FABRIC CONSTRUCT WITH INTERLOCKED YARN

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 63/720,569 filed on November 14, 2024, the entirety of which is incorporated herein by reference.

TECHNICAL FIELD

This disclosure is directed to fabric constructions, more particularly, fabrics formed of specifically arranged hydrophilic yarns, hydrophobic yarns, hydrophilic yarns interlocked with hydrophobic yarns, and elastic yarns for articles of clothing.

BACKGROUND

Collars for skirts, headbands, and the like are known in a wide variety of types and constructions. In many conventional collars having opposite sides, a skin-facing side and an opposed outside, the materials used to form each of the skin-facing and/or outside surfaces both have hydrophilic and/or moisture wicking properties. This configuration results in the absorbed or wicked moisture and/or perspiration in or on the skin-facing fabric surface to remain in contact with the skin, which is generally undesirable and/or uncomfortable and possibly contributory to causing skin aliments, such as rashes or other microbial maladies.

During normal or athletic activity, fabric which contacts the skin surface of the wearer inevitably collects perspiration and body oils, leading to the possibility of rashes and other skin conditions as well as general discomfort.

SUMMARY

A collar, cuff, hem, sock, or glove structure having moisture management functionality utilizing hydrophilic and hydrophobic knitted yarns, and a method of manufacturing such a collar, cuff, hem, sock, or glove are described. The collar, cuff, hem, sock, or glove is knit using a patterning mechanism to form a tubular body having one or more individual courses, each of which have adjacent wales the tubular body comprising a collar, cuff, hem, sock, or glove fabric having moisture management functionality, in part by minimizing the amount of hydrophilic yarn or fabric construction directly adjacent the skin, maximizing the amount of hydrophobic yarn or fabric construction directly adjacent the skin and providing a hybrid layer of yarn or fabric of both hydrophobic and hydrophilic construction, the hybrid layer positioned between discrete hydrophobic and hydrophilic fabric layers that are skin-facing and non-skin facing sides, respectively, of the fabric construction.

In examples, a fabric construction is provided, the fabric construction comprising a skin facing hydrophobic surface; a non-skin facing hydrophilic fabric; and a hybrid fabric comprising interlocked hydrophobic yarn and hydrophilic yarn, the hybrid fabric being between the skin facing hydrophobic surface and the non-skin facing hydrophilic fabric.

In aspects, the fabric construction is an elongated strip of fabric having a first essentially linear section comprising a first layer of the skin facing hydrophobic surface integral with the hybrid fabric and a second essentially linear section separated from the first essentially linear section at a demarcation, the second essentially linear section comprising the hydrophilic fabric, wherein the first section and the second section are folded at the demarcation such that the hybrid layer is between the skin facing hydrophobic surface and the non-skin facing hydrophilic fabric.

In aspects, alone or in combination with any previous aspects, the hydrophilic fabric is multi-layer with the same or different hydrophilic fabric.

In aspects, alone or in combination with any previous aspects, the fabric construction is a continuous elongated tubular construction of fabric having a first tubular section comprising a first circumferential layer of the skin facing hydrophobic surface integral with the hybrid fabric and a second circumferential layer spatially separated from the first tubular section, the second section comprising the hydrophilic fabric, wherein the first section is positioned within the second circumferential layer section such that the hybrid layer is interposed there between.

In aspects, alone or in combination with any previous aspects, the hydrophilic fabric is multi-layer with the same or different hydrophilic fabric.

In aspects, alone or in combination with any previous aspects, the skin facing hydrophobic surface further comprises yarn comprising metal-containing fiber comprising copper, zinc, or silver metal, oxides, or salts.

In aspects, alone or in combination with any previous aspects, the skin facing hydrophobic surface is selected from polypropylene, polyethylene, or copolymers thereof.

In aspects, alone or in combination with any previous aspects, the skin facing hydrophobic surface further comprises elastic yarn.

In aspects, alone or in combination with any previous aspects, the elastic yarn is selected from spandex/elastane, LYCRA®, CREORA® and blends thereof.

In aspects, alone or in combination with any previous aspects, the non-skin facing hydrophilic fabric is selected from a polyester, a nylon, an acrylic, a wool, a wool blend, a viscose, a cotton, a cotton blend or mixtures thereof.

In aspects, alone or in combination with any previous aspects, the non-skin facing hydrophobic surface further comprises elastic yarn.

In aspects, alone or in combination with any previous aspects, the elastic yarn is selected from spandex/elastane, LYCRA®, CREORA® and blends thereof.

In aspects, alone or in combination with any previous aspects, the hybrid fabric comprises interlocked hydrophobic and hydrophilic yarns.

In aspects, alone or in combination with any previous aspects, the outer layer comprises terry looped fabric.

In aspects, alone or in combination with any previous aspects, the interlocked fabric portion comprises 73-27 weight percent hydrophobic yarn, the remainder weight being hydrophilic yarn. In aspects, alone or in combination with any previous aspects, the interlocked fabric portion comprises 56-44 weight percent hydrophobic yarn, the remainder weight being hydrophilic yarn. In aspects, alone or in combination with any previous aspects, the interlocked fabric portion comprises 51-49 weight percent hydrophobic yarn, the remainder weight being hydrophilic yarn. In aspects, alone or in combination with any previous aspects, the interlocked fabric portion comprises essentially equal amounts by weight of the hydrophobic (less than half) and the hydrophilic yarns.

In aspects, alone or in combination with any previous aspects, the hybrid fabric transitions from the hydrophobic yarns to the hydrophilic yarns throughout a thickness of the hybrid fabric.

In aspects, alone or in combination with any previous aspects, the hybrid fabric further comprises yarn comprising metal-containing fiber comprising copper, zinc, or silver metal, oxides, or salts.

In aspects, alone or in combination with any previous aspects, the fabric construction is coupled with an article of clothing. In aspects, alone or in combination with any previous aspects, the fabric construction is bonded with the article of clothing. In aspects, alone or in combination with any previous aspects, the fabric construction is sewn together the article of clothing. In aspects, alone or in combination with any previous aspects, the fabric construction is adhesively coupled with the article of clothing. In aspects, alone or in combination with any previous aspects, the fabric construction is sonically bonded with the article of clothing.

In aspects, alone or in combination with any previous aspects, the fabric construction is at least a portion of a collar. In aspects, alone or in combination with any previous aspects, the fabric construction is at least a portion of a cuff. In aspects, alone or in combination with any previous aspects, the fabric construction is at least a portion of a hem. In aspects, alone or in combination with any previous aspects, the fabric construction is at least a portion of headband. In aspects, alone or in combination with any previous aspects, the fabric construction is at least a portion of a skull cap. In aspects, alone or in combination with any previous aspects, the fabric construction is at least a portion of a head wrap. In aspects, alone or in combination with any previous aspects, the fabric construction is at least a portion of a head tie. In aspects, alone or in combination with any previous aspects, the fabric construction is at least a portion of a compression sleeve.

In other examples, a method of managing moisture transport in an article of clothing is provided, the method comprising providing the fabric construction as defined in any previous aspects coupled to the article of clothing; and managing moisture transport from the skin facing surface of the fabric construction to the non-skin facing surface.

In aspects, the fabric construction is a linear strip or a tubular body.

In aspects, alone or in combination with any previous aspects, the fabric construction is an elongated strip of fabric having a first essentially linear section comprising a first layer of the skin facing hydrophobic surface integral with the hybrid fabric and a second essentially linear section separated from the first essentially linear section at a demarcation, the second essentially linear section comprising the hydrophilic fabric, wherein the first section and the second section are folded at the demarcation such that the hybrid layer is between the skin facing hydrophobic surface and the non-skin facing hydrophilic fabric. In aspects, alone or in combination with any previous aspects, the hydrophilic fabric is multi-layer with the same or different hydrophilic fabric.

In aspects, alone or in combination with any previous aspects, the fabric construction is a continuous elongated tubular construction of fabric having a first tubular section comprising a first circumferential layer of the skin facing hydrophobic surface integral with the hybrid fabric and a second circumferential layer spatially separated from the first tubular section, the second section comprising the hydrophilic fabric, wherein the first section is positioned within the second circumferential layer section such that the hybrid layer is interposed there between. In aspects, alone or in combination with any previous aspects, the hydrophilic fabric is multi-layer with the same or different hydrophilic fabric.

In aspects, alone or in combination with any previous aspects, the skin facing skin facing hydrophobic surface further comprises yarn comprising metal-containing fiber comprising copper, zinc, or silver metal, oxides, or salts.

In aspects, alone or in combination with any previous aspects, the skin facing hydrophobic surface is selected from polyethylene, polypropylene or copolymers thereof. In aspects, alone or in combination with any previous aspects, the skin facing hydrophobic surface further comprises elastic yarn. In aspects, alone or in combination with any previous aspects, the elastic yarn is selected from spandex/elastane, LYCRA®, CREORA® and blends thereof.

In aspects, alone or in combination with any previous aspects, the non-skin facing hydrophilic fabric is selected from a polyester, a nylon, an acrylic, a wool, a wool blend, a viscose, a cotton, a cotton blend or mixtures thereof. In aspects, alone or in combination with any previous aspects, the non-skin facing hydrophobic surface further comprises elastic yarn. In aspects, alone or in combination with any previous aspects, the elastic yarn is selected from spandex/elastane, LYCRA®, CREORA® and blends thereof.

In aspects, alone or in combination with any previous aspects, the hybrid fabric comprises interlocked hydrophobic and hydrophilic yarns. In aspects, alone or in combination with any previous aspects, the hybrid fabric comprises essentially equal amounts by weight of the hydrophobic and the hydrophilic yarns. In aspects, alone or in combination with any previous aspects, the hybrid fabric transitions from the hydrophobic yarns to the hydrophilic yarns throughout a thickness of the hybrid fabric. In aspects, alone or in combination with any previous aspects, the hybrid fabric further comprises yarn comprising metal-containing fiber comprising copper, zinc, or silver metal, oxides, or salts.

In aspects, alone or in combination with any previous aspects, the fabric construction comprises metal-containing yarn comprising copper, zinc, or silver metal, oxides, or salts.

In aspects, alone or in combination with any previous aspects, the fabric construction includes an elastic yarn. In aspects, alone or in combination with any previous aspects, the fabric construction is coupled with an article of clothing.

In aspects, alone or in combination with any previous aspects, the fabric construction is bonded with the article of clothing. In aspects, alone or in combination with any previous aspects, the fabric construction is sewn together the article of clothing. In aspects, alone or in combination with any previous aspects, the fabric construction is adhesively coupled with the article of clothing. In aspects, alone or in combination with any previous aspects, the fabric construction is sonically bonded with the article of clothing.

In aspects, alone or in combination with any previous aspects, the fabric construction is at least a portion of a collar. In aspects, alone or in combination with any previous aspects, the fabric construction is at least a portion of a cuff. In aspects, alone or in combination with any previous aspects, the fabric construction is at least a portion of a hem. In aspects, alone or in combination with any previous aspects, the fabric construction is at least a portion of headband. In aspects, alone or in combination with any previous aspects, the fabric construction is at least a portion of a skull cap. In aspects, alone or in combination with any previous aspects, the fabric construction is at least a portion of a head wrap. In aspects, alone or in combination with any previous aspects, the fabric construction is at least a portion of a head tie. In aspects, alone or in combination with any previous aspects, the fabric construction is at least a portion of a compression sleeve.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to understand and to see how the present disclosure may be carried out in practice, examples will now be described, by way of non-limiting examples only, with reference to the accompanying drawings, in which:

FIG. 1 is a perspective view of an exemplary fabric construct disclosed and described herein;

FIG. 2 is a perspective view of a shirt comprising the exemplary fabric construct disclosed and described herein;

FIGS. 3A, 3B depict front and back views, respectively, of an unfolded exemplary linear fabric construct as disclosed and described herein;

FIG. 3C depicts an enlarged view of section 3C of FIG. 3A;

FIG. 3D depicts a side view of FIG. 3A;

FIG. 3E depicts an enlarged view of section 3E of FIG. 3D;

FIGS. 4A, 4B depict front and back views, respectively, of a folded exemplary linear fabric construct corresponding to FIGS. 3A, 3B, respectively;

FIG. 4C depicts a partially folded exemplary linear fabric construct of FIG. 4A, as disclosed and described herein;

FIG. 4D depicts a side view taken along section line 4D-4D of FIG. 4A as disclosed and described herein;

FIG. 5A depicts a side view of a folded exemplary linear fabric construct coupled to an article of clothing, as disclosed and described herein;

FIG. 5B depicts a side view of an alternative folded exemplary linear fabric construct, as disclosed and described herein;

FIG. 6A depicts an exemplary fabric sleeve construction as disclosed and described herein;

FIGS. 6B, 6C depict enlarged views 6B, 6C of FIG. 6A;

FIGS. 6D, 6E, 6F, 6G depict an exemplary fabric sleeve construction as disclosed and described herein;

FIG. 6H depicts another exemplary fabric sleeve construction as disclosed and described herein;

FIGS. 6I, 6J depict section views along section lines 6I-6I and 6J-6J of FIG. 6H;

FIGS. 6K, 6L, and 6M depict an exemplary fabric sleeve construction of the sleeve of FIG. 6H, as disclosed and described herein;

FIG. 6N depicts an enlarged cross-section view of sleeve construction of FIG. 6M as disclosed and described herein;

FIG. 6O depicts another exemplary fabric sleeve construction as disclosed and described herein;

FIGS. 6P, 6Q, and 6R depict an exemplary fabric sleeve construction of the sleeve of FIG. 6O, as disclosed and described herein;

FIG. 7A depicts an exemplary fabric sleeve/brace construction as disclosed and described herein;

FIG. 7B is an exemplary fabric sleeve/brace, as disclosed and described herein;

FIG. 8A depicts a sectional view along section line 8A-8A of FIG. 7B;

FIG. 8B depicts an enlarged view of section 8B of FIG. 8A;

FIG. 9A depicts an exemplary fabric head band;

FIGS. 9B, 9C depict section views 9B, 9C of FIG. 9A;

FIG. 10A depicts an exemplary skull wrap;

FIGS. 10B, 10C depict section views 10B, 10C of FIG. 10A;

FIG. 11A depicts another exemplary skull wrap

FIGS. 11B, 11C depict section views 11B, 11C of FIG. 11A;

FIGS. 12A, 12B depict front and back views showing an exemplary skull wrap fabric construction;

FIG. 13A depicts an exemplary skull cap with lid;

FIGS. 13B depicts cut away view of FIG. 13A;

FIG. 13C depicts enlarged view of section 13C of FIG. 13A;

FIG. 13D depicts enlarged view of section 13D of FIG. 13A;

FIGS. 14A, 14B, 14C, and 14D depict side view, unfolded configuration/folded skin side view, folded non-skin side view, and section view along section line 14D-14D, respectively, of an exemplary head tie construct.

DETAILED DESCRIPTION

The present disclosure provides a technical solution to the technical problem disclosed above. A collar construct is provided which maintains the skin facing hydrophobic surface presentation to the skin of the wearer and avoids the accumulation of moisture and the uncomfortable sensation of wetness at the distal end of the cuff of an article of clothing. Moreover, the collar construct provides for the presentation of metal-containing yarn in the skin facing hydrophobic surface for providing the various functional benefits such as antimicrobial functionality, etc.

As used throughout this application, the term “hydrophilic fabric” and its grammatical equivalents mean fabrics having an affinity for moisture and/or water or readily absorbing or wicking water, or liquid compositions of biological origin comprised mostly of water, e.g., perspiration. The hydrophilic properties of the fabric may be intrinsic to the materials used to form the fabric, the shape/surface area or size/denier per filament of one or more yarns, or the hydrophilic properties may be imparted to the fabric by treating the fabric or its yarn with one or more hydrophilic compositions.

In addition, the more filaments, the more interfaces and surface area for moisture to wick or be drawn from skin or hydrophobic yarn adjacent the skin. For example, a yarn that is 100 denier with 34 filaments will not move moisture as fast as a 100 denier 100 filament yarn.

As used throughout this application, the term “skin facing hydrophobic surface” and its grammatical equivalents mean yarns having an essentially no affinity for moisture and/or water, repel moisture and/or water, or that essentially resist absorbing water, or liquid compositions of biological origin comprised mostly of water, e.g., perspiration. The hydrophobic properties of the fabric may be intrinsic to the materials used to form the fabric, the shape/surface area or size/denier per filament of one or more yarns, or the hydrophobic properties may be imparted to the fabric by treating the fabric or its yarn with one or more hydrophobic compositions.

As used throughout this application, the term “interlocked” is intended to mean the ordinary and customary meaning of yarns knitted or woven together in a manner consistent with fabric construction and for providing an intended purpose of the fabric, for example, as an article of clothing with desired drape, stretch, texture, etc. Interlocked is a broad term encompassing single or double knit and woven structures (weaves, stitches, stretches, etc.) for example, jersey, French terry, fleece, velour, interlock, and the like.

As used herein, the phrase "single yarn" is intended to mean that the same yarn from a single feed forms a course or wale. The single yarn can be a single-ply or multi-ply yarn or a group of yarns, for example, the singularly fed yarn can include plural yarns being provided as one to the needles.

As used herein the phrases “metal-containing fiber,” “metal-containing single yarn” and “metal-containing yarn” are inclusive of fibers/yarns coated with metal, metal oxides, and/or metal salts impregnated with metal, metal oxides, and/or metal salts or containing particles of metal, metal oxides, and metal salts dispersed therein. Metal-containing fiber/yarn, as used herein, is inclusive of copper, copper oxide, and copper salt containing fiber/yarn and silver, silver oxide, and silver salt containing fiber/yarn. Copper containing fiber/yarn is inclusive of (micro) copper filaments with one or more of Cu+, Cu++, Cu+++ ions of a copper salt, zinc, zinc oxide, and/or zinc ions. Copper containing fiber/yarn is inclusive of combined Cu+/Cu+++ ions, e.g., essentially no Cu++ ions.

As used herein, the term “tubular” encompasses a tube shape, e.g., a hollow, elongated body or part with an internal diameter defining a void, an external diameter, and a length, including an elongated body or part with constant or fixed internal and external diameters along its length. Tubular encompasses an elongated body or part with variable internal and external diameters along its length, where the ratio of the internal and external diameters are substantially constant along the length or where the ratio of the internal and external diameters vary along the length. In examples, “tubular” encompasses a seamless construction. In examples, “tubular” encompasses a linear construction coupled at opposite ends to form a tubular construction. With regard to a knitted/woven tubular body, it is understood that variations in yarn and fiber thicknesses, among other variables during the knitting operation, can provide for slight variations in the internal diameter and external diameter along the length of the elongated body or part, such that the terms “constant or fixed” are understood to encompass such variation. Likewise, it is understood that variations in variables during the knitting operation can provide for deliberate variations in the internal diameter and external diameter along the length of the elongated body or part, either in a fixed ratio of such diameters or with variation in the ratios of such diameters so as to accommodate the tubular body to accept and/or receive collar, cuff, or hems of various dimensions.

Used herein, the phrases “inner surface” and “skin facing surface,” with reference to the collar and and/or fabric, are used interchangeably and refer to the surface(s) of the collar and and/or fabric in direct contact with or facing the skin when the article of clothing is worn in a customary manner. Likewise, as used herein, the phrases “inner section,” “inner portion,” “skin facing portion,” and “skin facing section,” with reference to the collar and and/or fabric, are used interchangeably.

As used herein, the phrases “outer surface” and “outer portion” with reference to the collar and and/or fabric construct for example, encompass a “non-skin facing surface.” As used herein, each of the phrases “non-skin facing surface,” “non-skin facing section,” and “non-skin facing portion” are used interchangeably with reference to the collar and and/or fabric construct.

A collar (or cuff or hem) comprising the fabric construct disclosed herein provides for preventing adverse effects to a wearer’s skin and/or eliminates or reduces wetness of the collar or cuff in proximity to the wearer’s skin during adornment and use of an article of clothing. In examples, the collar, cuff, hem, sock, or glove comprises at least one elastic yarn. In examples, the article of clothing attached to the collar, cuff, hem, sock, or glove comprises at least one elastic yarn. The type of elastic yarn of the collar, cuff, hem, sock, or glove construction and that of the article of clothing can be the same or different. The amount of elastic yarn of the collar, cuff, hem, sock, or glove construction and that of the article of clothing can be the same or different.

In examples, the collar, cuff, hem, sock, or glove is a substantially linear fabric construct with one ply construction. In examples, the collar, cuff, hem, sock, or glove is a substantially linear fabric construct of two ply construction. In examples, the collar, cuff, hem, sock, or glove is a substantially linear fabric construct of at least three ply or more construction. In examples, the substantially linear fabric construct of the collar, cuff, or hem, comprises circularly-knitted fabric comprising: a skin-facing fabric surface comprising one or both of a hydrophobic yarn and metal-containing yarn. In examples, the circularly-knitted linear fabric skin-facing fabric surface comprises a hydrophobic metal-containing yarn interwoven with a hydrophilic fabric. In examples, the linear fabric is a circularly-knitted hydrophobic metal-containing fabric layer interwoven with a hydrophilic fabric layer, where the hydrophobic metal-containing fabric layer provides a skin facing surface and the a hydrophilic fabric layer provides a outwardly or opposed surface that is configured to avoid contact with the skin of the wearer.

In examples, the collar, cuff, hem, sock, or glove comprises a tubular body with an opening therethrough for receiving an arm, leg, neck, or head. In examples, the tubular body is a circularly-knitted fabric comprising: a skin-facing fabric surface comprising one or both of a hydrophobic yarn and metal-containing yarn. In examples, the tubular body is a circularly-knitted fabric comprising: a skin-facing fabric surface comprising a hydrophobic metal-containing yarn interwoven with a hydrophilic fabric. In examples, the tubular body is a circularly-knitted hydrophobic metal-containing fabric layer interwoven with a hydrophilic fabric layer, where the hydrophobic metal-containing fabric layer provides a skin facing surface and the hydrophilic fabric layer provides a outwardly or opposed surface that is configured to avoid contact with the skin of the wearer.

In examples, a linear fabric as disclosed above is cut to length and attached at opposing linear ends to form a tubular body. Attachment of the opposing linear ends of the linear fabric can be with stitching, staple, heat, solvent, or adhesive. In examples, an elastic adhesive is used to attach the opposing linear ends of the linear fabric to form the tubular body. In examples, the opposing linear ends of the linear fabric are sonically welded to form the tubular body.

In examples, the collar, cuff, hem, sock, or glove fabric construct comprises at least one section being knit (linearly or “seamless,” and/or circularly,) from one or more “functional” yarns designed to enhance particular performance characteristics of the collar, cuff, hem, sock, or glove during use, e.g., for an athletic activity, including, but not limited to stretchability, enhanced wicking, antimicrobial resistance, moisture absorption, or thermal regulating functionality.

In examples, the one or more functional yarns comprises hydrophobic yarns configured to provide the fabric surface with hydrophobicity. An exemplary hydrophobic fiber includes polypropylene. In other examples, the hydrophobic fiber includes polypropylene having infused metal or a metal coating. An exemplary metal-containing yarn includes copper-containing yarn such as those sold by Cupron Inc. (Richmond, Virginia).

In examples, the one or more functional yarns comprises hydrophilic yarns configured to provide the fabric surface with hydrophilicity. Examples of hydrophilic yarns include polyester or nylon.

In examples, the one or more functional yarns comprises moisture wicking/absorbing fibers. Examples of yarns with moisture wicking/absorbing fibers include yarns comprising fibers of cotton and cotton blends.

In examples, the one or more functional yarns comprises elastic yarns. An exemplary elastic yarn includes spandex/elastane, LYCRA®, CREORA® and the like.

In examples, the one or more functional yarns comprises thermoregulating yarns. An example of a thermal regulating yarn is sold under the trade names COOLMAX®, THERMOLITE® (The Lycra Company, Wilmington, DE). Other yarns may be used in combination with one or more of the elastic yarns, moisture wicking yarns, antimicrobial yarns, and thermal regulating yarns.

In examples, the fabric suitable for the manufacture of a collar, cuff, hem, sock, or glove is knit such that selected adjacent wales in one or more of the individual courses are knit from distinct yarns, for example, to form a design or discrete structure or pattern in at least a portion of the collar, cuff, hem, sock, or glove fabric section so as to provide specific functionality for the collar, cuff, or hem. The design or discrete structure or pattern can be uniform or non-uniform across the length or width of the collar, cuff, hem, sock, or glove fabric section and can be on only one or on both opposing skin-facing and non-skin facing surfaces. Specific functionality in at least a portion of the collar, cuff, hem, sock, or glove fabric can extend through the entirety of the welt. Specific functionality in at least a portion of the collar, cuff, hem, sock, or glove fabric is prevented from folding over in the collar, cuff, hem, sock, or glove fabric as a result of the presently disclosed structural arrangement described herein.

In examples, a tubular body is knit to a length and/or diameter approximating the desired length and/or diameter for a collar, cuff, or hem, for example, of an article of athletic apparel. The desired length and thickness of the fabric can be adjusted for different sized collar, cuff, or hems associated with different sized articles of clothing. Athletic clothing can include form-fitting, elastic or stretch athletic apparel with elastic or stretchable collars and cuffs configured to hold the collar or cuff in position about the neck or arm/leg when the article of clothing is in use, such as headbands, head ties, skull caps, shirts, leggings, leotards, tights, and the like.

In one embodiment, the collar, cuff, hem, sock, or glove comprises a knitted or woven fabric. The knitted fabric can be linear, seamless or circularly knitted. In one embodiment, the collar, cuff, hem, sock, or glove (hereinafter “product” or “main body”) comprises a knitted fabric of a plurality of yarns including an elastic yarn formed in needle loops extending in circumferential courses and axial wales. The product fabric comprises a welt beginning course, a welt ending course, and a plurality of intervening courses, the welt beginning and ending courses being connected with one another by a set of connecting needle loops formed in selected spaced wales, e.g., every fourth wale, and the intervening courses comprising needle loops formed only in wales other than the selected spaced wales and in yarn floats across such wales. Other selected spaced wales can be used.

In examples, the main body includes at least one selected courses which have needle loops formed in every wale and, thus, the main body is of a greater diameter than the main body fabric of the main body as a result of the absence of needle loops in the selected spaced wales of the welt's intervening courses, thereby forming the main body of a tapered configuration.

For example, In examples, the main body of the collar, cuff, hem, sock or glove comprises a first annular region adjacent the main body fabric having courses formed of alternating needle loops and yarn floats and courses formed entirely of successive needle loops appearing in every wale, and a second annular region adjacent the first annular region having courses formed of alternating needle loops and tuck stitches and courses formed entirely of successive needle loops appearing in every wale.

In examples, both S-twist and Z-twist fibers are used as one unit for one or more portions of the collar, cuff, or hem. In other examples, a Z-twist fiber is used for backing or loading the dial jacks of the circular knitting machine. In yet another example, alternating and intervening courses of the circularly-knitted fabric tubular body with S-twist and Z-twist yarns are used so as to cooperatively provide a flattening effect on the fabric of the tubular body.

Alternatively, a ribbed texture on one or more of the skin facing or opposing sides of the main body are provided. A ribbed texture, for example, can be provided using a 1X1 tuck high selection with the elastomeric yarn feed, e.g., one needle up (elastomeric yarn in needle) and one needle down (no elastomeric yarn in needle) and repeating that pattern 360 degrees about the circular arrangement of needles. Other ribbing selections, as are known, can be chosen.

In examples, main body disclosed herein comprises yarn comprising functional fiber providing antimicrobial properties forming a major portion of the skin facing section of the collar, cuff, or hem. For example, where a functional yarn having antimicrobial functionality is used alone or in part to form the skin facing portion of the tubular body preventing or eliminating skin issues of the user during use. In other examples, a yarn comprising functional hydrophobic fiber having antimicrobial functionality is used in combination with another yarn having a hydrophobic or super hydrophobic functionality for managing moisture from a wearer’s skin and facilitating transport from the skin facing surface of the main body fabric to at least a portion of the outer surface of the main body fabric for evaporation, or for absorption by a hydrophilic yarn or moisture absorbing functional fiber (i.e., a cotton or cotton blend yarn). Other yarns with unique functional fiber characteristics can be used in combination with the above.

A method of producing a collar, cuff, hem, sock, or glove is provided, the method comprises knitting, using a patterning mechanism, a small diameter tubular body so as to integrally form a defined inside and outside portion of the tubular body by causing one or more individual courses to have adjacent wales knit from the two or more functional yarns.

Basically, the knitting of each collar, cuff, hem, sock, or glove comprises the steps of forming, on the circular knitting machine, a main body fabric presenting a beginning main body welt, knitting integrally to the beginning welt an annular main body central body of a single-ply knitted construction, and then discharging from the knitting machine a main body upon completion of the knitting, which can be further manipulated to form a headband, headwrap, knee brace, arm or sleeve brace, sock, or glove. The end opposite the collar, cuff, or hem fabric of the presently disclosed main body structure can be secured without removal of the tubular body from the circular knitting machine so as to prevent or eliminate unwinding of the yarn during use. In examples, the end opposite the collar, cuff, or hem fabric of the main body/tubular body is secured using a pattern mechanism coupled to the circular knitting machine prior to removal of the tubular body from the circular knitting machine.

Thus, in examples of the manufacture of the disclosed main body, a circular warp knitting machine (Cifra S.p.a., Italy) or a circular knitting machine such as a Santoni MECMOR™ or Lonati SM-DJ series circular knitting machine is used, while a cylinder of the circular knitting machine is in counter clockwise motion (s-direction), a second feed 1 x 1 needle selection is activated and a yarn finger is lowered so that needles take in a first yarn, e.g., an elastic yarn (also known as the "make-up") for 2 revolutions of the cylinder. With the main feed (the first feed) needles in clear high position and with alternate 1 x 1 needles selected (opposite the 1 x 1 needles on second feed), a yarn finger on main feed is lowered mid height so that needle hooks take the functional yarn in so as to start making stitches around the elastic yarn.

In examples, a small diameter circular knitting machine such as a sock or hosiery machine is used to knit a tubular fabric that ultimately becomes the presently disclosed collar, cuff, or hem. In examples, the knitted main body is formed on a circular knitting machine which may be of a single or multi-feed type commonly known within the knitting industry. Such knitting machines basically include a rotatable needle cylinder of a relatively small diameter with axial needle slots formed in spaced relation to one another about the outer circumferential surface of the cylinder. A plurality of latch-type knitting needles, each having a yarn receiving hook and a closable latch assembly, are reciprocally disposed within the axial cylinder slots.

In other examples, the circular knitting machine has a plurality of knitting stations at which yarn feeding fingers or other feeding instruments are positioned into and out of yarn feeding disposition adjacent the upper end of the needle cylinder’s so as to feed one or more of the multiple yarns to the needles. In examples, a circular knitting machine having two, three or four knitting stations are used. The needles are operatively manipulated within their respective slots of the cylinder by stationary cams positioned adjacent the cylinder to engage and act on cam butts formed on the needles during the rotation of the needle cylinder. In examples, the circular knitting machine is operable to carry out the knitting of each main body beginning with a main body fabric and continuing therefrom through the main collar, cuff, or hem body.

A patterning mechanism associated with the circular knitting machine is utilized during the knitting process to select which yarn from a plurality of yarns accessible by the knitting machine will be fed to each needle on the knitting cylinder during each course. The patterning mechanism is further configured to determine which of a plurality of yarns provided will be fed to each individual needle in a predetermined manner so as to form a predetermined pattern. An exemplary patterning mechanism is a control drum or similar control arrangement of conventional construction provided on the circular knitting machine for determining the necessary transitional changes in the machine operation to form each portion or pattern of the collar, cuff, or hem.

The needle and yarn manipulations carried out by the circular knitting machine serves to stitch the yarns fed to the needles at the various knitting stations into successive needle loops which extend in the resultant fabric in circumferentially-extending courses of needle loops and axially-extending wales of needle loops , for example, forming “ribbing” in the central body of the collar, cuff, or hem.

As illustrated in FIG. 1 and FIG. 2, waistband/collar constructs 34, 35, respectively, incorporated in articles of clothing, e.g. waistband for shorts 10 and underband for sports bra 20, respectively, (hereinafter “waistband” and “elastic band” are used interchangeably) and collar 35 of an article of clothing 10, 20 may include a knitted or woven fabric structure of a desired length coupled to the article of clothing. It will be seen that the waistband is composed of an outer surface layer 14 and an inside skin facing surface layer 16. Optional indicia, such as a brand name or “logo” 75 is integral with one or both of the outer surface layer 14 and inside skin facing surface layers 16. Reverse image 75’ of logo 75 appears on inside surface layer 16.

In examples, fabric construct 134 (shown, for example, as a collar 35 of shirt 20) comprises a skin-contacting hydrophobic fabric surface and an outward-facing hydrophilic fabric surface. In examples, outward-facing hydrophilic fabric surface is configured to absorb and/or collect perspiration presented by the hydrophobic fabric surface.

With reference to FIGS. 3A-3B and enlarged view of section 3C of FIG. 3A (FIGURE an exemplary fabric construct is provided, configured for incorporation into articles of clothing, e.g. of shorts 10, or shirt 20, for a collar, hem, etc.

The fabric construct surfaces 134’, 134” of FIGS. 3A, 3B are manufactured and configured to be folded longitudinally and optionally affixed in part to form a multi-layer fabric construct having moisture management and/or air circulation functionality, among other things that improve the comfort of the wearer. In some examples, each layer of the multi-layer fabric construct includes a plurality of openings 126 that facilitate the moisture management and/or air circulation functionality of the multi-layer fabric.

In FIG. 3A,3B, opposing surfaces 134’,134” of exemplary fabric construct is shown, each opposing surface presented in a flat, unfolded condition, that is, before the sections 102 and 103 thereof are superimposed or juxtaposed upon one another. In examples, section 102 comprises subsections 105, 110, and 115. In examples, one or more subsections of section 102 is constructed of predominantly hydrophobic yarn in combination with elastomeric yarn. In examples, all subsections of section 102 comprise predominantly hydrophobic yarn in combination with elastomeric yarn. Subsections 105, 110, and 115 are generally arranged in parallel with each other, thus, forming parallel sections that traverse longitudinally around the fabric construct with their individual longitudinal axes generally parallel to a stretching direction. Subsections 105110 and 115 independently have opposing surfaces 106, 106’, 109, 109’, 116 and 116’, respectively.

In examples, section 103 comprises subsections 120, 125, and 130. In examples, one or more subsections of section 103 is constructed of predominantly hydrophilic fabric in combination with elastomeric yarn. In examples, all subsections of section 103 comprise predominantly hydrophilic fabric in combination with elastomeric yarn. Subsections 120, 125, and 130 are generally arranged in parallel with each other, thus, forming parallel sections that traverse longitudinally around the fabric construct with their individual longitudinal axes generally parallel to the stretching direction of the fabric construct. Subsections 120, 125, and 130 independently have opposing surfaces 121, 121’, 127, 127’, 131 and 131’, respectively.

In examples, subsection 110 comprises a plurality apertures having an average first size and subsection 125 comprises a plurality of apertures having an average second size. The first size and second size of the apertures of the respective subsections 110 and 125, respectively can be the same or different.

As shown in FIGS. 3A, 3B, 3C, section 102 of the fabric construct 134 is an apertured section 110 interposed between a first section 105 and a second section 115. First section 105 is integrally connected to and formed from apertured section 110. Section 103 comprises an apertured section 125 interposed between a third section 120 and a fourth section 130. Fourth section 130 is integrally connected to and formed from apertured section 125.

Section 115 transitions to section 120 through demarcation 113 that extends longitudinally between section 115 and section 120. Demarcation 113 can be a dropped stitch so that upon folding thereon, a smooth non-bulging edge is formed. As shown, a portion of section 115 extends past demarcation 113 such that when fabric construct 134 is in a folded configuration a portion of section 115 is presented on opposing surfaces of the fabric construct. In examples, apertured section 110 transitions from hydrophobic yarns to hydrophilic apertured section 120 in at least a portion of section 115. The transition can be abrupt or gradual. In examples, hydrophobic inside section 102 transitions to hydrophilic section 103, with some of the hydrophobic material of section 102 being present in section 103 in proximity to demarcation 113, as shown in FIGS. 3A, 3B. In examples, the transition from hydrophobic apertured section 110 transitions to hydrophilic apertured section 120 in at least a portion of section 115 distal from demarcation 113 such that a portion of section 115 (hydrophobic yarn) is presented on opposing surfaces of the fabric construct, as shown in FIGS. 3A, 3B.

With reference to FIGS. 3D, an edge view along section line 3D-3D of FIG. 3A is shown with hydrophobic layer 214 of interlocking hydrophobic yarn 218 with hydrophilic yarn 217 (“hybrid layer 215”), this layering extending along a longitudinal length of fabric construct 134 to demarcation 225 and beyond, the remainder of the longitudinal length of fabric construct 134 therefrom being hydrophilic layer 103. In examples, hydrophilic layer 103 is a mono-layer construct of one or more hydrophilic yarns. In examples, hydrophilic layer 103 is a multi-layer construct of the same or different hydrophilic layers or hydrophilic yarns.

Enlarged view of section 3E of FIG. 3D is shown in FIG. 3E and depicts hydrophobic layer 214 and interlocking layer 215 comprising interlocking hydrophobic yarn 218 with hydrophilic yarn 217. In examples, at least some of hydrophilic yarn 217 of hybrid layer is different from at least some of that in hydrophilic layer 103. In examples, at least some of hydrophilic yarn 217 of hybrid layer is the same as at least some of that in hydrophilic layer 103. In examples, hydrophilic yarn 217 of hybrid layer is the same as that in hydrophilic layer 103.

In examples, fabric construct 134 comprises a hydrophobic yarn with hydrophilic yarn alone or in combination with a metal-containing yarn to present on the inside or skin-facing surface combined with a mono- or multi-layer hydrophilic layer on the outside/non-skin-facing surface. In other examples, fabric construct 134 comprises a hydrophilic yarn with hydrophobic yarn alone or in combination with a metal-containing yarn to present on the inside or skin-facing surface combined with a mono- or multi-layer hydrophilic layer combined with a metal-containing yarn on the outside/non-skin-facing surface. In yet another example, fabric construct 134 comprises a skin-facing hydrophobic yarn without a metal-containing yarn to present on the inside or skin-facing surface combined with a mono- or multi-layer hydrophilic layer combined with a metal-containing yarn on the outside/non-skin-facing surface.

In examples, section 102 of the construct 134 comprises skin-facing hydrophobic yarn in combination with elastomeric yarn. In examples, section 103 of the construct 134 comprises non-skin-facing hydrophilic yarn in combination with elastomeric yarn. In other examples, section 102 comprises skin-facing hydrophobic yarn in combination with elastomeric yarn and section 103 comprises non-skin facing hydrophilic yarn in combination with elastomeric yarn.

In examples, hydrophobic yarn of section 102 comprises yarns of polypropylene in combination with elastomeric yarn. In an exemplary aspect, section 102 is formed using approximately 50-90%, polypropylene yarn and the remainder % spandex yarn although other ratios are contemplated herein. In other examples, hydrophobic yarn of section 102 comprises yarns of polypropylene containing zinc, silver, copper, or their oxides and/or salts in combination with elastomeric yarn. Copper oxide and copper sites include compounds having copper cations Cu+, Cu++, Cu+++, and mixtures thereof. In other examples, hydrophobic yarn of section 102 comprises polypropylene containing zinc, zinc oxide, silver, silver oxide, or a silver salt in combination with elastomeric yarn. Silver oxide and silver salts include compounds having silver cations Ag+, Ag++, Ag+++, and mixtures thereof. In examples, non-metallic anti-microbial agents can be used alone or in combination with the above metal-based materials.

In examples, hydrophilic yarn of one or more sections 120, 125, and 130 comprises yarns polyester, nylon, acrylic, viscose, cotton, cotton blends, wool, wool blends or blended yarn thereof in combination with spandex yarns although other types of elastic yarns are contemplated. In an exemplary aspect, the section 103 is formed using approximately 50-90% polyester, nylon, acrylic, viscose, cotton, cotton blends, wool, wool blends or blended yarn and the remainder % spandex yarn although other ratios are contemplated herein.

Use of spandex, elastane, etc., yarns in one or more sections 105, 110, 115, 120, 125, and 130 imparts elastic functionality (e.g., two-way stretch and/or four-way stretch) and shape retention/memory to the construct 134 while maintaining structural integrity of the construct 134, for example, to hold or secure the textile in place about the body. Use of these yarn combinations and in the recited ratio may improve moisture management from one or more hydrophilic sections 120, 125, and 130 and/or improve moisture transport from one or more hydrophobic layer/sections 105, 110, and 115, thereby increasing wearer comfort.

Further, the construct 134 and/or the materials used to form the construct 134 may be treated and/or coated for mildew resistance, stain resistance, and fade resistance. As shown, sections 105, 110, 115, 120, 125, and 130 all lie in essentially the same two-dimensional plane in the unfolded configuration.

In examples, first section 105 and a second section 115 of section 102 are devoid of apertures. In other examples, first section 120 and a second section 130 of section 103 are devoid of apertures. In yet another example, first section 105 and a second section 115 of section 102 and first section 120 and a second section 130 of section 103 are devoid of apertures.

The construct 134 may be formed by a knitting or weaving process that utilizes a plurality of filaments, fibers, and/or yarns to integrally form the apertured sections and the first, second, third, and fourth sections 105, 110, 115, 120, 125, and 130 respectively.

With reference now to FIGS. 4A, 4B and 4C, fabric construct 134 is shown in folded configurations, suitable for attachment to an article of clothing, depicting opposing surfaces 134a, 134b, thereof. In FIG. 4A, surface 134a of fabric construct 134 represents the skin facing surface, while surface 134b of FIG. 4B represents the outside of the fabric construct (non-skin facing) surface.

Surface 134a of FIG. 4A presents hydrophobic apertured section 110 interposed between subsection 105 and subsection 115. In examples, apertured section 110, first section 105, and second section 115 (also referred to as apertured section 110, first section 105, and second section 115) of surface 134a comprise hydrophobic polypropylene with metal-, metal oxide-, metal salt-containing in combination with elastomeric yarn.

Surface 134b of FIG. 4B presents hydrophilic apertured subsection 125 interposed between subsection 120 and second subsection 130. In examples, apertured subsection 125, section 120, and section 130 of surface 134b comprise hydrophilic polyester, acrylic, nylon, viscose, cotton, cotton blend, wool, wool blend and blended yarns thereof in combination with elastomeric yarn. Surface 134b of FIG. 4B presents a portion of hydrophobic subsection 115 on its outside surface to further improve the moisture management functionality of the present fabric construct 134, as the interface between the hydrophilic and hydrophobic sections are not located at the upper edge of the fabric construct, and therefore avoid or eliminate collection and holding or wicking of moisture and/or perspiration that otherwise causes discomfort.

In aspects, apertured section 125 ultimately forms the exterior layer and apertured section 110 forms the interior layer of the fabric construct in the folded configuration. By having the skin-contacting interior layer comprised of a hydrophobic material adjacent a hybrid layer of interlocked hydrophobic and hydrophilic yarns, moisture is repelled away from the wearer's skin and into the hydrophilic material of exterior, non-skin-facing layer. The surface area created by the apertures (either the apertures 111 or the apertures 126) of one or both apertured sections 110 and 125 helps to disperse moisture and/or perspiration. In examples, upon transport to the exterior layer, the apertures 126 help to disperse the moisture as well as heat along the entirety of the external-facing layer 16. Further, the apertures in the interior layer (skin-facing) facilitate increased air circulation which may also assist in the evaporation of the moisture during use.

In examples, sections 105 and 130 extends in the folded configuration, so that a marginal zone is provided for sewing to a garment, e.g., shorts or sports bra as indicated at 136. In examples, a marginal zone is not used and the sections 105 and 130 be coextensive in their folded configuration.

FIG. 4D depicts a sectional view of FIG. 4A along section line 4D-4D of fabric construct 134 showing the multi-layer fabric configuration. Skin-contacting surface of hydrophobic section 102 extends to demarcation 225 with hydrophilic section 103. Hybrid layer 215 comprising one or more hydrophobic yarns 218 and one or more hydrophilic yarns 217 is integral with hydrophobic section 102 making up the skin-facing or skin contacting fabric portion of the fabric construct. In examples, hybrid layer 215 comprises one or more hydrophobic yarns 218 comprising zinc, silver, copper, or their oxides and/or salts. In examples, hybrid layer 215 comprises one or more hydrophobic yarns of polypropylene comprising zinc, silver, copper, or their oxides and/or salts. In examples, hybrid layer 215 further comprises elastomeric yarn.

FIG. 5A depicts the fabric construct 134 coupled to an article of clothing, e.g., shirt 20. Coupling of fabric construct to the article of clothing can be by stitching, fusion, and/or adhesive bonding. In examples, adhesive bonding is done with at least partially elastic material. In examples, sonic welding is done with at least partially elastic material. FIG. 5A depicts a multi-layer construction for hydrophilic layer 216. In examples, the knitting process transitions from the hydrophobic layer 214 and hybrid layer 215 and continues using the hydrophilic yarn 217 along with additional hydrophilic yarns and/or elastomeric yarn (spandex/elastane) to provide a multi-layer hydrophilic layer 216 as shown in FIG. 5A.

FIG. 5B depicts an alternative fabric construct where the knitting process transitions from the hydrophobic layer 214 and hybrid layer 215 and uses just hydrophilic yarn 217 without additional hydrophilic yarns, but may include elastomeric yarn (spandex/elastane) to provide a single-layer hydrophilic layer 216.

FIGS. 6A-6G depicts an exemplary fabric construct being predominantly of a circularly-knitted construction for economical conservation of materials with hydrophobic section 102 transitioning to hydrophilic section 103 from corresponding annular openings, sections 102 and 103 separated by demarcation 225. In examples, a width of demarcation 225 extends around the entire circumference of fabric construct 600. In examples, each section 102, 103 is entirely of an integrally knitted construction. In other examples, each section 102, 103 is entirely a multi-ply knitted construction integrally knitted.

As shown in FIG. 6C, enlarged section 6C of hydrophobic section 102 of fabric construct 600 of FIG. 6A comprises one or more hydrophobic yarns 218 interlocked with hydrophilic yarns 217. In examples, hydrophobic section 102 of fabric construct 600 comprises metal-containing hydrophobic yarns 218 that are interlocked with non-metal containing hydrophilic yarns 217 as shown in section 6C of FIG. 6A. In examples, hydrophobic section 102 of fabric construct 600 comprises metal-containing hydrophobic yarns that are interlocked with non-metal-containing hydrophobic yarns 218 interlocked with one or more hydrophilic yarns so as to provide a gradient of metal-containing yarn throughout the thickness of section 102 of fabric construct 600. Suitable yarn comprising copper-containing fiber, includes yarn sold by Cupron Inc. (Richmond, Virginia).

In examples, hydrophilic section 103 of fabric construct 600 comprises one or more hydrophilic yarns 217 as previously disclosed above, providing a hydrophilic surface 216 as shown in section 6B of FIG. 6B. In examples, hydrophilic section 103 of fabric construct 600 comprises substantially hydrophilic yarns with less than 10% hydrophobic yarn and/or elastomeric yarn. In examples, hydrophilic section 103 of fabric construct 600 comprises only hydrophilic yarns and elastomeric yarn as needed to provide sufficient stretchability.

FIGS. 6D-6G depict construction of a multi-layer sleeve, where hydrophobic section 102 of fabric construct 600 is introduced into and adjacent with hydrophilic section 103 as shown by arrows 602. Introduction of hydrophobic section 102 into and adjacent with hydrophilic section 103 can be performed manually or by machine. Once hydrophobic section 102 of fabric construct 600 is introduced into and adjacent with hydrophilic section 103 up to demarcation 225, a single end 604, comprising the overlapping layers of sections 102, 103, can be coupled 610 together, e.g., sewn, glued, etc. to provide sleeve 650, sock (not shown) or glove (not shown). Sleeve 650 provides a hydrophobic section 102 configured to be directly adjacent the skin of a wearer, with hybrid layer 215 interposed between an outer hydrophilic layer 103.

FIGS. 6I-6N depict another exemplary fabric construct 675 being predominantly of a circularly-knitted construction, with hydrophobic section 102 transitioning to hydrophilic section 103 having at least one surface comprising a terry loop knit 679, sections 102 and 103 separated by demarcation 225. In examples, a width of demarcation 225 extends around the entire circumference of fabric construct 675. In examples, each section 102, 103 is entirely of an integrally knitted construction. In other examples, each section 102, 103 is entirely a multi-ply knitted construction integrally knitted.

In examples, hydrophilic section 103 of fabric construct 675 comprises one or more hydrophilic yarns 217 as previously disclosed above, providing a hydrophilic surface 216 as a terry loop knit 679. In examples, hydrophilic section 103 of fabric construct 675 comprises substantially hydrophilic yarns with less than 10% hydrophobic yarn and/or elastomeric yarn. In examples, hydrophilic section 103 of fabric construct comprises only hydrophilic yarns and elastomeric yarn as needed to provide sufficient stretchability.

With reference to FIGS. 6H-6L, construction of a multi-layer construct 675 is shown, where hydrophobic section 102 of fabric construct 675 is introduced into and adjacent with hydrophilic section 103 as shown by arrows 602. Hydrophilic section 103 is illustrated as being rolled up onto hydrophobic section 102 with interlocking yarns 680, which can be performed manually or by machine. Once hydrophobic section 102 of fabric construct 675 is introduced into and adjacent with hydrophilic section 103 up to demarcation 225, end 604, comprising the overlapping layers of sections 102, 103, can be coupled 610 together, e.g., sewn, glued, etc. to provide sleeve, sock (not shown) or glove (not shown). Fabric construct 675 provides a hydrophobic section 102 configured to be directly adjacent the skin of a wearer, with hybrid layer 215 interposed between an outer hydrophilic layer 103 with a presenting terry loop knit surface 679 outwardly facing when worn.

With reference to FIGS. 6O-6R, construction of another exemplary multi-layer construct 695 is shown, hydrophilic section 103 is bounded on both ends of tubular structure 693 by hydrophobic sections 102, each of the hydrophobic sections 102 connected to adjacent hydrophilic section 103 via hems 690.

Each hydrophobic sections 102 of fabric construct 695 is introduced into ends of the tubular structure 693 and adjacent with hydrophilic section 103 as shown by arrows 603. Hydrophilic section 103 is illustrated as being rolled up onto hydrophobic section 102, which can be performed manually or by machine. Once hydrophobic sections 102 of fabric construct 693 are introduced into and adjacent with hydrophilic section 103 up to hem 690, sections 102 can be coupled 604 together, e.g., sewn, glued, etc. to provide sleeve, sock (not shown) or glove (not shown) as illustrated in FIG. 6R showing sleeve 695 turned inside-out. Fabric construct 675 provides a hydrophobic section 102 configured to be directly adjacent the skin of a wearer, with interlocking layer 215 interposed between an outer hydrophilic layer 103 and inner hydrophobic layer 102..

FIG. 7A depicts an alternative sleeve construct 700 constructed from two separate components, where first component 702 comprises hydrophobic tubular form with opposing opened ends, the tubular form having hydrophobic inner layer 214 that transitions to exterior hybrid layer 215. First component 702 is introduced into second component 704 comprising a hydrophilic tubular form with opposing opened ends, as shown in FIG. 7A to provide sleeve 700 (e.g. sleeve-in-a-sleeve) as shown in FIG. 7B. Opposed opened ends of first and second component can be coupled 710 together, e.g., sewn, glued, etc. Sleeve construct 700 can be used on any appendage or part thereof, e.g., leg, arm.

FIG. 8A shows sectional view along section line 8A-8A of FIG. 7B depicting the layers of the sleeve 700 with fabric construct as disclosed herein, hydrophobic skin-facing surface 214, interposed hybrid layer 215 as disclosed above, and one or more hydrophilic layers 216, as shown in FIG. 8B, an enlarged view of section 8B of sleeve of FIG. 7A. In examples, each of the one or more hydrophilic layers 216 of sleeve 700 are the same fabric, color, thickness, etc. In other examples, each of the one or more hydrophilic layers 216 of sleeve 700 are different fabric, color, thickness, etc. Sleeve 700 can include apertured sections in one or both layers 214216 as discussed above.

The fabric construct disclosed herein, having a multi-layered construction of hydrophobic, hybrid, and hydrophilic layers can be incorporated in a variety of articles to provide moisture management benefits during user activities. Such articles can include one or more hems/cuffs/welts having a multi-layer construction as described herein. A sampling of such articles are provided below.

FIG. 9A depicts an exemplary fabric head band constructed from a tubular fabric construct 900, where hem/welts are structured with hydrophobic skin-facing surface 214, hybrid layer 215 as disclosed above, and one or more hydrophilic layers 216 as shown in FIGS. 9B, 9C, depicting section views 9B, 9C of hem/welts of FIG. 9A.

FIG. 10A depicts an exemplary skull wrap 1000 constructed from a tubular fabric construct as disclosed and described above, where hem/welts are structured with hydrophobic skin-facing surface 214, hybrid layer 215 as disclosed above, and one or more hydrophilic layers 216 as shown in FIGS. 10B, 10C, depicting section views 10B, 10C of FIG. 10A. FIG. 11A depicts another exemplary skull wrap 1001 with a larger skin facing surface 214 and FIGS. 11B, 11C depict section views 11B, 11C of FIG. 11A with similar construction as FIG. 10A. Skull wraps 1000, 1001 can include apertured sections 1025.

FIGS. 12A, 12B depict front and back views showing an exemplary skull wrap fabric construction having hydrophobic skin facing surface 214 and one or more hydrophilic layers 216 constructed in pairs for cutting away separate skull wraps along demarcation 1020.

FIG. 13A depicts an exemplary skull cap 1300 with lid 1302 with optional apertures 1325, where lid 1302 is configured for coupling 1310 with skull cap 1300 as shown in FIG. 13D such that hydrophobic skin facing side of both cap 1300 and lid 1302 present to skull of wearer. The one or more hydrophilic layers 216 are presented adjacent hybrid layer 215 to facilitate moisture management as discussed herein.

FIGS. 13B, 13C depict section views 13B, 13C of a cut away section of folded linear fabric construct 1305, where folded ends of section layers 214, 216 are coupled 1310 together. FIG. 13A showing coupling 1310 of the folded tubular multi-layer fabric construct as described above. FIG. 13D depicts section 13D of FIG. 13A showing coupled lid 1312 to folded linear fabric construct 1305. Demarcation 225 can be a drop out stitch to provide a folding edge.

FIGS. 14A, 14B, 14C, and 14d depict side view, unfolded configuration/folded skin side view, and folded non-skin side view, respectively, of an exemplary linear head tie fabric construct 1400. Side view shows isolated hydrophobic skin facing surface 214 with hydrophilic layers 216 adjacent both sides and corresponds to section view along section line 14D-14D of FIG. 14D.

An exemplary method of preparing fabric construct as herein disclosed includes a circular knitting machine initially set up with one yarn feeding finger at each of the multiple knitting stations of the circular knitting machine equipped with an appropriate elastic (multi-) filament, alone or in combination with a hydrophilic yarn, e.g., polyester or nylon yarn, suitable for forming the main fabric structure (body yarn) of the cuff 210. In addition, a designated one of a plurality of knitting stations is set up with another of its yarn feeding fingers equipped with a metal-containing yarn and hydrophilic yarn to be fed to the needles with the body yarn at such knitting station after the demarcation point.

With the second feed needle selection switching to the same selection as the first feed, the dial cam is activated to extract the dial jacks in between the 1 x 1 needle selection so that the functional yarn now lays over the selected dial jacks and ties in to previous stiches/make-up for one revolution.

After the dial jacks are loaded with yarn, the dial cam is deactivated, the first feed needle selection changes to select all needles up clear high and the yarn finger selection on first feed changes from one finger to three, where one finger engages the metal-containing and/or hydrophobic yarn plaited towards the inside of the cylinder and the other finger engages the hydrophilic yarn plaited towards outside of the cylinder for a width of approximately ten needles, providing a lap. Then, the first feed finger comes out of needle selection.

The process then diverts to formation of an outside of the welt with the first feed finger change and pattern activation. This pattern allows for providing hydrophilic yarn plaited towards inside of cylinder while having a hydrophobic/metal-containing yarn plaited towards outside of cylinder. The first feed finger change inserts backing yarns (spandex, hydrophilic yarn) and after the lap, the inside welt yarns come out of needle selection. The metal-containing yarn comes from 1 of 6 pattern feeds and ties into the first feed backing yarn, but is plaited to the outside of the backing side for presentation to the skin of the wearer. The outside welt revolutions closely match the inside welt revolutions so that the hydrophobic and/or metal-containing yarn is at the demarcation 225 of the fabric construct 134, 600.

In examples, the hydrophobic inner layer 214 of fabric construct 134, 600 is polypropylene from 50% to 70% by weight. Other hydrophobic yarns can be used for inner layer 214.

In examples the hybrid layer 215 is polypropylene and one or more of polyester, nylon, acrylic, wool, cotton, or cotton blend. In examples the hybrid layer 215 of cuff 310 is polypropylene and equal amounts by weight of the one or more of polyester, nylon, acrylic, wool, cotton, or cotton blend. In examples the hybrid layer 215 of cuff 310 is arranged as a gradient of essentially polypropylene proximal to the inner layer 214 and transitioning to essentially the one or more of polyester, nylon, acrylic, wool, cotton, or cotton blend distal from the inner layer 214. In examples the hybrid layer 215 of cuff 310 is arranged as a gradient of essentially the one or more of polyester, nylon, acrylic, wool, or cotton blend proximal to the inner layer 214 and transitioning to essentially polypropylene distal from the inner layer 214. In examples the hybrid layer 215 of cuff 310 is the same thickness as the inner layer 214.

In examples, the hydrophilic outer layer 216 is selected from one or more of polyester, nylon, acrylic, wool, cotton, or cotton blend from 30% to 50% by weight. In examples, spandex/Elastane (stretch fibers) is positioned between the outer layer 216 and/or inner layer 214 or hybrid layer 215 is from 10% to 30% by weight.

In examples, the main body fabric is polypropylene from 20% to 40% by weight and the hydrophilic layer(s) 216 is polyester/nylon/acrylic/wool/cotton blend from 40% to 70% by weight and spandex/Elastane (stretch fibers), positioned between the outer layer 216 and inner layer 214 is used from 7% to 17% by weight.

Advantageously, the fabric construct 134, 600 when used with an article of clothing produced by the present disclosure in the manner above-described, minimizes or reduces the collection of moisture on the skin facing surface.

While certain embodiments of the present disclosure have been illustrated with reference to specific combinations of elements, various other combinations may also be provided without departing from the teachings of the present disclosure. Thus, the present disclosure should not be construed as being limited to the particular exemplary embodiments described herein and illustrated in the Figures, but may also encompass combinations of elements of the various illustrated embodiments and aspects thereof.