Garment with discrete integrally-formed, electrically-conductive region and associated blank and method

Abstract

A circularly knit garment is provided, the garment comprising a circularly knit fabric body having an inner surface adapted to be disposed adjacent to a wearer's skin when the garment is worn. The garment further includes at least one discrete electrically-conductive region formed at the inner surface of the body during the circular knitting thereof in such as manner as to contact the wearer's skin when the garment is worn. The at least one electrically-conductive region is comprised of electrically-conductive threads, wherein the electrically-conductive threads are knit into the body such that the electrically-conductive threads at the inner surface are confined to the at least one electrically-conductive region. The at least one electrically-conductive region is further adapted to cooperate with the wearer's skin to conduct an electrical signal therebetween. An associated blank and a method of making such a garment are also provided.

That which is claimed:  
     
         1 . A circularly knit garment, comprising: 
 a circularly knit fabric body having an inner surface adapted to be disposed adjacent to a wearer's skin when the garment is worn; and    at least one discrete electrically-conductive region formed at the inner surface of the body during the circular knitting thereof in such as manner as to contact the wearer's skin when the garment is worn, the at least one electrically-conductive region being comprised of electrically-conductive threads knit into the body such that the electrically-conductive threads at the inner surface are confined to the at least one electrically-conductive region, the at least one electrically-conductive region being further adapted to cooperate with the wearer's skin to conduct an electrical signal therebetween.    
     
     
         2 . A garment according to  claim 1  wherein the body is substantially seamless.  
     
     
         3 . A garment according to  claim 1  further comprising an electrical signal processing device in communication with the at least one electrically-conductive region and configured to receive the electrical signal from the wearer's skin.  
     
     
         4 . A garment according to  claim 1  further comprising a display in communication with the at least one electrically-conductive region and configured to display a representation of the electrical signal.  
     
     
         5 . A garment according to  claim 1  wherein the body further comprises an outer surface and includes at least one conductive element in electrical contact with the at least one electrically-conductive region, the at least one conductive element extending between the electrically-conductive region and the outer surface.  
     
     
         6 . A garment according to  claim 5  further comprising a pocket defined by the body, wherein the at least one conductive element extends from the electrically-conductive region into the pocket.  
     
     
         7 . A garment according to  claim 6  further comprising an electrical signal processing device configured to be housed by the pocket and to be communicable with the at least one conductive element so as to receive the electrical signal from the at least one electrically-conductive region.  
     
     
         8 . A garment according to  claim 5  wherein the at least one conductive element is integrally formed with the at least one electrically-conductive region during the circular knitting of the body.  
     
     
         9 . A garment according to  claim 1  wherein the body comprises an inner ply, having an inner surface disposed adjacent to the wearer's skin when the garment is worn and an outer surface, and an outer ply, having an inner surface opposing the outer surface of the inner ply and an outer surface.  
     
     
         10 . A garment according to  claim 9  wherein the at least one electrically-conductive region is formed at the inner surface of the inner ply so as to be capable of contacting the wearer's skin.  
     
     
         11 . A garment according to  claim 9  further comprising at least one conductive element in electrical contact with the at least one electrically-conductive region and extending between the at least one electrically-conductive region and at least one of the outer surface of the inner ply and the inner surface of the outer ply.  
     
     
         12 . A garment according to  claim 11  further comprising at least one electrical connector operably engaged with each conductive element in opposing relation to the at least one electrically-conductive region.  
     
     
         13 . A garment according to  claim 9  wherein the at least one conductive element is integrally formed with the at least one electrically-conductive region during the circular knitting of the body, and the at least one conductive element extends in a continuous path between the at least one electrically-conductive region and at least one of the outer surface of the inner ply and the inner surface of the outer ply.  
     
     
         14 . A garment according to  claim 9  wherein the body is formed of a circularly knit fabric blank folded upon itself along a fold line defining an edge of the body, the inner ply opposing the outer ply about the fold line.  
     
     
         15 . A garment according to  claim 9  wherein the inner ply and the outer ply are secured together at a turned welt so as to define an edge of the body.  
     
     
         16 . A garment according to  claim 9  further comprising a pocket formed between the inner and outer plies and having at least one electrical connector therein in communication with the at least one electrically-conductive region via at least one conductive element operably engaged therebetween, the pocket being configured to accept an electrical signal processing device therein, the electrical signal processing device being configured to operably engage the at least one electrical connector for receiving the electrical signal from the wearer's skin.  
     
     
         17 . A circularly knit blank for making a substantially seamless garment, said blank comprising a fabric structure having: 
 a first series of courses having an inner surface and an outer surface, the first series of courses beginning at a first end and extending to an opposite second end;    a second series of courses having a first end knitted to the second end of the first series of courses and extending to an opposite second end, the second series of courses having an inner surface adapted to be disposed adjacent to a wearer's skin when the garment is worn and an opposing outer surface, one of the inner and outer surfaces of the first series of courses being configured to overlie the outer surface of the second series of courses to create a two-ply fabric structure; and    at least one discrete electrically-conductive region formed at the inner surface of the second series of courses during the circular knitting thereof in such as manner as to contact the wearer's skin when the garment is worn, the at least one electrically-conductive region being comprised of electrically-conductive threads knit into the second series of courses such that the electrically-conductive threads at the inner surface of the second series of courses are confined to the at least one electrically-conductive region, the at least one electrically-conductive region being further adapted to cooperate with the wearer's skin to conduct an electrical signal therebetween.    
     
     
         18 . A blank according to  claim 17  wherein the fabric structure comprises a circularly knit single ply fabric tube having opposed ends.  
     
     
         19 . A blank according to  claim 18  wherein the fabric tube further comprises a turned welt knit at each end of the tube.  
     
     
         20 . A blank according to  claim 18  wherein the fabric tube further comprises a fold region disposed intermediate to the first series of courses and the second series of courses, the blank being foldable about the fold region to create the two ply fabric structure.  
     
     
         21 . A blank according to  claim 20  wherein the fold region comprises a turned welt.  
     
     
         22 . A blank according to  claim 17  further comprising an electrical signal processing device in communication with the at least one electrically-conductive region and configured to receive the electrical signal from the wearer's skin.  
     
     
         23 . A blank according to  claim 17  further comprising a display in communication with the at least one electrically-conductive region and configured to display a representation of the electrical signal.  
     
     
         24 . A blank according to  claim 17  further comprising at least one conductive element in electrical contact with the at least one electrically-conductive region, the at least one conductive element extending between the at least one electrically-conductive region and at least one of the outer surface of the second series of courses and the inner surface of the first series of courses.  
     
     
         25 . A blank according to  claim 24  wherein the first series of courses and the second series of courses are configured so as to define a pocket therebetween, the at least one conductive element further being configured to extend from the at least one electrically-conductive region into the pocket.  
     
     
         26 . A blank according to  claim 25  further comprising at least one electrical connector operably engaged with each conductive element in opposing relation to the at least one electrically-conductive region.  
     
     
         27 . A blank according to  claim 26  further comprising an electrical signal processing device configured to be housed by the pocket and to be operably engageable with the at least one electrical connector so as to receive the electrical signal from the at least one electrically-conductive region.  
     
     
         28 . A blank according to  claim 24  wherein the at least one conductive element is integrally formed with the at least one electrically-conductive region during the circular knitting of the second series of courses.  
     
     
         29 . A method of making a substantially seamless garment, comprising: 
 knitting a tubular blank by: 
 circularly knitting a first series of courses to form first tubular structure having an inner surface, an outer surface and opposing ends; and  
 circularly knitting a second series of courses to one of the ends of the first series of courses to form a second tubular structure, the second tubular structure having an inner surface and an outer surface, the inner surface including at least one discrete electrically-conductive region formed therewith during the circular knitting thereof and adapted to contact a wearer's skin when the garment is worn, the at least one electrically-conductive region being further adapted to cooperate with the wearer's skin to conduct an electrical signal therebetween, the at least one electrically-conductive region being comprised of electrically-conductive threads knit into the second series of courses such that the electrically-conductive threads at the inner surface of the second series of courses are confined to the at least one electrically-conductive region, and the at least one electrically-conductive region further including at least one conductive element extending therefrom, one of the inner and outer surfaces of the first tubular structure being configured to overlie the outer surface of the second tubular structure so as to form a two-ply blank;  
   cutting the two-ply blank to define peripheral edges of the garment; and    selectively stitching the peripheral edges of the two-ply blank together.    
     
     
         30 . A method according to  claim 29  wherein circularly knitting a second series of courses further comprises selectively circularly knitting electrically conductive threads into the second series of courses so as to integrally form the at least one electrically-conductive region and the at least one conductive element.  
     
     
         31 . A method according to  claim 29  further comprising establishing communication between the at least one electrically-conductive region and an electrical signal processing device configured to receive the electrical signal from the wearer's skin.  
     
     
         32 . A method according to  claim 29  further comprising establishing communication between the at least one electrically-conductive region and a display configured to display a representation of the electrical signal.  
     
     
         33 . A method according to  claim 29  further comprising forming a pocket between the first series of courses and the second series of courses, the at least one conductive element extending from the at least one electrically-conductive region into the pocket.  
     
     
         34 . A method according to  claim 33  further comprising operably engaging at least one electrical connector with each conductive element in opposing relation to the at least one electrically-conductive region, the at least one electrical connector being disposed within the pocket.  
     
     
         35 . A method according to  claim 34  further comprising disposing an electrical signal processing device in the pocket in operable engagement with the at least one electrical connector, the electrical signal processing device being communicable with the at least one electrically-conductive region to receive the electrical signal.  
     
     
         36 . A method according to  claim 29  wherein stitching the peripheral edges of the two-ply blank further comprises stitching the second series of courses to the one end of the first series of courses at a turned welt so as to define an edge of the garment.