Engineered Flat Knit Upper Torso Bra and/or Bra components

Field of Invention

This invention relates to a flat-knit fabric or bra component that has multiple support zones integrated as a unitary engineered knit panel. The component may be used in everyday, active, and/or performance bras/bralettes.

Background

The listing or discussion of a prior-published document in this specification should not necessarily be taken as an acknowledgement that the document is part of the state of the art or is common general knowledge.

Contemporary upper torso garments, such as bras, may suffer from poor fit and comfort and it is difficult to provide a garment that can be adapted to fit the body of a wearer without making it overly complex and expensive to manufacture. Examples of products that suffer from one or more of the problems may include PVH true and core, Soma ™ vanishing bra, VS ™ knockout, Nike ™ Indie bra, and the like.

Therefore, there remains a need to overcome some or all of the problems identified above.

Summary of Invention

It has been surprisingly found that it is possible to solve some or all of the problems identified above by providing the whole or part of an upper torso garment as a fully knitted structure (e.g. a bra or part thereof) in one knit. If formed as a whole bra, it is possible to shape a panel that includes engineered cups with an integrated cookie pocket and inbuilt zonal structures that can provide the garment with a four-way stretch fabric that provides fit flexibility to the wearer. In addition, the whole or part of a garment can adapt to body changes. For example, if formed as a bra (or part thereof), the resulting bra can adapt to cup size variation of the wearer (e.g. due to the cookie pocket) or to different body shapes amongst wearers of the same size of bra. Additionally, the construction of the garment (or part thereof) may be conducted with minimal trims and operations, making the garment cost effective to manufacture, with minimal wastage, making it environmentally friendly.

Aspects and embodiments of the invention are set out in the following numbered clauses. 1. A double-knit flat-knit engineered fabric, comprising: multiple modulus zones; different fabric densities; different fabric weights; different stitch sequences; and different knit structures seamlessly integrated to create a bra/bralette or a bra- component which may be selected from one or more of a bra cup region, a bottom band, a wing area, and a back portion of a bra.

2. The double-knit flat-knit engineered fabric according to Clause 1 , wherein the multiple modulus zones comprise:

(a) a first zone that comprises a bra bottom band region adjoining to a bra cup region and a second zone of a bottom band region adjoining to a bra wing area, optionally wherein a third zone is a bra cup region and a fourth zone comprises a first and a second bra wing; or

(b) a first zone that comprises a bra bottom band region adjoining to a bra cup region and a second zone of a bottom band region adjoining to a bra wing area, a third zone is a bra cup region and a fourth zone comprises a first and a second bra wing.

3. The double-knit flat-knit engineered fabric according to Clause 2, wherein the first zone is formed:

(3. a.1 ) using a front bed and a back bed of a V-bed flatknit machine, where: a first set of front courses are knitted on the front bed of the machine; a second set of corresponding tuck stitches are made on the back bed of the machine; a third set of stitches are made as a back knit on the back bed of the machine; and a fourth set of stitches are a tuck stitch on the front bed of the machine while it makes a back knit on the back bed of the machine, where the abovementioned tuck stitches are aligned to one another and do not off-set each other, optionally wherein the above-mentioned stitch sequence has no transfers between the front bed and the back bed;

(3. a.2) using a front bed and a back bed of a V-bed flatknit machine, where: a first set of stitches will be knitted on the front bed and carried on to the back bed as a knit completing the first course; and a second set of stiches will be knitted on the back bed and carried on to the front bed to create a double jersey interlock, optionally wherein this double jersey interlock stitch sequence is created using gradually increasing the knit loop length or increasing the NP values; or

(3. a. 3) using a front bed and a back bed of a V-bed flatknit machine, wherein: a first set of stitches will be knitted on the front bed; a second set of stitches will be tuck stitches between the front bed and the back bed; and a third set of stitches will be knitted on the back bed, optionally wherein the tuck stitches are inter-tucking tuck stitches and the inter-tucking tuck stitches are aligned to each other along every needle and do not off-set each other.

4. The double-knit flat-knit engineered fabric according to Clause 3, is knitted using the front and back beds or along with a tuck stitch which differs in knit loop length laterally creating a multi-modulus bottom band or anchoring band across the body, optionally wherein this creates the second zone of the bottom band adjoining to the bra wing area.

5. The double-knit flat-knit engineered fabric according to Clause 2, wherein the third zone is formed:

(5.a.1) using a front bed and a back bed of a V-bed flatknit machine, where: a first set of front courses are knitted on the front bed of the machine; a second set of corresponding tuck stitches are made on the back bed of the machine; a third set of stitches are made as a back knit on the back bed of the machine; and a fourth set of stitches are a tuck stitch on the front bed of the machine while it makes a back knit on the back bed of the machine, where the tuck stitches in are aligned to one another and do not off-set each other, optionally wherein the above-mentioned stitch sequence has no transfers between the front bed and the back bed;

(5. a. 2) using a front bed and a back bed of a V-bed flatknit machine, where: a first set of stitches is knitted on the front bed and carried on to the back bed as a knit completing the first course; a second set of stiches are knitted on the back bed and carried on to the front bed to create a double jersey interlock, optionally wherein: this double jersey interlock stitch sequence is created by gradually increasing the knit loop length or increasing the NP values, where the change of the knit loop length the fabric creates a body contouring shape surrounding the cup area and provides an encapsulation of the breasts;

(5. a. 3) using a front bed and a back bed of a V-bed flatknit machine, where: a first set of stitches are knitted on the front bed; a second set of stitches will be tuck stitches between the front bed and the back bed; and a third set of stitches will be knitted on the back bed, optionally wherein the tuck stitches are inter-tucking tuck stitches and the inter-tucking tuck stitches are aligned to each other along every needle and do not off-set each other; or

(5. a. 4) using a front bed and a back bed of a V-bed flatknit machine, the fabric element can carry a double jersey and single jersey knit structures for aesthetics and can carry a transfer to create perforations.

6. The double-knit flat-knit engineered fabric according to Clause 2, wherein the fourth zone is formed

(6. a.1 ) using a front bed and a back bed of a V-bed flatknit machine, where: a first set of front courses are knitted on the front bed of the machine; a second set of corresponding tuck stitches are made on the back bed of the machine; a third set of stitches are made as a back knit on the back bed of the machine; a fourth set of stitches are a tuck stitch on the front bed of the machine while it makes a back knit on the back bed of the machine, where the abovementioned tuck stitches are aligned to one another and do not off-set each other, optionally wherein the above-mentioned stitch sequence has no transfers between the front bed and the back bed;

(6. a. 2) using a front bed and a back bed of a V-bed flatknit machine, where: a first set of stitches are knitted on the front bed and carried on to the back bed as a knit completing the first course; a second set of stiches are knitted on the back bed and carried on to the front bed to create a double jersey interlock, optionally wherein this double jersey interlock stitch sequence is created using gradually increasing the knit loop length or increasing the NP values

(6. a. 3) using a front bed and a back bed of the V-bed flatknit machine, where: a first set of stitches are knitted on the front bed; a second set of stitches are tuck stitches between the front bed and the back bed; a third set of stitches are knitted on the back bed, optionally wherein the tuck stitches are inter-tucking tuck stitches and the inter-tucking tuck stitches are aligned to each other along every needle and do not off-set each other.

7. A double-knit flat-knit engineered fabric, comprising of: multiple modulus zones; different fabric densities; different fabric weights; different stitch sequences; and different knit structures seamlessly integrated to create a bra/bralette or a bra-component which may comprise or be a bra cradle, where the bra cradle represents a section that connects a bra cup portion to a bottom band, optionally wherein the bra cradle has a first zone that is formed using:

(7. a.1) a front bed and a back bed of a V-bed flatknit machine, where: a first set of front courses are knitted on the front bed of the machine; a second set of corresponding tuck stitches are made on the back bed of the machine; a third set of stitches are made as a back knit on the back bed of the machine; and a fourth set of stitches are a tuck stitch on the front bed of the machine while it makes a back knit on the back bed of the machine, where the abovementioned tuck stitches are aligned to one another and do not off-set each other, further optionally wherein the above- mentioned stitch sequence has no transfers between the front bed and the back bed;

(7. a.2) a front bed and a back bed of a V-bed flatknit machine, where: a first set of stitches are knitted on the front bed and carried on to the back bed as a knit completing the first course; and a second set of stiches are knitted on the back bed and carried on to the front bed to create a double jersey interlock, optionally wherein this double jersey interlock stitch sequence is created by gradually increasing the knit loop length or increasing the NP values;

(7. a. 3) a front bed and a back bed of a V-bed flatknit machine, where: a first set of stitches are knitted on the front bed; a second set of stitches are tuck stitches between the front bed and the back bed; a third set of stitches are knitted on the back bed, optionally wherein the tuck stitches are inter-tucking tuck stitches and the inter-tucking tuck stitches are aligned to each other along every needle and do not off-set each other. 8. The double-knit flat-knit engineered fabric according to Clause 7, wherein the fabric is knitted using front and back beds or along with a tuck stitch which differs in knit loop length laterally creating a bra cradle across the body which has two or more modulus areas.

9. The double-knit flat-knit engineered fabric according to any one of the preceding clauses, may or may not be finished as a knit to shape with smooth finished edges and depending on the method of finish will carry an additional modulus zone next to the edge of the fabric to enhance the flat appearance and fit.

10. The double-knit flat-knit engineered fabric according to Clause 3 sub-sections (3.a.1- 3. a.3) when used together create a double knit flatknit engineered fabric to be used as a back panel.

11. The double-knit flat-knit engineered fabric according to Clauses 7 and 10 can be used as flat-knitted bra components, optionally wherein the final product can only be finished by the use of non-flat-knitted components which can be a knitted, a woven, or a composite material which may or may not be moulded, bonded or sewed together to create a bra/bralette.

12. The double-knit flat-knit engineered fabric according to according to Clause 2, wherein the flatknit engineered bottom band is the only flatknit fabric and is coupled to a non-flatknit bra cup region and a non-flatknit bra wing region, optionally wherein the coupling is by a nonflatknit fabric, other trims, bonding or by cut and sewing.

13. The double-knit flat-knit engineered fabric according to any one of Clauses 2 to 4 and 7, wherein one or more of the following apply: i. the bottom band has a first and a second modulus zone, each having different knit loop lengths that change both laterally and horizontally within the zones and thereby provide a multi-modulus bottom band, optionally wherein the first modulus zone of the bottom band is located at a central region adjacent to the bra cup region and the second modulus zone is located adjacent to the bra wing area of the bra/bralette; ii. the bottom band is split into two or more modulus zones to provide a a multimodulus knit fabric, where each zone has a different knit loop length horizontally along the x axis and vertically along the y axis relative to each other zone; iii. the bottom band is formed from a first and a second double jersey spacer knit structures, where the first spacer structure provides an even fabric surface enabling better on-body comfort, and the second spacer structure is formed as a rib-like knit structure that provides a better grip on the wearer’s body and adds to the aesthetic appearance of the bra/bralette; iv. the bottom band incorporates one or more colours to create a jacquard logo or provides an aesthetic pattern; v. the bottom band is formed using an interlock knit structure or using a spacer knit structure using both front and back beds; and vi. the bottom band is formed as a tubular knit structure having a hollow core, optionally wherein the hollow core houses an elastic or a chord to fasten the bottom band to the wearer’s body.

14. The double-knit flat-knit engineered fabric according to any one of Clauses 2 to 4 and 7, wherein the flatknit bottom band is knitted using the any one of the below listed stitch sequences in a repeating pattern comprising one or more of the following:

(a) a front stitch (1), rear stitch, rear stitch, rear stitch, rear stitch, miss stitch, miss stitch (2), rear tuck, front tuck, rear tuck, front tuck, rear tuck, front tuck (3), front stitch, front stitch, front stitch, front stitch, miss stitch, miss stitch (4), rear stitch (5), front tuck, rear tuck, front tuck, rear tuck, front tuck, rear tuck (6), as depicted in Figure 1 ;

(b) a front stitch (7), rear stitch (8), front stitch (9), rear stitch (10) rear tuck, front tuck, rear tuck, front tuck (11), front tuck, rear tuck, front tuck, rear tuck (12), as depicted in Figure 2;

(c) a front stitch, rear stitch (13), rear stitch, front stitch (14), as depicted in Figure 3;

(d) a front stitch (15), rear stitch (16), front tuck rear tuck (17), rear stitch (18), front stitch (19), front tuck rear tuck (20), as depicted in Figure 4;

(e) a front stitch, front stitch, rear stitch, rear stitch (21), front stitch, front stitch, rear stitch, rear stitch (22), as depicted in Figure 5

(f) a rear stitch, front stitch (23), front stitch, miss stitch (24), front stitch, rear stitch (25), miss stitch, front stitch (26), as depicted in Figure 6.

15. The double-knit flat-knit engineered fabric according to any one of Clause 7, Clause 8, Clauses 9 and 11 as dependent upon Clause 7 or Clause 8 or Clauses 13 and 14 as dependent upon Clause 7, wherein the cradle is knitted as:

(a) a combination of double jersey interlock and a spacer; or

(b) a combination of the knit structures in Figs 59 and 60, optionally wherein the cradle is knitted using the any one of the below listed stitch sequences in a repeating pattern comprising one or more of the following: I. a miss stitch, miss stitch, rear stitch, rear tuck (27), miss stitch, miss stitch, rear tuck, rear stitch (28), miss stitch, miss stitch, rear stitch, rear tuck (29), miss stitch, miss stitch, rear tuck, rear stitch (30), rear stitch, front stitch, rear stitch, rear tuck (31), front stitch, rear stitch, rear tuck, rear stitch (32), front stitch, front stitch, rear stitch, rear tuck (33), rear stitch, rear stitch, rear tuck, rear stitch (34), front tuck, front stitch, rear stitch, rear tuck (35), front stitch, front tuck, rear tuck, rear stitch (36), rear tuck, rear stitch, rear stitch, rear tuck (37), rear stitch, rear tuck, rear tuck, rear stitch (38), rear stitch, front stitch, rear stitch, rear tuck (39), front stitch, rear stitch, rear tuck, rear stitch (40), miss stitch, miss stitch, rear stitch, rear tuck (41), miss stitch, miss stitch, rear tuck, rear stitch (42), miss stitch, miss stitch, rear stitch, rear tuck (43), miss stitch, miss stitch, rear tuck, rear stitch (44), as depicted in Figure 7;

II. a front stitch, rear stitch, front stitch, rear stitch (45), rear stitch, front stitch, rear stitch, front stitch (46), front stitch, front tuck, front stitch, front tuck (47), rear tuck, rear stitch, rear tuck, rear stitch (48) as depicted in Figure 8;

III. a front tuck, miss stitch, rear tuck, miss stitch (49), front stitch, miss stitch, rear stitch, miss stitch (50), front stitch, miss stitch, rear stitch, miss stitch (51), miss stitch, front tuck, miss stitch, rear tuck (52), miss stitch, front stitch, miss stitch, rear stitch (53), miss stitch, front stitch, miss stitch, rear stitch (54) as depicted in Figure 9.

16. The double-knit flat-knit engineered fabric according to Clause 6, wherein the fourth zone has a different modulus compared to the rest of the fabric and is formed using one or more of the following: i. a flat bed or a V-bed knit machine to create a flat knitted wing as a bra component, which is knitted as a double jersey interlock or a spacer fabric which may or may not be knit to shape, optionally wherein when it is formed as knit to shape, the flat knitted wing has edge finishing, which is knitted using one or more typed of a covered nylon yarn; ii. when the wing is formed as a double jersey interlock fabric, the wing is further divided into a bottom modulus zone adjacent to the bottom band and a top modulus zone separated from the bottom band by the bottom modulus zone, with each zone having different knit loop lengths compared to each other, optionally wherein the bottom modulus zone of the wing portion has a shorter loop length compared to the top modulus zone and thereby having a higher modulus level than the top modulus zone; and iii. a double jersey, single jersey or a combination of double jersey and single jersey knit structures.

17. The double-knit flat-knit engineered fabric according to Clause 6 or Clause 16, wherein at least a portion of the fourth zone is formed using the stitch sequence having a repeating pattern of a front stitch, miss stitch, front stitch, miss stitch, front stitch (55), miss stitch, rear stitch, miss stitch, rear stitch, miss stitch (56), as depicted in Figure 10.

18. The double-knit flat-knit engineered fabric according to Clause 10, wherein one or more of the following apply: i. a flat bed or a V-bed knit machine is used to create the flat knitted back panel as a bra component, which component is provided as a double jersey fabric that is a spacer fabric, an interlock fabric, a tubular fabric, a combination of a spacer and an interlock fabric or a combination of spacer and tubular fabric; ii. the back panel may or may not be knit to shape, optionally wherein when it is knit to shape the component will carry edge finishing, which finishing is knitted as a semi-shaped knit component where edge finishing will be done by attaching a foldable elastic, which is optionally knitted using one or more type of a covered or uncovered nylon yarn. iii. the back panel comprises multiple zones, where a first zone forms part of a bottom band, and the remaining zones are formed as part of the unitary back panel above the bottom band (e.g. each of the remaining modulus zone are created vertically or horizontally on the unitary panel located above the bottom band), optionally wherein:

(a) the back panel is knitted as a plurality of double jersey tubular structures with the incorporation of a rib between each two of the plurality of double jersey tubular structures ; and/or

(b) each of the modulus zones are different from one another based on the knit structure type and the knit loop lengths; and iv. the back panel is attached to other components to form a full bra by combining the back panel with other knitted fabrics and other components as may be needed (e.g. moulded cups and elastic).

19. The double-knit flat-knit engineered fabric according to Clause 10 or Clause 18, wherein the back panel is formed as a panel with two different modulus zones as depicted in fig 62, 63, 64, 65, optionally wherein said back panels are formed using one or more of the following stitch sequences:

(a) rear tuck, front tuck (57), front stitch (58), rear stitch, miss stitch (59), front tuck, rear tuck (60), front stitch (61), miss stitch, rear stitch (62), as depicted in Figure 11 ;

(b) miss stitch (63), rear stitch, miss stitch (64), miss stitch, front stitch (65), miss stitch (66), miss stitch, rear stitch (67), front stitch, miss stitch (68) as depicted in Figure 12;

(c) front stitch, rear stitch, rear tuck, rear stitch (69), rear stitch, front stitch, rear stitch rear tuck (70), as depicted in Figure 13; and

(d) front stitch, miss stitch (71), miss stitch, rear stitch (72), rear stitch, miss stitch (73) as depicted in Figure 14.

20. The double-knit flat-knit engineered fabric according to any one of Clauses 2 to 8 and 10, wherein a flat bed or a V-bed knit machine is used to create a flat knitted one-piece fabric that can be used as a bra component or as a flat knitted fabric to finish an entire bra by attaching the required trims, optionally wherein one or more of the following apply:

(a) the one piece is formed as a spacer fabric, interlock fabric, tubular fabric or as a combination of a spacer and an interlock fabric, or as a singular knit sequence that changes its knit loop length vertically; and

(b) the one piece fabric is divided into three different knit modulus zones categorised as a bottom band, a cup area and a wing portion of a bra/bralette, which can carry a combination of the aforementioned double jersey fabric types as described in (a) above, optionally wherein: the bottom band is sub-divided into six modulus zones which offers better grip and support to the wearer’s body, and the cup area and wing portion are each sub-divided into four different knit modulus zones as a result of knit loop length variations within the zone; and/or an area adjacent to the bottom band may or may not carry the same amount of yarn ends or a different number of yarn ends when compared to the wing area on either side of the bra/bralette and the bra cup region.

(c) the one piece is knitted to shape and so has edge finishing, which finishing is provided by a semi-shaped knit component where edge finishing is completed by attaching a foldable elastic; (d) the one piece fabric is divided into three different knit modulus zones categorised as a bottom band, a cup area and a wing portion of a bra/bralette, where the cup area has a required volume for encapsulation, which volume is achieved by moulding the cup area, incorporating laminated foam cups, or by changing the knit loop length in the cup region which creates volume by shrinking the knit loop during the finishing process, this latter option can be knitted using one or more type of a covered or uncovered nylon yarn.

(e) the one piece fabric can incorporate double jersey or single jersey structures designed to provide an aesthetic appearance and which have a different modulus value compared to the rest of the fabric;

(f) the one piece fabric is provided as knit to shape, such that it has a first major knit zone and a second major knit zone, the first major knit zone being the bottom band which is split into three different knit zones in a horizontal direction, and the second major knit zone is split into three modulus zones corresponding to two wing areas, a cup area and a strap area, with the wing areas at either side of the cup area have the same modulus as each other, but the wing areas, the cup area and strap area each have a different modulus compared to each other, optionally wherein: the cup area has the highest modulus; and/or the cup area is knitted using a knit loop length sequence which gradually lengthens when reaching the highest point of the bra cup, where the gradual change of knit loop length creates encapsulation at the bra cup region (which will be further enhanced during the finishing process as and when the knit panel shrinks), resulting in a fabric which has an element of three-dimensional attribute to the bra cup region.

21. The double-knit flat-knit engineered fabric according to Clause 20 as dependent upon Clause 7 or Clause 8, wherein the integrated one piece flatknit fabric is knitted as a combination of the bottom band, the cradle and the wing area, which integrated one piece flatknit fabric is formed from a double jersey interlock knit structure, a double jersey spacer knit structure a combination of a double jersey interlock knit structure and a double jersey spacer knit structure, or a singular knit sequence which changes its knit loop length vertically, which knit structures are depicted in Figures 66, 67, 68, alternatively this integrated one piece flatknit fabric is knitted using a stitch sequence of front stitch, rear stich, rear stitch, rear tuck (74); rear stitch, front stitch, rear tuck, rear stitch (75); front stitch, front stitch, rear stitch, rear tuck (76); rear stitch, rear stitch, rear tuck, rear stitch (77); front tuck, front stitch, rear stitch, rear tuck (78); front stitch, front tuck, rear tuck, rear stitch (79); rear tuck, rear stitch, rear stitch, rear tuck (80); and rear stitch, rear tuck, rear tuck, rear stitch (81), as depicted in Figure 15. 22. The double-knit flat-knit engineered fabric according to Clause 21 , the double knit flat knit textile element can be used to create a single piece, bra/bralette with or without edge finishing as a knit to shape fabric, optionally wherein one or more of the following apply:

I. the bra comprises a double knit flatknit anchoring band/bottom band which is split into six different modulus zones as described in Clause 20(f);

II. the adjacent cup and wing areas are knitted as a double jersey interlock structure and these areas will also comprise a double jersey knit structure adjacent to the cradle to create an aesthetically pleasing design, which is placed at a predefined location, optionally wherein the wing areas have the same stitch sequence and loop length and have the same modulus;

III. the cup area adjacent to the bottom band is knitted using a double jersey interlock knit structure, optionally wherein the cup area adjacent to the bottom band has a stitch sequence that has a varied knit loop length, which creates encapsulation of the breasts by providing a three dimensional appearance in the bra cup region once the fabric goes through the finishing process (i.e. the fabric is scoured, dried, steamed and ironed);

IV. the strap area is formed from a left strap zone and a right strap zone that is created using a double knit interlock which gradually changes its knit loop length, thereby creating a fabric which has a higher modulus compared to the cup region and the wing area, optionally wherein, when the double knit flatknit textile element is knit to shape, the flatknit edges will carry a tubular knit structure around the aperture created as a neckline and an armhole, this will create a smooth edge finish;

V. each of the double bed textile elements disclosed in I to IV above further comprise one or more covered synthetic yarns, optionally wherein the number of ends used in a specific area of the bra/bralette can change depending on the placement, modulus, and performance required; and

VI. when the one piece flatknit fabric is knitted to shape in order to remove additional assembly processes as well as to reduce waste a stitch sequence of a front stitch, miss stitch (82). miss stitch, rear stitch (83). miss stitch, rear stitch (84). front stitch, miss stitch (85), as depicted in Figure 16 is used.

23. The double-knit flat-knit engineered fabric according to Clauses 14, 15, 17, 19, 20(i), and 22(H) , wherein one or more of the below stitch sequences are used to create flat knit fabric bra components applicable to a bra/bralette:

I. a stitch sequence comprising of a repeating pattern of a front stitch (86), rear stitch (87), rear tuck, front tuck, rear tuck, front tuck (88).; front stitch (89), rear stitch (90), front tuck, rear tuck, front tuck, rear tuck (91), as depicted in Figure 17, which is suitable for use to create one or more of a flat-knit bottom band and a part of a back panel of a flatknit bra/bralette;

II. a stitch pattern suitable for use to form one or more of a band, cradle, back, wing, as well as an integrated one-piece fabric of a flatknit bra/bralette, as selected from one or more of the following stitch patterns:

(a) a front stitch, rear stitch (92), rear stitch, front stitch (93), as depicted in Figure 18;

(b) a front stitch (94), rear stitch (95), front tuck rear tuck (96), front stitch (97), rear stitch (98), front tuck rear tuck (99), depicted in Figure 19;

(c) a front stitch (100), front tuck rear tuck (101), rear stitch (102), depicted in Figure 20;

(d) a front stitch (106), rear stitch (107) as depicted in Figure 22;

(e) a front stitch rear stitch (108) as depicted in Figure 23;

(f) a front stitch rear stitch (134), front stitch (135), front stitch (136), front stitch (137), front stitch (138) as depicted in Figure 31 ;

(g) a front tuck rear stitch (141), front stitch (142), front stitch rear tuck (143), rear stitch (144) as depicted in 33;

(h) a front stitch, rear stitch, front stitch, rear stitch (145), rear stitch, front stitch, rear stitch, front stitch (146), front stitch (147), rear stitch (148) as depicted in Figure 34;

III. a stitch pattern suitable for use to form one or more of a band, a wing, or an integrated one-piece flat knit fabric , as selected from one or more of the following stitch patterns:

(aa) a front stitch rear stitch (109), front stitch (110), rear stitch (111) as depicted in Figure 24; or

(ab) a front stitch rear stitch (112), rear stitch (113) as depicted in Figure 25;

IV. a stitch pattern suitable for use to form one or more of a band, a wing, a back and an integrated one-piece fabric that is used to create a flatknit bra/bralette, as selected from one or more of the following stitch patterns :

(ba) a front stitch (114), rear stitch (115), front tuck rear tuck, miss stitch, front tuck rear tuck, miss stitch (116), front stitch (117), rear stitch (118), miss stitch, front tuck rear tuck, miss stitch, front tuck rear tuck (119) as depicted in Figure 26; (bb) a front stitch, rear tuck, front stitch, rear tuck (128), front tuck, rear stitch, front tuck, rear stitch (129) as depicted in Figure 28;

(be) a front stitch (165), front tuck rear stitch, rear stitch, front tuck rear stitch, rear stitch (166), front stitch (167), rear stitch, front tuck rear stitch, rear stitch, front tuck rear stitch (168) as depicted in Figure 39;

(bd) a front stitch rear tuck, front stitch, front stitch, front stitch, front stitch rear tuck, front stitch, front stitch (169), front stitch, front stitch, front stitch rear tuck, front stitch, front stitch, front stitch, front stitch rear tuck (170), miss stitch, miss stitch, rear stitch, miss stitch, miss stitch, miss stitch, rear stitch (171), rear stitch, miss stitch, miss stitch, miss stitch, rear stitch, miss stitch, miss stitch (172) as depicted in Figure 40.

V. one or more of a bottom band, a back portion, and an integrated one-piece flatknit fabric may be formable from one or more of the following stitch patterns:

(ca) a front stitch, rear stitch (132), rear stitch, front stitch (133) as depicted in 30;

(cb) a rear stitch, front stitch, rear stitch, front stitch (149), miss stitch, rear stitch, miss stitch, rear stitch (150), front stitch, rear stitch, front stitch, rear stitch (151), rear stitch, miss stitch, rear stitch, miss stitch (152) as depicted in Figure 35;

(cc) a front tuck, rear tuck (153), front stitch, rear stitch (154), rear tuck, front tuck (155), rear stitch, front stitch (156) as depicted in Figure 36;

(cd) a rear tuck, front tuck, rear tuck, front tuck (157), front stitch, rear stitch, front stitch, rear stitch (158), front tuck, rear tuck, front tuck, rear tuck (159), rear stitch, front stitch, rear stitch, front stitch (160) as depicted in Figure 37;

(ce) a miss stitch, rear tuck, front tuck, miss stitch (161), miss stitch, rear stitch, miss stitch, rear stitch (162), front tuck, miss stitch, miss stitch, rear tuck (163), front stitch, miss stitch, front stitch, miss stitch (164) as depicted in Figure 38;

VI. a stitch pattern suitable for use to form one or more of a bottom band, a cradle and an integrated one-piece flatknit fabric that creates a bra/bralette, the stitch pattern using a front stitch (120), rear stitch (121), miss stitch (122), front tuck rear tuck, miss stitch, front tuck rear tuck, miss stitch (123), front stitch (124), rear stitch (125), miss stitch (126), miss stitch, front tuck rear tuck, miss stitch, front tuck rear tuck (127), as depicted in Figure 27;

VII. a stitch pattern suitable for use to form one or more of a bottom band, a cradle, a wing and an integrated one-piece portion of a flatknit bra/bralette, the stitch pattern using a stitch sequence of front stitch, rear stitch, front stitch, rear stitch (139), front stitch, rear stitch, front stitch, rear stitch (140), as depicted in Figure 32; VIII. a stitch pattern suitable for use to form one or more of a bottom band and an integrated one-piece fabric used to form a flatknit bra/bralette, the stitch pattern using a stitch sequence of a front stitch (103), front tuck rear tuck, front tuck rear tuck, front tuck rear tuck, front tuck rear tuck, miss stitch, miss stitch (104), rear stitch (105) as depicted in Figure 21 ;

IX. a stitch pattern suitable for use to form one or more of a bottom band, a wing portion, and an integrated one-piece fabric, the stitch pattern using a stitch sequence of a front stitch, rear stitch, front stitch, rear stitch (130), front tuck, rear stitch, front tuck, rear stitch (131), as depicted in Figure 29;

X. a stitch pattern suitable for use to form one or more of a cradle, wing, a back portion, and an integrated one-piece fabric that creates a flatknit bra/bralette follows a repeating stitch pattern of front stitch (173), front stitch (174), as depicted in Figure 41 ;

XI. a stitch pattern suitable for use to form one or more of a cradle, a back portion, and an integrated one-piece of a flatknit bra/bralette, the stitch pattern using a stitch sequence of a rear stitch, miss stitch, miss stitch, miss stitch (175); Front stitch (176); Miss stitch, miss stitch, rear stitch, miss stitch (177); Front stitch (178), as depicted in Figure 42;

XII. a stitch pattern suitable for use to form one or more of a back portion of a flatknit bra/bralette and an integrated one-piece fabric the stitch pattern using a stitch sequence of a miss stitch, rear stitch, miss stitch, rear stitch, miss stitch (179); Rear stich, miss stitch, rear stitch, miss stitch, rear stitch (180); Miss stitch, rear stitch, miss stitch, rear stitch, miss stitch (181); Rear stitch, miss stitch, rear stitch, miss stitch, rear stitch (182), as depicted in Figure 43;

XIII. a stitch pattern suitable for use to form one or more of an integrated one-piece fabric which forms a flatknit bra/bralette incorporating all aspects of a bottom band, a cradle, a wing and a back portion the stitch pattern using a stitch sequence of a front stitch, rear stitch, rear tuck, rear stitch (183); Rear stitch, front stitch, rear stitch, rear tuck (184), as depicted in Figure 44. 24. The double-knit flat-knit engineered fabric according to any one of Clauses 20 to 22, coupled with non-flatknit fabrics and trims to create a bra/bralette, optionally wherein the flatknit textile is semi-shaped or is fully knit to shape.

In embodiments of the invention, the bra may be a fully knitted bra in one knit to shape panel that includes engineered cups with an integrated cookie pocket and inbuilt zonal structures with four way stretch to offer fit flexibility. As the bra provides fir flexibility, it will give the wearer confidence to “move with me”. That is, to move more freely and trust in the bra to do its job. This may include providing a better unlined breast support and nipple concealment, which may be especially compelling for a plus-size consumer base. The bras disclosed herein may also reduce the bottom band riding up and flipping during movement, and may be comfortable for a prolonged period of over multiple activities. Additionally, the bras disclosed herein may provide comfort with seamless contouring for the backs and sides, which provides a smoothing effect (to eliminate “bra bulges”), which may be considered to be a useful feature, especially for plus size consumers.

In embodiments disclosed herein, where the wings of the bra are finished, then no bra lines will show through the outer wear. That is, the bra will appear to be invisible and smooth to the wearer and observers of the wearer.

Removable cookies may be added to the bras disclosed herein to give the wearer an option to add (or enhance) modesty/nipple concealment. The bras may provide a comfortable support across the entire size range - with the support provided to plus-size consumers being especially good.

Figures

Figures 1 and 44 depict stitch patterns that may be used in areas of the bras disclosed herein. Figures 45 to 48 each depict possible modulus zones in embodiments of bottom bands that may be used in the bras disclosed herein.

Figure 49 schematically depicts modulus zones of a portion of a bottom band underlying the cradle of a bra, as well as the cradle region.

Figures 50 and 51 schematically depict modulus zones of back panels that may be used in embodiments of the invention.

Figures 52 and 53 schematically depict modulus zones that may be present in embodiments of a one-piece portion or bra according to the current invention.

Figure 54 depicts modulus levels in a bra according to the current invention. Figures 55 to 57 depict various bottom bands that may be used in bras disclosed herein.

Figure 58 depicts a bra according to an embodiment of the invention and shows the cradle portion using crosshatching.

Figures 59 to 61 depict various possible arrangements of the cradle modulus zones in embodiments of the current invention.

Figures 62 to 65 depict various possible arrangements of modulus zones used in a flat-knit back panel according to embodiments of the current invention.

Figures 66 to 68 depict various possible arrangements of modulus zones used in a one-piece component that may be used in embodiments of the current invention.

Figure 69 depicts a bra according to the current invention, schematically showing components of the bra.

The knit to shape upper portion of the fabric will be split into three modulus zones as the wing area, the cup area, and the strap area (fig 69). The wing areas of either sides will have the same modulus which is different compared to the cup area and the strap area.

Flat bed or a V-bed knit machine can be used to create flat knitted one piece can be used as a bra component or as a flat knitted fabric to finish an entire bra by attaching the required trims. The one piece can be created as a spacer fabric, interlock fabric, tubular fabric or as a combination of a spacer and an interlock (fig 66, 67,68).

Description

As noted hereinbefore, the current invention relates to a flat knitted fabric that has been fully or partially shaped to create a fabric to be used in a bra/bralette or as a bra component. The fabric may be a single layer knitted fabric with inbuilt zones with different knit structures and modulus zones that provides a four-way stretch to offer fit flexibility. The fabric offers a smooth effect when worn, as well as on-body contouring and support.

The fabric may be a fully shaped or partially shaped unitary panel which may or may not have an anchoring band at the bottom. When used herein the terms “anchoring band” and “bottom band” may be used interchangeably. In embodiments where there is a bottom band present in the flatknit fabric, it can extend into the upper torso area as an engineered fabric. An engineered bottom band may also help to prevent the fabric from riding up when worn. The flatknit fabric or bra-component may be applied to any part of a bra/bralette, such as bra back, wing, cradle or anchoring band and straps; it could also be used to provide the entire bra. The fabric may be a single-layer fabric that replaces and offers seamless integration of different bra components (i.e. this may increase the flexibility afforded to designers and may also reduce or eliminate the need to attach additional components such as cups, bottom band and wing etc. separately to form a bra).

Each fabric described herein may be constructed using different knit structures and stitch sequences. The exact stitch sequences used may depend on the intended use and location of the fabric in a bra. This will be expanded on in more detail hereinbelow.

The flatknit fabric or bra-component may or may not have a three-dimensional fabric surface. This means that the fabric/bra component may have a freestanding internal volume or it may have no such volume to speak of (i.e. just being a flat panel of fabric).

The final product may be finished by assembling the knit component with trims (e.g. bra cups, hook & eye, elastics, sliders etc.) and may or may not be molded to create bra cup volume. The product may be further refined through cut and sew methods, such as stitching, linking or bonding. The knit component may also be finished using wash and dye methods to enhance aesthetic and performance values. The flat knit component may also be created with logo or branding, and this can be placed on the anchoring band, or any other placement based on the requirement.

V bed knitting allows one to create zonal knitting that can create different knit structures and modulus zones, which may be integrated seamlessly together to form a bra/bralette or a bra- component (the latter may be a single component as provided by the processed discussed herein).

As will be discussed in more details hereinbelow, an anchoring band (when present) may have a double knit structure that has more modulus than the other areas of the finished bra. This anchoring band may comprise one or more modulus zones. This offers more stability and support to the wearer. Such an engineered bottom band may also avoid the fabric from riding up especially during movement.

A further advantage to the fabrics and componets (as well as finished bras) discussed herein is that the flatknit engineered fabrics disclosed herein offer unlined breast support and nipple concealment. This may be particularly important for the plus size consumer base.

Additionally, the seamlessly integrated engineered flatknit fabric with multiple modulus zones, different fabric densities, fabric weights, stitch sequences and, different knit structures disclosed herein allow one to create a fabric option that can be integrated with other methods to create a final product that offers fit flexibility, support, enhanced modesty and functionality of an existing product category (i.e. bras). The knit processed disclosed herein may also be used to reduce the number of operations and simplify the assembling process. This will reduce the utilization of trims and also trim fabrics.

The following products or knit components can be created through flat knitting to create a knitted or a hybrid bra.

Area wise description

An embodiment of the invention will now be described by reference to the following areas of a bra that may be formed from the textile element disclosed herein. These areas may be grossly defined as: Bottom band/Anchoring band Cradle Wing portion Back panel One unitary piece

It will be appreciated that one or more of the above components may be formed as a flat knit textile element/fabric as disclosed herein. a. Bottom band/Anchoring band

A flat bed or a V-bed knit machine can be used to create a flat knitted bottom band as a bra component. Said component can be knitted as a double jersey spacer fabric as claimed below using the stitch sequences shown in Figures 55, 56 and 57. This can be knitted using one or more types of a covered nylon yarn.

The bottom band may comprise at least two distinct modulus areas each having different knit loop lengths which changes both laterally and horizontally. This will create a multi modulus bottom band. For example, a first modulus zone of the bottom band may be located at the centre - adjacent to a bra cup region. A second modulus zone may be formed at either side of this central first modulus zone (so is provided as two zones with similar properties), so as to be formed below wing portions of the bra/bralette. The ability to split the bottom band or anchoring band into two or more modulus zones enables the formation of a multi modulus knit fabric. The aforementioned zones may be created by changing the knit loop length horizontally along the x axis and along the y axis vertically. Alternatively, the two zones may be formed by changing the knit loop length both horizontally and vertically.

The bottom band can be formed using one of two different double jersey spacer knit structure options. The first spacer option offers an even fabric surface enabling better on-body comfort, while the second spacer option is formed as a rib-like knit structure that provides a better grip on the wearer’s body and further adds to the aesthetic outcome of the bra/bralette.

The bottom band can also incorporate one or more colours to create a jacquard logo branding or to give additional aesthetic benefits.

Additionally, the bottom band may be formed using an interlock knit structure using both front and back beds.

Furthermore, the bottom band may be created using a tubular knit structure having a hollow core which may be used to insert an elastic or a chord to fasten the bottom band to the wearer’s body.

In addition to the above the bottom band can be formed as a knit to shape knit component as shown in figures 56 or figure 57, the latter being a cut and sewn non-shaped flat knit component. b. Cradle

Flat bed or a V-bed knit machine can be used to create flat knitted cradle as a bra component (fig 58). The cradle may be knitted as a double jersey fabric which can either be a combination of spacer and interlock (fig 59), fully spacer (fig 61) or a fully interlock fabric (fig 60). This can be knitted using one or more types of covered nylon yarn.

The cradle can be broken into two distinct knit zones (as shown in figs 59, 60, 61); one being the bottom band, and the other the adjacent upper portion of the flatknit fabric, which connects the bottom band to the bra cups. Unless otherwise specified herein, when the term “cradle” is used, it is intended to refer to the fabric adjacent to the bottom band that connects the bottom band to the cups. The bottom band may splits into three different modulus zones parallel to the “x” axis and the adjacent upper portion of the fabric may also be split into three different modulus zones parallel to the “x” axis.

The abovementioned three different modulus levels on the bottom band as well as the adjacent upper portion of the flatknit fabric decrease in modulus level as it moves upwards on the “y” axis. The knit loop length of a given modulus zone which changes vertically as mentioned above, will maintain the same horizontally on the “x” axis.

Based on the need to creating aesthetic appeal, double jersey or single jersey structures can be added into this area. These structures will have a different modulus compared to the rest of the fabric. c. Wing (left/right)

A flat bed or a V-bed knit machine can be used to create a flat knitted wing as a bra component. The wing component may be knitted as a double jersey interlock or a spacer fabric which may or may not be knit to shape. In an embodiment where it is knit to shape, the component may carry edge finishing. This can be knitted using one or more types of a covered nylon yarn.

In embodiments where an interlock double jersey fabric is formed as the wing, it can be further divided into two modulus zones which have different knit loop lengths compared to each other. For example, this may split the wing into a top and bottom zone. In this example, the bottom half of the wing portion may have a shorter loop length compared to the top half, meaning that the bottom half of the wing has a higher modulus level than the top half of the wing portion.

Based on the need of creating aesthetic appeal, double jersey or single jersey structures can be added into the wing if desired. These structures will have a different modulus compared to the rest of the fabric. d. Back panel

A flat bed or a V-bed knit machine can be used to create flat knitted back panel as a bra component (fig 62, 63, 64, 65). The back panel may be formed as a double jersey fabric, which can either be: a spacer fabric (fig 62); an interlock fabric (fig 65); a tubular fabric; a combination of a spacer and an interlock; a combination of spacer and tubular structure; or a combination of spacer, interlock and tubular structure

The back panel may or may not be knit to shape. In an embodiment where it is knit to shape, the back panel may carry edge finishing. Depending on the requirement of the desired final bra, the back panel may be knitted as a semi-shaped knit component where edge finishing may be accomplished by attaching a foldable elastic. The back panel can be knitted using one or more types of a covered or uncovered nylon yarn.

The back panel may comprise one or more modulus zones. When there are multiple zones, one zone may be a bottom band, with the other zones formed on a unitary panel above the bottom band, which makes up the rest of the back panel. These modulus zones may be created vertically or horizontally on the unitary panel located above the bottom band. In an embodiment where the back panel is a unitary knit zone, it may be knitted as a double jersey tubular structure with the incorporation of a rib between each two of the plurality of double jersey tubular structures. Each of the modulus zones may be different from one another based on their knit structure type and/or their knit loop length.

As such, the flat knit fabric discussed in (a) to (d) above are formed as components of a fully- formed bra which may be completed by combining other knitted fabrics, moulded cups, elastics and the like. e. One piece

A flat bed or a V-bed knit machine can be used to create flat knitted one piece that can be used as a bra component or as a flat knitted fabric to finish an entire bra by attaching the required trims.

The one piece can be created as a spacer fabric, interlock fabric, tubular fabric or as a combination of a spacer and an interlock (e.g. see figs 66, 67,68).

This fabric may be broadly divided into three different knit modulus zones categorised as bottom band, cup area and the wing portion of a bra/bralette, each of which may carry a combination of double jersey stitch/fabric types. These three broad knit modulus zones can be further divided into fourteen different knit zones (e.g. see figs 52, 53). For example, a first zone may be the bottom band, which has six modulus zones (e.g. see fig 48), which offers better grip and support to the wearer’s body, while a second (cup area) and third (wings) modulus zones may each also further divide into four different knit modulus zones as a result of knit loop length variations.

The adjacent area to the bottom band may or may not carry the same amount of yarn ends or a different number of yarn ends when compared to the wing area on either side of the bra/bralette and the bra cup region.

In an embodiment where the one piece is knitted to shape, the component may carry edge finishing. Depending on the requirements of the desired product, this can be knitted as a semishaped knit component where edge finishing may be accomplished by attaching a foldable elastic.

In certain embodiments, the required volume for encapsulation of the breasts may be created by means of one or more of moulding, incorporating laminated form cups, and by changing the knit loop length in the cup region which invariably creates volume by shrinking the knit loop during the finishing process.

The one-piece can be knitted using one or more types of a covered or uncovered nylon yarn.

Based on the need to creating aesthetic appeal, double jersey or single jersey structures may be added into the one-piece. These structures will have a different modulus compared to the rest of the fabric.

In embodiments where the one-piece is knit to shape, it may have two major knit zones defined as the bottom band and the upper portion. The bottom band as per the previous scenario may be split into three different knit zones horizontally. Furthermore, the bottom band may be be split into two major components: one adjoining to the wing area; and the other adjoining to the cup area. The knit to shape upper portion of the fabric may be split into three modulus zones, such as the wing area, the cup area, and the strap area (e.g. see fig 69). The wing areas at either side of the main body may have the same modulus, which is different compared to the cup area and the strap area. The strap area and the cup area are also different to each other in terms of modulus levels. The flat knit fabric on the cup area may have the highest modulus of the bra component. The flat knit fabric surrounding the breasts of the wearer may be knitted using a knit loop length sequence which gradually lengthens when reaching the highest point of the bra cup. The gradual change of knit loop length creates encapsulation at the bra cup region, and may be further enhanced during the finishing process as and when the knit panel shrinks. The result would be a fabric which has a three-dimensional attribute in the bra cup region.

Modulus Regions

Figure 69 depict various modulus levels that may be present in the flat knit fabric, which may be used as a bra component or as a one-piece flat knit bra/bralette. a. Bottom band/Anchoring band

The bottom band may comprise of two distinct modulus areas each having different knit loop lengths which change laterally and horizontally to create a multi modulus bottom band (e.g. see figs 45, 46, 47, 48). The first modulus zone of the bottom band may be located at the centre adjacent to the bra cup region, while the second modulus zone may be at either side of this region and below the wing portions of the bra/bralette.

Furthermore, the bottom band or anchoring band may be further split into two or more modulus zones to create a multi modulus knit fabric. These aforementioned zones may be created by changing the knit loop length horizontally along the x axis and along the y axis vertically, or by changing it both horizontally and vertically.

The two or more modulus zones on the bottom band of the flatknit fabric may decreases in modulus level as one moves upwards on the “y” axis. The knit loop length of a given modulus zone which changes vertically as mentioned above, will maintain the same horizontally on the “x” axis.

The bottom band may have the highest modulus level when compared to the upper portion of the flatknit fabric. Due to the its high modulus level, which is created through knit, the bottom band will grip the wearer’s body to give a better fit and eliminate the riding up of the fabric (e.g. during normal wear or, particularly, during exercise).

In certain embodiments the bottom band may have six modulus zones, which offer better grip and support to the wearer’s body. As described in the above paragraphs, the bottom band may incorporate four specific ways in which the modulus levels vary. The specific modulus levels that may be suitable for each of the regions identified in, for example, Figures 45, 46, 47 and 48 will now be listed below in Tables 1 , 2, 3 and 4 respectively.

Table 1

Table 2

Table 3 Table 4 b. Cradle

The cradle can be broken into two distinct knit zones; one being the bottom band, and the other the adjacent upper portion of the flat knit fabric. The bottom band further splits into three different modulus zones parallel to the “x” axis; and the adjacent upper portion of the fabric also further carries three different modulus zones parallel to the “x” axis.

Unless otherwise specified herein the term “cradle” will be used to refer to the portion of the cup portion of a bra that is not part of the cups, but lies between the cups and the bottom band

The above-mentioned three different modulus levels on the bottom band as well as the adjacent upper portion of the flatknit fabric may decrease in modulus level as it moves upwards on the “y” axis. The knit loop length of a given modulus zone which changes vertically as mentioned above, will maintain the same horizontally on the “x” axis. That is, in this embodiment, the knit loop length only changes in the vertical direction and not in the horizontal dirtection (e.g. see Fig 49). The bottom band has the highest modulus level when compared to the upper portion of the flatknit fabric. Due to the high modulus zone which is created through knit, the cradle bottom band will grip the wearer’s body to give a better fit and eliminate riding up of fabric.

As described in the above paragraphs, the modulus levels of the cradle may encompass the below listed values, and the regions identified in Figure 49 will now be listed below in Table 5. Table 5 c. Wing (left/right)

The interlock double jersey fabric of the wing can be further divided into two modulus zones which have different knit loop lengths compared to each other. For example, the wing may be split into top and bottom half/zones. The bottom half of the wing portion may have a shorter loop length compared to the top half and as a result, may have a higher modulus level than the top half of the wing portion. The bottom half of the fabric may be further segregated into three modulus zones. They will exist as horizontal zones which has different knit loop lengths vertically along the “y” axis. d. Back panel

The modulus levels in the back panels described hereinbefore may encompass the below listed values, and the regions identified in Figures 50 and 51 will now be listed below in Table 6 and 7 respectively.

Table 6 Table 7

One piece

Specific modulus levels that may be suitable for each of the regions identified in Figures 52 , 53 and 54 will now be listed below in Tables 8, 9 and 10, respectively.

Table 8 Table 9

Table 10

Stitch Nomenclature

In the figures disclosed herein, there may be reference to stitching patterns. The nomenclature used in these patterns is summarised below. Stitch sequences are described according to the knit direction.

A key to the stitch patterns depicted in Figures 1 to 44 may be found in Table 11 .

Table. 11

Bottom band

The anchoring (or bottom) band may be formed from a number of different stitch sequences. FIG 1 depicts a pattern of stitch sequences that make up the bottom band or the anchoring band. The repeating pattern comprises of a front stitch (1), rear stitch, rear stitch, rear stitch, rear stitch, miss stitch, miss stitch (2), rear tuck, front tuck, rear tuck, front tuck, rear tuck, front tuck (3), front stitch, front stitch, front stitch, front stitch, miss stitch, miss stitch (4), rear stitch (5), front tuck, rear tuck, front tuck, rear tuck, front tuck, rear tuck (6).

The anchoring (or bottom) band may be formed from a number of different stitch sequences. FIG 2 depicts a pattern of stitch sequences that make up the bottom band or the anchoring band. The repeating pattern comprises of a front stitch (7), rear stitch (8), front stitch (9), rear stitch (10) rear tuck, front tuck, rear tuck, front tuck (11), front tuck, rear tuck, front tuck, rear tuck (12).

In some embodiments, the flat-knit bottom band zone stitch sequence may comprise of a repeating pattern of front stitch, rear stitch (13), rear stitch, front stitch (14), as depicted in FIG 3. In other embodiments, the flat-knit bottom band zone stitch sequence may comprise of a repeating pattern of front stitch (15), rear stitch (16), front tuck rear tuck (17), rear stitch (18), front stitch (19), front tuck rear tuck (20), as depicted in FIG 4. Additionally, as shown in FIG 5, the flat-knit bottom band zone may include courses formed from a repeating pattern of front stitch, front stitch, rear stitch, rear stitch (21), front stitch, front stitch, rear stitch, rear stitch (22). Alternatively, the flat-knit bottom band zone may include courses formed from a repeating pattern of rear stitch, front stitch (23). Front stitch, miss stitch (24); front stitch, rear stitch (25); miss stitch, front stitch (26), as depicted in FIG 6.

Cradle

The cradle is depicted by the crosshatching in Fig. 58. The cradle may be knitted as a combination of double jersey interlock, double jersey spacer or as a combination of both these knit structures (e.g. see fig 59 and fig 60). wherein the cradle is knitted using the any one of the below listed stitch sequences in a repeating pattern comprising one or more of the following:

I. a miss stitch, miss stitch, rear stitch, rear tuck (27), miss stitch, miss stitch, rear tuck, rear stitch (28), miss stitch, miss stitch, rear stitch, rear tuck (29), miss stitch, miss stitch, rear tuck, rear stitch (30), rear stitch, front stitch, rear stitch, rear tuck (31), front stitch, rear stitch, rear tuck, rear stitch (32), front stitch, front stitch, rear stitch, rear tuck (33), rear stitch, rear stitch, rear tuck, rear stitch (34), front tuck, front stitch, rear stitch, rear tuck (35), front stitch, front tuck, rear tuck, rear stitch (36), rear tuck, rear stitch, rear stitch, rear tuck (37), rear stitch, rear tuck, rear tuck, rear stitch (38), rear stitch, front stitch, rear stitch, rear tuck (39), front stitch, rear stitch, rear tuck, rear stitch (40), miss stitch, miss stitch, rear stitch, rear tuck (41), miss stitch, miss stitch, rear tuck, rear stitch (42), miss stitch, miss stitch, rear stitch, rear tuck (43), miss stitch, miss stitch, rear tuck, rear stitch (44), as depicted in Figure 7;

II. a front stitch, rear stitch, front stitch, rear stitch (45), rear stitch, front stitch, rear stitch, front stitch (46), front stitch, front tuck, front stitch, front tuck (47), rear tuck, rear stitch, rear tuck, rear stitch (48) as depicted in Figure 8;

III. a front tuck, miss stitch, rear tuck, miss stitch (49), front stitch, miss stitch, rear stitch, miss stitch (50), front stitch, miss stitch, rear stitch, miss stitch (51), miss stitch, front tuck, miss stitch, rear tuck (52), miss stitch, front stitch, miss stitch, rear stitch (53), miss stitch, front stitch, miss stitch, rear stitch (54) as depicted in Figure 9. In an embodiment, the stitch sequence for at least a portion of the flat-knit bra wing follows a repeating pattern of a front stitch, miss stitch, front stitch, miss stitch, front stitch (55), miss stitch, rear stitch, miss stitch, rear stitch, miss stitch (56), as depicted in Figure 10.

Back Panel

The back panel may be created as a panel with two different modulus zones as shown in, for example, figs 62, 63, 64, and 65.

For example, the back panel may be formed using one or more of the following stitch sequences:

(a) rear tuck, front tuck (57), front stitch (58), rear stitch, miss stitch (59), front tuck, rear tuck (60), front stitch (61), miss stitch, rear stitch (62), as depicted in Figure 11 ;

(b) miss stitch (63), rear stitch, miss stitch (64), miss stitch, front stitch (65), miss stitch (66), miss stitch, rear stitch (67), front stitch, miss stitch (68) as depicted in Figure 12;

(c) front stitch, rear stitch, rear tuck, rear stitch (69), rear stitch, front stitch, rear stitch rear tuck (70), as depicted in Figure 13; and

(d) front stitch, miss stitch (71), miss stitch, rear stitch (72), rear stitch, miss stitch (73) as depicted in Figure 14.

One Piece

A one-piece fabric may be knitted as a combination of the bottom band/cradle and the wing portion which. The one-piece fabric may be formed as a spacer fabric, interlock fabric, tubular fabric or as a combination of a spacer and an interlock fabric. Alternatively, the one-piece fabric may be formed as a singular knit sequence that changes its knit loop length vertically. At least some of these options are shown in figures 66, 67, and 68. This strategically knitted fabric can be used to create a flatknit bra/bralette.

The one-piece fabric may be knitted using a stitch sequence of front stitch, rear stich, rear stitch, rear tuck (74); Rear stitch, front stitch, rear tuck, rear stitch (75); Front stitch, front stitch, rear stitch, rear tuck (76); Rear stitch, rear stitch, rear tuck, rear stitch (77); Front tuck, front stitch, rear stitch, rear tuck (78); Front stitch, front tuck, rear tuck, rear stitch (79); Rear tuck, rear stitch, rear stitch, rear tuck (80); Rear stitch, rear tuck, rear tuck, rear stitch (81), as depicted in FIG 15.

One piece extension

In some instances the one piece flat knit fabric may be knitted to shape in order to remove additional assembly processes as well as to reduce waste. This may follow a stitch sequence of a front stitch, miss stitch (82). miss stitch, rear stitch (83). miss stitch, rear stitch (84). front stitch, miss stitch (85), as depicted in FIG 16.

Common Stitch Sequences

The below stitch sequences may be used to create a flat-knit bottom band as well as a part of the back panel of a flatknit bra/bralette. The stitch sequence may be a repeating pattern of a front stitch (86), rear stitch (87), rear tuck, front tuck, rear tuck, front tuck (88); Front stitch (89), rear stitch (90), front tuck, rear tuck, front tuck, rear tuck (91), as depicted in FIG 17.

The following stitch pattern may be used to form a band, cradle, back, wing, as well as an integrated one-piece fabric of a flatknit bra/bralette. One or more of the following stitch patterns may be used:

(a) a front stitch, rear stitch (92), rear stitch, front stitch (93), as depicted in Figure 18;

(b) a front stitch (94), rear stitch (95), front tuck rear tuck (96), front stitch (97), rear stitch (98), front tuck rear tuck (99), depicted in Figure 19;

(c) a front stitch (100), front tuck rear tuck (101), rear stitch (102), depicted in Figure 20;

(d) a front stitch (106), rear stitch (107) as depicted in Figure 22;

(e) a front stitch rear stitch (108) as depicted in Figure 23;

(f) a front stitch rear stitch (134), front stitch (135), front stitch (136), front stitch (137), front stitch (138) as depicted in Figure 31 ;

(g) a front tuck rear stitch (141), front stitch (142), front stitch rear tuck (143), rear stitch (144) as depicted in 33; and

(h) a front stitch, rear stitch, front stitch, rear stitch (145), rear stitch, front stitch, rear stitch, front stitch (146), front stitch (147), rear stitch (148) as depicted in Figure In some embodiments, a stitch pattern suitable for use to form one or more of a band, a wing, or an integrated one-piece flat knit fabric may be selected from one or more of the following stitch patterns:

(aa) a front stitch rear stitch (109), front stitch (110), rear stitch (111) as depicted in Figure 24; or

(ab) a front stitch rear stitch (112), rear stitch (113) as depicted in Figure 25.

In some embodiments, one or more of a band, a wing, a back and an integrated one-piece fabric that is used to create a flatknit bra/bralette may be formed using one or more of the following stitch patterns:

(ba) a front stitch (114), rear stitch (115), front tuck rear tuck, miss stitch, front tuck rear tuck, miss stitch (116), front stitch (117), rear stitch (118), miss stitch, front tuck rear tuck, miss stitch, front tuck rear tuck (119) as depicted in Figure 26;

(bb) a front stitch, rear tuck, front stitch, rear tuck (128), front tuck, rear stitch, front tuck, rear stitch (129) as depicted in Figure 28;

(be) a front stitch (165), front tuck rear stitch, rear stitch, front tuck rear stitch, rear stitch (166), front stitch (167), rear stitch, front tuck rear stitch, rear stitch, front tuck rear stitch (168) as depicted in Figure 39;

(bd) a front stitch rear tuck, front stitch, front stitch, front stitch, front stitch rear tuck, front stitch, front stitch (169), front stitch, front stitch, front stitch rear tuck, front stitch, front stitch, front stitch, front stitch rear tuck (170), miss stitch, miss stitch, rear stitch, miss stitch, miss stitch, miss stitch, rear stitch (171), rear stitch, miss stitch, miss stitch, miss stitch, rear stitch, miss stitch, miss stitch (172) as depicted in Figure 40.

In further embodiments, one or more of a bottom band, a back portion, and an integrated one- piece flatknit fabric may be formable from one or more of the following stitch patterns:

(ca) a front stitch, rear stitch (132), rear stitch, front stitch (133) as depicted in 30;

(cb) a rear stitch, front stitch, rear stitch, front stitch (149), miss stitch, rear stitch, miss stitch, rear stitch (150), front stitch, rear stitch, front stitch, rear stitch (151), rear stitch, miss stitch, rear stitch, miss stitch (152) as depicted in Figure 35;

(cc) a front tuck, rear tuck (153), front stitch, rear stitch (154), rear tuck, front tuck (155), rear stitch, front stitch (156) as depicted in Figure 36;

(cd) a rear tuck, front tuck, rear tuck, front tuck (157), front stitch, rear stitch, front stitch, rear stitch (158), front tuck, rear tuck, front tuck, rear tuck (159), rear stitch, front stitch, rear stitch, front stitch (160) as depicted in Figure 37; and (ce) a miss stitch, rear tuck, front tuck, miss stitch (161), miss stitch, rear stitch, miss stitch, rear stitch (162), front tuck, miss stitch, miss stitch, rear tuck (163), front stitch, miss stitch, front stitch, miss stitch (164) as depicted in Figure 38.

The pattern depicted in FIG 27 may be used to form one or more of a bottom band, a cradle and an integrated one-piece flatknit fabric which creates a bra/bralette. The stitch sequence uses repating pattern of a front stitch (120), rear stitch (121), miss stitch (122), front tuck rear tuck, miss stitch, front tuck rear tuck, miss stitch (123), front stitch (124), rear stitch (125), miss stitch (126), miss stitch, front tuck rear tuck, miss stitch, front tuck rear tuck (127).

In an embodiment, the pattern depicted in FIG 32 may be used to form one or more of a bottom band, cradle, wing and an integrated one-piece portion of a flatknit bra/bralette. The stitch sequence uses a repeating pattern of a front stitch, rear stitch, front stitch, rear stitch (139), Front stitch, rear stitch, front stitch, rear stitch (140).

In an embodiment, the pattern depicted in FIG 21 may be used to form one or more of a bottom band and an integrated one-piece fabric used to form a flatknit bra/bralette. The stitch sequence uses a repeating pattern of a front stitch (103), front tuck rear tuck, front tuck rear tuck, front tuck rear tuck, front tuck rear tuck, miss stitch, miss stitch (104), rear stitch (105).

In an embodiment, the pattern depicted in FIG 29 may be used to form one or more of a bottom band, a wing portion and an integrated one-piece fabric. The stitch sequence uses a repeating pattern of a front stitch, rear stitch, front stitch, rear stitch (130), front tuck, rear stitch, front tuck, rear stitch (131).

In an embodiment, the pattern depicted in FIG 41 may be used to form one or more of acradle, wing, back portion and an integrated one-piece fabric that creates a flatknit bra/bralette. The stitch sequence uses a repeating pattern of a front stitch (173), front stitch (174).

In an embodiment, the pattern depicted in FIG 42 may be used to form one or more of acradle, back portion, and an integrated one-piece of a flatknit bra/bralette. The stitch sequence uses a repeating pattern of a rear stitch, miss stitch, miss stitch, miss stitch (175); Front stitch (176); Miss stitch, miss stitch, rear stitch, miss stitch (177); Front stitch (178).

In an embodiment, the pattern depicted in FIG 43 may be used to form one or more of a back portion of a flatknit bra/bralette, and an integrated one-piece fabric. The stitch sequence uses a repeating pattern of a miss stitch, rear stitch, miss stitch, rear stitch, miss stitch (179); Rear stich, miss stitch, rear stitch, miss stitch, rear stitch (180); Miss stitch, rear stitch, miss stitch, rear stitch, miss stitch (181); Rear stitch, miss stitch, rear stitch, miss stitch, rear stitch (182).

In an embodiment, the pattern depicted in FIG 44 may be used to form one or more of an integrated one-piece fabric which forms a flatknit bra/bralette incorporating all aspects of a bottom band, cradle, wing and a back portion. The repeating pattern may be formed as a front stitch, rear stitch, rear tuck, rear stitch (183). Rear stitch, front stitch, rear stitch, rear tuck (184).