Lower body garment

Abstract

The invention provides a garment formed via a continuous knitting process using a circular knitting machine, the garment including a knitted fabric waistband having an inner layer, an outer layer and an inwardly folded flap of knitted fabric sandwiched therebetween. The inwardly folded flap is closed by an integral seam that provides at least a portion of a peripheral edge of the waistband. The integral seam is formed by forming each of a first series of stitches of the inwardly folded flap integrally with a respective one of a second series of stitches of the inwardly folded flap. The first and second series of stitches preferably define a first seam edge and second seam edge of the inwardly folded flap, respectively. The first seam edge and second seam edge may have a curved shape.

Description

[0001] P4684PC00

[0002] LOWER BODY GARMENT

[0003] TECHNICAL FIELD

[0004] This invention relates to garments for wearing on the lower body, such as leggings, and methods for forming such garments using a circular knitting machine.

[0005] BACKGROUND

[0006] Lower body garments such as leggings can be formed using a circular knitting machine. The waistbands of such garments can be prone to undesirable rolling or folding during use, and the present application addresses this issue.

[0007] SUMMARY OF THE INVENTION

[0008] The invention provides a garment formed via a continuous knitting process using a circular knitting machine, the garment including a knitted fabric waistband having an inner layer, an outer layer and an inwardly folded flap of knitted fabric sandwiched therebetween. The inwardly folded flap is closed by an integral seam that provides at least a portion of a peripheral edge of the waistband. The integral seam is formed by forming each of a first series of stitches of the inwardly folded flap integrally with a respective one of a second series of stitches of the inwardly folded flap. The first and second series of stitches preferably define a first seam edge and second seam edge of the inwardly folded flap, respectively. The first seam edge and second seam edge may have a curved shape, as described further below.

[0009] A first aspect of the invention provides a lower body garment, the garment being formed via a continuous knitting process from a plurality of yarns using a circular knitting machine, and comprising: a knitted fabric sheath formed using the plurality of yarns; and a knitted fabric waistband formed integrally with the knitted fabric sheath using the plurality of yarns, the waistband having a peripheral edge and comprising: an inner waistband portion of knitted fabric providing an inner face of the waistband; an outer waistband portion of knitted fabric providing an outer face of the waistband; and an inwardly folded flap of knitted fabric concealed by the inner waistband portion and the outer waistband portion, the flap of knitted fabric being closed by an integrally-formed shaping seam joining the inner waistband portion with the outer waistband portion, the shaping seam defining at least a portion of the peripheral edge of the waistband, P4684PC00 wherein the flap of knitted fabric and the shaping seam are formed integrally with one another from the plurality of yarns using the circular knitting machine.

[0010] A problem with prior art leggings and other similar lower body garments formed using a circular knitting machine is that the knitted waistband can roll up, fold or otherwise deform in use, leaving an unsightly bulge or causing discomfort to the wearer.

[0011] The inwardly folded flap provides improved rigidity to the waistband, and in particular to an uppermost portion thereof, to thereby inhibit unwanted rolling and folding. Moreover, the shape and size of the inwardly folded flap can be controlled to adjust this effect for particular applications.

[0012] In addition, the shape and size of the inwardly folded flap can be controlled to define a nonlinear shape of the peripheral edge of the waistband. In this way, the shape of the peripheral edge can be optimised for each application to enhance waistband fit, or to suit a particular wearer anatomy.

[0013] Known solutions addressing this problem require time-consuming modifications after the knitted sheath has been removed from the circular knitting machine. Such approaches rely on human effort and are thus subject to human error, and as such there may be issues with consistency between garments, as well as limitations on the speed with which garments can be manufactured. In contrast, the invention provides a solution that can be implemented as part of the continuous knitting operation performed by the circular knitting machine. That is, the invention allows an improved waistband to be constructed in an automated fashion, with improved product quality, consistency and speed.

[0014] The garment is suitable for wearing on a lower body region of a wearer, so that the waistband is positioned at or near a waist or hip region of the wearer in use.

[0015] In preferred embodiments the circular knitting machine comprises a series of needles arranged in a ring and movable between a knitting position and a held position, and the lower folded flap and integral seam are formed using the series of needles arranged so that alternate needles are in the knitting position and held position, respectively. For example, a plurality of (e.g. a subset of) needles may be arranged as follows: needle 1 knitting position, needle 2 held position, needle 3 knitting position, needle 4 held position, needle 5 knitting position, and so on. Alternatively, the needles may be arranged in groups, so that alternate groups of one or more needles are in the knitting position and held position, respectively. For example: group 1 knitting position, group 2 held position, group 3 knitting position, group 4 held position, group 5 knitting position, and so on.

[0016] Circular knitting machines are also known as seamless knitting machines, because they typically produce fabric in a tubular form that is continuous (or seamless) in the P4684PC00 circumferential direction, i.e. there are no seams that extend axially. A key aspect of the claimed circular knitting process is that certain needles of the subset of needles are held (i.e. stop knitting), while others continue to knit through a folded flap sequence of a knitting pattern (e.g. the tapered fold zone) corresponding to the inwardly folded flap of knitted fabric. When the held needles reach a point in the pattern outside of the folded flap sequence, they begin to knit again, thereby joining edges of the inwardly folded flap of knitted fabric to create the integrally-formed shaping seam.

[0017] The needles are preferably latch needles, or latch-hook needles, of the type suitable for use with a circular knitting machine.

[0018] The knitting position of the needles is a position in which they are capable of knitting stitches. In the knitting position each needle may move in an up-and down motion, such that a hooked portion of the needle latches onto a yarn (or thread) fed into the circular knitting machine, to thereby knit one or more stitches of a knitted fabric. The hold position of the needles is a position in which each held needle does not knit. That is, each held needle is not able to latch onto the yarn (or thread) being fed into the circular knitting machine.

[0019] The fabric sheath and waistband are knitted via a continuous knit process so as to be formed integrally. The garment may be formed by operating the circular knitting machine according to a circular knit process. The circular knit process may comprise feeding the plurality of yarns into the circular knitting machine.

[0020] The fabric sheath is preferably continuous, or seamless, circumferentially. That is, there are preferably no integrally-formed seams that extend in an axial direction.

[0021] The peripheral edge is preferably an outermost edge or an uppermost edge of the waistband. For example, a peripheral edge of the waistband that defines its outermost or uppermost extent.

[0022] The shaping seam is preferably formed by forming each of a first series of stitches of the inwardly folded flap integrally with a respective one of a second series of stitches of the inwardly folded flap. That is, the shaping seam preferably comprises a first series of stitches of the inwardly folded flap knitted integrally with a second series of stitches of the inwardly folded flap. The first and second series of stitches preferably define a first seam edge and second seam edge of the inwardly folded flap, respectively. Similarly, the folded flap of knitted fabric may have a first seam edge and a second seam edge, stitches of the first seam edge being knitted integrally with corresponding stitches of the second seam edge to provide the shaping seam. P4684PC00

[0023] This arrangement provides a particularly neat and efficient means of integrally forming the shaping seam.

[0024] In preferred embodiments the first seam edge and second seam edge have corresponding curved shapes, such that the shaping seam has a curved shape to provide a curved portion of the peripheral edge of the waistband. Similarly, in preferred embodiments the shaping seam has a curved shape, such that it provides a curved portion of the peripheral edge of the waistband. The folded flap of knitted fabric preferably has a corresponding curved shape, for example it preferably has edges with a corresponding curved shape.

[0025] In this way, the peripheral edge of the waistband can be shaped to enhance waistband fit, and thus to further inhibit unwanted rolling or folding thereof.

[0026] The curved portion is preferably at a front region of the waistband, and the curved portion may be shaped so that the front region of the waistband has a smallest height at a midpoint thereof, and progressively increases in height to left and right sides thereof. Similarly, the inwardly folded flap of knitted fabric is preferably shaped so that it is deepest at a midpoint thereof and progressively tapers to left and right sides thereof.

[0027] This configuration provides a low-rise waistband that benefits from improved comfort and enhanced rigidity and stability.

[0028] In some embodiments a portion of the peripheral edge of the waistband is formed by a folded edge between the inner waistband portion and the outer waistband portion. For example, a rear portion of the peripheral edge of the waistband may be formed by the folded edge. Thus, a rear region of the waistband may be formed by the inner and outer waistband portions, and not the inwardly folded flap.

[0029] In other embodiments the shaping seam provides a full extent of the peripheral edge of the waistband. In such embodiments the inwardly folded flap may extend around a full extent of the waistband.

[0030] This configuration provides an anti-roll waistband that benefits from enhanced rigidity and stability.

[0031] The garment may comprise an integrally-formed waistband seam joining the inner waistband portion, outer waistband portion and knitted fabric sheath, wherein the inner waistband portion, outer waistband portion and waistband seam are formed integrally with one another from the plurality of yarns using the circular knitting machine. That is, the waistband seam may join the waistband to the knitted fabric sheath. P4684PC00

[0032] The knitted fabric sheath provides a body portion of the garment. For example, the knitted fabric sheath may comprise a hip region for encircling a wearer's hips, and a leg portion modifiable to provide a pair of leg portions for encircling a wearer's legs.

[0033] In such embodiments the outer waistband portion may have a first seam edge and the inner waistband portion may have a second seam edge, stitches of the first seam edge being knitted integrally with corresponding stitches of the second seam edge to provide the waistband seam. For example, the first seam edge of the outer waistband portion may correspond to a first row of stitches or a last row of stitches of the outer waistband portion, respectively, and the second seam edge of the inner waistband portion may correspond to a last row of stitches or a first row of stitches of the inner waistband portion, respectively.

[0034] The garment may comprise a pair of leggings, a pair of shorts, a skirt, a skort, a pair of underwear, or an item of swimwear.

[0035] A second aspect of the invention provides a method of forming a garment according to the first aspect using a circular knitting machine comprising a series of needles arranged in a ring, the needles each being movable between a knitting position and a held position, the method including using the circular knitting machine to knit the following rows of stitches from a plurality of yarns via a continuous knitting process: an outer waistband sequence of rows of stitches to form the inner waistband portion of knitted fabric; a folded flap sequence of rows of stitches to form the folded flap of knitted fabric; and an inner waistband sequence of rows of stitches to form the outer waistband portion of knitted fabric, wherein each stitch at a start of the folded flap sequence is knitted integrally with a corresponding stitch at an end of the folded flap sequence to thereby form the shaping seam.

[0036] This method thus forms the waistband of the garment as part of a continuous knitting process performed by the circular knitting machine. That is, the garment with improved waistband is constructed in an automated fashion, with improved product quality, consistency and speed.

[0037] Preferably, each of a first series of stitches of the folded flap sequence is knitted integrally with a respective one of a second series of stitches of the folded flap sequence. The first and second series of stitches preferably define a first seam edge and second seam edge of the inwardly folded flap, respectively. Similarly, stitches of the first seam edge may be knitted P4684PC00 integrally with corresponding stitches of the second seam edge to provide the shaping seam.

[0038] The folded flap sequence may comprise a series of rows of stitches in a tapered fold zone between the inner and outer waistband sequences, the tapered fold zone having a shape that is deepest at a mid-point thereof and progressively tapers to left and right sides thereof.

[0039] For each row of stitches of the folded flap sequence, the method may include arranging alternating needles of the series of needles in the held position and remaining needles of the series of needles in the knitting position, maintaining each of the alternating needles in the held position continuously through all of the rows of stitches of the folded flap sequence, and then arranging each of the alternating needles in the knitting position. This arrangement provides a particularly efficient automated means of forming the folded flap and the shaping seam.

[0040] For example, a plurality of (e.g. a subset of) needles may be arranged as follows: needle 1 (remaining) knitting position, needle 2 (alternating) held position, needle 3 (remaining) knitting position, needle 4 (alternating) held position, needle 5 (remaining) knitting position, and so on. Alternatively, the needles may be arranged in groups, so that alternate groups of one or more needles are in the knitting position and held position, respectively. For example: group 1 (remaining) knitting position, group 2 (alternating) held position, group 3 (remaining) knitting position, group 4 (alternating) held position, group 5 (remaining) knitting position, and so on.

[0041] Preferably the method further includes maintaining the remaining needles in the knitting position continuously through all of the rows of stitches of the folded flap sequence.

[0042] In some embodiments the method includes, for each row of stitches of the folded flap sequence, using a subset of the series of needles to knit the folded flap of knitted fabric, and successively through the rows of stitches progressively increasing a number of needles in the subset of needles, then progressively decreasing the number of needles in the subset of needles. This arrangement enables the inwardly folded flap to be shaped such that the shaping seam has a non-linear shape. In particular, the inwardly folded flap may be shaped such that it is deepest at a mid-point thereof and progressively tapers to left and right sides thereof.

[0043] As the skilled reader will understand, as the width of the inwardly folded flap (or the shape of the tapered fold zone) progressively increases then decreases to provide the tapered shape, the number of needles in the subset of needles correspondingly progressively increases then decreases. For example, a smaller number of needles may correspond to a first width of the inwardly folded flap (and a first number of stitches) and a larger number of P4684PC00 needles may correspond to a second width of the inwardly folded flap (and a second number of stitches). The number of needles in the subset thus progressively varies between the smaller number of needles and the larger number of needles as dictated by the shape of the inwardly folded flap (or tapered fold zone).

[0044] In preferred embodiments each stitch at a start of the outer waistband sequence or inner waistband sequence, respectively, is formed integrally with a corresponding stitch at an end of the inner waistband sequence or outer waistband sequence, respectively, to thereby fold the inner waistband portion and outer waistband portion together and form a waistband seam. For example, each stitch at a start of the outer waistband sequence or inner waistband sequence, respectively, may comprise a zig-zag stitch, and dial jacks may be used to hold the zig-zag stitches during formation of the outer waistband sequence and inner waistband sequence until each held zig-zag stitch is picked up and integrated into the corresponding stitch at the end of the inner waistband sequence or outer waistband sequence, respectively.

[0045] The method may further include using the circular knitting machine to knit, via the continuous knitting process, a body portion sequence of rows of stitches forming the knitted fabric sheath, and the method may further include modifying the knitted fabric sheath to provide a body portion of the garment.

[0046] A third aspect of the invention provides a garment knitted using the method of the second aspect, optionally wherein the garment comprises a pair of leggings, a pair of shorts, a skirt, a skort, a pair of underwear, or an item of swimwear.

[0047] For the avoidance of doubt, features of the first aspect described herein apply equally to the second or third aspects.

[0048] Throughout the description and claims of this specification, the words "comprise" and "contain" and variations of the words, for example "comprising" and "comprises", mean "including but not limited to", and do not exclude other components, integers or steps. Moreover the singular encompasses the plural unless the context otherwise requires: in particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.

[0049] Preferred features of each aspect of the invention may be as described in connection with any of the other aspects or embodiments. Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and / or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and / or features of any embodiment can be combined in any way and / or combination, unless such features are incompatible. P4684PC00

[0050] BRIEF DESCRIPTION OF THE DRAWINGS

[0051] One or more embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0052] Figure 1 shows a pair of leggings with a low-rise waistband according to an embodiment of the invention, including a front view (a), rear view (b) and side view (c), in which concealed features are shown in phantom;

[0053] Figure 2 is a schematic partial sectional view through a front portion of a low-rise waistband of a garment according to an embodiment of the invention;

[0054] Figure 3 illustrates a knitting pattern suitable for following to form a low-rise waistband of a garment according to an embodiment of the invention;

[0055] Figure 4 shows a pair of leggings with an anti-roll waistband according to an embodiment of the invention, including a front view (a), rear view (b) and side view (c), in which concealed features are shown in phantom;

[0056] Figure 5 is a schematic partial sectional view through an anti-roll waistband of a garment according to an embodiment of the invention;

[0057] Figure 6 illustrates a knitting pattern suitable for following to form an anti-roll waistband of a garment according to an embodiment of the invention; and

[0058] Figure 7 shows an illustrative representation of a series of needles of a circular knitting machine arranged in a circle.

[0059] DETAILED DESCRIPTION

[0060] In general terms, the invention provides a garment 100, 200 as illustrated in Figures 1 to 2 and 4 to 5, produced by a circular knitting machine using a pattern 150, 250 having the features illustrated in Figures 3 and 6. Figure 7 provides a schematic not-to-scale representation of a series of needles 300 of a circular knitting machine suitable for forming such garments.

[0061] Circular knitting machines knit together fabric yarns, or threads, to create a knitted fabric tube, or sheath, that is continuous, or seamless, in the circumferential direction. That is, typically there are no integrally-formed seams extending in an axial direction. Such machines comprise a series of latch-hook needles arranged in a ring, the shape and size of the ring of needles controlling the shape and size of the fabric tube. The needles can each be moved between a knitting position, in which they move in a reciprocating motion to knit together fabric yarns, and a held position, in which they do not knit. Circular knitting machines can knit using multiple different knitting stitch types, so that different visual patterns and functional effects can be achieved in the fabric tube that is produced. Example P4684PC00 fabric finishes that can be produced include single or double jersey, mesh knit, rib knit or jacquard knit. Suitable circular knitting machines for knitting garments 100, 200 according to embodiments of the invention include single knit circular knitting machines produced by Santoni™.

[0062] Garments 100, 200 and methods of the present invention utilise a circular knitting machine (not shown) comprising a series of needles 300 arranged in a ring, the circular knitting machine being fed with a plurality of yarns (threads).

[0063] The garment 100, 200 is configured for wearing on a lower body portion of a wearer. In the illustrated embodiments the garment 100, 200 is a pair of leggings. However, other embodiments are encompassed by the inventive concept, including shorts, skirts, skorts, undergarments, swimwear and other garments having a waistband.

[0064] The garment 100, 200 comprises a body portion 10, including a hip region 20 and left 30 and right 32 leg regions. The body portion 10 is formed integrally with a waistband 110, 210 to form a knitted fabric sheath via a continuous knitting process using a circular knitting machine (not shown).

[0065] The body portion 10 of the garment 100, 200 is formed via conventional means. The left 30 and right 32 leg regions of the garment 100, 200 are completed by cutting the knitted fabric sheath along pre-defined cut lines (not shown) and forming inside leg stitched seams 34, 36. In some embodiments the hip region 20 and waistband 110, 210 may be configured to conform to a desired shape or size by cutting the knitted fabric sheath in a generally axially- extending direction and forming a rear stitched seam 38.

[0066] The waistband 110, 210 comprises novel features of the inventive concept, and the illustrated embodiments show two possible configurations thereof. A low-rise waistband 110 is illustrated in Figures 1 to 3, and an anti-roll waistband 210 is illustrated in Figures 4 to 6.

[0067] The low-rise waistband 110 has a peripheral uppermost edge 122 forming an uppermost extent of the garment 100 that is shaped so that it is lower at a front portion thereof than at a rear portion thereof. This shape provides improved fit and comfort.

[0068] The low-rise waistband 110 generally comprises a folded upper region of the knitted fabric sheath with an inner portion 112 and an outer portion 114. Each of the inner 112 and outer 114 portions has a lowermost edge that is joined to the body portion 10 by an integrally- formed waistband seam 120. By integrally-formed it is meant that the waistband seam 120 is formed by the circular knitting machine during creation of the waistband 110, as described further below. P4684PC00

[0069] A rear portion 124 of the peripheral edge 122 is defined by a fold line between the inner portion 112 and the outer portion 114. A front portion 126 of the peripheral edge 122 is defined by an integrally-formed shaping seam 130 with a curved shape. By integrally- formed it is meant that the shaping seam 130 is formed by the circular knitting machine during creation of the waistband 110, as described further below.

[0070] The curved shape of the shaping seam 130 is such that the waistband 110 is shallower at a mid-point of the front portion 126 and gradually increases in depth to right and left sides thereof. This is achieved by forming an inwardly folded flap 140 of knitted fabric that is sandwiched between the inner portion 112 and the outer portion 114, such that the integrally-formed shaping seam 130 is formed integrally with the inwardly folded flap 140. That is, the shaping seam 130 joins the inwardly folded flap 140 to the inner portion 112 and outer portion 114. The curved shape of the integrally-formed shaping seam 130 is defined by the shape of the inwardly folded flap 140, which is deepest at a mid-point of the front portion 126 and gradually tapers to zero depth to right and left sides thereof. Thus, the inwardly folded flap has a curved first seam edge and a curved second seam edge, stitches of the first seam edge being knitted integrally with corresponding stitches of the second seam edge to provide the shaping seam 130.

[0071] While the curved shape of the shaping seam 130 provides a desired shape for the waistband, and hence improved fit and comfort, the inwardly-folded flap 140 of knitted fabric further provides increased stability and rigidity to the front portion of the waistband 110, and serves to inhibit unwanted rolling or folding thereof.

[0072] Figure 3 illustrates a knitting pattern 150 suitable for following to knit a low-rise waistband 110 as illustrated in Figures 1 and 2 using a circular knitting machine. The pattern 150 is shown in a two-dimensional form, but the skilled reader will understand that, in the resulting fabric sheath, the left and right edges of the pattern are joined together in a seamless fashion.

[0073] The pattern 150 is followed from the top to the bottom, as illustrated in Figure 3. The pattern 150 provides a series of sequences of stitches that together provide the low-rise waistband 110, as described below.

[0074] The pattern 150 commences with an outer waistband sequence 160 comprising a series of rows of stitches starting with a first row of waistband stitches. Each of the rows of stitches is formed using the needles of the series of needles in the knitting position to form the outer waistband portion 114. Each of the rows of stitches may be formed from e.g. a rib knit stitch, such as a three by one rib stitch.

[0075] An inner waistband sequence 170 follows the outer waistband sequence 160, and comprises a series of rows of stitches formed using the needles of the series of needles in the knitting P4684PC00 position to form the inner waistband portion 112. Each of the rows of stitches may be formed from e.g. a rib knit stitch, such as a three by one rib stitch.

[0076] The first row of stitches of the outer waistband sequence 160 is integrated with a final row of stitches of the inner waistband sequence 170 to form the integrally-formed waistband seam 120. Techniques for achieving this effect are known in the art. For example, a row of zig-zag stitches may be formed at the first row of stitches of the outer waistband sequence 160 and a series of dial jacks used to hold the zig-zag stitches while outer waistband sequence 160 and inner waistband sequence 170 are knitted. At the final row of stitches of the inner waistband sequence 170 the zig-zag stitches are picked up from the dial jacks and integrated into that final row of stitches. This causes the inner 112 and outer 114 waistband portions to be folded together, to create a fold line 172 that defines the rear portion 124 of the peripheral edge 122 of the waistband 110.

[0077] A folded flap sequence 180 comprises a series of rows of stitches in a tapered fold zone 182 between the inner 160 and outer 170 waistband sequences. The tapered fold zone 182 has a shape that corresponds to the shape of the inwardly folded flap 140. Thus, the tapered fold zone 182 progressively widens from a first width (corresponding to a first number of stitches) to a second width (corresponding to a second number of stitches larger than the first number of stitches), then progressively narrows from the second width to the first width. The tapered fold zone 182 thus has an upper curved edge 182a corresponding to the first seam edge and a lower curved edge 182b corresponding to the second seam edge. The upper and lower curved edges are shaped such that the tapered fold zone comprises a plurality of rows of stitches at a mid-line thereof to define a maximum depth of the folded flap 140, progressively tapering to zero rows of stitches to left and right extents of the tapered fold zone 182.

[0078] For each row of the folded flap sequence 180, stitches are knitted using a subset of the series of needles corresponding to a width of the tapered fold zone 182 for that row. The subset of needles are arranged so that alternating needles thereof are in the held position and the knitting position, respectively. That is, the needles are arranged in an alternating pattern of hold position, knitting position, hold position, knitting position, and so on. As the width of the tapered fold zone 182 progressively increases then decreases, the number of needles in the subset of needles correspondingly progressively increases then decreases. This is perhaps best understood from Figure 7, which schematically illustrates the series of needles 300. The figure indicates a smaller number of needles 310 corresponding to the first width of the tapered fold zone 182 (and the first number of stitches) and a larger number of needles 320 corresponding to the second width of the tapered fold zone 182 (and the second number of stitches). The number of needles in the subset thus progressively P4684PC00 varies between the smaller number of needles 310 and the larger number of needles 320 as required by the pattern 150.

[0079] The held needles of the subset of needles are maintained in the held position continuously until the pattern 150 reaches a row where that needle falls outside of the tapered fold zone 182, and therefore falls outside of the subset of needles, whereupon they are moved to the knitting position. This arrangement results in the integral knitting of each stitch at the start of the tapered fold zone 182 with its corresponding stitch at the end of the tapered fold zone 182. For example, stitch SI is knitted integrally with stitch S2, and stitch S3 is knitted integrally with stitch S4. In this way, stitches along the upper curved edge (including SI and S3) of the tapered fold zone 182 are integrally knitted with stitches along the lower curved edge (including S2 and S4) of the tapered fold zone 182 to create the shaping seam 130. The knitted fabric between the upper curved edge and lower curved edge forms the inwardly folded flap 140.

[0080] Note that for each row of stitches in which the folded flap sequence 180 appears, the remaining needles of the series of needles that are not within the subset of needles are maintained in the knitting position to knit the stitches of the inner 160 or outer 170 sequence of stitches outside of the tapered fold zone 182.

[0081] Since the folded flap 140 projects inwardly so that it is sandwiched between the inner 112 and outer 114 waistband portions, it is not visible in use. That is, all that is visible from an outer view of the garment 100 is the integrally-formed shaping seam 130. Moreover, it can be seen that the shape of the tapered fold zone 182 (and hence the shape of the folded flap 140) controls the curved shape of the integrally formed shaping seam 130, and hence the curved shape of the front portion 126 of the peripheral edge 122 of the waistband 110.

[0082] While the pattern 150 does not show any sequences of stitches for creation of the body portion 10, the skilled reader will readily understand that such stitches will directly follow the inner waistband sequence 170, and be formed integrally therewith. The body portion 10 is formed by knitting a fabric sheath extending from the waistband 110, and subsequently modifying the fabric sheath to form the hip portion 20 and left 30 and right 32 legs, as discussed previously.

[0083] The skilled reader will also understand that the pattern 150 may be modified so that it commences with the inner waistband sequence 170, with the outer waistband sequence 160 following thereafter. The order will depend on the application.

[0084] The anti-roll waistband 210 differs from the low-rise waistband 110 in that the inwardly folded flap 240 of knitted fabric sandwiched between inner 212 and outer 214 portions of the waistband 210 extends around a full extent of the waistband 210. This feature provides P4684PC00 increased stability and rigidity to the waistband 210, and serves to inhibit unwanted rolling or folding of the waistband 210.

[0085] The anti-roll waistband 210 generally comprises a folded upper region of the knitted fabric sheath with an inner portion 212 and an outer portion 214. Each of the inner 212 and outer 214 portions has a lowermost edge that is joined to the body portion 10 by an integrally- formed waistband seam 220. By integrally-formed it is meant that the waistband seam 220 is formed by the circular knitting machine during creation of the waistband 210, as described further below.

[0086] The anti-roll waistband 210 further comprises an inwardly folded flap 240 of knitted fabric that is sandwiched between the inner portion 212 and the outer portion 214, and closed by an integrally-formed shaping seam 230 that defines a peripheral uppermost edge 222 of the waistband 210. By integrally-formed it is meant that the shaping seam 230 is formed by the circular knitting machine during creation of the waistband 210, as described further below. That is, the shaping seam 230 is formed integrally with the inwardly folded flap 240 such that the shaping seam 230 joins the inwardly folded flap 240 to the inner portion 212 and outer portion 214. Thus, the inwardly folded flap 240 has a first seam edge and a second seam edge, stitches of the first seam edge being knitted integrally with corresponding stitches of the second seam edge to provide the shaping seam 230.

[0087] The inwardly folded flap 240 extends around a full extent of the waistband 210, so that the shaping seam 230 also extends around a full extent of the waistband 210 and defines a full extent of the peripheral edge 222 thereof.

[0088] In the illustrated embodiment the shaping seam 230 is straight, and the first and second seam edges are straight, so that the inwardly folded flap 240 has a uniform depth around its full extent. In other embodiments the shaping seam 230, and the first and second seam edges, may be curved to influence the shape of the peripheral edge of the waistband. For example, the invention encompasses embodiments which combine features of the low-rise waistband 110 and anti-roll waistband 210. The inwardly folded flap 140, 230 may have a uniform depth to a rear portion of the waistband 110, 210, and a progressively increasing depth towards a mid-line of a front portion of the waistband 110, 210.

[0089] Figure 6 illustrates a knitting pattern 250 suitable for following to knit a low-rise waistband 210 as illustrated in Figures 4 and 5 using a circular knitting machine. The pattern 250 is shown in a two-dimensional form, but the skilled reader will understand that, in the resulting fabric sheath, the left and right edges of the pattern are joined together in a seamless fashion. P4684PC00

[0090] The pattern 250 is followed from the top to the bottom, as illustrated in Figure 6. The pattern 250 provides a series of sequences of stitches that together provide the low-rise waistband 210, as described below.

[0091] The pattern 250 commences with an outer waistband sequence 260 comprising a series of rows of stitches starting with a first row of waistband stitches. Each of the rows of stitches is formed using all of the needles of the series of needles 300 in the knitting position to form the outer waistband portion 214. Each of the rows of stitches may be formed from e.g. a rib knit stitch, such as a three by one rib stitch.

[0092] A folded flap sequence 280 follows the outer waistband sequence 260, and comprises a series of rows of stitches using all of the needles of the series of needles 300, with alternating needles in the held position and the knitting position, respectively. That is, the needles are arranged in an alternating pattern of hold position, knitting position, hold position, knitting position, and so on. This arrangement has the effect of causing the first row of stitches 280a of the folded flap sequence 280 corresponding to the first seam edge to be formed integrally with the last row of stitches 280b of the folded flap sequence 280 corresponding to the second seam edge, to form the integrally-formed shaping seam 230. As a result, the knitted fabric between the first and last rows of stitches is folded to form the inwardly folded flap 240.

[0093] An inner waistband sequence 270 follows the folded flap sequence 280, and comprises a series of rows of stitches formed using all of the needles of the series of needles in the knitting position to form the inner waistband portion 212. Each of the rows of stitches may be formed from e.g. a rib knit stitch, such as a three by one rib stitch.

[0094] The first row of stitches of the outer waistband sequence 260 is integrated with a final row of stitches of the inner waistband sequence 270 to form the integrally-formed waistband seam 220. Techniques for achieving this effect are known in the art. For example, a row of zig-zag stitches may be formed at the first row of stitches of the outer waistband sequence 260 and a series of dial jacks used to hold the zig-zag stitches while outer waistband sequence 260 and inner waistband sequence 270 are knitted. At the final row of stitches of the inner waistband sequence 270 the zig-zag stitches are picked up from the dial jacks and integrated into that final row of stitches. This causes the inner 212 and outer 214 waistband portions to be folded together, so that the inwardly folded flap 240 is sandwiched therebetween.

[0095] Since the folded flap 240 projects inwardly so that it is sandwiched between the inner 212 and outer 214 waistband portions, it is not visible in use. That is, all that is visible from an outer view of the garment 200 is the integrally-formed shaping seam 230. Moreover, it can P4684PC00 be seen that the number of rows of stitches in the folded flap zone 280 controls the depth of the folded flap 240.

[0096] While the pattern 250 does not show any sequences of stitches for creation of the body portion 10, the skilled reader will readily understand that such stitches will directly follow the inner waistband sequence 270, and be formed integrally therewith. The body portion 10 is formed by knitting a fabric sheath extending from the waistband 110, and subsequently modifying the fabric sheath to form the hip portion 20 and left 30 and right 32 legs, as discussed previously.

[0097] The skilled reader will also understand that the pattern 250 may be modified so that it commences with the inner waistband sequence 270, with the outer waistband sequence 260 following thereafter. The order will depend on the application.

Claims

P4684PC00CLAIMS1. A lower body garment, the garment being formed via a continuous knitting process from a plurality of yarns using a circular knitting machine, and comprising: a knitted fabric sheath formed using the plurality of yarns; and a knitted fabric waistband formed integrally with the knitted fabric sheath using the plurality of yarns, the waistband having an outer peripheral edge and comprising: an inner waistband portion providing an inner face of the waistband; an outer waistband portion providing an outer face of the waistband; and an inwardly folded flap of knitted fabric concealed by the inner waistband portion and the outer waistband portion, the flap of knitted fabric being closed by an integrally- formed shaping seam joining the inner waistband portion with the outer waistband portion, the shaping seam defining at least a portion of the peripheral edge of the waistband, wherein the flap of knitted fabric and the shaping seam are formed integrally with one another from the plurality of yarns using the circular knitting machine.

2. A garment according to claim 1, wherein the folded flap of knitted fabric has a first seam edge and a second seam edge, stitches of the first seam edge being knitted integrally with corresponding stitches of the second seam edge to provide the shaping seam.

3. A garment according to claim 2, wherein the first seam edge and second seam edge have corresponding curved shapes.

4. A garment according to any preceding claim, wherein the shaping seam has a curved shape, such that it provides a curved portion of the peripheral edge of the waistband.

5. A garment according to claim 4, wherein the curved portion is at a front region of the waistband, and the curved portion is shaped so that the front region of the waistband has a smallest height at a mid-point thereof, and progressively increases in height to left and right sides thereof.

6. A garment according to any preceding claim, wherein a portion of the upper edge of the waistband is formed by a folded edge between the inner waistband portion and the outer waistband portion.P4684PC007. A garment according to any of claims 1 to 5, wherein the shaping seam provides a full extent of the peripheral edge of the waistband.

8. A garment according to any preceding claim, comprising an integrally-formed waistband seam joining the inner waistband portion, outer waistband portion and knitted fabric sheath, wherein the inner waistband portion, outer waistband portion and waistband seam are formed integrally with one another from the plurality of yarns using the circular knitting machine.

9. A garment according to claim 8, wherein the outer waistband portion has a first seam edge and the inner waistband portion has a second seam edge, stitches of the first seam edge being knitted integrally with corresponding stitches of the second seam edge to provide the waistband seam.

10. A garment according to any preceding claim, wherein the garment comprises a pair of leggings, a pair of shorts, a skirt, a skort, a pair of underwear, or swimwear.

11. A method of forming a garment according to any preceding claim using a circular knitting machine comprising a series of needles arranged in a ring, the needles each being movable between a knitting position and a held position, the method including using the circular knitting machine to knit the following rows of stitches from a plurality of yarns via a continuous knitting process: an outer waistband sequence of rows of stitches to form the inner waistband portion; a folded flap sequence of rows of stitches to form the folded flap of knitted fabric; and an inner waistband sequence of rows of stitches to form the outer waistband portion, wherein each stitch at a start of the folded flap sequence is knitted integrally with a corresponding stitch at an end of the folded flap sequence to thereby form the shaping seam.

12. A method according to claim 11, wherein the folded flap sequence comprises a series of rows of stitches in a tapered fold zone between the inner and outer waistband sequences, the tapered fold zone having a shape that is deepest at a mid-point thereof and progressively tapers to left and right sides thereof.

13. A method according to claim 11 or claim 12, comprising the step of, for each row of stitches of the folded flap sequence, arranging alternating needles of the series of needles in the held position and remaining needles of the series of needles in the knitting position, maintaining each of the alternating needles in the held position continuously through all ofP4684PC00 the rows of stitches of the folded flap sequence, and then arranging each of the alternating needles in the knitting position.

14. A method according to claim 13, including maintaining the remaining needles in the knitting position continuously through all of the rows of stitches of the folded flap sequence.

15. A method according to any of claims 11 to 14, including, for each row of stitches of the folded flap sequence, using a subset of the series of needles to knit the folded flap of knitted fabric, and successively through the rows of stitches progressively increasing a number of needles in the subset of needles, then progressively decreasing the number of needles in the subset of needles.

16. A method according to any of claims 11 to 15, including forming each stitch at a start of the outer waistband sequence or inner waistband sequence, respectively, integrally with a corresponding stitch at an end of the inner waistband sequence or outer waistband sequence, respectively, to thereby fold the inner waistband portion and outer waistband portion together and form a waistband seam.

17. A method according to any of claims 11 to 16, wherein the method includes using the circular knitting machine to knit, via the continuous knitting process, a body portion sequence of rows of stitches forming the knitted fabric sheath, and the method further includes modifying the knitted fabric sheath to provide a body portion of the garment.18

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