[0001] This invention concerns a procedure for forming a pantyhose product with continuous
processing motion on knitting machines with two needle beds.
[0002] The invention also concerns pantyhose products made according to said procedure and
also knitting machines with two needle beds which employ said procedure and are suitable
for making said products.
[0003] Procedures for the formation of pantyhose products on knitting machines with two
needle beds are already known and are especially suitable for machines with two cylinders
or machines with a cylinder and dial.
[0004] Said procedures envisage the formation of two knitted tubes, one within the other,
on the two circular needle beds.
[0005] According to said procedures the part relating to the legs is obtained with independent
tubular products.
[0006] In the tract corresponding to the panty portion said tubular products are connected
together along at least one lengthwise line and are separated along a lengthwise line
located intermediately in relation to said line of connection.
[0007] The inner tube is then withdrawn and turned inside out so as to obtain an open, symmetrical
pantyhose product.
[0008] In particular, patent IT 916700 (US 4,011,738) in the name of Solis S.r.l. describes
a procedure for knitting machines with two cylinders which envisages the formation
of the panty portion with alternate motion of the cylinders. Said procedure enables
360° knitted courses to be formed substantially with the passage of the yarn from
one needle bed to the other at every inversion of the motion of the cylinders.
[0009] This leads to the formation of two tubular tracts, one within the other, which are
open lengthwise and connected to each other along their lengthwise edges by the tracts
of yarn passing from one needle bed to the other during the processing.
[0010] The two leg portions are formed, one within the other, with smooth stitches and purl
stitches respectively, the processing being carried out with continuous motion of
the cylinders and with an independent feed on the two needle beds.
[0011] Said procedure entails considerable limitations as regards the speed of output owing
to the inversion of the motion of the cylinders and to the need to limit the feeds
of yarn.
[0012] This procedure also involves a poor appearance owing to the presence of a lengthwise
portion without stitches which is formed with straight yarns and which corresponds
to the line of the crutch of the panty portion.
[0013] During processing on the machine this line of the crutch corresponds to said lengthwise
edges connecting the outer knitted tube to the inner knitted tube.
[0014] Said lengthwise portion without stitches is produced by the yarn passing from one
needle bed to the other and has a width substantially the same as the distance between
the two opposed cylinders.
[0015] Owing to the constructional requirements of the machine the distance between the
two opposed cylinders obviously cannot be lessened and said lengthwise portion without
stitches is very evident in the product.
[0016] Moreover, said lengthwise portion without stitches impairs the strength and stability
of the panty portion of the product.
[0017] Patent IT 992231 (US 3,975,924), also in the name of Solis Srl, describes a procedure
for knitting machines with two cylinders which envisages the formation of the panty
portion with a continuous rotary motion of the cylinders.
[0018] Said procedure envisages that the yarn passes from the needles of the first cylinder
to the needles of the second cylinder at a position distanced at an angle from the
position at which the yarn passes from the needles of the second cylinder to the needles
of the first cylinder.
[0019] This enables the tubular fabrics formed by the two cylinders to be connected together
at least at said two positions, a lengthwise separating cut being made so as to correspond
with the space between said two positions.
[0020] Said procedure overcomes the limitations regarding the speed of output imposed by
the earlier patent, but the nature of the connection made between the two knitted
tubes remains unchanged.
[0021] In fact the problems of appearance and strength are made worse by the fact that said
lengthwise portion without stitches lies beside the edges obtained after said lengthwise
separating cut, and the quality of the product is rendered wholly unacceptable.
[0022] Certificate of authorship CS 169.533 (UHLIR) visualises a procedure whereby it is
necessary to employ a machine working with needles with a double spring so as to obtain
the fabric as envisaged in the connecting zone.
[0023] In fact, said connecting zone comprises courses of stitches formed with plain and
purl stitches in a varying succession and said stitches can be obtained with the same
needle only if the latter has a double spring.
[0024] Furthermore, CS 169.533 provides a body portion which, given the same gauge of cylinders,
is made with half the number of needles as are used in the invention we are proposing.
[0025] Instead, our invention visualises stitches which are all of the same kind and the
connection between the two fabrics which open out and form the panty portion is made
in a different way.
[0026] The solution we are proposing not only enables a body (panty) portion to be obtained
which is better to wear but also enables a connection to be made between the two edges
which is stable in the long term and acceptable from the point of view of appearance.
[0027] Certificate of authorship CS 195.758 (JAVOREK) offers a procedure with substantial
limitations. Said procedure envisages that the needles of the lower cylinder work
offset in relation to those of the upper cylinder and that therefore the panty portion,
given the same gauge of cylinders, is obtained with half of the needles used in the
procedure of our invention and is therefore less easy to wear.
[0028] Each of the two edges of fabric which are united with loops consists of stitches
made with the same yarn, whereas our invention envisages that the stitches of the
connecting loops are made with the yarn with which the other edge is processed, thereby
ensuring greater stability.
[0029] Besides these substantial differences there is another aspect which makes us doubt
the possibility of embodying the procedure of CS 195.758 with an industrial process.
If we examine needles such as 11 (Fig.3) intended to make the connection, we shall
see that they do not knit the yarn
PI inasmuch as they do not make stitches with it in correspondence with the point of
formation of stitches of the upper cylinder (needle 9) although they do make stitches
with the yarn P2 in a position thereafter.
[0030] To obtain this result, it is necessary to raise the needles such as 11 of the lower
cylinder above the abutting surface of the sinkers of the upper cylinder by an amount
greater than the distance between their hooks and the ends of their latches in their
position of maximum opening.
[0031] The needles of the lower cylinder will therefore have to penetrate into appropriate
grooves in the opposite cylinder and we cannot see how they can still take the yarn
P2 in such a position.
[0032] Patent application IT 9522 A/80 (EP 81830142.6) in the name of the author of the
present invention describes a procedure for knitting machines with two cylinders or
with a cylinder and dial whereby it is envisaged that the panty portion is formed
with continuous motion of the cylinders. This is done by forming the two tubular parts
connected along a lengthwise zone, where needles of both the needle beds are actuated
during the formation so as to obtain, with one or more feeds, a structure of rib stitches
with continuous plain stitches and purl stitches. The produce visualises that a lengthwise
separating cut is made.
[0033] Besides allowing a good speed of output, said procedure ensures greater strength
and stability in the panty part of the product but does not overcome the problem of
appearance which, given the nature of the product, is the most important problem.
[0034] It can be understood from the foregoing that the appearance, strength and stability
of the panty portion depend on the zone of mutual connection of the two knitted tubes.
[0035] The lack of strength and stability and, above all, the unsatisfactory appearance
are shortcomings common to all the known procedures even though the problems of strength
and stability were partly overcome with the processing procedure described in patent
application IT 9522 A/80 submitted by the present author.
[0036] However, given the nature of the product, a basic problem of the known procedures
continues to be the presence, on at least one side of the line connecting the two
tubes, of a lengthwise portion without stitches which has a width substantially the
same as the distance between the two opposed cylinders.
[0037] The presence of said lengthwise portion without stitches depends on the nature of
the connection made between the two knitted tubes in the known procedures and also
on the distance between the two opposed needle cylinders.
[0038] As we said earlier, the distance between the opposed cylinders cannot be lessened
owing to constructional requirements.
[0039] The purpose of our invention is to embody a procedure for processing the products
which overcomes the aforesaid technical problems and provides a product with an excellent
appearance.
[0040] According to the invention a procedure is envisaged for forming a pantyhose product
with continuous processing motion on knitting machines with two needle beds and at
least two feeds, one for each needle bed, said procedure visualising the formation
of two knitted tubes, one within the other, on two needle beds, whereby the two tubular
fabrics are joined .. together along a lengthwise connecting zone having a length
which corresponds to the panty portion of the product, and a lengthwise separating
cut is made substantially at the centre line of said connecting zone, and whereby
said procedure envisages that, so as to form the zone connecting the two knitted tubes
with at least one feed, the yarn is knitted by a given portion of needles selected
at substantially regular intervals on one needle bed and also by some needles of the
opposed needle bed, and whereby said selected needles pass with their own hooks at
the same level as the respective sinkers so as not to take the yarn, while the corresponding
needles of the opposed needle bed, aligned with said former needles and set to work
to knit the yarn with the stitch of the tubular fabric knitted by said former needles,
form a connecting loop, said selection being performed in such a way that said needles
in one course pass at the same level as the sinkers without taking the yarn whereas
they take the yarn and make a stitch in the next course.
[0041] This invention also concerns a machine with opposed needle beds to make two concentric
tubular fabrics with at least two feeds of yarn, one for each needle bed, whereby
the connection between said fabrics is processed with an arc of needles corresponding
to the connecting zone in width and with at least one of the two feeds of yarn; in
said zone the needles of said corresponding needle bed are selected in such a way
that one needle in every N needles passes with its own hook at the same level as the
respective sinker so as not to take the yarn, and in such a way that the corresponding
needle of the opposite needle bed, aligned with said former needle, is set to work
to knit the yarn with the stitch of the tubular fabric processed by said former needle,
thus forming a connecting bridge; said selection of needles is performed in such a
way that said needles which pass at the same level as the sinkers in one course without
taking the yarn are brought to take the yarn in the next course and to knit.
[0042] This invention is also embodied with a pantyhose product made with said procedure
and with a machine as in the foregoing.
[0043] According to the invention said processing procedure obtains an excellent appearance
and very good strength and stability in the panty portion of the product.
[0044] We shall give hereinafter, as a non-restrictive example, the description of a preferential
embodiment of the invention with the help of the attached tables, wherein:-
Figs.l 2 and 3 show the actuation of the needles according to a preferential embodiment
of the procedure of the invention;
Figs.4 5 and 6 show the connections obtained between the knitted tubes with the selection
of needles shown in the first three figures;
Figs.7 show some possible applications with an enlargement of the interlacing made
at one of the points of connection between the two knitted tubes;
Figs.8 9 and 10 show diagrammatically cross sections of the panty portion of the product
made with the selection of needles given in Figs.1, 2 and 3 respectively;
Fig.11 gives diagrammatically a front view of the panty portion of the product.
[0045] It is known that two knitted tubes 53A and 53B, one within the other, are formed
so as to embody a pantyhose product 50 and that each knitted tube is processed on
a needle bed with at least one feed 56 of yarn 55.
[0046] It is known that a connection between said tubes is made during processing along
a tract of the lengthwise development of the two knitted tubes 53A-53B so as to form
the body portion, or panty portion, 51 of the product 50, and that a separating cut
62 is also made substantially on the centre line of the connecting zone 52.
[0047] After the processing on the machine the inner tube is withdrawn from the outer one
and the product 50 is then turned inside out so as to attain the condition shown in
Fig.11, to which the sections shown in Figs.8, 9 and 10 also correspond.
[0048] According to said condition of the product 50 the parts 61 of the connecting zone
52 which are nearest to the line of the cut 62 and are like the so-called loose threads
at the end of work are inside the panty portion 51 of the product 50.
[0049] According to the invention continuous motion is used to form the panty portion 51
of the product 50 and it is envisaged that needles 54 and 154 of both the needle beds
A and B are actuated at the same time in the zone 52 of connection of the two knitted
tubes 53A-53B.
[0050] In particular, needles 54 at regular intervals are actuated on one needle bed A and
some needles 154 of the opposite needle bed B too are actuated at the same time so
as to connect the two knitted tubes 53A-53B together.
[0051] Such a procedure obtains stitches which are all of the same type, and the union of
the two fabrics constituting the two knitted tubes 53A-53B which open out and form
the panty is obtained with connecting loops between two edges of fabric overlaid on
each other.
[0052] Said solution not only enables a more wearable body portion (panty) to be obtained
but also enables a long-term stable union to be obtained between the two edges.
[0053] In the present description let us consider the embodiment of the product 50 on a
machine with two cylinders, each of which has a feed of yarn that supplies the yarn
55 to one of the two knitted tubes 53A-53B; but the procedure can be applied equally
well to a greater number of feeds for each knitted tube or else to a machine with
a cylinder and dial.
[0054] According to the invention the connection is obtained by knitting the yarn 55 on
both the needle beds A and B.
[0055] Moreover, according to the invention at least the last needles 154 towards the end
of the connecting zone which are selected on said opposed needle bed have to be offset
in relation to the needles 154 actuated for the previous course and for the next course
made with the same feed 56 of yarn 55.
[0056] The purpose of this is that each connection, if it takes place every revolution,
will take place on a wale of stitches different from those of the connections made
in the previous course of stitches and the next course of stitches.
[0057] This prevents the knitted loops from not being well enough anchored and also improves
still further the good-looking appearance of said connecting zone 52 by giving it
a more graduated aspect.
[0058] Figs.l, 2 and 3 show a preferential embodiment of the procedure according to the
invention.
[0059] The zone 52 connecting the knitted tubes 53A-53B is embodied in this instance within
a sector corresponding substantially to thirty-two positions of needles 54-154 and
a lengthwise separating cut is performed so as to correspond with position 16.
[0060] The needles 54 on the needle bed A are actuated with a selection of one yes, the
next not, and so on, whereas only given needles 154 are actuated on the opposed needle
bed B.
[0061] Figs.l, 2 and 3 show the needles 154 respectively selected in the connecting zone
52 after N successive.revolutions of- the cylinders.
[0062] The same kind of selection is repeated in the preferential embodiment of the invention
every three revolutions of the cylinders or every three courses of stitches, but according
to the invention it is possible to repeat a given selection after a number N of courses
of stitches other than three.
[0063] In particular, in Fig.l the needles 54 on needle bed A which correspond to positions
1 to 32 are selected alternately one yes, the next no, and so on, whereas on the opposite
needle bed B the needles 154 corresponding to positions 10, 16 and 22 are actuated.
[0064] In the next revolution the same needles 54 are selected on needle bed A, but needles
154 corresponding to positions 2, 14 and 18 are selected on the opposite needle bed
B.
[0065] Positions such as 10, 16, 22 have to be separated from each other by a number of
needles proportioned to the distance between the plane of formation of stitches of
the sinkers of the upper cylinder and the plane of formation of stitches of the lower
cylinder; in practice it can be seen that a position such as 10, 16, 22 must exist
at least every three needles.
[0066] Smaller distances between these positions would lead to the breakage of the yarn
during processing.
[0067] In the third revolution shown in Fig.3 the needles 54 selected on needle bed A are
still the same, whereas the needles 154 corresponding to positions 12, 20, 26 and
32 are selected on the opposite needle bed B.
[0068] Said figures bring out the fact that for the connecting zone 52 needles 154 are actuated
in differing positions on the opposite needle bed B for each of said revolutions and,
in any event, are offset in relation to the needles 154 actuated for the previous
and successive revolutions, and that the same selection is repeated every N revolutions
of the cylinders, N being three revolutions in our example.
[0069] However, according to the invention, if we keep to the criteria for actuating the
needles 54-154 which characterize the procedure in question, it is possible to vary
as wished the number and position of the needles 54-154 selected for the connecting
zone 52.
[0070] Figs.4, 5 and 6 respectively show the connections made between the two knitted tubes
53A-53B after actuation of needles 54-154 comprised in positions 1 to 32 according
to the selection shown in Figs.l, 2 and 3.
[0071] Thus, the machine with opposed needle beds for making two concentric tubular fabrics
57A-57B by means of at least two feeds 56 of yarn, one for each needle bed A-B, is
character- erized by the fact that the selection of needles is one needle every N
needles and is changed in the courses thereafter by being moved by N-x needles, whereby
N equals, five and N-x equals three advantageously.
[0072] Said actuation of needles 54-154 at the zone 52 of connection of the two knitted
tubes 53A-53B (each of which is made with its own feed 56 of yarns 55) entails the
embodiment of two fabrics 57A-57B with smooth stitches, which are respectively plain
and purl.
[0073] Said fabrics 57A-57B comprise connecting bridges 59, each of which also bears a specific
reference number in the figures, namely 110, 116, 122, 102, 108, 114, 118, 112, 120,
126 and 132, depending on the position where they have been embodied.
[0074] In our example each of said connecting bridges 59 consists of a loop 60 of one of
the two fabrics 57A, said loop being extended and knitted into the other fabric 57B,
as shown in Figs.7 for instance.
[0075] Said Figs.7 show a front enlargement of some connecting bridges 59 in two fabrics
57A-57B which have by now been opened and turned inside out as in the diagrammatic
figures 8, 9 and 10.
[0076] For clarity of illustration three possible connecting bridges 59 which have been
made between said two tubular fabrics 57A-57B are shown. Said figures show the flexibility
of the procedure and the possible variants inasmuch as the selection of the needles
can be inverted from one needle bed to the other and moved by one or more wales and
repeated after at least one course in which the successive stitch is a smooth stitch,
and so on.
[0077] Thus, Fig.7a shows the case wherein the connecting bridges 59 are made in one revolution
but not in the next revolution, and so on, thus ensuring proper fastening of the loops.
[0078] It can also be seen in Fig.7a how the substitutive fastening of the loop missing
at the beginning and also the integrating fastening of the auxiliary anchorage loop
are made.
[0079] Fig.7b shows the example of connecting bridges 59 located in each line; in this case
the bridges have to be offset by one wale so as to have a proper, stable anchorage
of the loops.
[0080] Fig.7c instead shows the case of inverted bridges which start now from the fabric
57A and are knitted into 57B and then start now from 57B and are knitted into 57A.
[0081] These examples, which are obviously limitative, show precisely the great variability
of solutions which can be obtained and therefore of aesthetic effects which can be
sought.
[0082] Fig.ll gives a diagrammatical front view of the panty portion 51 of a product 50
made with the procedure of the invention; in said product the fabrics 57A-57B of the
panty portion 51 are fully open and stretched out. The exceptionally good-looking
appearance of the connecting zone like a slide fastener can be seen clearly.
[0083] The edges of said zone can be distinct or graduated and said zone can also comprise
one or more layers of connecting bridges 59.
[0084] Said figures 8, 9 and 10 show cross sections of the panty portion 51 of the product
turned inside out and opened; said sections correspond respectively to courses of
stitches of the product which are made in the connecting zone with the selection of
needles as shown in Figs.l, 2 and 3.
[0085] Said cross sections make evident the fact that said connecting bridges 59 made between
the two knitted tubes 57A-57B vary cyclically in position and number along the connecting
zone 52 of the two knitted tubes.
[0086] Besides eliminating the presence of the aforesaid shortcoming which appears at the
side of the connecting zone of the panty portion in products made with procedures
of the prior art using continuous motion, said criteria of actuation of the needles
entail the formation of a connecting zone 52 having an increased thickness and consistency
and the further improvement of the appearance of the part connecting the two knitted
tubes 57A-57B that constitute the product 50.
[0087] The selection of needles described for making the connecting zone 52 with a given
feed 56 linked substantially to one needle bed and thus to the relative knitted tube
57A can equally well be repeated, inverted on the needle beds, with a possible offsetting
also for the feed 56 which supplies the yarn 55 to the other knitted tube 57B.
[0088] According to one variant of the invention the connecting courses comprising the connecting
bridges 59 are spaced apart from each other, that is to say, they are not consecutive
courses.
[0089] According to another variant the connecting courses comprising the connecting bridges
59 are separated'from each other by one or more connecting courses forming one single
ribbed fabric in the connecting zone 52, said fabric being made by cooperation between
the needles of both needle beds A-B in the connecting zone 52.
[0090] According to a further variant a connecting tract formed of one single ribbed fabric
obtained by cooperation between the needles of both the needle beds A-B in the connecting
zone 52 is comprised in the connecting zone 52 at every two connecting tracts obtained
with a number of courses comprising connecting bridges 59, whether separated or not
by courses of rib stitches.
[0091] We have described here a preferential embodiment of the invention, but many variants
are possible for a person skilled in this field; for instance, it is possible to change
the number of needles 54-154 which take part in forming the connecting zone 52; it
is possible to change the cycle of revolutions of the cylinders after which a given
selection of needles 54-154 is repeated; the needles 54 of needle bed A can be selected
at wider intervals than the 1:1 selection, or else all the needles 54 of needle bed
A can be selected except those located in positions corresponding to the needles 154
selected in the opposite needle bed B; it is possible to make the connecting bridges
by forming more than one stitch on the opposite needle bed B; it is possible to perform
special interlacings of stitches or to suspend the actuation of the needles 54-154
in the lengthwise portions of the connecting zone 52 immediately next to the cutting
line; it is possible to apply the procedure to a greater number of feeds for each
knitted tube 53, all the foregoing being possible without departing thereby from the
scope of the idea of the solution proposed by this invention. n
1 - Procedure for forming a pantyhose product (50) with continuous processing motion
on knitting machines with two needle beds and with at least two feeds, one for each
needle bed, said procedure envisaging the formation of two knitted tubes (57A-57B),
one within the other, on two needle beds, whereby the two tubular fabrics are joined
together along a lengthwise connecting zone (52) having a length which corresponds
substantially to the panty portion (51) of the product (50), and a lengthwise separating
cut is made substantially at the centre line of said connecting zone (52), said procedure
being characterized by the fact that, so as to form the zone (52) connecting the two
knitted tubes (57A-57B) with at least one feed, the yarn (55) is knitted by a given
portion of needles (54) selected at substantially regular intervals on one needle
bed (A) and also by some needles (154) of the opposed needle bed (B), and whereby
said selected needles (54) pass with their own hooks at the same level as the respective
sinkers so as not to take the yarn, while the corresponding needles (154) of the opposed
needle bed (B) which are aligned with said needles (54) and which are set to work
to knit the yarn with the stitch of the tubular fabric processed by said needles (54)
form a connection bridge (59), said selection being performed in such a way that said
needles (54) which pass at the same level as the sinkers in one course without taking
the yarn take the yarn and make a stitch in the next course.
2 - Procedure for forming a pantyhose product (50) with continuous processing motion
on knitting machines with two needle beds as in Claim 1, characterized by the fact
that the selection of needles performed in one course of stitches is repeated after
at least one course of normal stitches in the same wale of stitches. n
3 - Procedure for forming a pantyhose product (50) with continuous processing motion
on knitting machines with two needle beds as in Claim 1, characterized by the fact
that the selection of needles performed in one course of stitches is. repeated in
the next course but is offset by at least one wale of stitches.
4 - Procedure for forming a pantyhose product (50) with continuous processing motion
on knitting machines with two needle beds as in Claim 1 and in one or the other of
the Claims thereafter, characterized by the fact that the same selection of needles
(154)with at least the interposition of one course of stitches is repeated on one
needle bed for the zone (52) which connects the two knitted tubes (57A-57B). 5 - Procedure
for forming a pantyhose product (50) with continuous processing motion on knitting
machines with two needle beds as in Claim 1 and in one or another of the Claims thereafter,
characterized by the fact that not only the position but also the number of needles
(154) selected on one needle bed will vary at regular intervals of courses of stitches.
6 - Procedure for forming a pantyhose product (50) with continuous processing motion
on knitting machines with two needle beds as in Claim 1 and in one or another-of the
Claims thereafter, characterized by the fact that the selection of needles (54-154)
for the zone (52) connecting the two knitted tubes (57A-57B) as performed for one
feed (56) is repeated in an inverted form on the needle beds (B-A) in correspondence
with the feed of the opposed needle bed (B).
7 - Procedure for forming a pantyhose product (50) with continuous processing motion
on knitting machines with two needle beds as in Claim 1 and in one or another of the
Claims thereafter, characterized by the fact that the connecting courses which comprise
the connecting bridges (59) are spaced apart.
8 - Machine with opposed needle beds for making two concentric, tubular fabrics (57A-57B)
by means of at least two feeds (56) of yarn, one for each needle bed (A-B), whereby
for the connection of said tubes an arc of needles is employed which has a width corresponding
to the connecting zone (52), together with the use of at least one (56) of the two
feeds of yarn, said machine being characterized by the facts that in said connecting
zone (52) the needles (54) of the corresponding needle bed are selected in such a
way that one needle in every N needles passes with its own hook at the same level
as the respective sinkers so as not to take the yarn, and that the corresponding needle
(154) aligned with said needle (54) and positioned in the opposed needle bed is set
to work and knits the yarn with the stitch of the tubular fabric processed by said
needle (54), thereby forming a connecting bridge (59), said selection being performed
in such a way that said needles (54) which pass at the same level as the sinkers without
taking the yarn are brought to take the yarn in the next course and to make stitches.
9 - Machine with opposed needle beds for making two concentric, tubular fabrics (57A-57B)
by means of at least two feeds (56) of yarn, one for each needle bed (A-B), as in
Claim 8, characterized by the fact that the selection of needles is performed with
one needle in every N needles and is changed in the courses thereafter by being moved
by N-x needles, whereby advantageously N equals five and N-x equals three. 10 - Pantyhose
product (50) or the like, manufactured according to said procedure or with said machine.