CN119546203A

CN119546203A - Pantyhose products with ultra-high molecular weight polyethylene and methods for making the same

Info

Publication number: CN119546203A
Application number: CN202380053395.9A
Authority: CN
Inventors: A·布里森; E·布斯凯; Z·霍穆特; K·劳; A·皮农
Original assignee: Shuertes Co ltd
Current assignee: Shuertes Co ltd
Priority date: 2022-05-12
Filing date: 2023-05-12
Publication date: 2025-02-28
Also published as: AU2023266586A1; CA3185681A1; WO2023215999A1; KR20250009512A; EP4521979A1

Abstract

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

Description

Panty hose product with ultra-high molecular weight polyethylene and method for manufacturing same

RELATED APPLICATIONS

The present PCT application claims priority from U.S. provisional application 63/341,160 filed on day 2022, 5, 12 and canadian patent application 3,185,681 filed on day 2022, 12, 23, which are incorporated herein in their entirety.

Technical Field

The present disclosure relates generally to a panty hose article having Ultra High Molecular Weight Polyethylene (UHMWPE) and a method of making the same, and more particularly to a panty hose article having a plurality of different knit fabrics, including at least two knit fabrics having UHMWPE.

Background

Traditional knitted fabrics used to make hosiery items (e.g., pantyhose, stocking, sock, and briefs) include a combination of nylon and spandex fibers (e.g., lycra ^TM fibers belonging to spandex ^TM). However, these fabrics are prone to tearing or ripping when subjected to frictional forces. Transparent hosiery articles (e.g., 30 denier and less) made using these fibers have been observed to be very fragile. They can be easily torn by hand, foot or hanging nails and are therefore generally considered to be disposable. Thus, there remains a need for commercially viable transparent (low denier) elastic knits that are not easily torn.

Ultra high molecular weight polyethylene (UHWMPE) fibers are considered desirable reinforcement components due to their high impact strength, low density, low elongation at break, corrosion resistant chemicals, low hygroscopicity and low coefficient of friction. Knitted fabrics comprising a combination of UHMWPE fibres and elastic fibres such as spandex, nylon or polyester have been shown to have enhanced tear resistance. However, UHMWPE fibers are very expensive and vary widely in quality from supplier to supplier and from batch to batch. Lower quality UHMWPE fibers may cause defects such as yarn looping or crosspieces, which cause the quality of the hosiery to be impaired and thus not available for sale as scrap.

Thus, there remains a need for a commercially viable knitted fabric for manufacturing hosiery articles which allows the use of lower amounts and/or lower grades of UHMWPE fibers, but which at the same time has sufficient tear resistance and durability.

Disclosure of Invention

According to one aspect, a panty hose article is provided that includes a first tubular member. The first tubular member includes a first panty portion extending from a waist end of the panty hose article to a bottom end of the first panty portion and a first tubular leg portion defining a first leg cavity and extending from a top end thereof to a first foot end of the first tubular leg portion, the first leg cavity top end corresponding to the bottom end of the first panty portion, the first tubular leg portion including a first main sub-portion extending from a first thigh region of the first tubular leg portion to the first foot end and a first transition sub-portion extending from a top end of the first tubular leg portion to a first thigh region of the first tubular leg portion, the first main sub-portion being formed of a first UHMWPE fiber and at least one first accompanying fiber, and the first transition sub-portion being formed of a second knitted fabric including a second UHMWPE fiber and at least one second accompanying fiber, and the first transition sub-portion being different from the first knitted fabric.

According to another aspect, a method for manufacturing a pantyhose article is provided. The method includes forming a first tubular member having a first panty portion and a first tubular leg portion, the first panty portion extending from a waist end of the panty hose article to a bottom end of the first panty portion, the first tubular leg portion defining a first leg cavity and extending from a top end thereof to a first foot end of the first tubular leg portion, the first leg cavity top end corresponding to the bottom end of the first panty portion, the first tubular leg portion including a first main sub-portion and a first transition sub-portion, the first main sub-portion extending from a first thigh region of the first tubular leg portion to the first foot end, and the first transition sub-portion extending from the top end of the first tubular leg portion to a first thigh region of the first tubular leg portion and extending circumferentially around the first tubular leg portion, the first main sub-portion being formed of a first knit including first Ultra High Molecular Weight Polyethylene (UHMWPE) fibers and at least one first companion fiber, and the first transition sub-portion being formed of a second knit including at least one second companion fiber and the second knit fabric. The method further includes forming a second tubular member having a second panty portion and a second tubular leg portion, the second panty portion extending from a top end of the panty hose article to a bottom end of the second panty portion aligned with a bottom end of the first panty portion, the second tubular leg portion defining a second leg cavity and extending from a top end thereof to a second foot end of the second tubular leg portion, the second leg cavity top end corresponding to the bottom end of the second panty portion, the second tubular leg portion including a second main sub-portion and a second transition sub-portion, the second main sub-portion extending from a second thigh region of the second tubular leg portion to a second foot end, and the second transition sub-portion extending from the top end of the second tubular leg portion to a second thigh region of the second tubular leg portion and extending circumferentially around the second tubular leg portion, the second main sub-portion being formed from a first knit fabric including first UHMWPE companion fibers and at least one second knit fabric including second UHMWPE companion fibers and at least one second knitted fabric fibers. The method further includes cutting a first panty portion in its longitudinal direction to form a first longitudinal edge therein and cutting a second panty portion in its longitudinal direction to form a second longitudinal edge therein, engaging the first longitudinal edge of the first panty portion with the second longitudinal edge of the second panty portion to form a panty tube defining a panty cavity for receiving a lower torso of a wearer, the panty cavity being in fluid communication with the first leg cavity of the first tubular leg portion and the panty cavity being in fluid communication with the second leg cavity of the second tubular leg portion, and engaging the longitudinal edge of the first panty portion with the first edge of the crotch portion and the second panty portion longitudinal edge with the second edge of the crotch portion.

Drawings

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

FIG. 1 is a front view of a pantyhose article when placed on a quality control device, according to an exemplary embodiment;

FIG. 2 is a top perspective view of the interior of a pantyhose article, when placed on a quality control device, according to an embodiment;

FIG. 3 is a bottom view of a crotch region of a pantyhose article, when placed on a quality control device, in accordance with an embodiment;

FIG. 4 is a front perspective view of a pantyhose article in accordance with an exemplary embodiment when worn;

FIG. 5 is a side perspective view of a pantyhose article in accordance with an exemplary embodiment when worn;

FIG. 6 is a rear perspective view of a pantyhose article in accordance with an exemplary embodiment when worn;

FIG. 7 is a bottom view of a pantyhose article in accordance with an exemplary embodiment when worn, and

Fig. 8 is a top view of a pantyhose article in accordance with an exemplary embodiment when worn.

Detailed Description

In the following description, certain specific details are set forth in order to provide a thorough understanding of various embodiments. However, it will be understood by those skilled in the art that the present invention may be practiced without these details. In other instances, well-known structures have not been shown or described in detail to avoid unnecessarily obscuring the description of the embodiments. Throughout the specification and the claims which follow, unless the context requires otherwise, the word "comprise" and variations such as "comprises" and "comprising" will be interpreted in an open, inclusive sense, i.e. "including but not limited to. Furthermore, the headings provided herein are for convenience only and do not interpret the scope or meaning of the claimed invention.

Reference throughout this specification to "one embodiment" or "an embodiment" means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, the appearances of the phrases "in one embodiment (in one embodiment)" or "in an embodiment (in an dimension)" in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. Furthermore, as used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the content clearly dictates otherwise. It should also be noted that the term "or" is generally employed in its sense including "and/or" unless the meaning clearly dictates otherwise. Furthermore, as used in this specification and the appended claims, the term "about" has the meaning reasonably given to those of ordinary skill in the art when used in conjunction with a specified value or range, i.e., indicates that it is within the range of + -20% of the specified value, + -19% of the specified value, + -18% of the specified value, + -17% of the specified value, + -16% of the specified value, + -15% of the specified value, + -14% of the specified value, + -13% of the specified value, + -12% of the specified value, + -11% of the specified value, + -10% of the specified value, + -9% of the specified value, + -8% of the specified value, + -7% of the specified value, + -6% of the specified value, + -4% of the specified value, + -3% of the specified value, + -2% of the specified value, or + -1% of the specified value.

Definition of the definition

As used herein, the following terms have the meanings indicated below, unless the context indicates otherwise.

The term "UHMWPE" refers to ultra high molecular weight polyethylene, also known as High Modulus Polyethylene (HMPE), or High Performance Polyethylene (HPPE).

The term "colored UHMWPE" refers to UHMWPE that has been colored (e.g., made non-white) by a non-additive coloring process.

As used herein, the term "fiber" refers to a single source of base material composed of one or more filaments. It has an elongated body with a length dimension that is much greater than the lateral dimensions of width and thickness.

The term "filament" as used herein refers to individual fibrils of a material, which may themselves be fibers or may be combined with other filaments to produce multifilament fibers. The individual fibers may be formed from only one filament or from multiple filaments.

The term "microfilament (microfilament)" as used herein refers to filaments having a denier of 5 or less.

The term "denier" as used herein refers to the unit of weight that represents the fineness of a fiber filament. It can be measured in grams per 9,000 meters of fiber. A lower denier means finer fibers and a higher denier means thicker or heavier fibers.

The term "dtex" as used herein refers to the alternative weight units that represent the fineness of a fiber filament. It can be measured in grams per 10,000 meters.

The term "tensile strength" as used herein relates to the durability of a garment and is measured by the maximum stress that a material can withstand before breaking during stretching or pulling. It is measured in force per unit area and can be expressed in grams force (gf) and centi-newton (cN)/dtex.

The term "elongation" as used herein refers to the degree of stretch of individual fibers and composite fibers, which results in the elasticity of the final embodiments of the present disclosure. Elongation is measured as a percentage relative to the starting length.

The term "natural fibers" as used herein refers to a class of fibers that are obtainable from materials of natural origin.

The term "synthetic fibers" as used herein is intended to refer to a class of fibers that are artificial. Synthetic fibers include, for example, polymeric materials synthesized by polymerization of monomers, fibers obtained by regeneration of natural fibers (e.g., after dissolution in a solvent), and glass fibers.

The term "stretch fiber" as used herein refers to a type of fiber that can be stretched to a degree of stretch of at least about 130% of its original dimension without breaking upon application of a force.

The term "non-stretch fibers" as used herein refers to a type of fibers that are substantially inelastic and have little or no elongation.

The term "high performance fibers" as used herein refers to a class of fibers having high tenacity values greater than, for example, 10 grams per denier, making them suitable for applications requiring high abrasion and/or cut resistance. Generally, high performance fibers have a high degree of molecular orientation and crystallinity in the final fiber structure.

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

The term "thermoplastic fibers" as used herein refers to a type of fibers obtained from plastic or deformable polymers that melt to a liquid when heated and freeze to a brittle glassy state when sufficiently cooled.

The term "abrasion resistant fibers" as used herein refers to a class of fibers that inhibit abrasion of the material with which they are in contact.

The term "knit fabric (knit)" as used herein refers to a fabric produced by combining one or more fibers on a flat knitting machine or circular knitting machine.

The term "gauge" as used herein is the number of needles on a pointer loom. High gauge knitting machines (e.g., 32 gauge and above) are required to produce transparent hosiery, such as transparent tights, stocking and pantyhose, while low gauge knitting machines (e.g., 18 to 32 gauge) are used to produce heavier garments, such as leggings, tights, socks, shirts and other athletic garments. Stitch length is also used to refer to machine-produced knitted fabrics, in other words, knitted fabrics produced on 32-stitch length machines are 32-stitch length knitted fabrics.

The term "plating" as used herein refers to a technique of knitting two fibers together in two different layers. Although in the same needle (stitch) one fiber stays behind, i.e. behind the front fiber.

The term "union" as used herein refers to a process of spinning two fibers together to produce a composite fiber.

The term "non-additive" as used herein refers to a coloring (typically dyeing) process that does not increase the total denier of the fiber.

"Tensile properties" are properties measured when a material is subjected to a tensile force, and properties measured when the tensile force is removed. Examples of tensile properties include, but are not limited to, tensile strength at break, percent elongation at break, elastic modulus, toughness or tensile energy at break, permanent set, tensile load at a particular elongation, and the like. The tensile properties of the polymer fibers may be determined, for example, by standard test methods (e.g., ASTM D2256/D2256M-21, "Standard test method for determining yarn tensile properties by Single Strand method").

The term "rail" as used herein is defined as an unintended, repetitive visual pattern of continuous strips or stripes generally parallel to the courses (course) of the circular knit.

UHMWPE fibers

Various aspects described herein relate to UHMWPE fibers for making a knit and methods for forming the knit.

In some embodiments, the UHMWPE fibers have high impact strength, low density, low elongation at break, corrosion resistant chemicals, low hygroscopicity, and/or low coefficient of friction. In other aspects, the material is self-lubricating and highly wear and odor resistant.

In some embodiments, the UHMWPE fibers have a weight average molecular weight (M _w) of at least about 200,000. In some embodiments, the UHMWPE fibers have a weight average molecular weight (M _w) of about 300,000 to about 7,000,000, about 700,000 to about 5,000,000, or about 900,000 to about 4,000,000. The molecular weight distribution of the UHMWPE fibers, i.e. the ratio of the weight average molecular weight (M _w) to the number average molecular weight (M _n) of the UHMWPE fibers, is about 5.0 or less, about 4.0 or less, or about 3.0 or less.

In some embodiments, the UHMWPE fibers are monofilaments. In some other embodiments, the UHMWPE fibers comprise a plurality of microfilaments. In some embodiments, each microfilament in the UHMWPE has a denier of about 5 or less, about 4 or less, about 3 or less, about 2.5 or less, about 2 or less, about 1.5 or less, about 1 or less, or about 0.5 or less.

The UHMWPE fibers may include any suitable number of microfilaments. In some embodiments, the UHMWPE fibers comprise 2 to 400 microwires, 10 to 300 microwires, 10 to 50 microwires, 5 to 25 microwires, or 20 to 200 microwires. In some embodiments, the UHMWPE fiber comprises 5, 7, 10, 15, 20, 25, 30, 35, 40, 45, or 50 filaments.

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

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

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

In some embodiments, the UHMWPE fibers allow an elongation of not greater than about 10%, not greater than about 8%, not greater than about 5%, not greater than about 4%, not greater than about 3.5%, not greater than about 3%, not greater than about 2.5%, not greater than about 2%, or not greater than about 1.5%.

In some embodiments, the UHMWPE fibers have a breaking force of about 10N or greater, about 11N or greater, about 12N or greater, about 13N or greater, about 14N or greater, about 15N or greater, about 16N or greater, about 18N or greater, or about 20N or greater. In some embodiments, the UHMWPE fibers have a work of fracture of at least about 100n·mm, at least about 110n·mm, at least about 120n·mm, at least about 130n·mm, at least about 140n·mm, at least about 150n·mm, at least about 160n·mm, or at least about 170n·mm.

In some embodiments, the UHMWPE fibers are colored UHMWPE fibers comprising a dye. In some embodiments, the dye has a color selected from the group consisting of black, blue, gray, red, blue, brown, yellow, green, orange, and bare.

In some embodiments, the UHMEPE fibers comprise a plurality of untwisted microfilaments. In some other embodiments, the UHMWPE fibers are twisted in order to hold the filaments together and increase strength and reduce pilling. In some embodiments, the UHMWPE fibers have a Twist Per Inch (TPI) of 1 to 30, 1 to 20, 1 to 10, 1 to 5, 4 to 25, 6 to 20, or 8 to 16, in some embodiments the TPI of the UHMWPE fibers is 1. In some embodiments, the UHMWPE fibers have a TPI of 2, in some embodiments, the UHMWPE fibers have a TPI of 3. In some embodiments, the UHMWPE fibers have a TPI of 4. In some embodiments, the UHMWPE fibers have a TPI of 5. In some embodiments, the UHMWPE fibers have a TPI of 6. In some embodiments, the UHMWPE fibers have a TPI of 8. In some embodiments, the UHMWPE fibers have a TPI of 10. In some embodiments, the UHMWPE fibers have a TPI of 12. In some embodiments, the UHMWPE fibers have a TPI of 15. In some embodiments, the UHMWPE fibers have a TPI of 16. In some embodiments, the UHMWPE fibers have a TPI of 18. In some embodiments, the UHMWPE fibers have a TPI of 20. In some embodiments, the UHMWPE fibers have a TPI of 25. In some embodiments, the UHMWPE fibers have a TPI of 30.

In various aspects, the UHMWPE fibers described herein may be prepared according to the method described in U.S. published application US 20220056620.

In some embodiments, the UHMWPE fibers have a color variation along the length of the UHMWPE fibers. In some embodiments, the color variation along the length of the 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%.

The use of UHMWPE fibers provides benefits to the knitted fabric such as cooling effect, light weight, moisture absorption and perspiration and/or antimicrobial. The tensile properties of the UHMWPE fibers also enhance the resistance of the knit to tearing, hooking or other abrasion or damage. In some embodiments, the UHMWPE fibers vary in denier along their length. In some embodiments, the UHMWPE fibers have a denier variation along their length of less than ±2.5%, less than ±3%, less than ±3.5%, less than ±4%, less than ±5%, less than ±6%, less than ±7%, less than ±8%, or less than ±9%, or less than ±10%. In some embodiments, the UHMWPE fibers vary in diameter along the length of the UHMWPE fibers by less than ±2.5%, less than ±3%, less than ±3.5%, less than ±4%, less than ±5%, less than ±6%, less than ±7%, less than ±8%, or less than ±9%, or less than ±10%. In some embodiments, the UHMWPE fibers have a cross-sectional shape substantially similar to a circle. In some embodiments, the UHMWPE fibers have a substantially oval-like cross-sectional shape. In some embodiments, the UHMWPE fibers have a cross-sectional shape substantially similar to a stadium. In some embodiments, the UHMWPE fibers have a substantially elliptical-like cross-sectional shape. In some embodiments, the cross-sectional shape of the UHMWPE fibers remains substantially unchanged along their length.

The amount of UHMWPE fibers in the knit may range from about 10 wt% to about 90 wt%, based on the total amount of fibers in the knit. In some embodiments, the content of UHMWPE fibers in the knit is in the range of about 15 wt% to about 80 wt%, about 20 wt% to about 80 wt%, about 30 wt% to about 70 wt%, or about 40 wt% to about 60 wt%.

In some embodiments, the knit comprises a plurality of UHMWPE fibers. Each of the UHMWPE fibers comprises a plurality of microfilaments, each of the microfilaments having a denier of 5 or less. Each of the UHMWPE fibers may comprise 50 or less filaments.

The companion fibers are selected for enhancing the performance of the knit (e.g., without limitation, comfort, durability, dyeability/printability, and/or stretchability). In some embodiments, the companion fiber comprises a single fiber. In some other embodiments, the companion fiber comprises a plurality of fibers.

The companion fibers may be synthetic fibers, natural fibers, drawn fibers, non-drawn fibers, high performance fibers, elastomeric fibers, thermoplastic fibers, or abrasion resistant fibers, or a combination of any of the foregoing.

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

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

In some embodiments, the companion fiber comprises a drawn fiber. Examples of drawn fibers include those made from polyurethane, polyolefin (e.g., low molecular weight polyethylene or polypropylene), and the like.

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

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

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

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

In some embodiments, the companion fiber comprises a wear resistant fiber. Examples of abrasion resistant fibers include those made of nylon, polyester, and polyamide.

The companion fiber may include any suitable number of microfilaments. In some embodiments, the companion fiber comprises 2 to 400 microwires, 10 to 300 microwires, 10 to 200 microwires, 10 to 150 microwires, 10 to 100 microwires, 10 to 50 microwires, 5 to 50 microwires, or 20 to 200 microwires.

The companion fiber may have any denier suitable for pantyhose. In some embodiments, the companion fiber has a denier in the range of 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 companion fiber has a denier of about 5, about 10, about 13, about 15, about 17, about 20, about 25, about 30, about 50, about 60, about 70, about 80, or about 90. In the case where the knitted fabric includes a plurality of accompanying fibers, the plurality of accompanying fibers may have the same or different deniers from each other.

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

In some embodiments, the companion fiber is a colored fiber comprising a dye. In some embodiments, the companion fiber has a color of black, blue, gray, red, blue, brown, yellow, green, orange, or bare. In some embodiments, the companion fiber is white. In some embodiments, the companion fibers have the same color as the UHMWPE fibers. In some other embodiments, the companion fibers have a different color than the UHMWPE fibers. The knitted fabric has high dimensional stability. In some embodiments, the knitted fabric has a dimensional stability of about ±6%, about ±4%, about ±2%, about ±1% or about ±0.5% in each of the length direction and the width direction.

In some embodiments, the knit fabric has a denier of about 150 or less, about 120 or less, about 100 or less, about 80 or less, about 60 or less, about 50 or less, about 40 or less, or about 30 or less. For example, the knitted fabric has a denier between 10 and 200, between 20 and 100, between 20 and 50, between 10 and 40, or between 20 and 40.

Method for manufacturing a panty hose article comprising UHMWPE

In another aspect, a method of making the above knitted fabric is provided. The knitted fabric disclosed in the present application is produced by knitting the UHMWPE fibers and the companion fibers using a knitting machine. The appropriate gauge of the knitting machine is selected according to the type of pantyhose article. The gauge of the knitting machine may affect the stretchability and basis weight of the resulting knitted fabric. The gauge of the knitted fabric may range from 10 to 40. In some other embodiments, the knitted fabric has a gauge range of 28 to 32, which is suitable for producing knitted fabrics for pantyhose or clear silk stockings. In some embodiments, the knit fabric can have a gauge of at least 32.

In some embodiments, a single knit type knitting machine is used. The size of the cylinder of the knitting machine is chosen according to the end use of the knitted fabric. In some embodiments, the knitting machine has a round needle cylinder sized from about 3 inches to about 14 inches, from about 10 inches to about 14 inches, or from about 3 inches to about 7 inches suitable for producing a knitted fabric for pantyhose. In some embodiments, a round syringe is not used.

In knitting the disclosed fabric, the skilled artisan can employ, as a matter of common sense, conventional knitting machines. The knitting machine may have any desired number of yarn feeders depending on the number of fiber types to be knitted and the knitting speed to be employed. Typically, knitting machines have 2, 4 or 8 yarn feeders, most commonly 4 or 8 yarn feeders. In some embodiments, the knitting machine may use more than 8 yarn feeders. In some embodiments, the knitting machine may use more than 16 yarn feeders. In one embodiment of the present disclosure, the garment is made using a four-feeder hosiery knitting machine. In weaving the garments of the present disclosure, each yarn feeder may use fibers in the range of 10 denier to 50 denier. The total denier of the fibers of the woven garment can be any desired, depending on the weight of the pantyhose produced and the degree of transparency desired. In some embodiments, all yarn feeders are used. In some embodiments, only 1 yarn feeder is used. In some embodiments, only 2 yarn feeders are used. In some embodiments, only 3 yarn feeders are used. In some embodiments, all of the yarn feeders employ the same UHMWPE fiber having the same properties and varying the same properties. In some embodiments, all yarn feeders employ the same UHMWPE fiber having the same properties and varying different properties. In some embodiments, all of the yarn feeders employ different types of UHMWPE fibers having different properties and varying different properties. In some embodiments, all of the yarn feeders employ different types of UHMWPE fibers having different properties but varying the same properties.

In some embodiments, the knitting machine may be equipped with a tensioner to maintain a constant tension on each feed fiber. In some embodiments, the tension is constant along the respective length of the feed fiber. In some embodiments, the tension is constant along the length of each feed fiber. In some embodiments, the tension variation along the length of the fed 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%. In some embodiments, the variation in tension of the UHMWPE fibers between different yarn feeders 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 order to achieve stretching effectively in the final knit without losing the strength properties provided by the UHMWPE fibers, the knitting of the UHMWPE fibers and the accompanying fibers comprises plating (plating) or combining (sizing) of the UHMWPE fibers and the accompanying fibers.

In some embodiments, to effectively achieve stretching in the final knit without losing the strength properties provided by the UHMWPE fibers, the UHMWPE fibers and accompanying fibers are woven to form a plated knit. In knitting the plated knit, UHMWPE fibers are required on each course (course) of the knit, while accompanying fibers may be present on each course or every other course. In some embodiments, the plating knit comprises UHMWPE fibers in each transverse row and companion fibers in at least every other transverse row and has a denier of no more than 30. In some embodiments, the plating knit comprises UHMWPE fibers in each transverse row and companion fibers in at least every other transverse row and has a denier of no more than 40. In some embodiments, the plating knit comprises UHMWPE fibers in each transverse row and companion fibers in at least every other transverse row and has a denier of no more than 50. In some embodiments, the plating knit comprises UHMWPE fibers in each transverse row and companion fibers in at least every other transverse row and has a denier of no more than 60. In some embodiments, the plating knit includes UHMWPE fibers in each transverse row and companion fibers in at least every other transverse row and has a denier of about 20, about 25, about 30, about 35, about 40, about 45, about 55, or about 65. After the knitting process is completed, one side of the knit more significantly exposes the UHMWPE fibers, while the other side exposes the companion fibers.

In some other embodiments, to effectively achieve stretching in the final knit without losing the strength properties provided by the UHMWPE fibers, the UHMWPE fibers and accompanying fibers are twisted to form composite fibers. This twisting forms a consolidated composite fiber. In some embodiments, the UHMWPE fibers and companion fibers are twisted with a twist of between 100 and 4500 Twists Per Meter (TPM). To ensure greater stretchability of the final product, as well as an increase in the durability of the final knitted fabric, a higher twist per meter may be required, as a higher twist results in a larger surface area of the accompanying fibers reinforced with UHMWPE fibers. In some embodiments, the UHMWPE fiber and companion fiber has a TPM of 100, the UHMWPE fiber and companion fiber has a TPM of 500, the UHMWPE fiber and companion fiber has a TPM of 1000, the UHMWPE fiber and companion fiber has a TPM of 1500, the UHMWPE fiber and companion fiber has a TPM of 2000, the UHMWPE fiber and companion fiber has a TPM of 2500, the UHMWPE fiber and companion fiber has a TPM of 3000, the UHMWPE fiber and companion fiber has a TPM of 3500, the UHMWPE fiber and companion fiber has a TPM of 4000, and the UHMWPE fiber and companion fiber has a TPM of 4500. In some embodiments, the UHMWPE fibers and accompanying fibers have a TPM of between 2 and 100. In some embodiments, the UHMWPE fibers and accompanying fibers have a Twist Per Inch (TPI) of 3, a TPI of 5, a TPI of 10, a TPI of 15, a TPI of 20, a TPI of 25, a TPI of 30, a TPI of 40, or a TPI of 50.

In some embodiments, UHMWPE fibers and nylon coated spandex fibers are used as companion fibers to make a knitted fabric. Both the UHMWPE fibers and the companion fibers may be twisted or flat. In some embodiments, the nylon has a denier in the range of 1 to 20. In some embodiments, the nylon has a denier in the range of 5 to 20. In some embodiments, the nylon is a multifilament fiber comprising 5 to 16 filaments. In some embodiments, the nylon-coated spandex fiber is formed by coating a 17 denier monofilament spandex fiber with a nylon fiber comprising 5 to 20 microfilaments and having a denier in the range of 1 to 20. In some embodiments, the knit has courses alternating between UHMWPE fibers and nylon-coated spandex fibers, wherein the spandex fibers are 40 denier monofilament fibers and the nylon fibers are multifilament fibers comprising 7 microfilaments and 20 denier. In some embodiments, the resulting knitted fabric has a denier in the range of 15 to 60. In some embodiments, the resulting knitted fabric has a denier of about 40.

In some embodiments, the knit is made using UHMWPE fibers and nylon fibers. The nylon fiber is a multifilament fiber comprising 40 filaments and having a denier of 40.

Panty hose article comprising UHMWPE

In one aspect, the present disclosure provides a pantyhose article. Referring to fig. 1, there is a front view of a pantyhose article 1 according to an exemplary embodiment when placed on a quality control device. The quality control device typically has two panel members spaced apart from each other, each panel member receiving a respective leg member of the pantyhose article under quality control testing. The leg members extending over the panel member allow visual inspection of the quality of the leg members of the pantyhose article. The stocking body member of the pantyhose article also extends between the panel members of the quality control device, thereby also allowing visual inspection of the quality of the stocking body member of the pantyhose. Fig. 4,5, 6, 7 and 8 show front, side, rear, bottom and top views, respectively, of a pantyhose article 1 according to an exemplary embodiment when worn. When worn, the knitted fabric of the item of pantyhose 1 stretches along the contour of the wearer.

The panty hose article 1 comprises a first tubular member 8 and a second tubular member 16, and a crotch portion 24, which are suitably joined together to form the panty hose article 1. The first tubular member 8 extends from the waist end 40 of the panty hose article 1 to the foot end 48 of the first tubular member 8.

In the embodiments shown in fig. 1, 4, 5,6, 7 and 8, the first tubular member 8 corresponds to the right side of the item of pantyhose 1, but it is notable that the actual side (left or right) will depend on the direction of wear of the item of pantyhose 1. In various embodiments, the pantyhose article 1 is unoriented, so the first tubular member 8 can be interchangeably worn on either the left or right leg. Similarly, according to these embodiments, the second tubular member 16 may be interchangeably worn on either the left or right leg.

The first tubular member 8 comprises a plurality of portions corresponding to different knitted fabrics of the first tubular member 8. The first tubular member 8 comprises a first panty portion 56 extending from the waist end 40 of the panty hose article 1 to a bottom end 64 of the first panty portion 56. The first panty portion 56 may include at least one waistband 44 at the waist end 40 to ensure a snug fit when the panty hose article 1 is worn.

According to the embodiment shown in fig. 1, 4, 5, 6, 7 and 8, the bottom end 64 of the first panty portion 56 corresponds substantially to the crotch area in the longitudinal direction 72 of the pantyhose article 1.

In another embodiment, the bottom end 64 of the first panty portion 56 is located at a lower (i.e., closer to the foot end 48) position than the crotch area of the pantyhose article 1 in the longitudinal direction 72.

The first tubular member 8 further includes a first tubular leg portion 80 extending from a top end 88 thereof to the first foot end 48 of the first tubular member 8. The top end 88 of the first tubular leg portion 80 corresponds to the bottom end 64 of the first panty portion 56. The first tubular leg portion 80 of the first tubular member 56 defines a first leg cavity 92 (fig. 2, 8).

According to one embodiment, the first foot end 48 of the first tubular member 8 may be closed, for example ending in the form of a closed sock, as shown in fig. 1,4, 5 and 6. In another embodiment, the first foot end 48 of the first tubular member 8 may have an opening, such as a footless panty hose, such that the first foot end 48 is positioned adjacent to the ankle of the wearer when the panty hose article 1 is worn. In yet another embodiment, the first foot end 48 of the first tubular member 8 may be partially open, such as with a clasp member (e.g., a foot pedal, toe strap) for holding the first tubular member 8 in place while being worn, but at the same time leaving the foot of the wearer at least partially exposed.

The panty hose article 1 further comprises a second tubular member 16 extending from the waist end 40 of the panty hose article 1 to the foot end 104 of the second tubular member 16.

The second tubular member 16 comprises a plurality of portions corresponding to different knitted fabrics of the second tubular member 16. The second tubular member 16 includes a second panty portion 112 that extends from the waist end 40 of the pantyhose article 1 to a bottom end 120 of the second panty portion 112. The bottom end 120 of the second panty portion 112 can be substantially aligned with the bottom end 64 of the first panty portion 56. The second panty portion 112 may also include at least one waistband to ensure a snug fit when the panty hose article 1 is worn. The waistband may be identical to the waistband 44 of the first tubular member 8.

According to the embodiment shown in fig. 1, 4, 5 and 6, the bottom end 120 of the second panty portion 112 corresponds substantially to the crotch area of the pantyhose article 1 in the longitudinal direction 72 of the pantyhose article 1. In another embodiment, the bottom end 120 of the second panty portion 112 is located at a lower (i.e., closer to the foot end 104) position than the crotch area of the pantyhose article 1 in the longitudinal direction 72.

The second tubular member 16 further includes a second tubular leg portion 128 extending from a top end 136 thereof to the second foot end 104 of the second tubular member 16. The top end 136 of the second tubular leg portion 128 corresponds to the bottom end 120 of the second panty portion 112. The second tubular leg portion 128 of the second tubular member 16 defines a second leg cavity 138 (fig. 2, 8).

According to one embodiment, the second foot end 104 of the second tubular member 16 may be closed, for example ending in the form of a closed sock, as shown in fig. 1,4, 5 and 6. In another embodiment, the second foot end 104 of the second tubular member 16 may have an opening, such as a footless panty hose, such that the second foot end 104 is positioned adjacent to the ankle of the wearer when the panty hose article 1 is worn. In yet another embodiment, the second foot end 104 of the second tubular member 16 may be partially open, such as with a clasp member (e.g., a foot peg, toe strap) for holding the second tubular member 16 in place while being worn, but at the same time leaving the foot of the wearer at least partially exposed.

According to one embodiment, and as shown in fig. 1, 4, 5 and 6, the first tubular leg portion 80 of the first tubular member 8 includes a first main subsection 140 and a first transition subsection 148. The first main sub-portion 140 extends from the first thigh region 156 of the first tubular leg portion 80 of the panty hose article 1 to the first foot end 48 of the first tubular member 8. The first transition subsection 148 extends between the bottom end 64 of the first panty portion 56 and the upper end of the first main subsection 140. More specifically, the first transition subsection 148 extends from the top end 88 of the first tubular leg section 80 to a first thigh region 156 of the first tubular leg section 80. Notably, the top end of the first transition sub-portion 148 corresponds to the top end 88 of the first tubular leg portion 80, which also corresponds to the bottom end 64 of the first panty portion 56.

According to one embodiment, and as shown in fig. 1,4, 5 and 6, the configuration of the second tubular leg portion 128 of the second tubular member 16 is identical to the configuration of the first tubular leg portion 80. The second tubular leg portion 128 of the second tubular member 16 includes a second main sub-portion 160 and a second transition sub-portion 164. The second main sub-portion 160 extends from the second thigh region 168 of the second tubular portion 128 to the second foot end 104 of the second tubular member 16 of the panty hose article 1. The second transition subsection 164 extends between the bottom end 120 of the second panty portion 112 and the upper end of the second main subsection 160. More specifically, the second transition sub-portion 164 extends from the top end 136 of the second tubular leg portion 128 to a second thigh region 168 of the second tubular leg portion 128. Notably, the top end of the second transition sub-portion 164 corresponds to the top end 136 of the second tubular leg portion 128, which also corresponds to the bottom end 120 of the second panty portion 112.

The longitudinal edge 172 of the first panty portion 56 engages the corresponding longitudinal edge 180 of the second panty portion 112 to form a panty tube 188 (FIG. 2) defining a panty cavity 196. The edges 172 and 180 may be joined by stitching.

Fig. 2 is a top perspective view of the interior of the pantyhose article 1 according to an embodiment when it is placed on a quality control device. Fig. 8 is a top view of the pantyhose article 1 as if it were worn (the pantyhose article 1 is shown as if it were stretched when worn, but the body of the wearer is not shown for clarity). The panty cavity 196 is in fluid communication with the first leg cavity 92 defined by the first tubular leg portion 80 and is also in fluid communication with the second leg cavity 138 defined by the second tubular leg portion 128.

The panty cavity 196 accommodates the lower body of the wearer when the panty hose article 1 is worn. The first leg cavity 92 receives a first leg of the wearer (e.g., a right leg) and the second leg cavity 138 receives a second leg of the wearer (e.g., a left leg).

The lower region of the longitudinal edge 172 of the first panty portion 56 (i.e., the region closer to the bottom end 64 of the first panty portion 56) is also joined by stitching, for example, through the crotch portion 24 to the corresponding lower region of the longitudinal edge 180 of the second panty portion 112 (i.e., the region closer to the bottom end 120 of the second panty portion 112). Thus, at least one edge of the bottom end 64 of the first panty portion 56 is joined to the crotch portion 24, such as by stitching, and at least one edge of the bottom end 120 of the second panty 112 is also joined to the crotch portion 24, such as by stitching.

Referring now to fig. 3, there is shown a bottom view of the crotch region of an item of pantyhose 1 when placed on a quality control device, according to an embodiment. Fig. 7 is a bottom view of a pantyhose article when worn, according to an embodiment. The first bottom edge 204 of the first pant portion 56 is directly joined (e.g., directly sewn) to the first edge 212 of the first end of the crotch portion 24, the second bottom edge 220 of the first pant portion 56 is directly joined (e.g., directly sewn) to the first edge 228 of the second end of the crotch portion 24, the first bottom edge 236 of the second pant portion 112 is directly joined (e.g., directly sewn) to the second edge 244 of the first end of the crotch portion 24, and the second bottom edge 252 of the second pant portion 112 is directly joined (e.g., directly sewn) to the second edge 262 of the second end of the crotch portion 24.

According to the embodiment shown in fig. 1 to 8, wherein the bottom parts 64 and 120 of the first and second panty parts 56 and 112 essentially correspond to the crotch area of the panty hose article 1, the first transition sub-part 148 is directly joined to the crotch 24 and the second transition sub-part 164 is also directly joined to the crotch 24. As best shown in fig. 3, the intermediate region 268 of the first edge of the crotch portion 24 (corresponding to the portion of the edge between the first edge 212 at the first end and the first edge 228 at the second end of the crotch portion 24) is directly joined (e.g., directly sewn) to a portion of the edge 276 of the first transition subsection 148. The engagement portion may be located at the top edge 88 of the first transition subsection 148. In addition, the intermediate region 284 of the second edge of the crotch portion 24 (corresponding to the portion of the edge between the second edge 244 at the first end and the second edge 260 at the second end of the crotch portion 24) is joined (e.g., directly sewn) directly to a portion of the edge 292 of the second transition subsection 164. The engagement portion may be located at the top edge 136 of the second transition sub-portion 164. Thus, the first panty portion 56, the second panty portion 112, the crotch portion 24, the first transition sub-portion 148 and the second transition sub-portion 164 are suitably joined to enclose (i.e., ensure that there are no openings or slits) the crotch area of the pantyhose article 1 and enclose the panty cavity 196.

According to an alternative embodiment, wherein the bottom end 64 of the first panty portion 56 and the bottom end 120 of the second panty portion 112 are both located in the longitudinal direction 72 below the crotch area of the panty hose article 1, a first side of the crotch portion 24 is directly joined (e.g. directly sewn) to a corresponding area of the longitudinal edge 172 of the first panty portion 56 and a second side of the crotch portion 24 is directly joined (e.g. directly sewn) to a corresponding area of the longitudinal edge 180 of the second panty portion 112 to close (i.e. ensure that there is no opening or slit) the crotch area of the panty hose article 1 and to enclose the panty cavity 196. According to this alternative embodiment, the top edges 88, 136 of the first and second leg portions 80 and 128 are not directly joined (e.g., directly sewn) to the crotch portion 24.

According to the embodiment shown in fig. 1 to 8, the thigh region 156 of the main subsection 140, which corresponds to the bottom end of the first transition subsection 148, is located in the mid-thigh region of the first tubular leg portion 80, which corresponds to the mid-thigh region of the first leg of the wearer when the panty hose article 1 is worn. Thus, the transition subsection 148 extends from the crotch region of the panty hose article 1 to the mid-thigh region of the first tubular leg member 8. The second transition sub-portion 164 also extends along a corresponding region of the second tubular leg member 16.

According to another embodiment, the thigh region 156 of the main subsection 140 is located at the upper thigh region of the first tubular leg section 80 which corresponds with the upper thigh region of the first leg of the wearer when the article of panty hose 1 is worn. Thus, the transition subsection 148 extends from the crotch region of the pantyhose article 1 to the upper thigh region of the first tubular leg member 8. The second transition sub-portion 164 also extends along a corresponding region of the second tubular leg member 16.

According to yet another embodiment, the thigh region 156 of the main subsection 140 is located at a lower thigh region (i.e., near the knee region) of the first tubular leg section 80 which corresponds to a lower thigh region of the first leg of the wearer when the pantyhose article 1 is worn. Thus, the transition subsection 148 extends from the crotch region of the panty hose article 1 to the lower thigh region of the first tubular leg member 8. The second transition sub-portion 164 also extends along a corresponding region of the second tubular leg member 16.

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

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

Notably, in each of the embodiments described herein, wherein the first and second leg portions 80 and 128 each include a transition sub-portion 148 and 164, the transition sub-portions 148, 164 always extend between the bottom ends 64, 120 of the respective panty portions 56, 112 and the respective thigh regions 156, 168 of the tubular leg portions 80, 128. The length and location of the transition sub-portions 148, 164 varies depending on whether the top ends of the transition sub-portions 148, 164 are located in the crotch region of the pantyhose article 1 and the location of the thigh regions 156 and 168 of the tubular leg portions 80, 128.

According to one embodiment, and as shown in the drawings, the first main subsection 140 of the first tubular leg section 80 is formed of a first knit comprising first UHMWPE fibers and at least one first companion fiber. The first transition sub-portion 148 of the first tubular leg portion 80 is formed from a second knit comprising second UHMWPE fibers and at least one second companion fiber. The first knit fabric of the first main subsection 140 of the first tubular leg section 80 is different from the second knit fabric of the first transition subsection 148 of the first tubular leg section 80.

According to one embodiment, the first knit of the first main subsection 140 differs from the second knit of the first transition subsection 148 in that the knit pattern of the first knit differs from the knit pattern of the second knit. The knitting pattern referred to herein, in reference to the first knitted fabric and the second knitted fabric, refers to how the UHMWPE fibers and the at least one accompanying fiber are joined to each other within the knitted fabric in a given knitted fabric. The difference in weave pattern may include, but is not limited to, how the UHMWPE fiber and the at least one companion fiber are looped around each other, hooked to each other, and/or which UHMWPE fiber(s) and/or companion fiber(s) are present on the courses of the knit.

According to an exemplary embodiment, the first knitted fabric of the first main subsection 140 differs from the second knitted fabric of the first transition subsection 148 in that the first UHMWPE fibers in the first knitted fabric differ from the second UHMWPE fibers in the second knitted fabric. The first and second UHMWPE fibers may differ in one or more of color, denier, tensile strength, modulus, twist per revolution, or whether or not coated.

According to one embodiment, the first knit fabric of the first main subsection 140 differs from the second knit fabric of the second transition subsection 148 in that at least one first companion fiber of the first knit fabric differs from at least one second companion fiber of the second knit fabric. The collection of at least one first companion fiber may include at least one companion fiber that is not in the collection of at least one second companion fiber, and vice versa. The at least one second companion fiber may include at least one of the first companion fibers, but may also include at least one additional at least one second companion fiber that is not in the collection of the at least one first companion fiber, and vice versa. In one embodiment, the set of at least one second companion fiber includes all of the set of at least one first companion fiber and further includes at least one additional at least one second companion fiber that is not in the set of at least one first companion fiber. Any first fiber and any second fiber may differ in one or more of fiber type, fiber material, fiber structure, fiber architecture, color, denier, tensile strength, modulus, whether coated or not.

In one embodiment, the second knit of the first transition subsection 148 is reinforced as compared to the first knit of the first main subsection 140. For example, the second knit of the first transition sub-portion 148 employs the same UHMWPE fibers as the first UHMWPE fibers of the first main sub-portion 140, and the second knit of the first transition sub-portion 148 further includes at least one accompanying fiber that is the same as the at least one first accompanying fiber of the first main sub-portion 140, but the second knit of the first transition sub-portion 148 further includes at least one additional accompanying fiber that is knitted within the second knit to provide additional reinforcement to the second knit of the first transition sub-portion 148 relative to the first knit of the first main sub-portion 140.

The second knit of the first transition sub-portion 148 may have a greater resistance to sewing than the first knit of the first main sub-portion 140 of the first tubular leg portion 80. The stronger sewing durability referred to herein means durability when the second knitted fabric is pierced by a sewing needle of a sewing operation during the assembling process, or means stronger tear resistance of the second knitted fabric when one or more threads sewn to the second knitted fabric exert a pulling force thereon during the sewing operation.

The second knitted fabric of the first transition sub-portion 148 has a stronger resistance to raveling when torn or cut than the first knitted fabric of the first main sub-portion 140 of the first tubular leg portion 80, which refers to the ability to prevent the tear or cut from continuing to propagate along the longitudinal direction 72 of the tubular leg member 1 after the initial tear or cut has occurred.

According to one embodiment, the second knit of the first transition subsection 148 comprises a mesh knit. The open knit fabric refers to a knitted fabric in which a yarn of the open knit fabric is not looped in each given number of courses of the yarn. For example, the open knit may be a1 x 1 knit, i.e., the yarns form stitches in one course and do not form stitches in a second course. The open mesh knit may also be a 3x 1 knit, i.e., the yarns form stitches in three courses and do not form stitches in the fourth course. The open mesh knit may also be a 5 x 1 knit, i.e., the yarns form stitches in five courses and do not form stitches in the sixth course. In a preferred embodiment, the open mesh knit may be a 7x 1 knit, i.e., the yarns form stitches in seven courses and not in the eighth course. It was observed that the open mesh knit had anti-ravel properties, i.e., when the second knit was cut or torn, the ravel caused by the cut or tear continued until a position was encountered where no loop was formed by the open mesh knit. The absence of a given coil may prevent the spread of the wire break. By making the cases of the stitches missing in the open knit fabric occur frequently enough, the open knit fabric can prevent the thread from being stripped when the second knit fabric is torn or cut.

According to an exemplary embodiment, the open mesh knit of the second knit of the first transition subsection 148 is configured such that the location of the stitch jump (i.e., one course that is not looped) in any given row of the second knit is staggered relative to the location of the stitch jump in the immediately next row of the open mesh knit. This non-aligned arrangement of the different rows of stitch-breaking positions in the open mesh knit improves the resistance to thread-breaking by ensuring that the thread-breaking of the tubular leg member at any given angular position eventually encounters one stitch-breaking position.

According to one exemplary embodiment, the second knit of the first transition subsection 148 includes a combination of a flat knit and a open knit. Plain knit fabrics are also commonly referred to as single knit fabrics. The jersey of the second knit may be woven from a second UHMWPE of the second knit that is the same as the first UHMWPE of the first knit of the first main subsection 140 and companion fibers that are the same as the first companion fibers of the first knit. The open knit of the second knit may be knitted from at least one additional companion fiber in the second knit, the at least one additional companion fiber being knitted within the jersey knit to form the open knit depending on the configuration of the open knit. For example, in knitting a jersey, the at least one additional accompanying fiber of the second knit is suitably looped with stitches of the jersey according to the arrangement of the open knit, and is suitably hopped (i.e., not looped) at the position where the jersey is looped according to the arrangement of the open knit. More specifically, in the n×1 open knit of the additional companion fibers of the second knit, in every n courses of the jersey formed from UHMWPE and the second companion fibers, the additional companion fibers are also looped with the yarns of the jersey knit, while in n+1 courses of the jersey, the jersey yarns are looped and the additional companion fibers are not looped.

According to one exemplary embodiment, the open mesh knit is knit in a second knit to provide a knit loop that resists spreading in the longitudinal direction 72 toward the foot end 48. That is, the mesh knit is able to resist a thread break that begins at a location near the top end 40 of the first tubular leg member 8 (e.g., caused by cutting or tearing) and propagates toward the foot end 48, thereby limiting the thread break from continuing downwardly toward the foot end 48 when the mesh knit is encountered.

The second transition subsection 164 of the second tubular leg section 128 may be made of a second knit fabric comprising at least one second UHMWPE fiber and at least one accompanying drawn fiber identical to the first transition subsection 148 of the first tubular leg section 80. Thus, the second knit of the second transition subsection 164 differs from the first knit of the second main subsection 160 in accordance with the various manners described herein.

According to one embodiment, the first panty portion 56 of the first tubular member 8 is made of a knitted fabric without (e.g. without) UHMWPE. Thus, the first panty portion 56 may be made of one or more knitted fabrics of drawn fibers without UHMWPE. The most costly material in the panty hose product 1 is observed to be UHMWPE fibres. It is also observed that the first panty portion 56 is typically worn under one or more layers of other garments and is not in direct contact with external objects that may cause tearing, breakage or pilling. Thus, there is no need to reinforce the first panty portion 56 with a knitted fabric comprising UHMWPE to improve its tear resistance. Accordingly, it is further observed that the first panty portion 56 is a suitable area in the panty hose article 1 where UHMWPE may be omitted without significantly degrading its performance. However, as described elsewhere herein, other portions of the pantyhose article 1 may require additional adjustment to accommodate the fact that the first panty portion 56 is made of a knit fabric that does not contain UHMWPE. The second panty portion 112 of the second tubular member 16 may also be made of a knitted fabric without UHMWPE in the same way as the first panty portion 56. The first panty portion 56 and the second panty portion 112 may be made of the same knit fabric.

The first tubular member 8 is formed or woven in a continuous knitting operation. More specifically, the first panty portion 56, the first transition sub-portion 148, and the first main sub-portion 140 are formed in the same continuous knitting operation. A continuous knitting operation refers to a continuous run by one knitting machine (e.g., a circular knitting machine) such that portions of the first tubular member 8 (e.g., the first panty portion 56, the first transition sub-portion 148, and the first main sub-portion 140) produced by the continuous knitting operation are continuously or integrally knit one after another. In such a continuous knitting operation, after a given portion of the first tubular member 8 (e.g., the first panty portion 56) is knitted, the next portion of the first tubular member 8 (e.g., the first transition sub-portion 148) continues to be knitted from the last interface of fibers of the given portion just completed (e.g., the last stitch of the knit forming the first panty portion 56). The braiding is continued by switching from the just completed fibre and braiding pattern of the given portion to a fibre and braiding pattern suitable for the next portion of the first tubular member 8. It will be appreciated that at any stage of the braiding operation, the continuous braiding operation of the first tubular member 8 does not produce the first panty portion 56, the first transition sub-portion 140 and the first main sub-portion 148 as separate and discrete portions that need to be subsequently joined together in any manner (e.g., by sewing the portions together).

It has been observed that the interface between the different knitted fabrics in the first tubular member 8 creates a weak point in the first tubular member 8. This weak point may lead to defects, such as tears or breaks, that propagate in the panty-hose article 1 at the interface. These defects may be caused by repeated stress applied to the panty hose article 1, such as repeated pulling and stretching in the longitudinal direction 72, when the panty hose article 1 is worn by a wearer. In addition, this transition between different knitted fabrics can also cause discomfort when wearing the panty hose article 1.

The continuous knitting of the second knitted fabric of the first panty portion 56 and the first transitional sub-portion 148 reduces tearing at a transition between the two portions that corresponds to the bottom end 64 of the first panty portion 56. The second knit of the first transition subsection 148 is also utilized to enhance durability and reduce tearing along the transition at the bottom end 64. According to one embodiment, one of the one or more drawn fibers used to knit the first panty portion 56 is also present in the second knitted fabric of the first transition sub-portion 148, which ensures continuity of the knitted fabric at the transition between the panty portion 56 and the first transition sub-portion 148, thereby also reducing the likelihood of tearing. This conversion may also improve comfort.

The continuous braiding of the first transition sub-portion 148 with the main sub-portion 140 reduces tearing at a transition between the two portions corresponding to the first thigh region 156 of the tubular leg portion 80. The second knit of the first transition subsection 148 and the first knit of the first main subsection 140 are used to enhance the durability of the first thigh region 156 at the transition and to reduce tearing. According to one embodiment, the UHMWPE in the first knit of the first main subsection 140 is also present in the second knit of the first transition subsection 148 in combination with accompanying fibers, which ensures continuity of the knit at the transition between the first transition subsection 148 and the main subsection 140, thereby also reducing the likelihood of tearing. This conversion may also improve comfort.

It will be appreciated that the inclusion of the first transition subsection 148 in the first tubular leg member 8 results in two knit transitions, a first transition being located between the first panty portion 56 and the first transition subsection 148 at the bottom end 64 of the first panty portion 56 and a second transition being located between the first transition subsection 148 and the first main subsection 140 at the thigh region 156. Thus, a pulling force applied along the longitudinal direction 72 of the first tubular member 8 (e.g. when the panty hose 1 is worn by a wearer) will be distributed between said first transition and said second transition. Such distribution of tensile forces may reduce the likelihood of tearing compared to a first tubular member 8 having only one transition (e.g., a single transition from the panty portion 56 directly to the first main sub-portion 140).

As described above, the second knitted fabric of the first transition subsection 148 may optionally be selected such that there is continuity between the knitted fabric of the first panty section 56 and the second knitted fabric of the first transition subsection 140 by virtue of the two knitted fabrics having fibers in common in their respective knitted structures. Furthermore, the second knit of the first transition subsection 148 may optionally be selected such that continuity is provided between the knit of the first transition subsection 148 and the first knit of the first main subsection 140 by virtue of the two knits having at least one fiber in common in their respective knit constructions. It has been observed that the low denier of the first panty portion 56 is directly transferred to the first knit of the main subsection 140, which tends to cause tearing, as the knit of the first panty portion 56 is relatively thin (e.g., has a total denier of less than 200) and thus can be worn under a tight fitting garment. The addition of the first transition subsection 148 as an intermediate knit between the first panty portion 56 and the first knit of the main subsection 140 solves the disadvantage that would otherwise occur with tubular members that include substantially only the first panty portion and the main subsection.

According to one embodiment, the first panty portion 56 is formed from a knitted fabric having a total denier of about 20 to 250. It will be appreciated that the knitted fabric of the first panty portion 56 is of sufficiently low denier so as to fit snugly under a tight garment, such as a tight dress or a hip-pack skirt. According to one embodiment, the first panty portion 56 is made primarily of a knitted fabric of nylon fibers having a denier of about 20 to 100 and nylon-covered spandex fibers having a denier of about 20 to 120. In one embodiment, the nylon fibers are doubled 40 denier nylon fibers and the nylon covered spandex fibers are comprised of two 20 denier spandex fibers covered with 40 denier nylon.

Notably, when the first main sub-portion 140 is worn on the leg, it is typically exposed to environmental factors that may cause tearing and/or breakage. The first knitted fabric of the first main sub-portion 140 is specifically designed to have at least tear and pilling resistance properties. Since the first main subsection 140 is exposed and visible, the first knit fabric is also purposely designed to have desired aesthetic characteristics. According to an exemplary embodiment, the first UHMWPE fibers in the first knitted fabric of the first main subsection 140 comprise a first UHMWPE fiber having a denier of about 10 to 60 and the first companion fiber has a denier of about 10 to 100. According to various exemplary embodiments described herein, the first UHMWPE fibers and the first companion fibers may be woven into plated knits having different appearances.

In one exemplary embodiment, if the first main subsection 140 is desired to exhibit a transparent appearance, the first UHMWPE fibers in the first knit should have a denier of between about 25 and about 35, while the first companion fibers comprise primarily drawn fibers having a denier of between about 10 and about 20. According to one exemplary embodiment, the first UHMWPE fiber has a denier of about 30, and the drawn fiber is a nylon-coated spandex fiber of about 15 denier.

According to one exemplary embodiment, when the first main subsection 140 is to exhibit a translucent appearance, the first UHMWPE fibers in the first knit should have a denier of between about 25 and about 35, while the first companion fibers comprise fibers having a total denier of between about 40 and about 80. According to one exemplary embodiment, the first UHMWPE fiber has a denier of about 30 and the companion fiber comprises one or more nylon-coated spandex fibers having a total denier of about 50.

According to one exemplary embodiment, when the first main subsection 140 is to exhibit an ultra-thin transparent appearance, the first UHMWPE fibers in the first knit should have a denier of between about 10 and about 20, while the first companion fibers comprise fibers having a total denier of between about 5 and about 15. According to one exemplary embodiment, the first UHMWPE fiber has a denier of about 15 and the first companion fiber is a coated spandex fiber of about 9 denier.

According to an exemplary embodiment, when the first main subsection 140 is to exhibit a translucent appearance, the first UHMWPE fibers in the first knit should have a denier of between about 25 and about 50, while the first companion fibers include fibers having a total denier of between about 60 and about 150. According to one exemplary embodiment, the first UHMWPE fiber has a denier of about 30 and the first companion fiber is a coated spandex fiber of about 75 denier.

According to one exemplary embodiment, the second knit of the first transition subsection 148 is woven from second UHMWPE fibers having a denier of about 10 to about 60 and the second companion fiber has a total denier of about 50 to about 150. According to an exemplary embodiment of a second knitted fabric to be combined with a first main subsection 140 having a transparent appearance, the second UHMWPE fibers in said second knitted fabric also have a denier of about 25 to about 35, preferably about 30 denier, which UHMWPE fibers are knitted together with a second accompanying fiber, which second accompanying fiber essentially comprises drawn fibers having a denier of about 10 to about 20, preferably about 15 denier, covered spandex fibers. The second UHMWPE fibers and the second companion fibers may be woven into a plating knit. Notably, such UHMWPE fibers and such accompanying fibers are present in both the first knit of the main subsection 140 and in the first transition subsection 148. The second knit of the first transition subsection 148 also includes a mesh knit as described elsewhere herein. The open mesh knit may be woven from additional companion fibers comprising nylon covered lycra fibers having a denier of about 40 to about 120, preferably two 20 denier spandex fibers covered with 40 denier nylon. Notably, such additional accompanying fibers in the second knit of the first transition subsection 148 are also present in the knit of the first panty section 56.

According to one embodiment, and as shown in fig. 1,4, 5, 6, 7 and 8, the first tubular member 8 is made in a non-directional manner about its longitudinal axis 212. That is, the first tubular member 8 is identical at any angular position about its longitudinal axis 212 prior to assembly with the crotch portion 24 and the second tubular member 16. The first panty portion 56 extends circumferentially about the longitudinal axis 212 and thus can be cut at any angular position about the longitudinal axis 212 to form the longitudinal edge 172 thereof for engagement with the corresponding edge 180 of the second panty portion 112. The second tubular member 16 may also be made in a similar non-directional manner about its own axis.

The first transition sub-portion 148 also extends circumferentially about the longitudinal axis 212 and the first tubular leg portion 80. According to one embodiment, wherein the edge of the first transition sub-portion 148 is directly joined to the edge of the crotch portion 24, the joint between said edge 228 of the first transition sub-portion 148 and said edge of the crotch portion 24 may be made at any angular position of the tubular leg portion 80 about the longitudinal axis 212 (as long as the angular position is common to the first main sub-portion 140 and the first transition sub-portion 148). That is, the engagement need not be performed at a precise angular region/position of the circumferential edge 228 of the first transition sub-section 148 that is predetermined after the first tubular leg section 80 is formed. The second transition sub-portion 164 may also extend circumferentially about the second tubular leg portion 128 about its own axis.

In addition, the cut to the first panty portion 56 is made in the longitudinal direction 72 from the top edge 40 to the bottom edge 64 and may extend slightly to the first transition subsection 148. Such cutting may otherwise cause a thread break on the first tubular member 8, but due to the presence of the reinforcing knit (e.g., open knit) in the first transition subsection 148, the thread break is restricted from continuing to propagate toward the foot end 48 of the first tubular member 8. Furthermore, since the first transition sub-portion 148 extends circumferentially around the first tubular member 8, the cut can be made at any angular position around the axis 212, and the reinforced knit of the first transition sub-portion 148 will limit the continued propagation of the ravel. The second transition sub-portion 164 extends circumferentially about the respective axis of the second tubular leg portion 128, providing a similar limitation to the spread of the line of weakness that may result when cutting on the second panty portion 112 to form the longitudinal edge 180.

According to various embodiments described herein, the first and second transition sub-portions 148, 164 of the first and second leg portions 80, 128, respectively, extend between the bottom ends of the respective panty portions 56, 112 and the thigh regions 156, 168 of the tubular leg portions 80, 128, respectively. Because of this positioning, the first and second transition sub-portions 148, 164 will be located in the thigh area of each leg of the wearer when the pantyhose article 1 is worn. Further, because the first transition sub-portion 148 and the second transition sub-portion 164 extend circumferentially about their respective leg portions 80, 128, when the pantyhose article 1 is worn, a first thigh inner region at the thigh level of the wearer's first leg will be covered by a first corresponding angular region of the first transition sub-portion 148 and a second thigh inner region at the thigh level of the wearer's second leg will be covered by a second corresponding angular region of the second transition sub-portion 164. Notably, when the pantyhose article 1 is worn, the first corresponding angular region of the first transition sub-portion 148 will face the second corresponding angular region of the second transition sub-portion 164 (because the thigh-inner region of the first leg will face the thigh-inner region of the second leg). It has been observed that friction of the wearer's inner thigh areas is a common cause of wear or damage to the leg garments. It has further been observed that positioning the first transition sub-portion 148 and the second transition sub-portion 164 at the thigh level of the respective first and second tubular leg portions better prevents wear or damage to the panty hose article 1 due to rubbing on the inner side of the thigh. Notably, the second knit of the first and second transition sub-portions 148, 164 is a knit including UHMWPE fibers and at least one accompanying fiber, and the addition of UHMWPE fibers provides additional protection against wear or damage to the knit due to its higher durability.

According to a method for manufacturing a panty hose product 1 according to one embodiment, a first tubular member 8 is first manufactured. As described herein, the first tubular member 8 is manufactured in a continuous knitting operation, for example using a circular knitting machine. Likewise, a second tubular member 16 is also manufactured. As described herein, the second tubular member 16 is also manufactured in a continuous knitting operation, for example using a circular knitting machine.

After the first tubular member 8 and the second tubular member 16 are formed, the tubular members 8, 16 are suitably cut and joined, thereby forming the panty hose article 1. The first tubular member 8 is manufactured in a non-directional manner, wherein the first panty portion 56 extends circumferentially about the longitudinal axis 212 and the first transition sub-portion 148 also extends circumferentially about the longitudinal axis 212 (the second tubular member 16 also has these same characteristics), enabling the panty hose article 1 to be assembled in a substantially automated process. An automated assembly process herein refers to performing one or more machine-completed cuts, alignments, and/or joins (e.g., sutures) without human manual intervention. After the knitting machine has finished knitting the first tubular member 8 and the second tubular member 16, the tubular members 8 and 16 are properly loaded onto an automated assembly machine. Since the first tubular member 8 is non-directional and has a first panty portion 56 extending circumferentially about the longitudinal axis 212, the panty portion 56 can be cut in the longitudinal direction 72 at any angular position of the first tubular member 8 to form its longitudinal edge 172. Cutting may be performed on the second tubular member 16 in a similar manner to form the longitudinal edges 180.

Furthermore, according to one embodiment, wherein the edge of the first transition subsection 148 is directly joined to the edge of the crotch portion 24, any region of the edge 228 of the top edge of the transition subsection 140 is adapted to be stitched to the crotch portion 24 as the first transition subsection 148 extends circumferentially about the longitudinal axis 212. The edge 228 of the transition sub-portion 140 (corresponding to the angular position at which the panty portion 56 is cut on the first tubular member 8) is joined (e.g., sewn) to the crotch portion 24. In the second transition subsection 164, the crotch portion 24 may be joined (e.g., sewn) in a similar manner.

The longitudinal edge 172 of the first panty portion 56 is further joined (e.g., sewn) together with the longitudinal edge 180 of the second panty portion 112 to form a panty tube 188. The edges of the panty portions 56, 112 are further sewn to the respective edges of the crotch portion 24 to close any gaps and enclose panty cavity 196.

It is noted that the steps of automatically assembling the panty-hose product 1 described above can be performed in a different order than described above, depending on the configuration and function of the assembly machine. Further, one or more steps may be accomplished in a single operation, such as stitching multiple edges together in a single stitching operation.

As described elsewhere herein, the first tubular member 8 and the second tubular member 16 are made by a continuous knitting operation on a circular knitting machine. According to some exemplary embodiments, the tubular leg members 8 and 16 are formed by continuously feeding fibers from the same number of yarn feeders of the knitting machine throughout the continuous knitting operation, i.e., throughout the knitting of the panty portions 56 and 112, the transition sub-portions 148 and 164, and the main sub-portions 140 and 160. In one embodiment, both tubular leg members 8 and 16 are woven using 2 yarn feeders of the knitting machine throughout the full continuous knitting operation.

It has been observed that the first and second main sub-portions 140, 160 and the first and second transition sub-portions 148, 164, each formed of a knit comprising UHMWPE, require fewer yarn feeders (i.e. 2 or fewer yarn feeders) to knit due to the complexity introduced by the nature of the UHMWPE. It is also observed that the UHMWPE-free panty portion 56, 112 can be knitted with more yarn feeders (i.e. more than 2 yarn feeders, for example 4 or more yarn feeders) of the knitting machine. It has further been observed that switching from 4 or more yarn feeders (corresponding to the knitted fabric of the panty part 56, 112) to 2 or less yarn feeders (corresponding to the knitted fabric of the transition sub-part 148, 164 and the main sub-part 140, 160) introduces a weak point in this switching position of the tubular leg part 8, 16. The weak point may appear as a hole in the tubular leg member 8, 16 at the transition position. However, it has also been observed that by continuously feeding fibres from the same number of feeders of the knitting machine to knit the tubular leg members 8, 16 throughout the continuous knitting operation, this weak point can be eliminated, thereby improving the strength/durability of the knitted fabric.

While examples of embodiments are provided above, it will be understood that certain features and/or functions of the described embodiments may be modified without departing from the spirit and principles of these embodiments. Accordingly, the foregoing description is intended to be illustrative, and not limiting, and it will be understood by those skilled in the art that other variations and modifications may be made without departing from the scope of the invention as defined in the following claims.

Claims

1. A pantyhose product, comprising:

A first tubular member having:

a first panty portion extending from a waist end of the pantyhose article to a bottom end of the first panty portion;

A first tubular leg portion defines a first leg cavity and extends from its top end to a first foot end of the first tubular leg portion, the top end corresponding to the bottom end of the first panty portion, the first tubular leg portion comprising a first main sub-portion and a first transition sub-portion, the first main sub-portion extending from a first thigh region of the first tubular leg portion to the first foot end, and the first transition sub-portion extending from the top end of the first tubular leg portion to the first thigh region of the first tubular leg portion, the first main sub-portion being formed by a first knitted fabric comprising first ultra-high molecular weight polyethylene (UHMWPE) fibers and at least one first accompanying fiber, and the first transition sub-portion being formed by a second knitted fabric comprising second UHMWPE fibers and at least one second accompanying fiber, the first knitted fabric being different from the second knitted fabric.

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

3. The pantyhose article of claim 2, wherein the second knitted fabric of the first transition sub-portion has a stronger sewing resistance than the first knitted fabric of the first main sub-portion of the first tubular leg portion.

4. The pantyhose article according to claim 2 or 3, wherein the second knitted fabric of the first transition sub-portion has a stronger resistance to unraveling when being torn or cut than the first knitted fabric of the first main sub-portion of the first tubular leg portion.

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

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

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

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

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

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

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

12. The pantyhose article of claim 11, wherein the same number of yarn feeders is 2 yarn feeders or less.

13. The pantyhose article according to any one of claims 1 to 12, wherein the first panty portion is formed from a knitted fabric that does not contain UHMWPE.

14. The pantyhose article according to any one of claims 1 to 13, wherein the knitted fabric of the first panty portion and the second knitted fabric of the first transition sub-portion have at least one common fiber.

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

16. The pantyhose article of claim 15, wherein the first UHMWPE fiber and the at least one first companion fiber are knitted together in a plated knit in the first knit of the first main subsection;

wherein the second UHMWPE fiber of the second knitted fabric of the first transition sub-portion is the same as the first UHMWPE fiber of the first knitted fabric;

wherein at least one of said second companion fibers of said second knitted fabric of said first transition subsection is identical to at least one of said first companion fibers of said first knitted fabric;

wherein the second UHMWPE fiber and the at least one second companion fiber are knitted together in the second knitted fabric of the first transition subsection, the at least one second companion fiber being identical to the at least one first companion fiber;

The second knitted fabric of the first transition sub-portion further comprises at least one additional companion fiber.

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

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

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

20. The pantyhose article of claim 19, wherein the second UHMWPE fiber of the first transition subsection has a denier of about 25 to about 35, and the at least one second companion fiber comprises at least one stretch fiber having a total denier of about 10 to about 20 knitted together with the second UHMWPE fiber; and

The at least one second companion fiber further comprises an additional companion fiber reinforcing the second knitted fabric of the first transition sub-portion.

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

22. The pantyhose article of any one of claims 1 to 21, further comprising a second tubular member, the second tubular member having:

a second panty portion extending from a waist end of the pantyhose article to a bottom end of the second panty portion aligned with a bottom end of the first panty portion;

a second tubular leg portion defining a second leg cavity and extending from a top end thereof to a second foot end of the second tubular leg portion, the top end corresponding to a bottom end of the second panty portion, the second tubular leg portion comprising a second main sub-portion and a second transition sub-portion, the second main sub-portion extending from a second thigh region of the second tubular leg portion to the second foot end, and the second transition sub-portion extending from the top end of the second tubular leg portion to the second thigh region of the second tubular leg portion, the second main sub-portion being formed by a first knitted fabric comprising first UHMWPE fibers and at least one first companion fiber, and the second transition sub-portion being formed by a second knitted fabric comprising the second UHMWPE fibers and the at least one second companion fiber;

The longitudinal edges of the first panty part are joined to the corresponding longitudinal edges of the second panty part to form a panty tube defining a panty cavity for accommodating the wearer's lower body, the panty cavity being fluidically connected to the first leg cavity of the first tubular leg part, and the panty cavity being fluidically connected to the second leg cavity of the second tubular leg part.

23. The pantyhose article according to claim 22, wherein the first transition subportion formed by the second knitted fabric having the second UHMWPE fiber and the second transition subportion formed by the second knitted fabric having the second UHMWPE fiber provide protection against wear of the first transition subportion and the second transition subportion caused by friction against the inner thigh of a person wearing the pantyhose article.

24. A method for making a pantyhose article, the method comprising:

A first tubular member is formed, the first tubular member having:

a first tubular leg portion defining a first leg cavity and extending from a top end thereof to a first foot end of the first tubular leg portion, the top end corresponding to a bottom end of the first panty portion, the first tubular leg portion comprising a first main sub-portion and a first transition sub-portion, the first main sub-portion extending from a first thigh region of the first tubular leg portion to the first foot end, and the first transition sub-portion extending from the top end of the first tubular leg portion to the first thigh region of the first tubular leg portion, the first main sub-portion being formed of a first knitted fabric comprising first ultra-high molecular weight polyethylene (UHMWPE) fibers and at least one first companion fiber, and the first transition sub-portion being formed of a second knitted fabric comprising second UHMWPE fibers and at least one second companion fiber, the first knitted fabric being different from the second knitted fabric;

A second tubular member is formed, the second tubular member having:

a second tubular leg portion defining a second leg cavity and extending from a top end thereof to a second foot end of the second tubular leg portion, the top end corresponding to a bottom end of the second panty portion, the second tubular leg portion comprising a second main sub-portion and a second transition sub-portion, the second main sub-portion extending from a second thigh region of the second tubular leg portion to the second foot end, and the second transition sub-portion extending from the top end of the second tubular leg portion to the second thigh region of the second tubular leg portion and extending circumferentially around the second tubular leg portion, the second main sub-portion being formed by a first knitted fabric comprising first UHMWPE fibers and at least one first companion fiber, and the second transition sub-portion being formed by a second knitted fabric comprising the second UHMWPE fibers and the at least one second companion fiber;

cutting the first panty portion along a longitudinal direction thereof to form a first longitudinal edge therein, and cutting the second panty portion along a longitudinal direction thereof to form a second longitudinal edge therein;

joining the first longitudinal edge of the first panty portion with the second longitudinal edge of the second panty portion to form a panty tube defining a panty cavity for receiving the lower torso of a wearer, the panty cavity being in fluid communication with the first leg cavity of the first tubular leg portion, and the panty cavity being in fluid communication with the second leg cavity of the second tubular leg portion; and

The longitudinal edge of the first panty portion is joined to a first edge of a crotch, and the longitudinal edge of the second panty portion is joined to a second edge of the crotch.

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

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

27. The method of claim 26, wherein the same number of yarn feeders is 2 yarn feeders or less.

28. The method of any one of claims 24 to 27, further comprising joining an angled region of an edge of the first transition subsection to the first edge of the crotch portion, and joining an angled region of an edge of the second transition subsection to the second edge of the crotch portion.