RADIAL KNIT GARMENT

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 63/720,993 filed November 15, 2024 and entitled “Radial Knit Garment.” The aforementioned application is hereby incorporated by reference in its entirety.

BACKGROUND

[0002] Conventional lower-body garments, including those formed from a knit textile, are typically made using a cut-and-sew construction that introduces multiple seam lines. Conventional pattern pieces for knit lower-body garments also generally lack three-dimensional shaping. The design and manufacture of conventional knit lower-body garments that are knit on a flat bed or v-bed knitting machine may also be constrained by the working width of the knitting bed. For example, knit blanks for leggings are conventionally knit from side-to-side, that is, with the edge corresponding to the waistband being at one end of the knitting bed and the edge corresponding to the leg cuffs at the opposite end of the knitting bed. However, this typically means that the maximum width of a knit blank, and consequently the dimensions of a completed garment, can be limited by the width of the knitting bed.

BRIEF DESCRIPTION OF THE DRAWINGS

[0003] The radial knit garments, e.g., lower-body garments, of the present disclosure are described in detail herein with reference to the attached figures, wherein:

[0004]FIG. 1 depicts a front perspective view of a lower-body garment, in accordance with aspects herein;

[0005]FIG. 2 depicts a rear perspective view of the lower-body garment of FIG. 1, in accordance with aspects herein;

[0006]FIG. 3 depicts a schematic view of an example knitted component of the lower-body garment of FIG. 1, in accordance with aspects herein;

[0007]FIG. 4 depicts a bottom-up view of the lower-body garment of FIG. 1, in accordance with aspects herein;

[0008]FIG. 5 depicts a first example of a knit blank map and/or schematic that can be used to form a lower-body garment, in accordance with aspects herein;

[0009]FIG. 6 depicts a second example of a knit blank map and/or schematic that can be used to form a lower-body garment, in accordance with aspects herein; and

[0010]FIG. 7 depicts a block diagram of a method of manufacturing radial knit garments, in accordance with aspects herein.

DETAILED DESCRIPTION

[0011] In general, disclosed herein are radially knitted garments, including radially knitted lower-body garments, along with knitted components and knitted blanks suitable for the same, and methods of manufacturing the same, among other things.

[0012] In aspects, a lower-body garment or other article of apparel formed from an integrally knitted component, such as a knit blank, is provided. The knitted component includes a plurality of radially extending knitted courses that extend from a common portion. In some aspects, the common portion can be a first seam edge located in a central region of the knit blank. In some aspects, the first seam edge may be curved, e.g., in a U-shaped fashion, e.g., forming part of a crotch or underbody area of the garment or article of apparel.

[0013] In aspects, a knitting process can be used to produce a radially knitted garment. In aspects, the knitting process can include knitting a first section that forms an end of an extremity of the garment, such as an end of a first leg of a lower-body garment. The knitted courses of the first section may extend between a first seam edge and an opposite second seam edge. Once the first section is knit, a second section can subsequently be knit, such that the second section and the first section are formed as an integrally-knit construction with courses of the second section being angled with respect to courses of the first section. In aspects, the second section may also form part of the first seam edge as it is adjacent to the first seam edge of the first section. During the process of knitting the radially knitted garment, multiple additional sections, each having courses angled with respect to the courses of the preceding section, can be knitted until the knitted component is generally full formed, e.g., with a U-shaped first seam edge along an interior portion of the knitted component, and one or more outer edges around an outer perimeter of the knitted component. During the process of knitting the radially knitted garment, the first seam edge can be joined with one or more other edges using one or more joining seams to thereby create a generally fully formed and dimensional garment. In some aspects, a knitted component can include a first seam edge, a second seam edge, and in addition a third seam edge, such that parts of the first seam edge and the second seam edge are joined together to form at least part of a first leg portion, and parts of the first seam edge and the third seam edge are joined together to form at least part of a second leg portion. In aspects, other edges of a knit blank can be joined together to form other portions of a garment, e.g., a back rise of a back torso portion of a lower-body garment, among other things.

[0014] In aspects, a knitted component can include one or more knitted courses extending between an outer perimeter of the knitted component and an inner perimeter of the knitted component. The courses can be formed in a continuous knitting process performed by a knitting machine, e.g., an automated knitted machine. The courses that are formed by the knitting machine can have different lengths, e.g., longer and shorter lengths, e.g., forming wedges, in aspects. The wedges can create a radial knit structure in a garment, or rather, can create a garment with integrally knitted courses that are angled relative to each other, with the knitted courses extending outward from a common portion in a radial configuration.

[0015] In aspects, and as discussed above, to generate a curved shape with a knitted component, a plurality of “wedges” can be formed using a knitting machine. Each “wedge” is formed from a series of knitted courses formed on the knitting machine, in which the length of each knitted course is gradually increased along a series of sequentially knitted rows, and then the length is gradually decreased along another series of sequentially knitted rows, thereby forming a wedge-like shape. The resulting wedge can have a particular geometry that can be determined by the change in the length of the sequentially knitted rows and/or the change in the number of sequentially knitted rows. The result of creating wedges is that the orientation of a knit blank as it is being knitted can change, thereby causing the resulting knitted structure to have a curved or arcuate geometry. For example, turning of the knitted structure can be used to form a curved or U-shaped knit blank. This type of knit blank can then be used to form a radial knit garment.

[0016] In some aspects, using the knitting processes described herein, sections of a knit blank can be formed to have complex shapes, e.g., curved perimeter edges, or perimeter edges that have multiple straight or curved line segments. These more complex shapes can be knit by a knitting machine by modifying the beginning and end points of each course in addition to modifying a length of each course. For the purposes of this disclosure, the term “wedge” can include sections formed with these more complex shapes.

[0017] Radially knitted garments can have unique benefits over traditional circular or flat knitted structures including increased containment along desired lines and/or orientations, among other benefits. In addition, by periodically modifying the angle of knit courses of a knitted component formed on a knitting machine, and in particular for each successive section of the knitted component formed on the knitting machine, in a radial fashion, different designs and geometries of a knitted garment can be realized. In addition to providing different aesthetic properties to a finished garment, a garment knitted with a radial configuration can provide better support or fit compared to garments knitted in a more traditional configuration that produces uniformly parallel courses.

[0018] The radial knitting methods of the present disclosure can also allow garments with larger dimensions, e.g., lower-body-garments of larger sizes, to be knit more efficiently. For example, knit blanks having overall dimensions larger than the maximum knitting width of a particular knitting machine can be knit as a series of integrally knit sections with each section being knit in an orientation that allows it to fit within the operating parameters of the knitting machine. To state it differently, if a width of each section of a knit blank is less than a knitting width of a knitting machine, rotating the knit blank during the knitting process allows for the knit blank to be integrally knit on the knitting machine when it might otherwise not be possible if the knit blank had the same angle of orientation during the entire knitting process, or rather, was formed with uniformly parallel courses. In one aspect, a knit blank includes a series of sections arranged radially around a central region of the knit blank, and includes a U-shaped first seam edge. In aspects, a knit blank may include multiple curves, with different portions of the knit blank being arranged radially around different central regions rather than just a single common region.

[0019] Herein, the term “lower-body garment” is intended to encompass garments configured to at least partially cover a lower torso and/or legs of a wearer. Lower-body garments can include shorts, pants, three-quarter pants, tights, unitards, skirts, and other garments worn at least in part on a wearer’s lower body. In one example aspect, a lower-body garment is a pair of shorts. Positional terms used when describing lower-body garments herein, e.g., such as front, back, sides, upper, lower, and the like, are used in relation to a lower-body garment being worn as intended by a wearer standing in an upright position. Thus, the front of the lower-body garment is configured to cover or be positioned adjacent to a front lower torso portion and/or front leg areas of a wearer, and the back of the garment is configured to cover or be positioned adjacent to a back lower torso portion (e.g., gluteal region) and/or back leg areas of a wearer. The sides of a lower-body garment are configured to cover or be positioned adjacent to the sides of the wearer's lower torso portion and/or side leg areas of the wearer. The term “upper” used in connection with a lower-body garment means closer to a head area of a wearer when the garment is worn, and the term “lower” when used in connection with a lower-body garment means closer to a foot area of the wearer when the garment is worn.

[0020] The terms "knitted component" and "knit element" are intended to encompass a textile piece that is formed from at least one yarn that is manipulated (e.g., by a knitting machine) to form a plurality of intermeshed loops that define courses and wales. The term "knit blank" as used herein is intended to encompass a knitted component that is produced by a knitting machine, where the knit blank is later used to form at least part of a garment, such as a lower-body garment as described herein.

[0021] The term "course," as used herein, refers to a predominantly horizontal row of knit loops (in an upright textile as it is knit on a knitting machine) that is produced by adjacent needles during a common knitting operation. The course may include one or more stitch types, such as a knit stitch, a missed stitch, a tuck stitch, a transfer stitch, a rib stitch, and the like as these terms are known in the art of knitting. The term "knit stitch," as used herein, is intended to encompass basic stitch types where the yarn is cleared from the needle after pulling a loop of the yarn from the back to the front of the textile through a previous stitch. Thus, the legs of the stitch appear on the technical face of the knit textile and the top and bottom of the stitch appear on the technical back of the textile. The term "wale," as used herein, is a predominantly vertical column of intermeshed or interlooped knit loops, generally produced by the same needle at successive (but not necessarily all) courses or knitting cycles. The term "integrally knit," as used herein, is intended to encompass a knitted component that has a yarn of one or more knitted courses in a first area or region interlooped with one or more knitted courses of another area or region. The interlooping may be provided through a simple knit stitch, a tuck stitch, a held stitch, a float stitch, a miss stitch, or the like. With this configuration, areas that are integrally knit together can have a generally seamless transition.

[0022] The term “crotch gusset,” as used herein, is intended to encompass an area of a lower-body garment configured to cover a crotch area between a wearer's legs when a lower-body garment is worn. Herein, a “gusset” is an extra volume of material created through a knitting process. Herein, a “seam” is a structure that affixes two terminal or boundary edges of a textile together. Herein “affixing” is a process that joins two textile edges together using affixing technologies such as one or more of stitching, bonding, welding, adhesives, and the like. In example aspects, a seam is created in a post-processing operation performed after a one-piece knit textile is knit on a knitting machine as described herein.

[0023] The terms "radial" or “radially-extending,” as used herein, refer to an orientation of a plurality of elongate structures, such as courses and/or wedge portions and/or inlaid elements such as yarns, threads, fibers, filaments including monofilaments and multi-filaments, cables, strands, and the like. Radial or radially-extending elongate structures are those that radiate outward from a common portion, e.g., of a knitted component. For example, a knit course may be radially extending if it extends at least partially from a common portion to an outer perimeter edge of a knitted component and at an angle compared to other knit courses in other sections or regions of the knitted component that are also extending from the common portion to the outer perimeter edge of the knitted component. This is in contrast to, for example, elongate structures that extend continuously across a body of a knitted component between edges and generally in parallel with each other (although, in aspects contemplated herein, such configurations may be present in combination with a radial knit structure forming part of a knit blank). In addition, elongate structures of a knitted component can be radially extending from a common portion when the knitted component is laid out in a flat configuration after knitting, but it is also contemplated that determining whether structures are radially extending may be based on the orientation of the elongate structures towards the common portion after the knitted component is folded into the shape of a garment.

[0024] The term "common portion," as used herein, refers to an area of a knitted component towards which and/or away from which multiple similar elongate structures (e.g., multiple knitted courses) extend. For example, in aspects, multiple knitted courses may extend from an outer perimeter edge of a knitted component to a single common portion of the knitted component rather than extending from the outer perimeter edge to different portions. The common portion can be spaced apart from the outer perimeter edge and, in various aspects, may be relatively centrally located within a knitted component. In aspects, a common portion may encompass or may be directly adjacent to a longitudinal axis of the knitted component. In some examples described herein, a common portion may include a U-shaped first seam edge or a portion thereof.

[0025] The term "perimeter" or "perimeter edge" as used herein, refers to an area forming a boundary of an object referred to in a description. For example, a perimeter of a knitted component can be a portion that extends along an outer boundary edge of the knitted component. In addition, the term "outer perimeter" or "outer perimeter edge" may refer to portions of a perimeter of a knitted component, such as a knit blank, that form an outer-facing edge of the knitted component. In contrast, an "inner perimeter" or "inner perimeter edge" may refer to portions of a perimeter of a knitted component that form an inner region or inner edge of the knitted component or knit blank. The perimeter (outer perimeter or inner perimeter) may refer to an edge of the knitted component or to a peripheral area adjacent to or proximate to the edge.

[0026] The term “boundary,” as used herein, can refer to a border of a portion or a section of a knit blank. In aspects, a boundary can be, but is not necessarily, a free edge of a knit blank, or it can be part of a perimeter of a knit blank portion that is subsequently knit together with a boundary of one or more other knit blank portions. In aspects, a boundary can run along a length of a single course, or can run along the ends of multiple courses. Boundaries of two or more knitted portions as described herein can be, as part of the knitting process, integrally knit with each other, resulting in a substantially seamless joining or integration of different portions or sections of a knitted component.

[0027] Examples herein contemplate using a knitting machine, e.g., a dual-bed knitting machine such as a V-bed knitting machine, to produce a knit blank that forms at least part of a lower-body garment. This is in contrast to use of circular knit machines where a knit blank comes off of the machine in a tubular form. Rather, in accordance with aspects herein, a knit blank can be produced such that it comes off of a knitting machine in a flat form (a planar form that extends along an x-y plane). Dual-bed weft knitting machines allow for the creation of a knit blank having a specified shape with one or more finished edges free from a surrounding textile as the knit blank comes off of the machine (finished edges may also be referred to herein as a "free edge"). Producing blanks with finished edges on a knitting machine can allow certain post-processing operations to then be performed. For example, such post-processing operations can include cutting shapes, attaching edges together (e.g., via the use of seams), creating attachments at select locations, and/or attaching additional components or embellishments at select locations, and the like.

[0028] Looking now at FIGS. 1 and 2, a lower-body garment 100 is shown, in accordance with aspects herein. Lower-body garment 100 includes a first leg portion 102 and a second leg portion 104 extending from a torso portion 105, which includes a front torso portion 106 and a back torso portion 107. First leg portion 102 has a first leg opening 108 and terminates at a first leg cuff 112. Second leg portion 104 has a second leg opening 110 and terminates at a second leg cuff 114. The torso portion 105 extends to a waist opening 116. In the example of FIG. 1, a waistband 120 encircles the waist opening 116. The upper edge 406 of the torso portion 105 abuts the lower edge of the waistband 120.

[0029] In the example of FIGS. 1 and 2, a Y-shaped seam 450 joins together distinct edges of the first leg portion 102, the second leg portion 104, and the back torso portion 107. In addition, a first seam part 452 runs along an inner side of the first leg portion 102, a second seam part 454 runs along an inner side of the second leg portion 104, and a third seam part 456 runs along the center of the back torso portion 107 to form a back rise of the lower-body garment 100.

[0030] The lower-body garment 100 can be formed from a knit blank 301 as depicted in FIG. 3. In aspects, the knit blank 301 is a knitted component used to form at least part of the lower-body garment 100, e.g., after knitting is completed, but before the seam edges of the knitted component are joined together to form the dimensional shape of the lower-body garment 100. The knit blank 301 includes a perimeter with a first seam edge 400 forming a U-shaped section on an inner portion of the knit blank 301, and with the outer perimeter portions including the edge of the first leg cuff 112, the second seam edge 402, the first back rise edge 404, an upper edge 406, the second back rise edge 408, the third seam edge 410, and the edge of the second leg cuff 114.

[0031] Looking back at FIGS. 1 and 2, when the knit blank 301 of FIG. 3 is formed into the lower-body garment 100 having a dimensional configuration, the first seam part 452 joins the second seam edge 402 to one side of the first seam edge 400, and the second seam part 454 joins the third seam edge 410 to the other side of the first seam edge 400. The third seam part 456 joins the first back rise edge 404 to the second back rise edge 408. Looking at FIG. 4, the first seam part 452, the second seam part 454, and the third seam part 456 meet at a junction 458 in the crotch area of the lower-body garment 100 such that the resulting seam 450 is Y-shaped. The different edges of the knit blank 301 may be affixed together using, for example, stitching, bonding, welding, adhering, or similar attachment techniques suitable for joining textiles together.

[0032] Each of the plurality of sections of the knit blank 301 in FIG. 3 includes a set of courses running generally parallel to each other within each respective section and perpendicular to the machine direction in which each section is knit, with the courses of each successive section being angled with respect to the courses of the preceding section. To state it differently, the courses in different sections extend at an angle to each other due to being produced with wedging, as further discussed with respect to FIGS. 5 and 6 below.

[0033] First leg portion 102 includes a plurality of sections 130, 140, 150, 160, with the first section 130 forming the lowermost part of the first leg portion 102. The first section 130 includes a first edge 132 which forms the edge of the first leg cuff 112. In addition, a second edge 134 of the first section 130 is integrally knit with a first edge 142 of the second section 140 along a boundary 300. Similarly, a second edge 144 of the second section 140 is integrally knit with a first edge 152 of the third section 150 along a boundary 310, and a second edge 154 of the third section 150 is integrally knit with a first edge 162 of the fourth section 160 along a boundary 320. In the depicted aspect of FIGS. 1 and 2, each of the sections 130, 140, 150 extends between the first seam edge 400 and the second seam edge 402, with the first seam edge 400 being shorter than the second seam edge 402.

[0034] With the knit blank 301 and the lower-body garment 100, each of the sections 130-220 may include one or more radially-extending courses. That is, each section may include knit courses that extend between an outer perimeter of the knit blank 301 a common portion of the knit blank 301. The common portion may be an area, edge, and/or section of the knit blank 301 that some or substantially all of the knit courses extend towards once the knit blank has been fully knitted on a knitting machine. In aspects, and as in the example of FIGS. 1-4, the common portion may be the first seam edge 400, which generally forms a U-shaped inner perimeter.

[0035] Forming a knitted component to have radially-extending courses can include forming the knitted component to have full-length and partial-length knit courses in different aspects. An example full-length knit course, such as course 135 shown in FIG. 3, may extend from one edge of a section, such as the first seam edge 400 of the first section 130, to another edge of the section, such as the second seam edge 402 of the first section 130. Another example full-length knit course is course 145 of the second section 140 shown in FIG. 3.

[0036] In aspects herein, a partial-length knit course within a section may not extend fully between two opposite edges of the section, or rather, one or both ends of a partial-length knit course may end before the edge of the section is reached. Example partial-length knit courses include a course 136 in the first section 130 and a course 146 in the second section 140. The partial-length knit courses may still be considered radially-extending as they extend in a direction towards the common portion (e.g., the first seam edge 400). Utilizing partial-length knit courses to create angled edges of one or more sections may aid in the forming of “wedge-like” shapes so that adjacent sections have their courses angled with respect to each other when their respective edges are integrally knit together. Partial-length knit courses may also be distributed or interspersed between full-length knit courses within a section to create shape and dimension in the knit blank 301 as shown in the example of FIG. 3.

[0037] Looking at FIGS. 1-3, a fourth section 160 shares the first seam edge 400 with the first section 130, the second section 140, and the third section 150. Opposite the first seam edge 400 of the fourth section 160 is the first back rise edge 404 and a portion of the upper edge 406. In addition, a second edge 164 of the fourth section 160 is integrally knit with a fifth section 170, which is positioned on the left side of the front torso portion 106 of the lower-body garment 100. In addition, a second edge 174 of the fifth section 170 runs along the centerline of the knit blank 301 of FIG. 3 and the lower-body garment 100.

[0038] Looking still at FIGS. 1-3, a sixth section 180, a seventh section 190, an eighth section 200, a ninth section 210, and a tenth section 220 form the second or right side of the knit blank 301 of FIG. 3 and the lower-body garment 100 of FIGS. 1 and 2. The orientation of the courses of each section 130-220 are represented by courses 135, 145, 155, 165, 175, 185, 195, 205, 215, 225. As seen, the courses in each section are angled relative to the courses of the section that preceded it. The sections 180, 190, 200, 210, 220 are generally mirrored counterparts of the sections 130, 140, 150, 160, 170 of the first or left side of the knit blank 301 and the lower-body garment 100. However, as seen in FIG. 3, the sections 180, 190, 200, 210, 220 are knit in the opposite order from their first side counterparts. That is, while the first section 130 is knit first and forms the lowest part of the first leg portion 102, the tenth section 220, which forms the lowest part of the second leg portion 104, is knit last. In the same way, for the sections on the first side of the knit blank 301, the first edge that is knit is the lower edge of the section, and for the second sections on the second side of the knit blank 301, the first edge that is knit is the upper edge of the section.

[0039] In some examples, the transition of one section to the next section as shown in FIGS. 1-3 for example may be without significant visual demarcation, delineation, and/or boundary. In other examples, the transition between two sections may be demarcated visually to highlight the radially knit nature of the garment, as it offers an unconventional aesthetic along with other unique properties.

[0040] Looking at FIGS. 3 and 4, the lower-body garment 100 also includes a crotch gusset 250, with a lower edge 252 of the crotch gusset 250 forming a central section of the first seam edge 400. First edge 254 and second edge 256 of the crotch gusset 250 are integrally knit with a first side edge 176 of the fifth section 170 and a first side edge 186 of the sixth section 180. Thus, the crotch gusset 250, the fifth section 170, and the sixth section 180 as depicted in FIG. 3 only share one edge with the outer perimeter of the knit blank 301. While not shown herein, it is further contemplated that other examples of completed knit blanks formed in accordance with the present disclosure may include sections that do not share any edges with the outer perimeter of the completed knit blank.

[0041] The crotch gusset 250 may be knit with a number of widening reciprocated sections and narrowing reciprocated sections using a set of needles such that some needles of the set of needles are active when knitting particular sections of the crotch gusset and other needles of the set of needles are inactive, locked, deactivated, or programmed not to operate. The shape of the crotch gusset 250 in FIG. 3 is illustrative only, and it is contemplated herein that the crotch gusset 250 may have different shapes, e.g., triangular, trapezoidal, circular, or another shape.

[0042] Looking now at FIG. 5, a knit blank map and/or schematic 500 suitable for use in forming a radially knitted blank and/or garment is depicted, in accordance with aspects herein. The knit blank map 500 includes a first section 510, a second section 520, a third section 530, a fourth section 540, a fifth section 550, a sixth section 560, and a crotch gusset 570. In this example, a first edge 512 of the first section 510 forms a leg band and/or cuff of a first leg portion of a resulting lower-body garment formed from the completed knit blank, and a second edge 564 of the sixth section 560 forms a leg band and/or cuff of a second leg portion of the resulting lower body garment formed from the completed knit blank. The adjacent edges or boundaries of neighboring sections (e.g., 514 and 522, 524 and 632, 534 and 542, 544 and 552, 554 and 562) may be knit together, e.g., integrally knitted together, to form the knit blank via a wedging technique. While the courses of each section may be knit in the same orientation relative to the knitting machine (e.g., courses 516 and 526 are shown to be parallel in the knit blank map of FIG. 5), the resulting angles between courses of the different sections may be determined at least in part by the angles and geometries between the adjacent edges or boundaries of the neighboring sections. For example, the angle between edges 514 and 522 can be relatively smaller, so the angle between the courses of the first section 510 and the second section 520 may correspondingly be relatively smaller, while the angle between the courses of the second section 520 and the third section 530 can be relatively larger due to the larger angle between edges or boundaries 524 and 532. Larger angles between the radially knitted sections produces a sharper turn, or rather, results in a smaller radius of curvature between the sections in the resulting knitted structure. This, in turn, helps define a particular angular geometry. By adjusting the angle between the radially knitted sections produced on a knitting machine as described herein, a radially-knitted garment of a different size and/or geometry can be achieved.

[0043]FIG. 6 is another knit blank map and/or schematic 600 of a knitted component or knit blank for a lower-body garment, in accordance with aspects of the present disclosure. In this example, each side of the resulting lower-body garment is formed from nine sections, with a first side formed from sections 602, 604, 606, 608, 610, 612, 614, 616, and 618, and a second side formed from sections 620, 622, 624, 626, 628, 630, 632, 634, and 636. In the example of FIG. 6, a crotch gusset 640 is also included to be knit between the last section of the first side of the knit blank (section 618) and the first section of the second side of the knit blank (section 620).

[0044]FIG. 6 also depicts waistband sections 638 that may be knit simultaneously with a plurality of sections forming a torso portion of the lower-body garment (e.g., sections 612, 614, 616, 618, 620, 622, 624, 626 and crotch gusset 640). In other examples, a waistband may be attached to the completed knit blank in a separate post-processing operation. Similarly, leg bands 639 may be knit with the knit blank or attached to the completed knit blank during a separate post-processing operation, which may form leg cuffs on the finished lower-body garment.

[0045] Furthermore, linking sections 650 may be knit between the sections that have a relatively larger angle and/or distance between their respective edges. The linking sections 650 may be a set of parallel courses knit together with each edge of a connecting line integrally knit with the adjacent edges of the sections the connecting line is in between. The connecting lines, by reducing the angle or the distance that a set of loops needs to be held by the knitting needles before being joined to the next knitted section of the knitted component, help to reduce tension in the loops of the fully formed knit blank and resulting lower-body garment. While these linking sections 650 may not be in the form of a “wedge” it is to be appreciated that their courses will still extend radially out from the common portion of the knit blank once all of the sections are knit together.

[0046] In the example of FIGS. 5 and 6, the courses of all of the sections can be perpendicular to the machine direction or knitting production direction (hereinafter “MD”; identified in FIG. 5), as depicted by courses 516, 526 and 528 in FIG. 5. However, as sections of the knit blank are completed, the partially-knitted knit blank will turn or rotate as the just-completed section is integrally knit with the lower edge of the next section, so that adjacent sections have courses that are angled with respect to each other, due to the wedging that is generated.

[0047] As seen from the examples shown in FIGS. 1, 5 and 6, examples of the present disclosure may include more or fewer sections to form different portions of the lower-body garment, such as the leg and torso portions, with varying angles between the courses of adjacent sections. It has generally been observed that increasing the number of sections may require less turning between sections and result in greater knit efficiency but may also require more total knitting time to complete the garment.

[0048] Each section of a knitted component and/or knit blank formed in accordance with the present disclosure may be parallel to the first edge of the section, the second edge of the section, or neither. Furthermore, corresponding regions of a first side and a second side of a lower-body garment may have courses that have the same corresponding angles relative to a midline of the lower-body garment. For example, in the knit blank formed by the knit blank map 600 of FIG. 6, the first section 602 includes a first edge 652 and a second edge 654 that are relatively straight, with the first edge 652 being generally parallel to the courses 655 in the first section 602 and angled with respect to the second edge 654. In contrast, seventh section 614 has a first edge 652 that is curved, and both its first edge 656 and second edge 658 are angled relative to its courses 660, which are knit perpendicular to the machine direction MD. The twelfth knit section 624, which is a mirrored counterpart of seventh section 614, has edges 674 and 672 that have the same corresponding angles with respect to its courses 676 as edges 656 and 658 of the seventh section 614. In other examples, while counterpart sections of the knit blank may have a mirrored outer perimeter, the courses may be angled differently with respect to the section edges.

[0049]FIG. 7 depicts a block diagram of an example method 700 of manufacturing a lower-body garment, such as the lower-body garment 100 of FIG. 1, in accordance with the present disclosure. In examples the lower-body garment includes a first leg portion and a second leg portion extending from a torso portion. In block 710, a knitted component, such as the knit blank 301 of FIG. 3, is knit, with the knitted component including a first seam edge (such as first seam edge 400), a second seam edge (such as second seam edge 402). Block 710 further includes knitting a first leg section (such as first section 130) having a first plurality of courses extending between the first seam edge and the second seam edge and knitting a second leg section (such as second section 140) with a second plurality of courses, with the first leg section and the second leg section being integrally knit together and with the first plurality of courses and the second plurality of courses extending at a first angle relative to each other. In block 712, the first seam edge is joined with the second seam edge to form at least a part of the first leg portion.

[0050] The method 700 may further include knitting a third leg section that is integrally knit with the second leg section and having a third plurality of courses extending at a second angle relative to the second plurality of courses. In other examples, the method 700 may further comprise the knitted component including a fourth knit section extending between the first seam edge and a third seam edge, and joining together the first seam edge and the third seam edge to form at least part of the second leg portion of the lower-body garment.

[0051] In accordance with aspects herein, a knit blank of a lower-body garment formed in accordance with the present disclosure may be knit on a knitting machine having a maximum knitting width that is less than the overall length and width dimensions of a fully formed knit blank that is produced on the knitting machine. For example, the fully formed knit blank 301 of FIG. 3 has an overall length L and an overall width W. However, each of the sections of the knit blank 301, being knit using the radial knit and wedging concepts discussed herein, has a relative section width that is significantly less than that of the overall length L and width W of the knit blank. Accordingly, the knit blank 301 can be knit by a knitting machine that can knit the greatest relative section width of the respective sections – in this case, fourth section 160 and its counterpart seventh section 190. This allows for greater flexibility in utilizing available knitting machines and in designing knit blanks for garments with larger dimensions.

[0052] In the examples of FIGS. 1, 5, and 6, the knit blank that forms a completed lower-body garment has a general U-shape, with an inner first seam edge also generally being in the form of a U-shape, and the courses of each adjacent section extending radially out from the U-shaped first seam edge. However, knit blanks having other configurations are also contemplated. For example, an S-shaped knit blank may also be formed in accordance with the present disclosure, with a first series of sections having courses extending radially out from a first region or edge, and a subsequent second series of sections having courses extending radially out from a second region or edge. A knit blank having a series or sections with courses that are parallel to each other in addition to radially-oriented sections is also within the scope of the present disclosure.

[0053] The lower-body garment may be knit using yarns (or other types of strands) of any suitable material. These materials include, but are not limited to, nylon, polyester, bi-component yarns such as elastane wrapped in nylon, and the like. In aspects, yarns having elastic properties or that are elasticated may be used in a knit blank that forms a lower body garment. In addition, yarns that are non-elasticated may also be used.

[0054] The following clauses represent example aspects of concepts contemplated herein. Any one of the following clauses may be combined in a multiple dependent manner to depend from one or more other clauses. Further, any combination of dependent clauses (clauses that explicitly depend from a previous clause) may be combined while staying within the scope of aspects contemplated herein. The following clauses are examples and are not limiting.

[0055] Clause 1. A lower-body garment comprising a first leg portion and a second leg portion extending from a torso portion, the first leg portion formed from a knitted component comprising a first seam edge and a second seam edge joined together by a seam, the first leg portion comprising: a first leg section comprising a first plurality of courses extending between the first seam edge and the second seam edge; a second leg section comprising a second plurality of courses extending between the first seam edge and the second seam edge; wherein: the first leg section is integrally knit with the second leg section, and the first plurality of courses and the second plurality of courses extend at a first angle relative to each other.

[0056] Clause 2. The lower-body garment of clause 1, wherein: the first leg section comprises a first lower edge between the first seam edge and the second seam edge, and an opposing first upper edge; the second leg section comprises a second lower edge between the first seam edge and the second seam edge and an opposing second upper edge; and the first upper edge is integrally knit with the second lower edge.

[0057] Clause 3. The lower-body garment of clause 2, wherein the first plurality of courses is parallel to the first lower edge.

[0058] Clause 4. The lower-body garment of clause 3, wherein the first lower edge forms a leg cuff of the first leg portion.

[0059] Clause 5. The lower-body garment of claim 4, wherein the first lower edge comprises a first length, and the first seam edge as it extends between the first lower edge and the first upper edge comprises a second length that is at least two times longer than the first length.

[0060] Clause 6. The lower-body garment of any of clauses 2 to 5, further comprising a third leg section comprising: a third plurality of courses extending between the first seam edge and the second seam edge, and a third lower edge and a third upper edge; wherein the third lower edge is integrally knit with the second upper edge, and the third plurality of courses extends at a second angle relative to the second plurality of courses.

[0061] Clause 7. The lower-body garment of clause 6, wherein the third plurality of courses extends at a third angle relative to the first plurality of courses, and third angle being greater than the first angle.

[0062] Clause 8. The lower-body garment of clause 7, wherein the knitted component comprises a waistband edge and the torso portion comprises a first torso section comprising a fourth plurality of courses extending between the first seam edge and the waistband edge, the fourth plurality of courses extends at a fourth angle relative to the first plurality of courses, the fourth angle being greater than the third angle.

[0063] Clause 9. The lower-body garment of clause 8, wherein the knitted component further comprises a crotch gusset, the crotch gusset being integrally knit with the first torso section.

[0064] Clause 10. The lower-body garment of clause 9, wherein the crotch gusset extends from the first seam edge.

[0065] Clause 11. A method of manufacturing a lower-body garment comprising a first leg portion and a second leg portion extending from a torso portion, the method comprising: knitting a knitted component comprising a first seam edge and a second seam edge, wherein knitting the knitted component comprises: knitting a first leg section comprising a first plurality of courses extending between the first seam edge and the second seam edge; and knitting a second leg section comprising a second plurality of courses; and joining together the first seam edge and the second seam edge to form at least a part of the first leg portion; wherein: the first leg section is integrally knit with the second leg section, and the first plurality of courses and the second plurality of courses extend at a first angle relative to each other.

[0066] Clause 12. The method of clause 11, wherein knitting the knitted component further comprises knitting a third leg section comprising a third plurality of courses, and the second plurality of courses and the third plurality of courses extend at a second angle relative to each other.

[0067] Clause 13. The method of clause 12, further comprising joining together the first seam edge and the second seam edge to form a tubular shape of the first leg portion.

[0068] Clause 14. The method of any of clauses 11 to 13, wherein the knitting is performed on a weft knitting machine.

[0069] Clause 15. The method of clause 14, wherein the weft knitting machine comprises at least one needle bed having a first width.

[0070] Clause 16. The method of clause 15, wherein the knitted component has a second width between the first seam edge and the second seam edge that is less than the first width, the second width comprising a greatest width between the first seam edge and the second seam edge.

[0071] Clause 17. The method of any of clauses 11 to 16, wherein the knitted component comprises a plurality of courses extending radially from the first seam edge, the plurality of courses located between a first leg cuff and a second leg cuff.

[0072] Clause 18. The method of any of clauses 11 to 17, wherein the first leg portion, the second leg portion and the torso portion are integrally knit, the first leg portion being knit prior to the torso portion, which is knit prior to the second leg portion.

[0073] Clause 19. An integrally knit blank for a lower-body garment comprising a first leg portion and a second leg portion extending from a torso portion, the integrally knit blank comprising: a first seam edge; a second seam edge opposite the first seam edge; a first leg section comprising a first plurality of courses extending between the first seam edge and the second seam edge; a second leg section adjacent to the first leg section and comprising a second plurality of courses extending between the first seam edge and the second seam edge; wherein: the first leg section is integrally knit with the second leg section; the first plurality of courses and the second plurality of courses extend at a first angle relative to each other; and the first seam edge and the second seam edge are configured to be joined together to form the first leg portion of the lower-body garment.

[0074] Clause 20. The integrally knit blank of clause 19, further comprising a third leg section adjacent to the second leg section and opposite to the first leg section, the third leg section comprising a third plurality of courses extending between the first seam edge and the second seam edge at a second angle relative to the second plurality of courses.

[0075] As used herein, a recitation of “and/or” with respect to two or more elements should be interpreted to mean only one element, or a combination of elements. For example, “element A, element B, and/or element C” may include only element A, only element B, only element C, element A and element B, element A and element C, element B and element C, or elements A, B, and C. In addition, “at least one of element A or element B” may include at least one of element A, at least one of element B, or at least one of element A and at least one of element B. Further, “at least one of element A and element B” may include at least one of element A, at least one of element B, or at least one of element A and at least one of element B.

[0076] This detailed description is provided in order to meet statutory requirements. However, this description is not intended to limit the scope of the invention described herein. Rather, the claimed subject matter may be embodied in different ways, to include different steps, different combinations of steps, different elements, and/or different combinations of elements, similar or equivalent to those described in this disclosure, and in conjunction with other present or future technologies. The examples herein are intended in all respects to be illustrative rather than restrictive. In this sense, alternative examples or implementations can become apparent to those of ordinary skill in the art to which the present subject matter pertains without departing from the scope hereof.