Textiles: knitting – Fabrics or articles – Articles
Reexamination Certificate
2001-01-26
2001-07-10
Worrell, Danny (Department: 3765)
Textiles: knitting
Fabrics or articles
Articles
C066S17800A
Reexamination Certificate
active
06257025
ABSTRACT:
FIELD OF THE INVENTION
This invention relates to knitted tubular structures such as hosiery having a self-closing end formed at the toe and a method for knitting such hosiery.
BACKGROUND OF THE INVENTION
Knitted hosiery, such as socks, womens' stockings and panty hose, have traditionally been knitted from the open end toward the toe of the garment, leaving an opening in the toe which is then closed by a separate manufacturing step. In one common procedure, the garment is transferred from the knitting machine to a sewing machine where an operator sews the opening closed, thereby finishing the hosiery.
It has long been recognized that this method of manufacturing hosiery is costly and inefficient because it requires extra manufacturing steps, more than one machine and a skilled operator performing a series of hand operations to complete a garment. This problem has been addressed in the past by the development of knitting methods and machines which knit hosiery with a closed toe automatically, but such machines tend to be very specialized, are complicated in construction and operation and costly to purchase and operate. There is clearly a need for a simplified, efficient, fully automated method of knitting hosiery which does not require expensive, specialized machinery or separate hand operations to produce acceptable hosiery.
SUMMARY AND OBJECTS OF THE INVENTION
The invention concerns a method of knitting tubular structures such as hosiery on a circular knitting machine having a plurality of needles. The method comprises knitting a plurality of first, substantially circular courses of stitches using a first group of machine needles to form a toe end of the hose. The first courses of stitches include at least an initial course of stitches and a final course of stitches.
A plurality of second, substantially circular courses of stitches are knitted using a second group of the needles. The second group has fewer needles than the first group, but the needles comprising the second group are drawn from among the needles comprising the first group. During knitting of the second courses of stitches, the final course of stitches (of the first courses) is retained on those needles of the first group which are not included in the second group.
A plurality of third, substantially circular courses of stitches are knitted using the needles of the first group.
A plurality of fourth, substantially circular courses of stitches are knitted using a third group of the needles. The third group has a greater number of needles than the first group but includes the first group of needles. Further pluralities of courses may also be knitted, preferably using more needles, but also using fewer.
For hosiery which is symmetrical at the toe, the needles comprising the first and second groups are substantially evenly space apart from one another around the knitting machine. Elastic yarn is preferably used in the area of the toe, the yarn being knitted under tension.
The invention also contemplates hosiery or similar tubular structures knitted according to the method described above. Hosiery according to the invention comprises a plurality of first, substantially circular courses of stitches defining a toe end. The plurality of first courses includes at least an initial course of stitches and a final course of stitches. Each of the first courses comprising a first number of stitches.
The hose also has a plurality of second, substantially circular courses of stitches comprising a second number of stitches, fewer in number than the first number of stitches. The plurality of second courses includes a beginning course of stitches and an end course of stitches. The beginning and the end courses are interknitted with the final course of stitches of the first courses. The second courses are reverse folded and form a double layer of adjacent courses at the toe end of the hosiery.
A plurality of third, substantially circular courses of stitches is also included in the hose. Each of the third courses comprise a third number of stitches equal in number to the first number of stitches. The third courses include a primary course of stitches interknitted with the end course of the second courses. The hose also has a plurality of fourth substantially circular courses of stitches, each of the fourth courses comprising a fourth number of stitches greater in number than the third number of stitches. At least one course of the plurality of fourth courses is interknitted with one course of the plurality of third courses. Additional pluralities of courses may also be added to the hose.
It is an object of the invention to provide a method of knitting hosiery which does not require manufacturing steps other than knitting to form a substantially closed toe.
It is another object of the invention to provide a method of knitting hosiery which can be performed on commonly available circular knitting machines.
It is still another object of the invention to provide a method of knitting hosiery from the toe end to the open end of the hose.
It is yet another object of the invention to provide hosiery which can be knitted from the toe having a substantially closed toe end.
It is yet again another object of the invention to provide a knitting method which is suitable to knit tubular structures other than hosiery.
These and other objects of the invention will become apparent upon consideration of the following drawings and detailed description of preferred embodiments of the invention.
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Synnestvedt & Lechner LLP
Worrell Danny
LandOfFree
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