Open-knit apparel comprising ultra-high molecular weight polyethylene homo or hybrid yarns

Abstract

Embodiments pertain to the use of ultra-high molecular weight polyethylene (UHMWPE) yarns to create fishnet hosiery and apparel with higher tear resistance and burst strength than conventional fishnet apparel. This approach allows for the creation of durable, stretchable, and comfortable garments suitable for both fashion and technical applications.

Description

OPEN-KNIT APPAREL COMPRISING ULTRA-HIGH MOLECULAR WEIGHT POLYETHYLENE HOMO OR HYBRID YARNS AND METHOD OF MANUFACTURING USING THE SAMETECHNICAL FIELD

[0001] The present disclosure relates to apparel, more specifically to hosiery and fishnet tights, made by knitting yams comprising of ultra-high molecular weight polyethylene (UHMWPE) fiber into textiles. These yarns may be homo or hybrid UHMWPE yarns. This disclosure relates to apparel, more specifically to hosiery and fishnet tights, made by warp knitting homo or hybrid ultra-high molecular weight polyethylene (UHMWPE) yarns, into textiles.BACKGROUND

[0002] In textile manufacturing, weft knitting, and warp knitting are distinguished by the orientation and movement of the yarns. Weft knitting involves horizontal yams forming rows of loops, creating fabrics with significant stretchability, commonly used in garments like t-shirts and hosiery. In contrast, warp knitting involves vertically aligned yarns interlinked through needles, producing more stable and durable fabrics. This method, utilizing machines such as Raschel or tricot knitting machines, is ideal for applications requiring specific fabric characteristics, such as swimwear, lingerie, and technical textiles. Warp knitting is particularly advantageous for producing fishnet tights due to its ability to create stable, open structures with consistent hole sizes. The process begins with yarns prepared on a warped beam, ensuring consistent tension and alignment, feeding multiple yams into the knitting machine to form complex, stable patterns.

[0003] Fishnet tights are a popular type of hosiery characterized by an open, diamondshaped knit pattern. Traditionally, these tights are made on warp knitting machines from materials like nylon, which, while providing elasticity, lack durability. Fishnet knits, typically used in women’s intimates and apparel, have very low burst strength due to the low tensile strength of the low denier yarn used to achieve fishnet look. There is a need for fishnet tights that offer enhanced strength and durability without compromising the desired stretch and comfort.

[0004] Prior technologies in the space of strong or rip-resistant hosiery have not been able to achieve strength in an open mesh or fishnet structure. This is due to the fact that existingtechnology to produce rip-resistant hosiery is only applicable to sheer circular knit hosiery garments, not fishnets. Circular or flat knitting uses a weft knit structure which does not allow for the large holes that are part of a fishnet design to be connected at all points with high tensile strength material, therefore allowing the garment to come apart at a variety of break points. There is a need for a knit that achieves the fishnet style with a higher burst strength.DETAILED DESCRIPTION

[0005] Embodiments of the invention pertain to a fishnet hosiery that achieves a high burst strength through the warp knitting of a high tensile strength yarn (ex; UHMWPE) into a honeycomb where all sides of the honeycomb include the high tensile strength material. In one example of the invention the breaking point required to achieve tear resistance is ION of force per 30 denier, substantially higher than the tensile strength of conventional materials used in fishnet hosiery (z.e., nylon, spandex, polyester). Embodiments provide fishnet hosiery for women’s apparel that is incredibly difficult to break by hand, with the result of producing a longer lasting garment.

[0006] In accordance with embodiments of the present invention for high burst strength hosiery, a knit is configured to comprise at least one UHMWPE fiber on every parallel path of the knitting machine in the case of warp knitting or every horizontal path in the case of weft knitting. Those UHMWPE fibers may be homo or hybrid yams. When knit the UHMWPE homo or hybrid fibers cover all edges of the knit honeycomb. In one application of this invention, this is achieved by placing the high tensile strength material on the jacquard beam, also sometimes referred to as the jacquard bar, of the warp knitting machine and the floor bar. The jacquard bar is normally reserved for stretch yarns when producing conventional fishnets but must be repurposed for a high tensile strength material to ensure that every parallel path is covered with UHMWPE. In another application of this invention, stretch yams with high elongation may also be included on the parallel paths of the knit to achieve not just high burst strength, but stretch in the final garment. This disclosure provides for a warp knit that is produced from beams of an ultra-high molecular weight polyethylene (UHMWPE) fiber to achieve strength. In some embodiments, the warp knit of the present disclosure is made from the UHMWPE fiber in combination with other fibers to achieve additional properties like stretch in the final garment.

[0007] The present disclosure provides for fishnet tights made using a warp knitting machine that employs an UHMWPE fiber alone and in combination with one or more fibers ofother polymers to create warp knit. The UHMWPE fiber is known for its exceptional strength and high breaking point, while additional fiber(s) can add additional properties such as elasticity and comfort. The resulting knits are significantly stronger than warp knits consisting just of conventional materials such as nylon and spandex, making them more durable and less prone to tearing or laddering.

[0008] The fishnet tights of the present disclosure are constructed using a warp knitting machine. The machine utilizes an UHMWPE fiber which may be combined with one or more stretch fibers either through the addition of other beams being fed into the warp knitting machine or by using a hybrid yam. In order to ensure the strength of embodiments of the resultant knit, a UHMWPE fiber is on every interlocking loop, providing strength to all sides of the characteristic mesh pattern. This can be either a homo UHMWPE yam or a hybrid yam. For warp knits, the UHMWPE yarn is on every parallel path. Those yarns are vertically knit down the product. For weft knits the UHMWPE yarn is present on every row. The machine’s settings, including needle spacing and yarn tension, are carefully controlled to achieve the desired size and shape of the holes in the knit.

[0009] As used herein, the term “denier” refers to a unit of weight indicating the fineness of fiber filaments. It may be measured in mass in grams per 9,000 meters.

[0010] As used herein, the term homo UHMWPE yarn refers to a yam that consists only of UHMWPE.

[0011] As used herein, the term hybrid UHMWPE yam refers to a yarn that consists of UHMWPE and at least one other polymer.

[0012] The term “tensile strength” used herein relates to the durability of the garment and is measured by the maximum stress that a material may withstand while being stretched or pulled before breaking. It is measured as force per unit area and may be expressed in units of gram force (gf) and centi-newton (cN) per denier.

[0013] The term “elongation” used herein refers to the stretch of individual fibers and composite yarns which results in the elasticity of the final embodiment of the present invention. Elongation is measured as a percentage of the starting length.

[0014] The term “fiber” used herein refers to a single origin base material made up of one or more filaments.

[0015] The term “filament” used herein refers to a single fibril of material that may be on its own a fiber or may be combined with other filaments to create a multifilament fiber.

[0016] The term “yam” used herein refers to 1 or more fibers combined and fed into a knitting needle.

[0017] The term “warp knit” used herein refers to the knitting of numerous parallel yams that are looped vertically at the same time.

[0018] The term “weft knit” used herein refers to the knitting of a single yarn looped horizontally to form a row, or course, with each row building on the previous one.

[0019] The term “UHMWPE” stands for ultra high molecular weight polyethylene fibers, also known as high-modulus polyethylene, (HMPE), or high-performance polyethylene (HPPE).

[0020] The term “burst strength” used herein refers to the strength of material in pounds per square inch.

[0021] The term “stretch yam” used herein refers to any yarn with an elongation of higher than 6%.

[0022] The term “jacquard bar” used herein refers to one beam of yams used in a warp knitting machine used to achieve more diverse patterns.

[0023] Embodiments of the present invention relate primarily to the use of high tensile strength yams in a warp knit to create fishnet hosiery with higher tear resistance and burst strength than conventional fishnet apparel. The present disclosure addresses the need for more durable fishnet tights by incorporating ultra-high molecular weight polyethylene (UHMWPE) fibers, known for their high tensile strength and durability, into warp knit structures. The use of a warp knitting machine enables the formation of warp knit structures that are not achievable with weft knitting. The present disclosure allows for precise control over the knitting pattern, ensuring that the tights retain their characteristic flexibility and aesthetic appeal while significantly improving their strength and durability.

[0024] Fishnets may not be effectively produced on a weft knitting machine due to the limitations in creating stable open structures with consistent hole sizes. Weft knitting machines, which interlock yarns horizontally, are typically used to produce fabrics with a tighter, more uniform loop structure. Thus, they lack the capability to form the large, evenly spaced openings characteristic of fishnet fabric. Additionally, the stretch characteristics of weft knits are predominantly horizontal, which does not provide the necessary strength and shape retention required for fishnet tights. Warp knitting machines, however, are designed to manipulate multiple yams in a vertical orientation, allowing for the precise control needed to create the intricate and stable open patterns of fishnet fabrics. Unlike existing technologies that producecircular knits, or sheets of tightly woven technical material using UHMWPE, the present disclosure focuses on the production of strong open knits.

[0025] The process of warp knitting begins with the preparation of yams on a warped beam, a crucial component in ensuring consistent tension and alignment of the fibers. The warped beam holds a large number of yarns, which are wound in parallel to maintain equal tension across all fibers. During the knitting process, this beam feeds the yarns into the machine, where they are guided into the needles. This setup allows for the simultaneous handling of multiple yams, essential for creating the complex interlinked structures characteristic of warpknit fabrics. The tension and feed rate of the yams are carefully controlled to ensure uniformity in the fabric’s construction, making the warped beam an indispensable element in the warp knitting process, particularly in applications like fishnet tights where precise patterning and fabric stability are critical.

[0026] This disclosure provides for a warp knit that is produced from beams of UHMWPE fiber to achieve strength. In some embodiments, the warp knit of the present disclosure is made from the UHMWPE fiber in combination with other fibers to achieve additional properties like stretch in the final garment.

[0027] The present disclosure introduces a novel approach to producing warp-knitted fabrics using ultra-high molecular weight polyethylene (UHMWPE) fibers, distinguished by two primary warp beam configurations: one utilizing a beam made from hybrid yams of UHMWPE and stretch fibers, and the other using a beam consisting solely of UHMWPE fibers. This disclosure is significantly differentiated from prior art by its innovative combination of materials and techniques, leading to fabrics with unique properties not previously achievable in warp knitting.

[0028] In a first configuration, UHMWPE fibers are spun together with secondary fibers to create a hybrid yarn. The UHMWPE fibers in that hybrid yarn may be twisted or untwisted. This yam combines properties like stretch with the strength of UHMWPE. In an exemplary embodiment of this hybrid yam UHMWPE fiber is twisted to 110 twists per meter before being spun around a spandex fiber to create a yarn with both high strength and stretch. This yarn can then be warped onto a beam, ensuring consistent tension and alignment, and subsequently fed into a warp knitting machine to produce tights. The resulting fabric, characterized by a fishnet structure, exhibits exceptional burst strength and significant elasticity. The use of UHMWPE imparts high tensile strength and durability, while in this example the addition of the stretch fibers enhances elasticity and comfort. This combination is particularly advantageous as itmerges the traditionally rigid characteristics of UHMWPE with the flexibility required for comfortable garments, making it ideal for products such as tights and activewear.

[0029] A second configuration focuses on fabrics comprising UHMWPE fibers that are in the form of a homo UHMWPE yam, meaning they have not been combined with a secondary fiber before knitting. Fabrics made using these yarns offer enhanced stability, reduced stretch, and superior resistance to abrasion, suitable for technical textiles and protective clothing where durability and dimensional stability are critical. A warp knit consisting of homo UHMWPE yarns represents a novel application of this material, exploiting its strength and lightweight properties to create robust, long-lasting fabrics with open holes. Homo yams can be warped onto beams alone or warped onto beams with fibers of other polymers. They can also be warp knit as a single beam or in combination with beams consisting of other polymers.

[0030] Embodiments of the invention are distinctive from the existing technologies in that they address the challenge of integrating UHMWPE, a material known for its high strength and low flexibility, into the warp knitting process. By combining UHMWPE with stretch fibers or utilizing it exclusively, certain embodiments achieve a balance of strength, durability, and other properties like elasticity that is unprecedented in the field. The resulting fabrics offer a versatile solution for both fashion and industrial applications, demonstrating significant advancements in textile technology. This innovative approach expands the potential uses of UHMWPE in textiles, pushing the boundaries of what may be achieved with warp knitting techniques.

[0031] The UHMWPE fibers used in embodiments of the present disclosure provide enhanced strength and durability to the knits over anything in the market today. In some embodiments, the fiber uses polyethylene of molecular weight (Mw) of at least about 200,000. In some embodiments, the UHMWPE fiber has a weight average molecular weight (Mw) ranging from about 300,000 to about 8,000, 000, from about 700,000 to about 5,000,000, or from about 900,000 to about 4,000,000.

[0032] In some embodiments, the UHMWPE fiber used has a cross-sectional shape substantially resembling a circle. In some embodiments, the UHMWPE fiber has a cross- sectional shape substantially resembling an oval. In some embodiments, the UHMWPE fiber has a cross-sectional shape substantially resembling an ellipse. In some embodiments, the UHMWPE fiber has a cross-sectional shape that remains substantially constant along the length of the fiber. In instances where the warp-knitted structure comprises a plurality of UHMWPEfibers, the plurality of UHMWPE fibers may have the same or different cross-sectional shapes from each other.

[0033] In some embodiments, the UHMWPE fiber is a monofilament fiber. In some other embodiments, the UHMWPE fiber is a multifilament fiber comprising multiple filaments. In some embodiments, each of the filaments in the UHMWPE fiber 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.

[0034] The UHMWPE fiber may include any suitable number of filaments. In some embodiments, the UHMWPE fiber comprises 2 to 400 filaments, 5 to 300 filaments, or 20 to 200 filaments. In some embodiments, the UHMWPE fiber comprises 10 to 50 filaments. In some embodiments, the UHMWPE fiber comprises 5 to 50 filaments. In some embodiments, the UHMWPE fiber comprises 5 to 25 filaments. In some embodiments, the UHMWPE fiber comprises 5, 7, 10, 15, 20, 25, 30, 35, 40, 45, or 50 filaments. In instances where the warp knit comprises a plurality of UHMWPE fibers, the plurality of UHMWPE fibers may have the same or different number of filaments from each other.

[0035] The UHMWPE fiber has a denier suitable for use in hosiery, ensuring that the tights remain lightweight and comfortable while providing the desired strength. In some embodiments, the UHMWPE fiber has a denier of about 500 or less, about 450 or less, about 300 or less, about 200 or less, about 150 or less, or about 50 or less. In some embodiments, the UHMWPE fiber has a denier ranging from about 5 to about 450. In some embodiments, the UHMWPE fiber has a denier ranging from about 5 to about 60. In some embodiments, the UHMWPE fiber has a denier ranging from about 150 to about 450. In some embodiments, the UHMWPE fiber has 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, about 175, about 200, about 225, about 250, about 300, about 350, about 400, about 450. In some embodiments, the UHMWPE fiber has a denier of 50 or less. In instances where the warp knit comprises a plurality of UHMWPE fibers, the plurality of UHMWPE fibers may have the same or different deniers from each other.

[0036] In some embodiments, the UHMWPE fiber has a variation of the denier along the length of said UHMWPE fiber. In some embodiments, a variation of the denier along the length of said 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 fiber has a variation of the diameter along the length of saidUHMWPE 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 instances where the warp knit comprises a plurality of UHMWPE fibers, the plurality of UHMWPE fibers may have the same or different variations of deniers from each other. In some embodiments, a variation of the denier among the plurality of UHMWPE fibers is from less than ±2.5% to less than ±10%. In some embodiments, a variation of the denier among the plurality of UHMWPE fibers 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%.

[0037] In some embodiments, the UHMWPE fiber has a tensile strength (z.e., tenacity) of at least 5cN / dex, at least 25 cN / dex, 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 fiber has a tensile strength of about 26 cN / dex, about 28 cN / dex, about 30 cN / dex, about 32 cN / dex, about 38 cN / dex, about 40 cN / dex, about 45 cN / dex, or about 50 cN / dex. In instances where the warp knit comprises a plurality of UHMWPE fibers, the plurality of UHMWPE fibers may have the same or different tensile strengths from each other. In some embodiments, a variation of the tensile strength among the plurality of UHMWPE fibers is from less than ±2.5% to less than ±10%. In some embodiments, a variation of the tensile strength among the plurality of UHMWPE fibers 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%.

[0038] In some embodiments, the UHMWPE fiber has a modulus of about 1000 cN / dtex or greater, about 1100 cN / dtex or greater about 1200 cN / dtex or greater, about 1300 cN / dtex or greater, about 1400 cN / dtex or greater, about 1500 cN / dtex or greater, about 1600 cN / dtex or greater. In some embodiments, the UHMWPE fiber has a modulus of about 1400 cN / dtex, about 1420 cN / dtex, about 1450 cN / dtex, about 1500 cN / dtex, or about 1360 cN / dtex. In instances where the warp knit comprises a plurality of UHMWPE fibers, the plurality of UHMWPE fibers may have the same or different modules from each other. In some embodiments, a variation of the modulus among the plurality of UHMWPE fibers is from less than ±2.5% to less than ±10%. In some embodiments, a variation of the modulus among the plurality of UHMWPE fibers 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%.

[0039] In some embodiments, the UHMWPE fiber allows an elongation of no more than about 10%, no more than about 8%, no more than about 5%, no more than about 4 %, no morethan about 3.5%, no more than about 3%, no more than about 2.5%, no more than about 2%, or no more than about 1.5%. In instances where the warp knit comprises a plurality of UHMWPE fibers, the plurality of UHMWPE fibers may have the same or different elongations from each other. In some embodiments, a variation of the elongation among the plurality of UHMWPE fibers is from less than ±2.5% to less than ±10%. In some embodiments, a variation of the elongation among the plurality of UHMWPE fibers 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%.

[0040] In some embodiments, the UHMWPE fiber has a force at breaking of about 5 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 18N or greater, or about 20 N or greater. In instances where the warp knit comprises a plurality of UHMWPE fibers, the plurality of UHMWPE fibers may have the same or different breaking forces from each other. In some embodiments, a variation of the force at breaking among the plurality of UHMWPE fibers is from less than ±2.5% to less than ±10%. In some embodiments, a variation of the force at breaking among the plurality of UHMWPE fibers 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%.

[0041] In some embodiments, the UHMWPE fiber has a breaking work of at least about 100 N-mm, at least about 110 N-rnm, 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. In instances where the warp knit comprises a plurality of UHMWPE fibers, the plurality of UHMWPE fibers may have the same or different breaking work from each other. In some embodiments, a variation of the breaking work among the plurality of UHMWPE fibers is from less than ±2.5% to less than ±10%. In some embodiments, a variation of the breaking work among the plurality of UHMWPE fibers 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%.

[0042] In some embodiments, the UHMWPE fiber is a colored UHMWPE fiber comprising a pigment. In some embodiments, the pigment has a color selected from black, blue, grey, red, blue, brown, yellow, green, orange, and nude. In instances where the warp knit comprises a plurality of UHMWPE fibers, the plurality of UHMWPE fibers may have the same or different colors from each other.

[0043] In some embodiments, the UHMWPE fiber comprises multiple filaments which are not twisted. In some other embodiments, to keep the filaments together and to increase strength and reduce pilling, the UHMWPE fiber is twisted. In some embodiments, the UHMWPE fiber has a twists per inch (TPI) between 1 to 30, between 4 and 25, between 6 and 20, or between 8 and 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 fiber has a TPI of 12. In some embodiments, the UHMWPE fiber has a TPI of 15. In some embodiments, the UHMWPE fiber has a TPI of 16. In some embodiments, the UHMWPE fiber has a TPI of 18. In some embodiments, the UHMWPE fiber has a TPI of 20. In some embodiments, the UHMWPE fiber has a TPI of 25. In some embodiments, the UHMWPE fiber has a TPI of 30. In instances where the warp knit comprises a plurality of UHMWPE fibers, the plurality of UHMWPE fibers may have the same or different TPIs from each other.

[0044] The UHMWPE fibers are present in an amount sufficient to significantly increase the tensile strength of the fishnet tights compared to those made with conventional materials. The amount of the UHMWPE fiber in most embodiments is at least 5 % by weight based on the total amount of fibers in the warp-knitted structure. For example, in some embodiments, the amount of the UHMWPE fiber in the warp knit may be in the range of about 10% by weight to about 90% by weight based on the total amount of fibers in the warp-knitted structure. In some embodiments, the amount of the UHMWPE fiber in the warp knit ranges from about 15% by weight to about 80% by weight, from about 20% by weight to about 80% by weight, from about 30% by weight by weight to about 70% by weight or from about 40% by weight to about 60% by weight. A higher UHMWPE fiber content means a more durable end product with greater antimicrobial properties.

[0045] Additional polymers may be added through additional beams, in the warping process or as part of a hybrid yarn. Other polymers may provide elasticity and comfort. Examples of stretch polymers which may be added include spandex / lycra (a polyether-polyurea copolymer), elastane, or other elastomeric fibers such as nylon, polyurethane, polyolefins such as low molecular weight polyethylene or polypropylene, polyester, and the like. Other polymersmay be added as mono polymer fibers or may themselves be hybrid yarns when added to the UHMWPE to create a further hybrid yarn or knit structure.

[0046] Fibers and yarns including other polymers may include any suitable number of filaments. In some embodiments, the stretch fiber comprises 1 to 400 filaments, 10 to 300 filaments, 10 to 200 filaments, 10 to 150 filaments, 10 to 100 filaments, 10 to 50 filaments, 5 to 50 filaments, or 20 to 200 filaments.

[0047] The fibers of other polymers may be of any suitable denier. In some embodiments, the stretch fiber has a denier ranging from about 2 to about 1000, from about 10 to about 1000, from about 20 to about 1000. In some embodiments, the stretch fiber has a denier ranging from about 2 to about 100, from about 5 to about 100, from about 10 to about 100, or from about 15 to about 100. In some embodiments, the stretch 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 130, about 150, about 390, about 450, or about 900. In instances where the warp knit comprises a plurality of stretch fibers, the plurality of stretch fibers may have the same or different deniers from each other.

[0048] In some embodiments, the fibers of other polymers may have an elongation of greater than 100%. In some embodiments, the stretch fiber has an elongation of about 130% or greater, about 200 or greater, about 300 or greater, or about 400 or greater. In instances where the warp knit comprises a plurality of fibers, the plurality of fibers may have the same or different elongations from each other.

[0049] In some embodiments, the fibers of other polymers are colored fibers. In some embodiments, the stretch fiber has black, blue, grey, red, blue, brown, yellow, green, orange, or nude color. In some embodiments, the stretch fiber is white in color. In some embodiments, the stretch fiber has the same color as the UHMWPE fiber. In some other embodiments, the stretch fiber has a different color form the UHMWPE fiber.

[0050] In one aspect, a method for manufacturing fishnet tights is provided. The method includes providing a 10 TPI twisted 50 denier UHMWPE fiber and a 50 denier spandex fiber being combined into a hybrid yam that is then warped into a beam with 800 ends of fiber. That beam is then loaded onto a warp knitting machine. The warp knitting machine combines the ends of fibers into a three-dimensional open mesh warp knit pair of tights. As a result, the fishnet tights have enhanced strength and durability due to the inclusion of UHMWPE fibers. In order to ensure the strength of the resultant knit, the UHMWPE fiber is on every interlocking loop, providing strength to all sides of the characteristic mesh pattern. The machine’s settings,including needle spacing and yam tension, must be carefully controlled to achieve the desired size and shape of the holes.

[0051] The tights may be made in different sizes. In some embodiments, the warp knit may be cut into a number of pieces of different sizes to make the tights of different sizes.

[0052] The tights may be made in different colors. For example, the tights may be in black, blue, grey, red, blue, brown, yellow, green, orange, nude, or white color.

[0053] The tights exhibit a higher breaking point than traditional fishnet tights made from nylon or similar materials. In some embodiments, the tights may exhibit a force at break ranging from 10 to 50N, an elongation at break ranging from 200% to 400%, and a burst strength ranging from 20 to 40 psi.

[0054] The present disclosure thus provides an improved article of hosiery, specifically fishnet tights, with enhanced durability and comfort. The use of UHMWPE fibers in combination alone or with fibers of other polymers such as stretch fibers offers a novel solution to the limitations of traditional fishnet tights, making them suitable for a wider range of applications and users.

[0055] The various embodiments described above can be combined to provide further embodiments. All of the U.S. patents, U.S. patent application publications, U.S. patent applications, foreign patents, foreign patent applications and non-patent publications referred to in this specification and / or listed in the Application Data Sheet, including U.S. Provisional Patent Application No. 63 / 520,433, filed August 18, 2023, U.S. Provisional Patent Application No. 63 / 677,882, filed July 31, 2024, and International Patent Application No. PCT / US2024 / 040436, filed July 31, 2024, are incorporated herein by reference, in their entirety. Aspects of the embodiments can be modified, if necessary to employ concepts of the various patents, applications and publications to provide yet further embodiments.

[0056] These and other changes can be made to the embodiments in light of the abovedetailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure.

Claims

CLAIMS1. A warp knit comprising a yam on every parallel path, wherein the yarn comprises an ultra-high molecular weight polyethylene (UHMWPE) fiber.

2. A weft knit comprising a yam on every horizontal path, wherein the yarn comprises an ultra-high molecular weight polyethylene (UHMWPE) fiber.

3. The knit of claim 1 or 2, where the yarn comprises a UHMWPE fiber of 10 - 200 denier.

4. The knit of claims 1 - 3, where at least some of the paths further comprise a stretch yarn.

5. The knit of claim 3, where the yarn comprises a UHMWPE fiber of 10 - 110 denier.

6. The knit of any one of claims 1-5, wherein the UHMWPE fiber is present in an amount greater than 5% by weight based on the total weight of the knit.

7. The knit of any one of claims 1-6, wherein the yarn is a hybrid yarn comprising the UHMWPE fiber and at least one fiber of a second polymer.

8. The knit of claim 7, wherein the at least one fiber of the second polymer is a stretch fiber.

9. The knit of claim 8, wherein the UHMWPE fiber provides for high tensile strength and durability and the stretch fiber provides for elasticity.

10. The knit of any one of claims 8-9, wherein the stretch fiber is spandex or elastane.

11. The knit of any one of claims 1-10, wherein the knit is black, blue, grey, red, blue, brown, yellow, green, orange, nude, or white in color.

12. The knit of any one of claims 1-11, comprising interlocking loops of the yarn, wherein each interlocking loop comprises the UHMWPE fiber.

13. The knit of claim 12, wherein each interlocking loop further comprises a stretch fiber.

14. An article of clothing, preferably a pair of tights comprising the knit of any one of claims 1-13, wherein the article of clothing, preferably the tights, exhibit high strength, elasticity, and durability suitable for fashion and activewear applications.

15. A protective or activewear garment comprising the knit of any one of claims 1-13, wherein the garment provides enhanced abrasion resistance and strength, suitable for industrial or technical applications.

16. A hybrid yarn consisting of at least one ultra-high molecular weight polyethylene (UHMWPE) fiber in combination with at least one fiber of a second polymer.

17. The knit of any one of claims 1-13, comprising the hybrid yarn of claim 14.

18. The hybrid yarn or knit of claim 16 or 17, wherein the UHMWPE fiber has less than 500 denier.

19. The hybrid yarn or knit of any one of claims 16-18, wherein the UHMWPE fiber has less than 250 denier.

20. The hybrid yarn or knit of any one of claims 16-1 , wherein the UHMWPE fiber has less than 150 denier.

21. The hybrid yarn or knit of any one of claims 16-20, where the UHMWPE fiber has 110 or less denier.

22. The hybrid yarn or knit of any one of claims 16-21, wherein the yam comprises a twisted UHMWPE fiber, which is twisted prior to being made into a hybrid yarn.

23. The hybrid yarn or knit of any one of claims 16-22, where the UHMWPE fiber is twisted more than 10 twists per meter before being combined with the second polymer.

24. The hybrid yarn or knit of any one of claims 16-23, wherein the fiber of the second polymer is a stretch fiber.

25. The hybrid yarn or knit of claim 24, wherein the stretch fiber is spandex or elastane.

26. The hybrid yarn or knit of any one of claims 16-25, wherein the UHMWPE fiber covers the fiber of the second polymer.

27. A knit or woven textile comprising the hybrid yam of any one of claims 16-26.

28. The knit or woven textile of claim 27 wherein the knit is a weft knit.

29. The knit or woven textile of claim 27 wherein the knit is a warp knit.

30. The knit or woven textile of claim 27 wherein the knit or woven textile is woven on a loom.

31. A knit pair of tights made using the hybrid yarn of any one of claims 16-26.

32. A warp knit tights in an open fishnet pattern made using the hybrid yarn of any one of claims 16-26.

33. A method for manufacturing the knit of any one of claims 1-13 or 17-30, comprising: i) providing a beam comprising a plurality of UHMWPE fibers; and ii) combining the UHMWPE fibers into a three-dimensional open mesh pattern comprising interlocking loops defining the open mesh pattern, wherein each interlocking loop comprises a UHMWPE fiber.

34. The method of claim 33, further comprising providing both a jacquard beam and a ground beam comprising UHMWPE fibers on every parallel path.

35. The method of claim 33 or 34, further comprising providing a beam comprising a plurality of stretch fibers and combining the stretch fibers with the UHMWPE fibers to form the three-dimensional open mesh pattern, wherein each interlocking loop comprises a UHMWPE fiber and a stretch fiber.

36. The method of any one of claims 33-35, wherein the UHMWPE fiber comprises the hybrid yam as defined in any one of claims 16 or 18-26.

37. The method of claim 35 or 36, wherein the stretch fiber is spandex or elastane.