RELATED APPLICATIONS

[001] This Patent Cooperation Treaty application claims the benefit of priority of United States Provisional Application 63/341 ,160 filed on May 12, 2022, and Canadian Patent Application No. 3,185,681 filed on December 23, 2022, which are incorporated herein in their entirety.

TECHNICAL FIELD

[002] The present disclosure generally relates to a pantyhose article having ultra-high molecular weight polyethylene (UHMWPE) and a method for manufacturing thereof, and more particularly, to a pantyhose article having multiple different knits, including at least two knits having UHMWPE.

BACKGROUND

[003] T raditional knit fabrics for manufacture of hosiery products (such as pantyhose, stockings, socks, and tights) include nylon in combination with elastane (e.g., Lycra™ of Spandex™). However, these fabrics tend to rip or tear when subjected to frictional forces. It was observed that sheer hosiery products (e.g., 30 denier and below) made using these fibers are very fragile. They can easily be ripped by hand, foot or hang nail, and are generally considered disposable. Therefore, there remains a need for commercially viable sheer (low denier) elastic knits that are not easy to rip.

[004] Ultra-high molecular weight polyethylene (UHWMPE) fiber is considered as an ideal reinforcing component due its high impact strength, low density, low elongation at break, resistance to corrosive chemicals, low moisture absorption, and low coefficient of friction. The knits including UHMWPE fibers in combination with stretch fibers such as Spandex, nylon or polyester have shown increased rip resistance. However, UHMWPE fiber is very expensive, and its quality varies considerably from supplier to supplier and from batch to batch. Lower quality UHMWPE fiber may result in defects, such as yarn ring or barre, which leads to damaged hosiery that cannot be used in inventory and thus becomes waste. [005] Therefore, there remains a need for commercially viable knits for making hosiery that allow utilizing a lower amount, and/or lower grade LIHMWPE fiber while maintaining the desired rip resistance and durability.

SUMMARY

[006] According to one aspect, there is provided a pantyhose article that includes a first tubular member. The first tubular member includes a first panty portion and a first tubular leg portion, the first panty portion extending from a waist end of the pantyhose article to a bottom end of the first panty portion and the first tubular leg portion defining a first leg cavity and extending from a top end thereof, corresponding to the bottom end of the first panty portion, to a first foot end of the first tubular leg portion, the first tubular leg portion comprising a first principal sub-portion and a first transitional sub-portion, the first principal sub-portion extending from a first thigh region of the first tubular leg portion to the first foot end and the first transitional sub-portion extending from the top end of the first tubular leg portion to the first thigh region of the first tubular leg portion, the first principal sub-portion being formed of a first knit comprising a first ultra-high molecular weight polyethylene (UHMWPE) fiber and at least one first companion fiber and the first transitional subportion being formed of a second knit comprising a second UHMWPE fiber and at least one second companion fiber, the first knit being different from the second knit.

[007] According to another aspect, there is provided a method for manufacturing a pantyhose article. The method includes forming a first tubular member having a first panty portion extending from a waist end of the pantyhose article to a bottom end of the first panty portion and a first tubular leg portion defining a first leg cavity and extending from a top end thereof, corresponding to the bottom end of the first panty portion, to a first foot end of the first tubular leg portion, the first tubular leg portion comprising a first principal sub-portion and a first transitional sub-portion, the first principal sub-portion extending from a first thigh region of the first tubular leg portion to the first foot end and the first transitional sub-portion extending from the top end of the first tubular leg portion to the first thigh region of the first tubular leg portion and extending circumferentially about the first tubular leg portion, the first principal sub-portion being formed of a first knit comprising a first ultra-high molecular weight polyethylene (UHMWPE) fiber and at least one first companion fiber and the first transitional sub-portion being formed of a second knit comprising a second LIHMWPE fiber and at least one second companion fiber, the first knit being different from the second knit. The method also includes forming a second tubular member having a second panty portion extending from the top end of the pantyhose article to a bottom end of the second panty portion being aligned with the bottom end of the first panty portion and a second tubular leg portion defining a second leg cavity and extending from a top end thereof, corresponding to the bottom end of the second panty portion, to a second foot end of the second tubular leg portion, the second tubular leg portion comprising a second principal sub-portion and a second transitional sub-portion, the second principal sub-portion extending from a second thigh region of the second tubular leg portion to the second foot end and the second transitional sub-portion extending from the top end of the second tubular leg portion to the second thigh region of the second tubular leg portion and extending circumferentially about the second tubular leg portion, the second principal sub-portion being formed of the first knit comprising the first LIHMWPE fiber and the at least one first companion fiber and the second transitional sub-portion being formed of the second knit comprising the second LIHMWPE fiber and the at least one second companion fiber. The method further includes cutting the first panty portion along a longitudinal direction thereof to form first longitudinal edges therein and cutting the second panty portion along a longitudinal direction thereof to form second longitudinal edges therein, joining the first longitudinal edges of the first panty portion to the second longitudinal edges of the second panty portion to form a panty tube defining a panty cavity for receiving a lower torso of a wearer, the panty cavity being in fluid communication with the first leg cavity of the first tubular leg portion and the panty cavity being in fluid communication with the second leg cavity of the second tubular leg portion, and joining the longitudinal edges of the first panty portion to a first edge of a gusset and joining the longitudinal edges of the second panty portion to a second edge of the gusset.

BRIEF DESCRIPTION OF THE DRAWINGS

[008] The present disclosure is best understood from the following detailed description when read in conjunction with the accompanying drawings. It is emphasized that, according to common practice, the various features of the drawings are not necessarily to scale. On the contrary, the dimensions and spatial relationship(s) of the various features may be arbitrarily enlarged or reduced for clarity. Like reference numerals denote like features throughout specification and drawings.

[009] Figure 1 is a front elevation view of a pantyhose article according to one example embodiment when placed on a quality control apparatus;

[0010] Figure 2 is a top perspective view of an inside of the pantyhose article according to one embodiment when placed on a quality control apparatus;

[0011] Figure 3 is a bottom view of a crotch region of the pantyhose article according to one embodiment when placed on a quality control apparatus;

[0012] Figure 4 is a front elevation view of the pantyhose article according to one example embodiment when worn;

[0013] Figure 5 is a side elevation view of the pantyhose article according to one example embodiment when worn;

[0014] Figure 6 is a rear elevation view of the pantyhose article according to one example embodiment when worn;

[0015] Figure 7 is a bottom view of the pantyhose article according to one example embodiment when worn; and

[0016] Figure 8 is a top view of the pantyhose article according to one example embodiment as if worn.

DETAILED DESCRIPTION

[0017] In the following description, certain specific details are set forth in order to provide a thorough understanding of various embodiments. However, one skilled in the art will understand that the invention may be practiced without these details. In other instances, well-known structures have not been shown or described in detail to avoid unnecessarily obscuring descriptions of the embodiments. Unless the context requires otherwise, throughout the specification and claims which follow, the word “comprise” and variations thereof, such as, “comprises”, “comprising”, “includes” and “including” are to be construed in an open, inclusive sense, that is, as “including, but not limited to.” Further, headings provided herein are for convenience only and do not interpret the scope or meaning of the claimed invention. [0018] Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, the appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. Also, as used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the content clearly dictates otherwise. It should also be noted that the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise. Further, as used in this specification and the appended claim, the term “about” has the meaning reasonably ascribed to it by a person of ordinary skill in the art when used in conjunction with a stated numerical value or range, i.e. , denoting somewhat more or somewhat less than the stated value or range, to within a range of ±20% of the stated value; ±19% of the stated value; ±18% of the stated value; ±17% of the stated value; ±16% of the stated value; ±15% of the stated value; ±14% of the stated value; ±13% of the stated value; ±12% of the stated value; ±11 % of the stated value; ±10% of the stated value; ±9% of the stated value; ±8% of the stated value; ±7% of the stated value; ±6% of the stated value; ±5% of the stated value; ±4% of the stated value; ±3% of the stated value; ±2% of the stated value; or ±1% of the stated value.

Definitions

[0019] As used herein, and unless the context dictates otherwise, the following terms have the meanings as specified below.

[0020] The term “LIHMWPE” stands for ultra-high molecular weight polyethylene, also known as high-modulus polyethylene (HMPE), or high-performance polyethylene (HPPE).

[0021] The term “colored LIHMWPE” means LIHMWPE that has been colored (e.g., made nonwhite) by a non-additive coloring process.

[0022] The term “fiber” as used herein refers to a single origin base material made up of one or more filaments. It has an elongate body, the length dimension of which is much greater than the transverse dimensions of width and thickness. [0023] The term “filament” as used herein refers to a single fibril of material that can be on its own a fiber or can be combined with other filaments to create a multifilament fiber. A single fiber may be formed from just one filament or from multiple filaments.

[0024] The term “microfilament” as used herein refers to a filament having a denier of 5 or less.

[0025] The term “denier” used herein refers to a unit of weight indicating the fineness of fiber filaments. It can be measured in mass in grams per 9,000 meters of fiber. A lower denier indicates a finer fiber, and a higher denier indicates a thicker or heavier fiber.

[0026] The term “decitex (dtex)” as used herein refers to an alternate unit of weight indicating the fineness of fiber filaments. It can be measured in mass in grams per 10,000 meters.

[0027] The term “tensile strength” as used herein relates to the durability of the garment and is measured by the maximum stress that a material can withstand while being stretched or pulled before breaking. It is measured as force per unit area and can be expressed in units of gram force (gf) and centi-newton (cN) per dtex.

[0028] The term “elongation” as used herein refers to the stretch of individual fibers and composite fibers which results in the elasticity of the final embodiment of the present disclosure. Elongation is measured as a percentage of the starting length.

[0029] The term “natural fiber” as used herein refers to class of fibers obtainable from material of natural sources.

[0030] The term “synthetic fiber” as used herein is used to class of fibers made by humans. Synthetic fibers comprise for example polymeric material, synthesized by polymerization of monomers, fibers obtained by regeneration of natural fibers, for instance after dissolution in a solvent, and glass fibers.

[0031] Term “stretch fiber” as used herein refers to class of fibers that, upon application of a force, is stretchable to a stretched at least about 130% of its original dimension without breaking, [0032] The term “non-stretch fiber” refers to class of fibers which is substantially non-elastic with little or no elongation.

[0033] The term “high performance fiber” as used herein refers to class of fibers having high values of tenacity greater, for example greater than 10 g/denier, such that they lend themselves for applications where high abrasion and/or cut resistance is important. Typically, high performance fibers have a very high degree of molecular orientation and crystallinity in the final fiber structure.

[0034] The term "elastomeric fiber" as used herein refers to a fiber which has a break elongation in excess of 100% and which when stretched and released, retracts quickly and forcibly to substantially its original length.

[0035] The term “thermoplastic fiber” as used herein refers to class of fibers obtained from polymer that is plastic or deformable, melts to a liquid when heated and freezes to a brittle, glassy state when cooled sufficiently.

[0036] The term “abrasion resistant fiber” as used herein refers to class of fibers that inhibits abrasion of the material that it is proximate to.

[0037] The term “knit” as used herein refers to the fabric created by combining one or more fibers on a flat or circular knitting machine.

[0038] The term “gauge” as used herein refers to the number of needles on the knitting machine. A high gauge knitting machine (32 gauge and above) is required to produce sheer hosiery like sheer tights, stockings and trouser socks and a low gauge knitting machine (18 to 32 gauge) is used to produce heavier garments like leggings, bodysuits, socks, shirts and other active wear. Gauge is also used to refer to the knit that has been produced by a machine: in other words, a knit made on a 32 gauge machine is a 32 gauge knit.

[0039] The term “plating” as used herein refers to a technique of knitting two fibers together in two distinct layers. Where one fiber stays in the back, behind the front fiber despite being knit in the same stitch.

[0040] The term “serving” as used herein refers to the process of spinning two fibers together to produce a composite fiber.

[0041] The term “non-additive” as used herein refers to coloring, typically dyeing, methods that do not increase the total denier of the fiber.

[0042] “Tensile properties” are properties measured when a material is subjected to stretching forces, and also the properties measured when the stretching forces are removed. Example tensile properties include but are not limited to tensile strength at break, percent elongation to break, modulus of elasticity, toughness or tensile energy to break, permanent set, tensile load at specified elongations, etc. Tensile properties of polymer fibers can be determined for example by standard test methods such as ASTM D2256/D2256M-21 , “Tensile Properties of Yarns by the Single-Strand Method”.

[0043] The term “barre” as used herein is defined as unintentional, repetitive visual of continuous bars or stripes usually parallel to the courses of circular knit fabric.

UHMWPE Fibers

[0044] Various aspects described herein involve UHMWPE fibers for preparing knitted fabrics and methods for forming the same.

[0045] In some embodiments, the UHMWPE fiber has high impact strength, low density, low elongation at break, resistance to corrosive chemicals, low moisture absorption, and/or low coefficient of friction. In other aspects, the material is self-lubricating and highly resistant to abrasion and odor.

[0046] In some embodiments, the UHMWPE fiber has a weight average molecular weight (M _w ) of at least about 200,000. In some embodiments, the UHMWPE fiber has a weight average molecular weight (M _w ) ranging from about 300,000 to about 7,000, 000, from about 700,000 to about 5,000,000, or from about 900,000 to about 4,000,000. A molecular weight distribution of the UHMWPE fiber, that is the ratio of the weight average molecular weight (M _w ) to a number average molecular weight (M _n ) of the UHMWPE fiber is of about 5.0 or less, about 4.0 or less, or about 3.0 or less.

[0047] In some embodiments, the UHMWPE fiber is a monofilament. In some other embodiments, the UHMWPE fiber comprises a plurality of microfilaments. In some embodiments, each of the microfilaments in the UHMWPE has a denier of about 5 of less, about 4 or less, about 3 or less, about 2.5 or less, about 2 or less, about 1 .5 or less, about 1 or less, or about 0.5 or less. [0048] The UHMWPE fiber may include any suitable number of microfilaments. In some embodiments, the UHMWPE fiber comprises 2 to 400 microfilaments, 10 to 300 microfilaments, 10 to 50 microfilaments, 5 to 50 microfilaments, 5 to 25 microfilaments, or 20 to 200 microfilaments. In some embodiments, the UHMWPE fiber comprises 5, 7, 10, 15, 20, 25, 30, 35, 40, 45, or 50 microfilaments.

[0049] The UHMWPE fiber may be of any denier suitable for pantyhose. In some embodiments, the UHMWPE fiber has a denier ranging from about 10 to about 250. In some embodiments, the LIHMWPE fiber has a denier ranging from about 10 to about 60. In some embodiments, the LIHMWPE fiber has a denier of about 10, about 15, about 20, about 25, about 30, about 40, about 50, about 60, about 70, about 75, about 80, about 90, about 100, about 110, about 120, about 125, about 130, about 140, about 150. In some embodiments, the LIHMWPE fiber has a denier of 50 or less.

[0050] In some embodiments, the LIHMWPE fiber is a high strength fiber. In some embodiments, the LIHMWPE fiber has a tensile strength (i.e. , tenacity) of at least 20 cN/dtex, at least 25 cN/dtex, at least about 30 cN/dtex, at least about 35 cN/dtex, at least about 40 cN/dtex, at least about 45 cN/dtex, at least about 50 cN/dtex, or at least about 60 cN/dtex. In some embodiments, the LIHMWPE fiber has a tensile strength of about 26 cN/dtex, about 28 cN/dtex, about 30 cN/dtex, about 32 cN/dtex, about 36 cN/dtex, about 40 cN/dtex, about 45 cN/dtex, or about 50 cN/dtex.

[0051] In some embodiments, the LIHMWPE fiber has a modulus of about 1000 cN/dtex or greater, about 1100 cN/dtex or greater about 1200 cN/dtex or greater, about 1300 cN/dtex or greater, about 1400 cN/dtex or greater, about 1500 cN/dtex or greater, about 1600 cN/dtex or greater. In some embodiments, the LIHMWPE fiber has a modulus of about 1400 cN/dtex, about 1420 cN/dtex, about 1450 cN/dtex, about 1500 cN/dtex, or about 1360 cN/dtex.

[0052] In some embodiments, the LIHMWPE fiber allows an elongation of no more than about 10%, no more than about 8%, no more than about 5%, no more than about 4 %, no more than about 3.5%, no more than about 3%, no more than about 2.5%, no more than about 2%, or no more than about 1 .5%.

[0053] In some embodiments, the LIHMWPE fiber has a breaking force of about 10 N or greater, about 11 N or greater, about 12 N or greater, about 13 N or greater, about 14 N or greater, about 15 N or greater, about 16 N or greater, about 18N or greater, or about 20 N or greater.

[0054] In some embodiments, the LIHMWPE fiber has a breaking work of at least about 100 N mm, at least about 110 N mm, at least about 120 N mm, at least about 130 N mm, at least about 140 N mm, at least about 150 N mm, at least about 160 N mm, or at least about 170 N mm.

[0055] In some embodiments, the LIHMWPE fiber is a colored LIHMWPE fiber comprising a dye. In some embodiments, the dye has a color selected from black, blue, grey, red, blue, brown, yellow, green, orange, and nude. [0056] In some embodiments, the LIHMEPE fiber comprises multiple microfilaments which are not twisted. In some other embodiments, to keep the filaments together and to increase strength and reduce pilling, the LIHMWPE fiber is twisted. In some embodiments, the LIHMWPE fiber has a twists per inch (TPI) between 1 to 30, between 1 to 20, between 1 to 10, between 1 to 5, between 4 and 25, between 6 and 20, or between 8 and 16. In some embodiments, the LIHMWPE fiber has a TPI of 1. In some embodiments, the LIHMWPE fiber has a TPI of 2. In some embodiments, the LIHMWPE fiber has a TPI of 3. In some embodiments, the LIHMWPE fiber has a TPI of 4. In some embodiments, the LIHMWPE fiber has a TPI of 5. In some embodiments, the LIHMWPE fiber has a TPI of 6. In some embodiments, the LIHMWPE fiber has a TPI of 8. In some embodiments, the LIHMWPE fiber has a TPI of 10. In some embodiments, the LIHMWPE fiber has a TPI of 12. In some embodiments, the LIHMWPE fiber has a TPI of 15. In some embodiments, the LIHMWPE fiber has a TPI of 16. In some embodiments, the LIHMWPE fiber has a TPI of 18. In some embodiments, the LIHMWPE fiber has a TPI of 20. In some embodiments, the LIHMWPE fiber has a TPI of 25. In some embodiments, the LIHMWPE fiber has a TPI of 30.

[0057] In various aspects, the LIHMWPE fibers described herein can be produced according to methods described in U.S. publication no. US20220056620.

[0058] In some embodiments, the UHMWPE fiber has a variation of the color along the length of said UHMWPE fiber. In some embodiments, a variation of the color along the length of the UHMWPE fiber is less than ±2.5%, less than ±3%, less than ±3.5%, less than ±4%, less than ±5%, less than ±6%, less than ±7%, less than ±8%, or less than ±9%, or less than ±10%.

[0059] The use of UHMWPE fiber provides benefits to knit such as cooling effect, light weight, moisture wicking, and/or antimicrobial. The tensile properties of the UHMWPE fiber also provide increased resistance to ripping, snagging or otherwise wearing out or failing of the knit. In some embodiments, the UHMWPE fiber has a variation of the denier along the length of said UHMWPE fiber. In some embodiments, a variation of the denier along the length of said UHMWPE fiber is less than ±2.5%, less than ±3%, less than ±3.5%, less than ±4%, less than ±5%, less than ±6%, less than ±7%, less than ±8%, or less than ±9%, or less than ±10%. In some embodiments, the UHMWPE fiber has a variation of the diameter along the length of said UHMWPE fiber is less than ±2.5%, less than ±3%, less than ±3.5%, less than ±4%, less than ±5%, less than ±6%, less than ±7%, less than ±8%, or less than ±9%, or less than ±10%. In some embodiments, the LIHMWPE fiber has a cross sectional shape substantially resembling a circle. In some embodiments, the LIHMWPE fiber has a cross sectional shape substantially resembling an oval. In some embodiments, the LIHMWPE fiber has a cross sectional shape substantially resembling a stadium. In some embodiments, the LIHMWPE fiber has a cross sectional shape substantially resembling an ellipse. In some embodiments, the LIHMWPE fiber has a cross sectional shape which remains substantially constant along the length of the fiber.

[0060] The amount of the LIHMWPE fiber in the knit may be in the range of from about 10% by weight to about 90% by weight based on the total amount of fibers in the knit. In some embodiments, the amount of the LIHMWPE fiber in the knit ranges from about 15% by weight to about 80% by weight, from about 20% by weight to about 80% by weight, from about 30% by weight by weight to about 70% by weight or from about 40% by weight to about 60% by weight.

[0061] In some embodiments, the knit comprises a plurality of LIHMWPE fibers. Each of the LIHMWPE fibers includes multiple microfilaments, each of the microfilaments having a denier of 5 or less. Each of the LIHMWPE fibers may comprise 50 or less microfilaments.

[0062] The companion fiber is selected to enhance a property of the knit, such as, but not limited to, the comfort, durability, dyeability/printability, and/or stretchability of the knit. In some embodiments, the companion fiber comprises a single fiber. In some other embodiments, the companion fiber comprises a plurality of fibers.

[0063] The companion fiber may be a synthetic fiber, a natural fiber, a stretch fiber, a non-stretch fiber, a high performance fiber, an elastomeric fiber, a thermoplastic fiber, or an abrasion resistant fiber, or a combination of any of the foregoing fibers.

[0064] In some embodiments, the companion fiber comprises a synthetic fiber. Examples of organic synthetic fibers include those made of: polyolefin such as polyethylene, polypropylene, high molecular weight polypropylene, LIHMWPE, polybutylene and the like; polyamide such as nylon; polyester such as polyethylene terephthalate, polyethylene naphthalate, poly(ethylene succinate), polymethyl methacrylate; 1 ,2-polybutadiene; and copolymers of these polymers.

[0065] In some embodiments, the companion fiber comprises a natural fiber. Examples of natural fibers include cotton, silk, wool and the like. [0066] In some embodiments, the companion fiber comprises a stretch fiber. Examples of stretch fibers include those made of polyurethane, polyolefin such as low molecular weight polyethylene or polypropylene, and the like.

[0067] In some embodiments, the companion fiber comprises a non-stretch fiber. Examples of non-stretch fibers include those made of or comprising polyester, cotton, nylon, rayon, and/or wool.

[0068] In some embodiments, the companion fiber comprises a high performance fiber. Examples of high performance fibers include high molecular weight high molecular weight polypropylenes, aramids, high molecular weight polyvinyl alcohols, high molecular weight polyacrylonitriles, and liquid crystal polyesters.

[0069] In some embodiments, the companion fiber comprises an elastomeric fiber. Examples of elastomeric fibers include spandex (also called elastane), lastol, polyurethane, and polyetherester.

[0070] In some embodiments, the companion fiber comprises a thermoplastic fiber. Examples of thermoplastic fibers include those made of polyamides, polyimides, polyurethanes, polyolefins, polystyrenes, aromatic polyesters, polycarbonates, polyketones, polyureas, polyvinyl resins, polyacrylates, and polymethacrylates.

[0071] In some embodiments, the companion fiber comprises an abrasion resistant fiber. Examples of abrasion resistant fibers include those made of nylon, polyesters and polyamides.

[0072] The companion fiber may include any suitable number of microfilaments. In some embodiments, the companion fiber comprises 2 to 400 microfilaments, 10 to 300 microfilaments, 10 to 200 microfilaments, 10 to 150 microfilaments, 10 to 100 microfilaments, 10 to 50 microfilaments, 5 to 50 microfilaments, or 20 to 200 microfilaments.

[0073] The companion fiber may be of any denier suitable for pantyhose. In some embodiments, the companion fiber has a denier ranging from about 2 to about 100, from about 5 to about 100, from about 10 to about 100, or from about 15 to about 100. In some embodiments, the companion fiber has a denier of about 5, about 10, about 13, about 15, about 17, about 20, about 25, about 30, about 50, about 60, about 70, about 80, or about 90. In instances where the knit comprises a plurality of companion fibers, the plurality of companion fibers may have the same or different deniers from each other. [0074] In some embodiments, the companion fiber allows an elongation of greater than 100%. In some embodiments, the companion fiber has an elongation of about 130% or greater, about 200% or greater, about 300% or greater, or about 400% or greater.

[0075] In some embodiments, the companion fiber is a colored fiber comprising a dye. In some embodiments, the companion fiber has black, blue, grey, red, blue, brown, yellow, green, orange, or nude color. In some embodiments, the companion fiber is white. In some embodiments, the companion fiber has a same color as the LIHMWPE fiber. In some other embodiments, the companion fibers have a different color from the LIHMWPE fiber.

[0076] The knit has a high dimensional stability. In some embodiments, the dimension dimensional stability of the knit in each of a length direction and a width direction is of about ±6%, about ±4%, about ±2%, about ±1 %, or about ±0.5%.

[0077] In some embodiments, the knit has a denier of about 150 or less, about 120 or less, about 100 or less, about 80 or less, about 60 or less, about 50 or less, about 40 or less or about 30 or less. For example, the knit has a denier between 10 and 200, between 20 and 100, between 20 and 50, between 10 and 40 or between 20 and 40.

Methods for manufacturing a pantyhose article comprising UHMWPE

[0078] In another aspect, methods of producing the knits described above are provided. The knit of the present disclosure is produced by knitting the UHMWPE fiber and the companion fiber using a knitting machine. The appropriate gauge of the knitting machine is selected according to the type of pantyhose. The gauge number of the knitting machine can affect the stretchability and basis weight of the resulting knit. The knit may have a gauge ranging from 10 to 40. In some other embodiments, the knit has a gauge ranging from 28 to 32 suitable for producing a knit for pantyhose or sheer hosiery. In some embodiments, the knit may have a gauge of at least 32.

[0079] In some embodiments, a knitting machine of a single knit type is used. The cylinder size of the knitting machine is selected according to the end use of the knit. In some embodiments, the knitting machine has a cylinder having a size from about 3 inches to about 14 inches, about 10 to about 14 inches, or about 3 inches to about 7 inches suitable for producing a knit for pantyhose. In some embodiments, no cylinder is used. [0080] In knitting the fabric of the present disclosure, one can use a conventional knitting machine as a base. The knitting machine can have any desired number of feeds, depending on the number needed to cover the number of fiber types being knitted and the speed at which the knitting will occur. Typically knitting machines have 2, 4, or 8 feeds, with the most common being 4 or 8 feeds. In some embodiments, knitting machines can be used with more than 8 feeds. In some embodiments, knitting machines can be used with more than 16 feeds. In one embodiment of the present disclosure, the garment is made using a four feed hosiery knitting machine. In knitting the garments of the present disclosure, each feed can use fibers having deniers ranging from 10 to 50 denier. The total denier of the fibers making up the garment can be any desired, depending on the weight of pantyhose to be produced and the level of sheerness desired. In some embodiments, all of the feeds are used. In some embodiments, only 1 feed is used. In some embodiments, only 2 feeds are used. In some embodiments, only 3 feeds are used. In some embodiments, the same LIHMWPE fibers with the same properties and the same variations in properties are used on all feeds. In some embodiments, the same LIHMWPE fibers with the same properties and different variations in properties are used on all feeds. In some embodiments different LIHMWPE fibers with different properties and different variations in properties are used on all feeds. In some embodiments different LIHMWPE fibers with different properties and the same variations in properties are used on all feeds.

[0081] In some embodiments, the knitting machine can be fitted with tensioners to maintain constant tension on each of the fiber feeds. In some embodiments, the tension is constant along the length of the individual fiber feed. In some embodiments, the tension is constant along the length of each of the individual fiber feeds is constant. In some embodiments, the variation in the tension along the length of the LIHMWPE fiber feed is less than ±2.5%, less than ±3%, less than ±3.5%, less than ±4%, less than ±5%, less than ±6%, less than ±7%, less than ±8%, or less than ±9%, or less than ±10%. In some embodiments, the variation in the tension between the different LIHMWPE fiber feeds is less than ±2.5%, less than ±3%, less than ±3.5%, less than ±4%, less than ±5%, less than ±6%, less than ±7%, less than ±8%, or less than ±9%, or less than ±10%.

[0082] In order to effectively achieve stretch in the final knit without compromising the strength properties provided by the LIHMWPE fiber, the knitting of the LIHMWPE fiber and the companion fiber includes plating or serving of the LIHMWPE fiber and companion fiber. [0083] In some embodiments, to effectively achieve stretch in the final knit without compromising the strength properties provided by the LIHMWPE fiber, the LIHMWPE fiber and the companion fiber are knitted to form a plated knit structure. In knitting the plated knit, a LIHMWPE fiber is required on every course of the knit and a companion fiber can be on every course or every other course. In some embodiments, the plated knit comprises the LIHMWPE fiber on each course and the companion fiber on at least every other course and has a denier not exceeding 30. In some embodiments, the plated knit comprises the LIHMWPE fiber on each course and the companion fiber on at least every other course and has a denier not exceeding 40. In some embodiments, the plated knit comprises the LIHMWPE fiber on each course and the companion fiber on at least every other course and has a denier not exceeding 50. In some embodiments, the plated knit comprises the LIHMWPE fiber on each course and the companion fiber on at least every other course and has a denier not exceeding 60. In some embodiments, the plated knit comprises the LIHMWPE fiber on each course and the companion fiber on at least every other course and has a denier of about 20, about 25, about 30, about 35, about 40, about 45, about 55, about 55, or about 65. After the knitting process, one side of the knit exposes the LIHMWPE fiber more prominently, and the companion fiber is exposed on the other side.

[0084] In some other embodiments, to effectively achieve stretch in the final knit without compromising the strength properties provided by the LIHMWPE fiber, the LIHMWPE fiber and the companion fiber are twisted to form a composite fiber. This twisting forms a served composite fiber. In some embodiments, the LIHMWPE fiber and the companion fiber are twisted between 100 and 4500 twists per meter (TPM). A higher number of twists per meter may be desired to ensure more stretch in the end product, and increased durability in the final knit as it results in a larger surface area of the companion fiber being reinforced with the LIHMWPE fiber. In some embodiments, the LIHMWPE fiber and the companion fiber have a TPM of 100, the LIHMWPE fiber and the companion fiber have a TPM of 500, the LIHMWPE fiber and the companion fiber have a TPM of 1000, the LIHMWPE fiber and the companion fiber have a TPM of 1500, the LIHMWPE fiber and the companion fiber have a TPM of 2000, the LIHMWPE fiber and the companion fiber have a TPM of 2500, the LIHMWPE fiber and the companion fiber have a TPM of 3000, the LIHMWPE fiber and the companion fiber have a TPM of 3500, the LIHMWPE fiber and the companion fiber have a TPM of 4000, the LIHMWPE fiber and the companion fiber have a TPM of 4500. In some embodiments, the LIHMWPE fiber and the companion fiber have a TPM between 2 and 100. In some embodiments, the LIHMWPE fiber and the companion fiber have a twist per inch (TPI) of 3, a TPI of 5, a TPI of 10, a TPI of 15, a TPI of 20, a TPI of 25, a TPI of 30, a TPI of 40, or a TPI of 50.

[0085] In some embodiments, the knit is produced using a LIHMWPE fiber and a nylon covered spandex fiber as the companion fiber. Both the LIHMWPE fiber and the companion fiber may be textured or flat. In some embodiments, the nylon has a denier ranging from 1 to 20. In some embodiments, the nylon has a denier ranging from 5 to 20. In some embodiments, the nylon is a multifilament fiber including 5 to 16 microfilaments. In some embodiments, the nylon covered spandex fiber is formed by covering a monofilament spandex fiber having a denier of 17 with a nylon fiber containing 5 to 20 microfilaments and having a denier ranging from 1 to 20. In some embodiments, the knit has a course alternating between the LIHMWPE fiber and the nylon covering spandex fiber, in which the spandex fiber is a monofilament fiber having a denier of 40 and the nylon fiber is a multifilament fiber containing 7 microfilaments and having a denier of 20. In some embodiments, the resulting knit has a denier ranging from 15 to 60. In some embodiments, the resulting knit has a denier of about 40.

[0086] In some embodiments, the knit is produced using a LIHMWPE fiber and a nylon fiber. The nylon fiber is a multifilament fiber containing 40 microfilaments and having a denier of 40.

Pantyhose articles comprising UHMWPE

[0087] In one aspect, the present disclosure provides a pantyhose article. Referring to Figure 1 , therein is a front elevation view of a pantyhose article 1 according to one example embodiment when placed on a quality control apparatus. The quality control apparatus typically has two panel members spaced apart from one another, each panel member receiving a respective leg member of a pantyhose article under quality control testing. The leg members being stretched over the panel members allow a visual inspection of the quality of leg members of the pantyhose article. The body member of the pantyhose article is also stretched between the panel members of the quality control apparatus, which also allows for a visual inspection of the quality of the body member of the pantyhose. [0088] Figures 4, 5, 6, 7, and 8 show a front elevation view, side elevation view, rear elevation view, bottom view and top view, respectively, of the pantyhose article 1 according to the example embodiment when worn. When worn, knits of the pantyhose article 1 are stretched according to the silhouette of the wearer.

[0089] The pantyhose article 1 comprises first and second tubular members 8 and 16, and a gusset 24, which are appropriately joined together to form the pantyhose article 1.

[0090] The first tubular member 8 extends from a waist end 40 of the pantyhose article 1 to a foot end 48 of the first tubular member 8.

[0091] In the embodiment illustrated in Figures 1 , 4, 5, 6, 7 and 8, the first tubular member 8 corresponds to a right side of the pantyhose article 1 , but it will be understood that the actual side (left or right) will depend on the direction at which the pantyhose article 1 is worn. In various embodiments, the pantyhose article 1 is directionless in that the first tubular member 8 can be interchangeably worn on the left leg or right leg. Similarly, according to such embodiments, the second tubular member 16 can be interchangeably worn on the left leg or right leg.

[0092] The first tubular member 8 includes a plurality of portions corresponding to different knits of the first tubular member 8. The first tubular member 8 includes a first panty portion 56 that extends from the waist end 40 of the pantyhose article 1 to a bottom end 64 of the first panty portion 56. The first panty portion 56 can include at least one waist band 44 at the waist end 40 for ensuring a snug fit when the pantyhose article 1 is worn.

[0093] According to the embodiment illustrated in Figures 1 , 4, 5, 6, 7 and 8, the bottom end 64 of the first panty portion 56 substantially corresponds to a crotch region of the pantyhose article 1 along a lengthwise direction 72 thereof.

[0094] In another embodiment, the bottom end 64 of the first panty portion 56 is located along a lengthwise direction 72 that is lower (i.e. , closer towards the foot end 48) than the crotch region of the pantyhose article 1 .

[0095] The first tubular member 8 also includes a first tubular leg portion 80 that extends from a top end 88 thereof to the first foot end 48 of the first tubular member 8. The top end 88 of the first tubular leg portion 80 corresponds to the bottom end 64 of the first panty portion 56. The first tubular leg portion 80 of the first tubular member 56 defines a first leg cavity 92 (Figures 2, 8). [0096] According to one embodiment, the first foot end 48 of the first tubular member 8 can be closed, such as ending in a closed sock, as illustrated in Figures 1 , 4, 5, and 6. In another embodiment, the first foot end 48 of the first tubular member 8 can have an opening, such as a footless pantyhose, such that the first foot end 48 is located proximate the ankle of the wearer when the pantyhose article 1 is worn. In yet another embodiment, the first foot end 48 of the first tubular member 8 can be partially open, such as a having loop member (ex: stirrup, toe strap) for holding the first tubular member 8 in place when worn but otherwise leaving the foot of the wearer at least partially exposed.

[0097] The pantyhose article 1 also includes a second tubular member 16 extending from the waist end 40 of the pantyhose article 1 to a foot end 104 of the second tubular member 16.

[0098] The second tubular member 16 includes a plurality of portions corresponding to different knits of the second tubular member 16. The second tubular member 16 includes a second panty portion 112 that extends from the waist end 40 of the pantyhose article 1 to a bottom end 120 of the second panty portion 112. The bottom end 120 of the second panty portion 112 can be substantially aligned with the bottom end 64 of the first panty portion 56. The second panty portion 112 can also include at least one waist band for ensuring a snug fit when the pantyhose article 1 is worn. The waist band can be the same as the waist band 44 of the first tubular member 8.

[0099] According to the embodiment illustrated in Figures 1 , 4, 5 and 6, the bottom end 120 of the second panty portion 112 substantially corresponds to a crotch region of the pantyhose article 1 along the lengthwise direction 72 thereof. In another embodiment, the bottom end 120 of the first panty portion 112 is located along a lengthwise direction 72 that is lower (i.e., closer towards the foot end 104) than the crotch region of the pantyhose article 1.

[00100] The second tubular member 16 also includes a second tubular leg portion 128 that extends from a top end 136 thereof to the second foot end 104 of the second tubular member 16. The top end 136 of the second tubular leg portion 128 corresponds to the bottom end 120 of the second panty portion 112. The second tubular leg portion 128 of the second tubular member 16 defines a second leg cavity 138 (Figures 2, 8).

[00101] According to one embodiment, the second foot end 104 of the second tubular member 16 can be closed, such as ending in a closed sock, as illustrated in Figures 1 , 4, 5 and 6. In another embodiment, the second foot end 104 of the second tubular member 16 can have an opening, such as a footless pantyhose, such that the second foot end 104 is located proximate the ankle of the wearer when the pantyhose article 1 is worn. In yet another embodiment, the second foot end 104 of the second tubular member 16 can be partially open, such as having a loop member (ex: stirrup, toe strap) for holding the second tubular member 16 in place when worn but otherwise leaving the foot of the wearer at least partially exposed.

[00102] According to one embodiment, and as illustrated in Figures 1 , 4, 5 and 6, the first tubular leg portion 80 of the first tubular member 8 includes a first principal sub-portion 140 and a first transitional sub-portion 148. The first principal sub-portion 140 extends from a first thigh region 156 of the first tubular leg portion 80 to the first foot end 48 of first tubular member 8 of the pantyhose article 1. The first transitional sub-portion 148 extends between the bottom end 64 of the first panty portion 56 and the upper end of the first principal sub-portion 140. More particularly, the first transitional sub-portion 148 extends from the top end 88 of the first tubular leg portion 80 to the first thigh region 156 of the first tubular leg portion 80. It will be appreciated that the top end of the first transitional sub-portion 148 corresponds to the top end 88 of the first tubular leg portion 80, which also corresponds to the bottom end 64 of the first panty portion 56.

[00103] According to one embodiment, and as illustrated in Figures 1 , 4, 5 and 6, the second tubular leg portion 128 of the second tubular 16 member has a configuration that corresponds to that of the first tubular leg portion 80. The second tubular leg portion 128 of the second tubular member 16 includes a second principal sub-portion 160 and a second transitional sub-portion 164. The second principal sub-portion 160 extends from a second thigh region 168 of the second tubular leg portion 128 to the second foot end 104 of second tubular member 16 of the pantyhose article 1 . The second transitional sub-portion 164 extends between the bottom end 120 of the second panty portion 112 and the upper end of the second principal sub-portion 160. More particularly, the second transitional sub-portion 164 extends from the top end 136 of the second tubular leg portion 128 to the first thigh region 168 of second tubular leg portion 128. It will be appreciated that the top end of the second transitional sub-portion 164 corresponds to the top end 136 of the second tubular leg portion 128, which also corresponds to the bottom end 120 of the second panty portion 112. [00104] Longitudinal edges 172 of the first panty portion 56 are joined to respective longitudinal edges 180 of the second panty portion 112 to form a panty tube 188 that defines a panty cavity 196 (Figure 2). The edges 172 and 180 can be joined by sewing.

[00105] Figure 2 is a top perspective view of an inside of the pantyhose article 1 according to one embodiment when placed on a quality control apparatus. Figure 8 is a top view of the pantyhose article 1 according to one embodiment as if worn (the pantyhose article 1 is shown in a stretched state as if worn, but the body of the wearer is not shown for greater clarity). The panty cavity 196 is in fluid communication with the first leg cavity 92 defined by the first tubular leg portion 80 and is also in fluid communication with the second leg cavity 138 defined by the second tubular leg portion 128.

[00106] When the pantyhose article 1 is worn, the panty cavity 196 receives a lower torso of the wearer. The first leg cavity 92 receives a first leg (ex: right leg) of the wearer and the second leg cavity 138 receives a second leg (ex: left leg) of the wearer.

[00107] A lower region of longitudinal edges 172 of the first panty portion 56 (i.e. the region closer to the bottom end 64 of the first panty portion 56) are further joined to, such as by sewing, a corresponding lower region of longitudinal edges 180 of the second panty portion 112 (i.e. the region close to the bottom end 120 of the second panty portion 112) via the gusset 24. In this way, at least one edge of the bottom end 64 of the first panty portion 56 is joined to, such as by sewing, the gusset 24 and at least one edge of the bottom end 120 of the second panty 112 is also joined to, such as by sewing, the gusset 24.

[00108] Referring now to Figure 3, therein illustrated is a bottom view of the crotch region of the pantyhose article 1 according to one embodiment when placed on a quality control apparatus. Figure 7 is a bottom view of the pantyhose article according to one embodiment when worn. A first bottom edge 204 of the first panty portion 56 is directly joined (ex: directly sewn) to a first edge 212 at a first end of the gusset 24, a second bottom edge 220 of the first panty portion 56 is directly joined (ex: directly sewn) to a first edge 228 at a second end of the gusset 24, a first bottom edge 236 of the second panty portion 112 is directly joined (ex: directly sewn) to a second edge 244 at the first end of the gusset 24 and a second bottom edge 252 of the second panty portion 112 is directly joined (ex: directly sewn) to the second edge 262 at the second end of the gusset 24. [00109] According to the embodiment illustrated in Figures 1 to 8, in which the bottom ends 64 and 120 of the first and second panty portions 56, 112 substantially correspond to a crotch region of the pantyhose article 1 , the first transitional sub-portion 148 is directly joined to the gusset 24 and the second transitional sub-portion 164 is also directly joined to the gusset 24. As best shown in Figure 3, an intermediate region 268 of the first edge of the gusset 24 (corresponding to the portion of the edge located between the first edge 212 at the first end and the first edge 228 at the second end of the gusset 24) is directly joined (ex: directly sewn) to a portion of an edge 276 of the first transitional sub-portion 148. The joined portion can be at the top edge 88 of the first transitional sub-portion 148. Furthermore, an intermediate region 284 of the second edge of the gusset 24 (corresponding to the portion of the edge located between second edge 244 at the first end and the second edge 260 at the second edge of the gusset 24) is directly joined (ex: directly sewn) to a portion of an edge 292 of the second transitional subportion 164. The joined portion can be at the top edge 136 of the second transitional sub-portion 164. Accordingly, the first panty portion 56, the second panty portion 112, the gusset 24, the first transitional sub-portion 148 and the second transitional sub-portion 164 are appropriately joined to close out (i.e., ensuring no openings or gaps) the crotch region of the pantyhose article 1 and to enclose the panty cavity 196.

[00110] According to an alternative embodiment in which the bottom end 64 of the first panty portion 56 and the bottom end 120 of the second panty portion 112 are both located along the lengthwise direction 72 that is lower than the crotch region of the pantyhose article 1 , a first side of the gusset 24 is directly joined (ex: directly sewn) to corresponding regions of the longitudinal edges 172 of the first panty portion 56 and a second side of the gusset 24 is directly joined (ex: directly sewn) to corresponding regions of the longitudinal edges 180 of the second panty portion 112 to close out (i.e. ensuring no openings or gaps) the crotch region of the pantyhose article 1 and to enclose the panty cavity 196. According to the alternative embodiment, top edges 88, 136 of the first and second leg portions 80 and 128 are not directly joined (ex: directly sewn) to the gusset 24.

[00111] According to the embodiment illustrated in Figures 1 to 8, the thigh region 156 of the principal sub-portion 140, corresponding to the bottom end of first transitional sub-portion 148, is located at a mid-thigh region of the first tubular leg portion 80, which corresponds to a mid-thigh region of the first leg of the wearer when the pantyhose article 1 is worn. Accordingly, the transitional sub-portion 148 extends from a crotch region of the pantyhose article 1 to the midthigh region of the first tubular leg member 8. Second transitional sub-portion 164 also extends along corresponding regions of the second tubular leg member 16.

[00112] According to another embodiment, the thigh region 156 of the principal sub-portion 140 is located at an upper thigh region of the first tubular leg portion 80, which corresponds to an upper thigh region of the first leg of the wearer when the pantyhose article 1 is worn. Accordingly, the transitional sub-portion 148 extends from a crotch region of the pantyhose article 1 to the upper thigh region of the first tubular leg member 8. Second transitional sub-portion 164 also extends along corresponding regions of the second tubular leg member 16.

[00113] According to yet another example, the thigh region 156 of the principal sub-portion 140 is located at a lower thigh region of the first tubular leg portion 80 (i.e., in proximity of a knee region), which corresponds to a lower thigh region of the first leg of the wearer when the pantyhose article 1 is worn. Accordingly, the transitional sub-portion 148 extends from a crotch region of the pantyhose article 1 to the lower thigh region of the first tubular leg member 8. Second transitional sub-portion 164 also extends along corresponding regions of the second tubular leg member 16.

[00114] According to yet another embodiment, the bottom end 64 of the first panty portion 56, corresponding to a top end 88 of the first tubular leg portion 80 and also a top end of the first transitional sub-portion 148, is located along the lengthwise direction 72 that is lower than the crotch region of the pantyhose article 1 and the thigh region 156 of the principal sub-portion 140 (ex: a thigh region of first tubular member 8), corresponding to the bottom end of the first transitional sub-portion 148, is located at a mid-thigh region of the first tubular leg portion 80, which corresponds to a mid-thigh region of the first leg of the wearer when the pantyhose article 1 is worn. Accordingly, the transitional sub-portion 148 extends from below the crotch region of the pantyhose article 1 to the mid-thigh region of the first tubular leg portion 80. Second panty portion 112 and second transitional sub-portion 164 also extend along corresponding regions of the second tubular leg member 16.

[00115] According to yet another embodiment, the bottom end 64 of the first panty portion 56, corresponding to a top end 88 of the first tubular leg portion 80 and also a top end of the first transitional sub-portion 148, is located along the lengthwise direction 72 that is lower than the crotch region of the pantyhose article 1 and the thigh region 156 of the principal sub-portion 140 (ex: a thigh region of the first tubular member 8), corresponding to the bottom end of the first transitional sub-portion 148, is located at a lower thigh region of the first tubular leg portion 80 (i.e. in proximity of a knee region), which corresponds to a lower thigh region of the first leg of the wearer when the pantyhose article 1 is worn. Accordingly, the transitional sub-portion 148 extends from below the crotch region of the pantyhose article 1 to the lower thigh region of the first tubular leg portion 80. Second panty portion 112 and second transitional sub-portion 164 also extends along corresponding regions of the second tubular leg member 16.

[00116] It will be appreciated that in each of the embodiments described herein in which the first and second leg portions 80 and 128 include respective transitional sub-portions 148 and 164, the transitional sub-portions 148, 164 always extend between bottom ends 64, 120 of the respective panty portions 56, 112 and a respective thigh region 156, 168 of the tubular leg portions 80, 128. The length and location of the transitional sub-portions 148, 164 vary according to whether the top end of transitional sub-portions 148, 164 are located at a crotch region of the pantyhose article 1 and where the thigh regions 156 and 168 of the tubular leg portions 80, 128 are located.

[00117] According to one embodiment, and as illustrated in the Figures, the first principal sub-portion 140 of the first tubular leg portion 80 is formed of a first knit that includes a first LIHMWPE fiber and at least one first companion fiber. The first transitional sub-portion 148 of the first tubular leg portion 80 is formed of a second knit comprising a second LIHMWPE fiber and at least one second companion fiber. The first knit of the first principal sub-portion 140 of the first tubular leg portion 80 is different from the second knit of the first transitional sub-portion 148 of the first tubular leg portion 80.

[00118] According to one embodiment, the first knit of the first principal sub-portion 140 is different from the second knit of the first transitional sub-portion 148 in that the knitting pattern of the first knit is different from the knitting pattern of the second knit. Knitting pattern as it pertains to the first knit and the second knit refers to how the LIHMWPE fiber and the at least one companion within the given knit interfaces with one another within the knit. The difference in knitting pattern can include, but not limited to, how the LIHMWPE fiber and the least one companion fiber are looped with one another, hooked with one another, and/or which LIHMWPE fiber(s) and/or companion fibers(s) are present on courses of the knit.

[00119] According to one example embodiment, the first knit of the first principal subportion 140 is different from the second knit of the first transitional sub-portion 148 in that the first LIHMWPE fiber of the first knit is different from the second LIHMWPE fiber of the second knit. The first and the second LIHMWPE fibers may be different in one or more of their colors, deniers, tensile strength, modulus, twists per turn, or being covered/uncovered.

[00120] According to one embodiment, the first knit of the first principal sub-portion 140 is different from the second knit of the second transitional sub-portion 148 in that the at least one first companion fiber of the first knit is different from the at least one second companion fiber of the second knit. The set of at least one first companion fiber can include at least one companion fiber that is not found in the set of at least one second companion fiber, or vice versa. The at least one second companion fiber can include at least one of the first companion fiber but also at least one additional second companion fiber that is not found in the set of at least one first companion fiber, or vice versa. In one embodiment, the set of at least one second companion fiber includes all of the set of at least one first companion fiber but also includes at least one additional second companion fiber that is not found in the set of at least one first companion fiber. Any first fiber and any second fiber may be different in one or more of their fiber type, fiber material, fiber structure, fiber construction, color, denier, tensile strength, modulus, covered/uncovered, etc.

[00121] In one embodiment, the second knit of the first transitional sub-portion 148 is reinforced as compared to the first knit of the first principal sub-portion 140. For example, the second knit of the first transitional sub-portion 148 has the same LIHMWPE fiber as the first LIHMWPE fiber of the first principal sub-portion 140 and the second knit of the first transitional sub-portion 148 also includes at least one companion fiber that is the same as the at least one first companion fiber of the first principal sub-portion 140, but the second knit of the first transitional sub-portion 148 includes at least one additional companion fiber that is knit within the second knit to provide additional reinforcement to the second knit of the first transitional sub-portion 148 relative to the first knit of the first principal sub-portion 140.

[00122] The second knit of the first transitional sub-portion 148 can have a greater durability to sewing as compared to the first knit of the first principal sub-portion 140 of the first tubular leg portion 80. Greater durability to sewing herein refers to durability of the second knit being punctured by a sewing needle from a sewing operation during assembly and/or refers to the second knit being more resistant to tearing from a pulling force applied by one or more threads sewn to the second knit from the sewing operation.

[00123] The second knit of the first transitional sub-portion 148 can have a greater resistance to runs when torn or cut than the first knit of the first principal sub-portion 140 of the first tubular leg portion 80. Resistance to runs refers to resistance to a tear or cut continuing to run in a lengthwise direction 72 of the tubular leg member 1 after an initial tear or cut has been made.

[00124] According to one embodiment, the second knit of the first transitional sub-portion 148 includes a mesh knit. The mesh knit refers to a knit in which at every given number of courses of a feed that is knitting the mesh knit, a loop of the yarns of that feed is not made. For example, the mesh knit can be a 1x1 knit, in which for every 1 course in which a loop is made, in a second course a loop is not made. The mesh knit can be a 3 x 1 knit, in which for every 3 courses in which a loop is made, in a fourth course a loop is not made. The mesh knit can be a 5 x 1 knit, in which for every 5 courses in which a loop is made, in a sixth course a loop is not made. In a preferred embodiment, the mesh knit can be 7 x 1 knit, in which for every 7 courses in which a loop is made, in an eighth course a loop is not made. It was observed that the mesh knit provides resistance to runs in that any time a cut or tear in the second knit is made, the run caused by the cut or tear is continued until it meets a location within the knit in which a loop was not made due to the mesh knit. The absence of a given loop then stops the run. By having a mesh knit in which the absence of loop occurs sufficiently frequently, the mesh knit provides resistance against runs when the second knit is torn or cut.

[00125] According to one example embodiment, the mesh knit of the second knit of the first transitional sub-portion 148 is configured such that the location of a skipped loop (i.e. a course where a loop is not made) in a given row of the second knit is offset from the location of a skipped loop of an immediately subsequent row of the mesh knit. This non-alignment of the locations of the skipped loops across different rows of the mesh knit improves resistance against runs by ensuring that any run at any given angular position of a tubular leg member will eventually encounter a location of a skipped loop. [00126] According to one example embodiment, the second knit of the first transitional subportion 148 includes a plain knit in combination with the mesh knit. The plain knit is also commonly called a jersey knit. The plain knit of the second knit can be formed of the second LIHMWPE and a companion fiber of the second knit, in which the second LIHMWPE is the same as the first LIHMWPE of the first knit of the first principal leg sub-portion 140 and this companion fiber of the second knit is the same as the first companion fiber of the first knit. The mesh knit of the second knit can be formed of at least one additional companion fiber of the second knit that is knit within the plain knit to form the mesh knit according to the configuration of the mesh knit. For example, when knitting the plain knit, the at least one additional companion fiber of the second knit are appropriately looped with loops of the plain knit according to the configuration of the mesh knit and the at least one additional companion fiber of the second knit is appropriately skipped (i.e. loop not made) with loops of the plain knit according to the configuration of the mesh knit. More particularly, in a n x 1 mesh knit of the additional companion fiber of the second knit, in every n courses of the plain knit formed from the LIHMWPE and the second companion fiber, the additional companion fiber is also looped with loops of the plain knit, and at every n+7-th course of the plain knit, the additional companion fiber is not looped with the plain knit.

[00127] According to one example embodiment, the mesh knit is made within the second knit to provide resistance to runs in a direction along the lengthwise direction 72 towards the foot end 48. That is, the mesh knit provides resistance to a run that is started (ex: from a cut or tear) at a location closer to the top end 40 of the first tubular leg member 8 and running towards foot end 48, such that the run is restricted from continuing downwardly towards the foot end 48 upon meeting the mesh knit.

[00128] The second transitional sub-portion 164 of the second tubular leg portion 128 can be formed of the same second knit as the first transitional sub-portion 148 of the first tubular leg portion 80, being the second knit that includes the at least one second LIHMWPE fiber and the at least one companion stretch fiber. Accordingly, the second knit of the second transitional subportion 164 is different from the first knit of the second principal sub-portion 160 according to the various manners described herein.

[00129] According to one embodiment, the first panty portion 56 of the first tubular member 8 is formed of a knit that is free of (i.e., does not include) LIHMWPE. Accordingly, the first panty portion 56 can be formed of a knit of one or more stretch fibers that is free of LIHMWPE. It was observed that the LIHMWPE fiber is by far the costliest material within the pantyhose article 1. It was also observed that the first panty portion 56 is typically worn underneath one or more other layers of clothing and is not directly exposed to environmental objects that can cause rip, tearing or pilling. Therefore, there is a less of a need to reinforce the first panty portion 56 with a knit that includes LIHMWPE to obtain increased rip resistant properties. Accordingly, it was further observed that the first panty portion 56 is an appropriate area within the pantyhose article 1 where LIHMWPE can be omitted without substantially reducing the performance of the pantyhose article 1. However, and as described elsewhere herein, additional adaptions may be required elsewhere in the pantyhose article 1 to account for the first panty portion 56 being formed of a knit that is free of LIHMWPE. The second panty portion 112 of the second tubular member 16 can also be formed of a knit that is free of LIHMWPE in the same manner as the first panty portion 56. The first panty portion 56 and the second panty portion 112 can be formed of the same knit.

[00130] The first tubular member 8 is formed or manufactured in a continuous knitting operation. More particularly, the first panty portion 56, the first transitional sub-portion 148 and the first principal sub-portion 140 are formed within the same continuous knitting operation. Continuous knitting operation refers to a single continuous run by a knitting machine, such as circular knitting machine, such that the various portions of the first tubular member 8 (ex: first panty portion 56, first transitional sub-portion 148 and first principal sub-portion 140) that results from the continuous knitting operation are contiguous or integrally formed. In such a continuous knitting operation, after knitting a given portion of the first tubular member 8 (ex: the first panty portion 56), the next portion of the first tubular member 8 (ex: the first transitional sub-portion 148) is knit by continuing from the last interface of fibers (ex: last loops of the knit forming the first panty portion 56) of the just-completed given portion. The knit is continued by swapping from the fibers and knitting pattern of the just-completed given portion and continuing the knit with the appropriate fibers and knitting pattern of the next portion of the first tubular member 8. It will be understood that the continuous knitting operation of the first tubular member 8 does not produce, at any point during the knitting operation, the first panty portion 56, the first transitional sub-portion 140 and the first principal sub-portion 148 as separate and discrete pieces that then need to be joined together in any manner, such as through sewing the pieces together. [00131] It was observed that the interface between different knits within the first tubular member 8 can produce a weak spot within the first tubular member 8. This weak spot can lead to defects, such as tearing or ripping at such an interface, developing within the pantyhose article 1. The defects can develop due to repeated stresses being applied to the pantyhose article 1 , such as from repeated pulling and stretching in the longitudinal direction 72, a wearer is putting on the pantyhose article 1. The transition can also cause discomfort when the pantyhose article 1 is worn.

[00132] The continuous knitting of the first panty portion 56 and the second knit of the first transitional sub-portion 148 reduces tearing along the transition between these two sub-portions, which transition corresponds to the bottom end 64 of the first panty portion 56. The second knit of the first transitional sub-portion 148 is also chosen to improve durability along this transition at the bottom end 64 and to reduce tearing. According to one embodiment, one of the one or more stretch fibers used in the knit of the first panty portion 56 is also present in the second knit of the first transitional sub-portion 148, which ensures continuity in the knit at the transition between the panty portion 56 and the first transitional sub-portion 148 and thereby also reduces likelihood of tearing. This transition can also improve comfort.

[00133] The continuous knitting of the first transitional sub-portion 148 and the principal sub-portion 140 reduces tearing along the transition between these two portions, which transition corresponds to the first thigh region 156 of the tubular leg portion 80. The second knit of the first transitional sub-portion 148 and the first knit of the first principal sub-portion 140 are chosen to improve durability along this transition at the first thigh region 156 and to reduce tearing. According to one embodiment, the same combination of the LIHMWPE and the companion fiber of the first knit of the first principal sub-portion 140 is also present in the second knit of the first transitional sub-portion 148, which ensures continuity in the knit at the transition between the first transitional sub-portion 148 and the principal sub-portion 140 and thereby also reducing likelihood of tearing. This transition can also improve comfort.

[00134] It will be appreciated that the inclusion of the first transitional sub-portion 148 within the first tubular leg member 8 creates two knit transitions: the first transition between the first panty portion 56 and the first transitional sub-portion 148 at the bottom end 64 of the first panty portion 56 and the second transition between the first transitional sub-portion 148 and the first principal sub-portion 140 at the thigh region 156. Accordingly, a pulling force applied in a longitudinal direction 72 of the first tubular member 8, such as from a wearer putting on the pantyhose article 1 , is distributed between the first and second transitions. This distribution of the pulling force can reduce the likelihood of tearing compared to the first tubular member 8 having a single transition (ex: a single transition from the panty portion 56 directly to the first principal subportion 140).

[00135] As described herein above, the second knit of the first transitional sub-portion 148 can optionally be chosen so that there is a continuity between the knit of the first panty portion 56 and the second knit of the first transitional sub-portion 140 provided by these two knits having a common fiber with their respective knits. Furthermore, the second knit of the first transitional subportion 148 can optionally be chosen so that there is a continuity between the knit of the first transitional sub-portion 148 and the first knit of the first principal sub-portion 140 provided by these two knits having at least one common fiber within their respective knits. It was observed that given the thinness of the knit of the first panty portion 56 (ex: below 200 total denier) so that it can be worn discreetly under tight-fitting clothing, the direct transition of the lower denier of the first panty portion 56 to the first knit of the principal sub-portion 140 was prone to tearing. The addition of the first transitional sub-portion 148 as an intermediate knit between the first panty portion 56 and the first knit of the principal sub-portion 140 addresses this weakness that would otherwise be present in a tubular member that essentially includes only the first panty portion and the principal sub- portion.

[00136] According to one embodiment, the first panty portion 56 is formed of a knit having a total denier of about 20 to about 250. It will be appreciated that this knit of the first panty portion 56 has a sufficiently low denier such that it can be worn underneath form-fitting clothes, such as a hip-hugging dress or skirt. According to one embodiment, the first panty portion 56 is formed essentially of a knit of a nylon fiber having a denier of about 20 to about 100 and nylon-covered elastane fiber having a denier of about 20 to about 120. In one embodiment, the nylon fiber is a two-plied 40 denier nylon fiber, and the nylon-covered elastane fiber consists of two 20 denier elastane covered by 40 denier nylon.

[00137] It will be appreciated that the first principal sub-portion 140, when worn on the leg, will typically be exposed to environmental elements likely to cause ripping and/or tearing. The first knit of the first principal sub-portion 140 is chosen to have at least rip resistant and pilling resistant properties. Because the first principal sub-portion 140 is exposed and will be visible, the first knit is chosen to also have desired aesthetic characteristics. According to one example embodiment, the first LIHMWPE fiber of the first knit of the first principal sub-portion 140 includes a first LIHMWPE fiber having a denier of about 10 to about 60 and the first companion fiber has a denier of about 10 to about 100. The first LIHMWPE fiber and the first companion fiber can be knit in a plated knit according to various example embodiments described herein having different appearances.

[00138] According to one example embodiment where the first principal sub-portion 140 is to have a sheer appearance, the first LIHMWPE fiber of the first knit has a denier of about 25 to about 35 and the first companion fiber essentially includes a stretch fiber having a denier of about 10 to about 20. According to one example embodiment, the first LIHMWPE fiber has a denier of about 30 and the stretch fiber is a nylon covered elastane of about 15 denier.

[00139] According to one example embodiment where the first principal sub-portion 140 is to have a semi-sheer appearance, the first LIHMWPE fiber of the first knit has a denier of about 25 to about 35 and the first companion fiber includes fibers having a total denier of about 40 to about 80. According to one example embodiment, the first LIHMWPE fiber has a denier of about 30 and the companion fiber includes one or more nylon covered elastane fiber having a total denier about 50.

[00140] According to one example embodiment where the first principal sub-portion 140 is to have an ultra-sheer appearance, the first LIHMWPE fiber of the first knit has a denier of about 10 to about 20 and the first companion fiber includes fibers having a total denier of about 5 to about 15. According to one example embodiment, the first LIHMWPE fiber has a denier of about 15 and the first companion fiber is a fiber of about 9 denier covered elastane.

[00141] According to one example embodiment, where the first principal sub-portion 140 is to have a semi-opaque appearance, the first LIHMWPE fiber of the first knit has a denier of about 25 to about 50 and the first companion fiber includes fibers having a total denier of about 60 to about 150. According to one example embodiment, the first LIHMWPE fiber has a denier of about 30 and the first companion is a fiber of about 75 denier cover elastane. [00142] According to one example embodiment, the second knit of the first transitional sub-portion 148 is formed of a second LIHMWPE fiber having a denier of about 10 to about 60 and the second companion fiber has a total denier of about 50 to about 150. According to one example embodiment of the second knit that is to be combined with the first principal sub-portion 140 having the sheer appearance, the second LIHMWPE fiber of the second knit also has a denier of about 25 to about 35, preferably about 30 denier, which LIHMWPE is knit with a second companion fiber essentially including a stretch fiber having a denier of about 10 to about 20, preferably a covered elastane of about 15 denier. The second LIHMWPE fiber and this second companion fiber can be knit in a plated knit. It will be appreciated that this LIHMWPE fiber and this companion fiber is common to both the first knit of the principal sub-portion 140 and the first transitional sub-portion 148. The second knit of the first transitional sub-portion 148 also includes a mesh knit, as described elsewhere herein. The mesh knit can be formed with an additional companion fiber that includes a nylon-covered lycra fiber having a denier of about 40 to about 120, preferably two 20 denier elastane covered by 40 denier nylon. It will be appreciated that this additional companion fiber of the second knit of the first transitional sub-portion 148 is also present in the knit of the first panty portion 56.

[00143] According to one embodiment, and as illustrated in Figures 1 , 4, 5, 6, 7 and 8, the first tubular member 8 is manufactured in a directionless manner about its longitudinal axis 212. That is, prior to being assembled with the gusset 24 and the second tubular member 16, the first tubular member s is identical at any angular position about its longitudinal axis 212. The first panty portion 56 extends circumferentially about the longitudinal axis 212 so that a cut can be made at any angular position about the longitudinal axis 212 to form its longitudinal edges 172 for joining to corresponding edges 180 of the second panty portion 112. The second tubular member 16 can be manufactured in a similarly directionless manner about its respective axis.

[00144] The first transitional sub-portion 148 also extends circumferentially about the longitudinal axis 212 and about the first tubular leg portion 80. According to embodiments in which an edge of the first transitional sub-portion 148 is directly joined to an edge of the gusset 24, the joint between that edge 228 of the first transitional sub-portion 148 and that edge of the gusset 24 can be made at any angular position of the tubular leg portion 80 about the longitudinal axis 212 (as long as this angular position is common to both the first principal sub-portion 140 and the first transitional sub-portion 148). That is, the joint need not be made at an exact angular region/position of the circumferential edge 228 of the first transitional sub-portion 148 that is predefined after making the first tubular leg portion 80. The second transitional sub-portion 164 can also extend circumferentially about the second tubular leg portion 128 about its respective axis.

[00145] Furthermore, the cut in the first panty portion 56 is made in the longitudinal direction 72 from the top edge 40 towards the bottom edge 64, and may extend slightly into the first transitional sub-portion 148. This cut would otherwise cause a run in the first tubular member 8, but the run is restricted from continuing towards the foot end 48 of the first tubular member 8 due to the presence of the reinforcing knit (ex: mesh knit) in the first transitional sub-portion 148. Furthermore, since the first transitional sub-portion 148 extends circumferentially about the first tubular 8, the cut can be made at any angular position about the axis 212 and the reinforcing knit of the first transitional sub-portion 148 will provide the restriction to the continuing of the run. The second transitional sub-portion 164 that extends circumferentially about its respective axis of the second tubular leg portion 128 provides a similar restriction to continuing of a run caused by making the cut in the second panty portion 112 to form longitudinal edges 180.

[00146] As described elsewhere herein according to various embodiments, the first and second transitional sub-portions 148, 164 of respective first and second leg portions 80 and 128 extend between bottom ends of the respective panty portions 56, 112 and respective thigh regions 156, 168 of the tubular leg portions 80, 128. Due to this positioning, when the pantyhose article 1 is worn, the first and second transitional sub-portions 148, 164 will be located at the thigh regions of each leg of the wearer. Furthermore, since each of the first transitional sub-portion 148 and second transitional sub-portion 164 extend circumferentially about their respective leg portions 80, 128, when the pantyhose article 1 worn, a first inner thigh region at the thigh height of the first leg of the wearer will be covered by a first corresponding angular region of the first transitional sub-portion 148 and a second inner thigh region at the thigh height of the second leg of the wearer will be covered by a second corresponding angular region of the second transitional sub-portion 164. It will be appreciated that the first corresponding angular region of the first transitional subportion 148 will face the second corresponding singular region of the second transitional subportion 164 when the pantyhose article 1 is worn (since the first inner thigh region of the first leg will be facing the second inner thigh region of the second leg). It was observed that the rubbing of the first and second inner thigh regions of the wearer is a common cause of wearing out or failing of the legwear. It was further observed that the positioning of the first transitional subportion 148 and the second transitional sub-portion 164 at the thigh heights on respective first and second tubular leg portion offered greater protection against wearing out or failing of the pantyhose article 1 due to inner thigh rubbing. It will be appreciated that the second knit of the first and second transitional sub-portion 148, 164 is a knit that includes LIHMWPE fiber knit with at least one companion fiber, and the inclusion of the LIHMWPE fiber, being more durable, provides the increased protection against wearing out or failing of the knit.

[00147] According to a method for manufacturing the pantyhose article 1 according to an embodiment, a first tubular member 8 is a manufactured. As described herein, the first tubular member 8 is manufactured in a continuous knitting operation, such as using a circular knitting machine. A second tubular member 16 is also manufactured. As described herein, the second tubular member 16 is also manufactured in a continuous knitting operation, such as using a circular knitting machine.

[00148] After forming the first tubular member 8 and the second tubular member 16, the tubular members 8, 16 are appropriately cut and joined to form the pantyhose article 1. The first tubular member 8 being manufactured in a directionless manner, in which the first panty portion 56 extends circumferentially about the longitudinal axis 212 and the first transitional sub-portion 148 also extends circumferentially about the longitudinal axis 212 (and the second tubular member 16 having these same properties) allows the pantyhose article 1 to be assembled in a substantially automatic process. Automatic assembly process herein refers to carrying out one or more machine-made cuts, alignments and/or joints (ex: sewing lines) without manual human intervention. After the first tubular member 8 and the second tubular member 16 have both been knit by a knitting machine, the tubular members 8 and 16 are appropriately loaded onto an automatic assembly machine. Since the first tubular member 8 is directionless and has a first panty portion 56 that extends circumferentially about the longitudinal axis 212, a cut in the longitudinal direction 72 can be in the panty portion 56 at any angular position of the first tubular member 8 to form the longitudinal edges 172 thereof. A cut can be made in a similar manner in the second tubular member 16 to form the longitudinal edges 180. [00149] Furthermore, according to embodiments in which an edge of the first transitional sub-portion 148 is directly joined to an edge of the gusset 24, since the first transitional subportion 148 extends circumferentially about the longitudinal axis 212, any region of the edge 228 of the top edge of the transitional sub-portion 140 is suitable for sewing to the gusset 24. The edge 228 of the transitional sub-portion 140, corresponding to the angular position of the first tubular member 8 at which the cut in the panty portion 56 is made, is joined (ex: sewn) to the gusset 24. The joint (ex: sewing line) to the gusset 24 can be made in a similar manner in the second transitional sub-portion 164.

[00150] The longitudinal edges 172 of the first panty portion 56 are further joined (ex: sewn) to the longitudinal edges 180 of the second panty portion 112 to form the panty tube 188. Edges of the panty portions 56, 112 are further sewn to corresponding edges of the gusset 24 to close out any gaps and enclose the panty cavity 196.

[00151] It will be understood that depending on the configuration and capabilities of the assembly machine, steps described above for automatically assembling the pantyhose article 1 can be performed in a different order than as described. Furthermore, one or more steps can be performed in a single operation, such as sewing multiple edges together in a single sewing operation.

[00152] As described elsewhere herein, the first tubular member 8 and second tubular member 16 are made in a continuous knitting operation on a circular knitting machine. According to some example embodiments, the tubular leg member 8, 16 is formed by continuously feeding fibers from a same number of yarn feeds of the knitting machine throughout the full continuous knitting operation, i.e., throughout knitting the panty portion 56, 112, the transitional sub-portion 148, 164 and the principal sub-portion 140, 160. In one embodiment, the tubular leg members 8, 16 are each formed using 2 feeds of the knitting machine throughout the full continuous knitting operation.

[00153] It was observed that the first and second principal sub-portions 140, 160 and the first and second transitional sub-portions 148, 164, which are each formed of a knit having LIHMWPE, requires knitting at a lesser (i.e., 2 feeds or less) number feeds due to complexities introduces from properties of the LIHMWPE. It was also observed that the panty portion 56, 112, being free of the LIHMWPE, can be knit at a higher number of feeds (i.e., greater than 2 feeds, for example 4 feeds or more) of the knitting machine. It was further observed that transitioning from knitting 4 feeds or more (to the knit panty portion 56, 112) to knitting at 2 feeds or less (to knit the transitional sub-portions 148, 164, and the principal sub-portions 140, 160) introduced a weakness within the tubular leg members 8, 16, at the location of that transition. This weakness can be in the form of a hole within the tubular leg members 8, 16 at that transition. However, it was also observed that knitting the tubular leg members 8, 16 by continuously feeding fibers from a same number of feeds of the knitting machine throughout the full continuous knitting operation eliminated this weakness, thereby increasing the strength/durability of the knit.

[00154] While the above description provides examples of the embodiments, it will be appreciated that some features and/or functions of the described embodiments are susceptible to modification without departing from the spirit and principles of operation of the described embodiments. Accordingly, what has been described above has been intended to be illustrative and non-limiting and it will be understood by persons skilled in the art that other variants and modifications may be made without departing from the scope of the invention as defined in the claims appended hereto.