the second knit of the first transition subsection 148 compared to the first knit of the first main subsection 140.

[0115] The second knit of the first transition sub-section 148 may be more resistant to sewing as compared to the first knit of the first main sub-section 140 of the first tubular leg portion 80. As used herein, greater resistance to sewing refers to the second knit's resistance to being punctured by a sewing needle from a sewing operation during assembly and / or the second knit being more resistant to tearing from a pulling force applied by one or more threads sewn into the second knit from a sewing operation.

[0116] The second knit of the first transition subsection 148, if torn or cut, may have a higher resistance to runs than the first knit of the first main subsection 140 of the first tubular leg section 80. Resistance to runs refers to resistance to successive running tears or cuts in the longitudinal direction 72 of the tubular leg member 1 after an initial tear or cut occurs.

[0117] According to one embodiment, the second knit of the first transition subsection 148 includes a mesh knit. A mesh knit refers to a knit in which no loops are made in the yarn of the feed in every given number of courses of the feed that knits the mesh knit. For example, the mesh knit can be a 1×1 knit, in which for every course in which a loop is made, no loops are made in the second course. The mesh knit can be a 3×1 knit, in which for every three courses in which a loop is made, no loops are made in the fourth course. The mesh knit can be a 5×1 knit, in which for every five courses in which a loop is made, no loops are made in the sixth course. In a preferred embodiment, the mesh knit can be a 7×1 knit, in which for every seven courses in which a loop is made, no loops are made in the eighth course. It has been observed that the mesh knit provides resistance to runs in that whenever a break or tear occurs in the second knit, the run caused by the break or tear continues until it crosses over a position in the knit where no loops were made due to the mesh knit. The absence of a given loop then stops the run. By having a mesh knit in which the absence of loops occurs frequently enough, the mesh knit provides resistance to runs if a second knit tears or breaks.

[0118] According to one example embodiment, the mesh knit of the second knit of the first transition subsection 148 is configured such that the location of the skipped loops (i.e., the course in which no loops are made) in a given row of the second knit is offset from the location of the skipped loops in the immediately succeeding row of the mesh knit. This misalignment of the skipped loop locations between different rows of the mesh knit improves resistance to runs by ensuring that any run at any given angular position of the tubular leg member will eventually encounter the location of a skipped loop.

[0119] According to an example embodiment, the second knit of the first transition subsection 148 includes a plain knit combined with a mesh knit. The plain knit is also commonly referred to as a jersey knit. The plain knit of the second knit can be formed from a second UHMWPE and a companion fiber of the second knit, where the second UHMWPE is the same as the first UHMWPE of the first knit of the first main leg subsection 140, and the companion fiber of the second knit is the same as the first companion fiber of the first knit. The mesh knit of the second knit can be formed from at least one additional companion fiber of the second knit that is woven within the plain knit to form the mesh knit according to the configuration of the mesh knit. For example, when knitting a plain knit, at least one additional companion fiber of the second knit is appropriately looped with the loops of the plain knit according to the configuration of the mesh knit, and at least one additional companion fiber of the second knit is appropriately skipped (i.e., not looped) with the loops of the plain knit according to the configuration of the mesh knit. More specifically, in an n×1 mesh knit of additional companion fibers of the second knit, in every n courses of the plain knit formed from UHMWPE and the second companion fiber, the additional companion fiber is also looped with the loops of the plain knit, and in every n+1 course of the plain knit, the additional companion fiber is not looped with the plain knit.

[0120] According to one example embodiment, the mesh knit is fabricated within the second knit to provide resistance to runs in a direction along the longitudinal direction 72 toward the foot end 48. That is, the mesh knit provides resistance to runs that initiate (e.g., from a cut or tear) near the top end 40 of the first tubular leg member 8 and travel toward the foot end 48 such that the run is limited from continuing downward toward the foot end 48 by encountering the mesh knit.

[0121] The second transition subsection 164 of the second tubular leg 128 can be formed from the same second knit as the first transition subsection 148 of the first tubular leg 80, the second knit including at least one second UHMWPE fiber and at least one companion elastic fiber. Thus, the second knit of the second transition subsection 164 differs from the first knit of the second main subsection 160 according to various manners described herein.

[0122] According to one embodiment, the first panty portion 56 of the first tubular member 8 is formed from a knit that is free of (i.e., does not include) UHMWPE. Thus, the first panty portion 56 can be formed from a knit of one or more stretchable fibers that are free of UHMWPE. It has been observed that UHMWPE fibers are by far the most expensive material in the pantyhose article 1. It has also been observed that the first panty portion 56 is typically worn under one or more other layers of clothing and is not directly exposed to objects in the environment that may cause tearing, rupture or pilling. Thus, there is less need to reinforce the first panty portion 56 with a knit that includes UHMWPE to obtain increased tear resistance properties. It has further been observed that the first panty portion 56 is therefore an appropriate area in which UHMWPE can be omitted in the pantyhose article 1 without substantially reducing the performance of the pantyhose article 1. However, and as described elsewhere herein, additional accommodations may be required elsewhere in the pantyhose article 1 to accommodate for the first panty portion 56 being formed from a UHMWPE-free knit. The second panty portion 112 of the second tubular member 16 can also be formed from a UHMWPE-free knit in the same manner as the first panty portion 56. The first panty portion 56 and the second panty portion 112 can be formed from the same knit.

[0123] The first tubular member 8 is formed or manufactured in a continuous knitting operation. More specifically, the first panty section 56, the first change subsection 148 and the first main subsection 140 are formed within the same continuous knitting operation. A continuous knitting operation refers to a single continuous run of a knitting machine, such as a circular knitting machine, in which the various portions of the first tubular member 8 resulting from the continuous knitting operation (e.g., the first panty section 56, the first change subsection 148 and the first main subsection 140) are continuous or integrally formed. In such a continuous knitting operation, after knitting a given portion of the first tubular member 8 (e.g., the first panty section 56), the next portion of the first tubular member 8 (e.g., the first change subsection 148) is knitted by continuing from the last interface of the fibers of the just-completed given portion (e.g., the last loop of the knit forming the first panty section 56). Knitting continues by replacing the fiber and pattern of a given portion just completed and continuing knitting with the appropriate fiber and pattern of the next portion of the first tubular member 8. It will be appreciated that the continuous knitting operation of the first tubular member 8 does not produce the first panty portion 56, the first transition sub-portion 140 and the first main sub-portion 148 as separate and discontinuous pieces that need to be subsequently joined together in any manner (e.g., through sewing the pieces together) at any point during the knitting operation.

[0124] It has been observed that interfaces between different knits within the first tubular member 8 may result in weak spots within the first tubular member 8. The weak spots may result in defects, such as ruptures or tears, occurring within the pantyhose article 1 at such interfaces. The defects may occur due to repeated stresses applied to the pantyhose article 1, such as from repeated pulling and stretching in the longitudinal direction 72 as the wearer puts on the pantyhose article 1. The transitions may also cause discomfort when the pantyhose article 1 is worn.

[0125] The continuous knitting of the first panty section 56 and the second knit of the first transition subsection 148 reduces tears along the transition between these two subsections, which transition corresponds to the bottom end 64 of the first panty section 56. The second knit of the first transition subsection 148 is also selected to improve durability and reduce tears along this transition at the bottom end 64. According to one embodiment, one of the one or more elastic fibers used in the knit of the first panty section 56 is also present in the second knit of the first transition subsection 148, which ensures continuity of the knit at the transition between the panty section 56 and the first transition subsection 148, and thereby reduces the possibility of tears. This transition can also improve comfort.

[0126] The continuous knitting of the first transition subsection 148 and the main subsection 140 reduces tearing along the transition between these two sections, which corresponds to the first thigh region 156 of the tubular leg section 80. The second knit of the first transition subsection 148 and the first knit of the first main subsection 140 are selected to improve durability and reduce tearing along this transition at the first thigh region 156. According to one embodiment, the same combination of UHMWPE and companion fiber of the first knit of the first main subsection 140 is also present in the second knit of the first transition subsection 148, which ensures continuity of the knit at the transition between the first transition subsection 148 and the main subsection 140, and thereby reduces the possibility of tearing. This transition can also improve comfort.

[0127] It will be appreciated that the inclusion of the first transition sub-section 148 within the first tubular leg member 8 creates two knit transitions: a first transition between the first panty section 56 and the first transition sub-section 148 at the bottom end 64 of the first panty section 56, and a second transition between the first transition sub-section 148 and the first main sub-section 140 at the thigh region 156. Thus, tensile forces applied in the longitudinal direction 72 of the first tubular member 8, for example from a wearer donning the pantyhose article 1, are distributed between the first transition and the second transition. This distribution of tensile forces reduces the likelihood of tearing, as compared to a first tubular member 8 having a single transition (e.g., a single transition from the panty section 56 directly to the first main sub-section 140).

[0128] As described herein above, the second knit of the first transition subsection 148 can be optionally selected such that there is a continuity between the knit of the first panty section 56 and the second knit of the first transition subsection 140 provided by these two knits having a common fiber with their respective knits. Furthermore, the second knit of the first transition subsection 148 can be optionally selected such that there is a continuity between the knit of the first transition subsection 148 and the first knit of the first main subsection 140 provided by these two knits having at least one common fiber within their respective knits. It has been observed that if the knit of the first panty section 56 is made thin enough to be worn covertly under a close-fitting garment (e.g., less than 200 total denier), a direct transition of the lower denier first panty section 56 to the first knit of the main subsection 140 is prone to tearing. The addition of the first transition sub-section 148 as an intermediate knit between the first panty section 56 and the first knit of the main sub-section 140 addresses this weakness that would otherwise be present in a tubular member essentially containing only the first panty section and the main sub-section.

[0129] According to one embodiment, the first panty portion 56 is formed of a knit having a total denier of about 20 to about 250. It will be appreciated that the knit of the first panty portion 56 has a sufficiently low denier so that it can be worn under a close-fitting garment such as a hip-hanging dress or skirt. According to one embodiment, the first panty portion 56 is formed essentially of a knit of nylon fibers having a denier of about 20 to about 100, and nylon-coated elastane fibers having a denier of about 20 to about 120. In one embodiment, the nylon fibers are two-ply 40 denier nylon fibers, and the nylon-coated elastane fibers are composed of two strands of 20 denier elastane coated with 40 denier nylon.

[0130] It will be appreciated that the first main subsection 140, when worn on the leg, will typically be exposed to environmental elements that may cause tearing and / or rupture. The first knit of the first main subsection 140 is selected to have at least tear-resistant and pilling-resistant properties. Because the first main subsection 140 will be exposed and seen, the first knit is also selected to have the desired aesthetic characteristics. According to one example embodiment, the first UHMWPE fiber of the first knit of the first main subsection 140 includes a first UHMWPE fiber having a denier number of about 10 to about 60, and the first companion fiber has a denier number of about 10 to about 100. The first UHMWPE fiber and the first companion fiber can be knitted in a plating knit according to various example embodiments having different appearances described herein.

[0131] According to one example embodiment in which the first major subsection 140 should have a sheer appearance, the first UHMWPE fiber of the first knit has a denier of about 25 to about 35 and the first companion fiber essentially comprises an elastic fiber having a denier of about 10 to about 20. According to one example embodiment, the first UHMWPE fiber has a denier of about 30 and the elastic fiber is a nylon coated elastane of about 15 denier.

[0132] According to one example embodiment, where the first major subsection 140 should have a semi-sheer appearance, the first UHMWPE fibers of the first knit have a denier of about 25 to about 35 and the first companion fibers include fibers having a total denier of about 40 to about 80. According to one example embodiment, the first UHMWPE fibers have a denier of about 30 and the companion fibers include one or more nylon-coated elastane fibers having a total denier of about 50.

[0133] According to one example embodiment, where the first major subsection 140 should have an ultra-sheer appearance, the first UHMWPE fibers of the first knit have a denier of about 10 to about 20 and the first companion fibers include fibers having a total denier of about 5 to about 15. According to one example embodiment, the first UHMWPE fibers have a denier of about 15 and the first companion fibers are coated elastane fibers of about 9 denier.

[0134] According to one example embodiment, where the first major subsection 140 should have a translucent appearance, the first UHMWPE fibers of the first knit have a denier of about 25 to about 50 and the first companion fibers include fibers having a total denier of about 60 to about 150. According to one example embodiment, the first UHMWPE fibers have a denier of about 30 and the first companion is a coated elastane fiber of about 75 denier.

[0135] According to one embodiment, the second knit of the first transition subsection 148 is formed from a second UHMWPE fiber having a denier of about 10 to about 60, and the second companion fiber has a total denier of about 50 to about 150. According to one embodiment of the second knit to be combined with the first main subsection 140 having a sheer appearance, the second UHMWPE fiber of the second knit also has a denier of about 25 to about 35, preferably about 30 denier, and this UHMWPE is knitted with a second companion fiber, preferably about 15 denier covered elastane, essentially comprising an elastic fiber having a denier of about 10 to about 20. The second UHMWPE fiber and this second companion fiber can be knitted in a plating knit. It will be understood that the UHMWPE fiber and the companion fiber are common to both the first knit of the main subsection 140 and the first transition subsection 148. The second knit of the first transition subsection 148 also includes a mesh knit as described elsewhere herein. The mesh knit may be formed with an additional companion fiber including a nylon-coated Lycra fiber having a denier of about 40 to about 120, preferably two strands of 20 denier elastane coated with a 40 denier nylon. It will be understood that the additional companion fiber of the second knit of the first transition subsection 148 is also present in the knit of the first panty section 56.

[0136] According to one embodiment, and as shown in Figures 1, 4, 5, 6, 7 and 8, the first tubular member 8 is manufactured in a non-directional manner about its longitudinal axis 212. That is, before being assembled with the gusset 24 and the second tubular member 16, the first tubular member 8 is identical at every angular position about its longitudinal axis 212. The first panty portion 56 extends circumferentially about the longitudinal axis 212 such that cuts can be made at any angular position about the longitudinal axis 212 to form its longitudinal edge 172 for joining to a corresponding edge 180 of the second panty portion 112. The second tubular member 16 can be manufactured in a similarly non-directional manner about its respective axis.

[0137] The first transition subsection 148 also extends circumferentially about the longitudinal axis 212 and about the first tubular leg 80. According to the embodiment in which the edge of the first transition subsection 148 is directly joined to the edge of the gusset 24, the joint between that edge 228 of the first transition subsection 148 and that edge of the gusset 24 can be made at any angular position of the tubular leg 80 about the longitudinal axis 212 (as long as this angular position is common to both the first main subsection 140 and the first transition subsection 148). That is, the joint does not have to be made at a precise angular region / position of the circumferential edge 228 of the first transition subsection 148 that is predefined after making the first tubular leg 80. The second transition subsection 164 can also extend circumferentially about the second tubular leg 128 about its respective axis.

[0138] Furthermore, the cut in the first panty portion 56 may be made in the longitudinal direction 72 from the top edge 40 toward the bottom edge 64 and extend slightly into the first transition sub-portion 148. This cut would otherwise cause a run in the first tubular member 8, but the run is limited from continuing toward the foot end 48 of the first tubular member 8 due to the presence of a reinforcing knit (e.g., mesh knit) in the first transition sub-portion 148. Furthermore, since the first transition sub-portion 148 extends circumferentially about the first tubular member 8, the cut can be made at any angular position about the axis 212, and the reinforcing knit of the first transition sub-portion 148 will provide a limit to the continuation of the run. The second transition sub-portion 164 of the second tubular leg portion 128, which extends circumferentially about its respective axis, provides a similar limit to the continuation of the run caused by making a cut in the second panty portion 112 to form the longitudinal edge 180.

[0139] As described elsewhere herein according to various embodiments, the first and second transition sub-portions 148, 164 of the first and second leg portions 80 and 128, respectively, extend between the bottom ends of the respective panty portions 56, 112 and the respective thigh regions 156, 168 of the tubular leg portions 80, 128. Due to this location, when the pantyhose article 1 is worn, the first and second transition sub-portions 148, 164 will be disposed in the thigh regions of each leg of the wearer. Moreover, because each of the first transition sub-portion 148 and the second transition sub-portion 164 extends circumferentially about their respective leg portions 80, 128, when the pantyhose article 1 is worn, a first inner thigh region at thigh level of a first leg of a wearer will be covered by a first corresponding angular region of the first transition sub-portion 148, and a second inner thigh region at thigh level of a second leg of a wearer will be covered by a second corresponding angular region of the second transition sub-portion 164. It will be understood that the first corresponding angular region of the first transition sub-portion 148 will face the second corresponding single region of the second transition sub-portion 164 (since the first inner thigh region of the first leg will face the second inner thigh region of the second leg) when the pantyhose article 1 is worn. It has been observed that friction between the first and second inner thigh regions of the wearer is a common cause of wear or tear on the legwear. It has further been observed that the location of the first transition sub-portion 148 and the second transition sub-portion 164 at thigh height on the respective first and second tubular leg portions provides greater protection against wear or tear on the pantyhose article 1 due to inner thigh friction. It will be appreciated that the second knit of the first and second transition sub-portions 148, 164 is a knit that includes a knit of UHMWPE fibers with at least one companion fiber, and the inclusion of the more durable UHMWPE fibers provides increased protection against wear or tear on the knit.

[0140] According to a method for manufacturing a pantyhose article 1 according to one embodiment, a first tubular member 8 is manufactured. As described herein, the first tubular member 8 is manufactured in a continuous knitting operation, for example, using a circular knitting machine. A second tubular member 16 is also manufactured. As described herein, the second tubular member 16 is also manufactured in a continuous knitting operation, for example, using a circular knitting machine.

[0141] After forming the first tubular member 8 and the second tubular member 16, the tubular members 8, 16 are appropriately cut and joined to form the pantyhose article 1. The fact that the first tubular member 8 is manufactured in a non-directional manner, with the first panty portion 56 extending circumferentially about the longitudinal axis 212 and the first transition sub-portion 148 also extending circumferentially about the longitudinal axis 212 (and the second tubular member 16 having these same characteristics) allows the pantyhose article 1 to be assembled in a substantially automated process. An automated assembly process herein refers to one or more machine cutting, aligning and / or joining (e.g., sewing lines) without manual human intervention. After both the first tubular member 8 and the second tubular member 16 are knitted by a knitting machine, the tubular members 8 and 16 are appropriately loaded into the automated assembly machine. Because the first tubular member 8 has a first panty portion 56 that is non-directional and extends circumferentially about the longitudinal axis 212, the cut in the longitudinal direction 72 can be at any angular position of the first tubular member 8 to form the longitudinal edge 172 of the panty portion 56. A cut can be made in a similar manner to form the longitudinal edge 180 of the second tubular member 16.

[0142] Moreover, according to the embodiment in which the edge of the first transition sub-section 148 is directly joined to the edge of the gusset 24, since the first transition sub-section 148 extends circumferentially about the longitudinal axis 212, any area of ​​the upper edge 228 of the transition sub-section 140 is suitable for sewing to the gusset 24. The edge 228 of the transition sub-section 140 that corresponds to the angular position where the cut is made in the panty portion 56 of the first tubular member 8 is joined (e.g., sewn) to the gusset 24. The join (e.g., sewing line) to the gusset 24 can be made in a similar manner as in the second transition sub-section 164.

[0143] The longitudinal edge 172 of the first panty portion 56 is further joined (e.g., sewn) to the longitudinal edge 180 of the second panty portion 112 to form a panty sleeve 188. The edges of the panty portions 56, 112 are further sewn to corresponding edges of the gusset 24 to close any gaps and enclose a panty cavity 196.

[0144] It will be appreciated that depending on the construction and capabilities of the assembly machine, the above steps for automatically assembling the pantyhose article 1 may be performed in a different order than that described, and furthermore, one or more steps may be performed in a single operation (e.g., sewing multiple edges together in a single sewing operation).

[0145] As described elsewhere herein, the first tubular member 8 and the second tubular member 16 are made in a continuous knitting operation on a circular knitting machine. According to some example embodiments, the tubular leg members 8, 16 are formed by continuously feeding fibers from the same number of yarn feeds of the knitting machine throughout the continuous knitting operation, i.e., throughout knitting the panty section 56, 112, the transition subsection 148, 164, and the main subsection 140, 160. In one embodiment, the tubular leg members 8, 16 are each formed using two feeds of the knitting machine throughout the continuous knitting operation.

[0146] It was observed that the first and second main subsections 140, 160 and the first and second transition subsections 148, 164, each formed from a knit with UHMWPE, required knitting with a smaller number of feeds (i.e., 2 feeds or less) due to the complexity introduced by the properties of UHMWPE. It was also observed that the panty section 56, 112, which is UHMWPE free, could be knitted with a higher number of feeds of the knitting machine (i.e., more than 2 feeds, e.g., 4 feeds or more). It was further observed that the transition from knitting with 4 feeds or more (to knit panty section 56, 112) to knitting with 2 feeds or less (to knit transition subsections 148, 164 and main subsections 140, 160) introduced a weakness in the tubular leg members 8, 16 at the location of the transition. This weakness could be in the form of a hole in the tubular leg members 8, 16 at the transition. However, it was also observed that knitting the tubular leg members 8, 16 by continuously feeding the fibers from the same number of feeds of the knitting machine throughout the entire continuous knitting operation eliminated this weakness, thereby increasing the strength / durability of the knit.

[0147] While the above description provides examples of embodiments, it will be understood that certain features and / or functions of the described embodiments are susceptible to modification without departing from the spirit and operating principles of the described embodiments. Accordingly, what is described above is intended to be illustrative and non-limiting, and it will be understood by those skilled in the art that other variations and modifications may be made without departing from the scope of the invention as defined in the claims appended hereto.

Claims

1. 1. A pantyhose article comprising: a first panty portion extending from a waist end of the panty hose article to a bottom end of the first panty portion; a first tubular leg portion defining a first leg cavity and extending from its upper end corresponding to a bottom end of the first panty portion to a first foot end of the first tubular leg portion, the first tubular leg portion including a first main sub-portion and a first transition sub-portion, the first main sub-portion extending from a first thigh region of the first tubular leg portion to the first foot end, and the first transition sub-portion extending from the upper end of the first tubular leg portion to the first foot end of the first tubular leg portion; a first tubular leg section extending to a first thigh region of the tubular leg section, the first main subsection being formed from a first knit including a first ultra-high molecular weight polyethylene (UHMWPE) fiber and at least one first companion fiber, and the first transition subsection being formed from a second knit including a second UHMWPE fiber and at least one second companion fiber, the first knit being different from the second knit; A first tubular member having 4. A pantyhose article comprising:

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

3. 3. The pantyhose article of claim 2, wherein the second knit of the first transition sub-section has a higher durability against stitching than the first knit of the first main sub-section of the first tubular leg section.

4. 4. The pantyhose article of claim 2 or 3, wherein the second knit of the first transition subsection has a higher resistance to runs, if torn or cut, than the first knit of the first main subsection of the first tubular leg section.

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

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

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

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

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

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

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

12. 12. The pantyhose article of claim 11, wherein the equal number of yarn feeds is no more than two feeds.

13. The pantyhose article according to any one of claims 1 to 12, wherein the first panty part is formed from a UHMWPE-free knit.

14. The pantyhose article according to any one of the preceding claims, wherein the knit of the first panty part and the second knit of the first transition sub-part have at least one fibre in common.

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

16. 16. The pantyhose article of claim 15, wherein the first UHMWPE fiber and the at least one first companion fiber are interwoven in a plating knit in the first knit of the first main subsection; wherein the second UHMWPE fiber of the second knit of the first transition subsection is the same as the first UHMWPE fiber of the first knit; wherein at least one of the second companion fibers of the second knit of the first transition subsection is the same as at least one of the first companion fibers of the first knit; wherein the second UHMWPE fiber and at least one second companion fiber, which is the same as the at least one first companion fiber, are interwoven in a second knit of the first transition subsection; wherein the second knit of the first transition subsection further comprises at least one additional companion fiber; Pantyhose items.

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

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

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

20. 20. The pantyhose article of claim 19, wherein the second UHMWPE fiber of the first transition subsection has a denier of about 25 to about 35, and the at least one second companion fiber comprises at least one elastic fiber having a total denier of about 10 to about 20 braided with the second UHMWPE fiber; and wherein the at least one second companion fiber further comprises an additional companion fiber reinforcing the second knit of the first transition subsection; Pantyhose items.

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

22. A second tubular member, a second panty portion extending from a top end of the panty hose article to a bottom end of the second panty portion aligned with the bottom end of the first panty portion; a second tubular leg portion defining a second leg cavity and extending from an upper end thereof corresponding to a bottom end of the second panty portion to a second foot end of the second tubular leg portion, the second tubular leg portion including a second main sub-portion and a second transition sub-portion, the second main sub-portion extending from a second thigh region of the second tubular leg portion to a second foot end, the second transition sub-portion extending from an upper end of the second tubular leg portion to a second thigh region of the second tubular leg portion, the second main sub-portion being formed from a first knit including a first UHMWPE fiber and at least one first companion fiber, and the second transition sub-portion being formed from a second knit including a second UHMWPE fiber and at least one second companion fiber. A second tubular member having Further comprising: wherein the longitudinal edges of the first panty portion are joined to respective longitudinal edges of the second panty portion to form a panty tubular portion defining a panty cavity for receiving a wearer's lower torso, the panty cavity being in fluid communication with the first leg cavity of the first tubular leg portion, and the panty cavity being in fluid communication with the second leg cavity of the second tubular leg portion. A pantyhose article according to any one of the preceding claims.

23. The pantyhose article of claim 22, wherein the first transition sub-portion formed from the second knit having the second UHMWPE fibers and the second transition sub-portion formed from the second knit having the second UHMWPE fibers provide protection against abrasion of the first transition sub-portion and the second transition sub-portion from friction of the inner thighs of a person wearing the pantyhose article.

24. 1. A method for manufacturing a pantyhose article, comprising: forming a first tubular member, the first tubular member comprising: a first panty portion extending from a waist end of the pantyhose article to a bottom end of the first panty portion; and a first tubular leg portion defining a first leg cavity and extending from an upper end thereof corresponding to a bottom end of the first panty portion to a first foot end of the first tubular leg portion, the first tubular leg portion including a first main sub-portion and a first transition sub-portion, the first main sub-portion extending from a first thigh region of the first tubular leg portion to the first foot end, and the first transition sub-portion extending from the upper end of the first tubular leg portion to the first thigh region of the first tubular leg portion; and extending circumferentially about the first tubular leg portion, the first main subsection being formed from a first knit including a first ultra-high molecular weight polyethylene (UHMWPE) fiber and at least one first companion fiber, and the first transition subsection being formed from a second knit including a second UHMWPE fiber and at least one second companion fiber, the first knit being different from the second knit. a process comprising: forming a second tubular member, wherein the second tubular member comprises: a second panty portion extending from a top end of the panty hose article to a bottom end of the second panty portion aligned with the bottom end of the first panty portion; and a second tubular leg portion defining a second leg cavity and extending from an upper end thereof corresponding to a bottom end of the second panty portion to a second foot end of the second tubular leg portion, the second tubular leg portion including a second main sub-portion and a second transition sub-portion, the second main sub-portion extending from a second thigh region of the second tubular leg portion to a second foot end, the second transition sub-portion extending from an upper end of the second tubular leg portion to the second thigh region of the second tubular leg portion and extending circumferentially about the second tubular leg portion, the second main sub-portion being formed from a first knit including a first UHMWPE fiber and at least one first companion fiber, and the second transition sub-portion being formed from a second knit including a second UHMWPE fiber and at least one second companion fiber. a process comprising: cutting the first panty portion along its length to form a first longitudinal edge therein, and cutting the second panty portion along its length to form a second longitudinal edge therein; joining a first longitudinal edge of the first panty portion to a second longitudinal edge of the second panty portion to form a panty tubular portion defining a panty cavity for receiving a wearer's lower torso, wherein the panty cavity is in fluid communication with the first leg cavity of the first tubular leg portion and the panty cavity is in fluid communication with the second leg cavity of the second tubular leg portion; and joining a longitudinal edge of the first panty portion to a first edge of the gusset, and joining a longitudinal edge of the second panty portion to a second edge of the gusset. A method comprising:

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

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

27. 27. The method of claim 26, wherein the equal number of yarn feeds is no more than two feeds.

28. 28. The method according to any one of claims 24 to 27, further comprising joining an angle region of an edge of the first transition subsection to a first edge of the gusset, and joining an angle region of an edge of the second transition subsection to a second edge of the gusset.

Images