Seamless circular knit fabric, a method of making same and a forming machine using this method, as well as articles comprising straps or bands made therefrom

Abstract

A seamless circular knit fabric (10) comprising an elastic yarn is provided. The fabric (10) has a continuous circular knit through the length thereof. The circular knit fabric (10) further includes a cured cushion filling (12) inside the circular knit fabric (10) and bonded thereto. The method of making same comprises knitting a yarn to produce a continuous length of circular knit fabric (10), and injecting a curable cushion filling in a pre-cured state inside the circular knit fabric (10). This method uses a circular knit fabric forming machine assembly comprising a circular knitting machine and an injector.

1 . A seamless circular knit fabric comprising an elastic yarn, the fabric having a continuous circular knit through a length thereof, the circular knit fabric further including a cured cushion filling that fills an inside of a cavity of the circular knit fabric and bonded thereto. 
     
     
         2 . The seamless circular knit fabric according to  claim 1  wherein the cured cushion filling is a thermoplastic or thermosetting polymer. 
     
     
         3 . The seamless circular knit fabric according to  claim 1  wherein the cured cushion filling is a two-part silicone gel. 
     
     
         4 . The seamless circular knit fabric according to  claim 1  having a cut end to define a discrete length of circular knit fabric. 
     
     
         5 . The seamless circular knit fabric according to  claim 1  having more than one filled portion, the filled portion being filled with the cured cushion filling, wherein each filled portion is separated by a non-filled portion, the non-filled portion being absent of the cured cushion filling. 
     
     
         6 . The seamless circular knit fabric according to  claim 1  having a minimum width of 2 mm, optionally 6 mm, optionally 8 mm. 
     
     
         7 . The seamless circular knit fabric according to  claim 1  having a maximum width of 20 mm, optionally 30 mm, optionally 50 mm. 
     
     
         8 . The seamless circular knit fabric according to  claim 1 , wherein the fabric forms at least one of:
 a shoulder strap secured at each end to a body portion, the body portion for positioning around a torso of a wearer in use;   an underband portion of a bra, the underband portion for positioning around a torso of a the wearer in use;   a stretchable waistband of a bottom garment, the stretchable waistband for positioning around a waist of the wearer; or   a head strap secured at each end to a face covering portion of a face mask.   
     
     
         9 . (canceled) 
     
     
         10 . (canceled) 
     
     
         11 . (canceled) 
     
     
         12 . The method according to claim  34  wherein the step of inserting the curable cushion filling includes:
 injecting the curable cushion filling in a pre-cured state inside the cavity of the circular knit fabric such that the cavity is filled with the curable cushion filling, wherein the injecting is being carried out as the fabric is being knitted. 
 
     
     
         13 . (canceled) 
     
     
         14 . (canceled) 
     
     
         15 . The method according to claim  34 , including curing the cushion filling as the continuous length of circular knit fabric is being made. 
     
     
         16 . (canceled) 
     
     
         17 . The method according to claim  34  including passing the continuous length of circular knit fabric with the curable cushion filling through an adjustment mechanism to adjust a shape of the fabric. 
     
     
         18 . The method according to claim  34  including feeding the yarn from a yarn platform upwards towards the circular knit machine head, and producing the continuous length of circular knit fabric in a space created between the circular knit head and the yarn platform. 
     
     
         19 . The method according to claim  34  including pulling the continuous length of circular knit fabric in the direction that the circular knit fabric is being produced. 
     
     
         20 . The method according to claim  34  further including cutting the continuous length of circular knit fabric to discrete lengths of circular knit fabric. 
     
     
         21 . (canceled) 
     
     
         22 . (canceled) 
     
     
         23 . The seamless circular knit fabric forming machine assembly
 according to claim  35  wherein the inserter includes an injector configured to inject the curable cushion filling in a pre-cured state inside the cavity of the circular knit fabric so as to fill the cavity with the curable cushion filling as the circular knit fabric is being knitted.   
     
     
         24 . (canceled) 
     
     
         25 . (canceled) 
     
     
         26 . (canceled) 
     
     
         27 . (canceled) 
     
     
         28 . The seamless circular knit fabric forming machine assembly according to claim  35 , further including an adjustment mechanism configured to receive the continuous circular knit fabric with the pre-cured cushion filling and to adjust a shape of the fabric as a result of the fabric passing through the adjustment mechanism. 
     
     
         29 . The seamless circular knit fabric forming machine assembly according to claim  35 , including a yarn platform wherefrom the yarn is fed upwards towards the circular knit machine head, wherein the continuous circular knit fabric is produced in a space created between the circular knit head and the yarn platform. 
     
     
         30 . The seamless circular knit fabric forming machine assembly according to claim  35 , further including a takedown mechanism configured to pull the continuous length of circular knit fabric in the direction that the circular knit fabric is being produced. 
     
     
         31 . (canceled) 
     
     
         32 . (canceled) 
     
     
         33 . (canceled) 
     
     
         34 . A method of forming a seamless circular knit fabric comprising:
 feeding an elastic yarn into a circular knit machine head;   knitting the yarn by bending the yarn into loops and intermeshing yarn loops in a horizontal direction in a seamless manner to produce a continuous length of circular knit fabric;   inserting a curable cushion filling inside a cavity of the circular knit fabric such that the cavity is filled with the curable cushion filling, wherein the inserting is being carried out as the fabric is being knitted.   
     
     
         35 . A seamless circular knit fabric forming machine assembly comprising:
 a circular knit machine head configured to bend elastic yarn into loops and intermesh the yarn loops in a horizontal direction in a seamless manner to produce a continuous length of circular knit fabric;   a yarn feeder configured to feed yarn into the circular knit machine head; and   an inserter configured to insert a curable cushion filling inside a cavity of the circular knit fabric so as to fill the cavity with the curable cushion filling as the circular knit fabric is being knitted.