U.S. patent application number 15/802317 was filed with the patent office on 2018-10-04 for base layer of a garment.
This patent application is currently assigned to Fox Head, Inc.. The applicant listed for this patent is Fox Head, Inc.. Invention is credited to Tom Burgher, David Durham, Lindsay Mellen, Jillian Miranda, Jake Theno.
Application Number | 20180279694 15/802317 |
Document ID | / |
Family ID | 62075848 |
Filed Date | 2018-10-04 |
United States Patent
Application |
20180279694 |
Kind Code |
A1 |
Theno; Jake ; et
al. |
October 4, 2018 |
BASE LAYER OF A GARMENT
Abstract
A base layer of a garment includes a waist section, an upper leg
section, and a lower leg section. The waist section is positioned
to correspond with and receive a waist and crotch region of a
wearer. The waist section includes a base portion, a mesh portion,
a compressive portion, and a durable portion. The upper leg section
is positioned to correspond with and receive a thigh and knee
region of the wearer. The upper leg section includes the base
portion and the mesh portion. The lower leg section is positioned
to correspond with and receive a shin and calf region of the
wearer. The lower leg section includes the base portion and the
compressive portion.
Inventors: |
Theno; Jake; (Irvine,
CA) ; Durham; David; (Irvine, CA) ; Miranda;
Jillian; (Irvine, CA) ; Burgher; Tom; (Irvine,
CA) ; Mellen; Lindsay; (Irvine, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Fox Head, Inc. |
Irvine |
CA |
US |
|
|
Assignee: |
Fox Head, Inc.
Irvine
CA
|
Family ID: |
62075848 |
Appl. No.: |
15/802317 |
Filed: |
November 2, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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62416825 |
Nov 3, 2016 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A41D 1/088 20130101;
A41B 11/02 20130101; A41D 2600/102 20130101; A41D 1/08 20130101;
A41D 13/05 20130101; A41D 1/084 20130101; A41D 13/0015 20130101;
A41D 1/067 20130101; A41D 27/28 20130101; A63B 71/1225 20130101;
A41B 9/12 20130101; A41D 31/145 20190201; A41D 2600/104 20130101;
A41D 2300/22 20130101; A63B 71/1216 20130101; A41D 31/185
20190201 |
International
Class: |
A41D 1/084 20060101
A41D001/084; A63B 71/12 20060101 A63B071/12 |
Claims
1. A base layer of a garment, comprising: a waist section
positioned to correspond with and receive a waist and crotch region
of a wearer, the waist section including a base portion, a mesh
portion, a compressive portion, and a durable portion; an upper leg
section positioned to correspond with and receive a thigh and knee
region of the wearer, the upper leg section including the base
portion and the mesh portion; and a lower leg section positioned to
correspond with and receive a shin and calf region of the wearer,
the lower leg section including the base portion and the
compressive portion.
2. The base layer of claim 1, wherein the waist section, the upper
leg section, and the lower leg section form a unitary, seamless,
and three-dimensional layer.
3. The base layer of claim 2, wherein the base portion, the mesh
portion, the compressive portion, and the durable portion have
different material characteristics relative to each other such that
each of the base portion, the mesh portion, the compressive
portion, and the durable portion has specific properties at desired
locations of the base layer.
4. The base layer of claim 3, wherein the material characteristics
include at least one of (i) a thread count or threads-per-inch,
(ii) courses per inch, (iii) wales per inch, (iv) a warp thread
density or ends-per-inch, (v) a weft thread density or
picks-per-inch, (vi) a fabric density, and (vii) a fabric
thickness.
5. The base layer of claim 4, wherein the base portion has a first
thread count, the mesh portion has a second thread count, the
compressive portion has a third thread count, and the durable
portion has a fourth thread count, wherein the first thread count,
the second thread count, the third thread count, and the fourth
thread count are all different.
6. The base layer of claim 1, wherein the mesh portion of the waist
section is positioned to at least one of (i) surround a front
crotch area of the waist and crotch region of the wearer, (ii)
extend along a midline of a buttocks area of the waist and crotch
region of the wearer, and (iii) extend at least partially around a
periphery of the waist section to correspond with a waistline of
the waist and crotch region of the wearer.
7. The base layer of claim 6, wherein the base portion of the waist
section is positioned to correspond with the front crotch area of
the waist and crotch region of the wearer such that the base
portion is at least partially surrounded by the mesh portion of the
waist section.
8. The base layer of claim 7, wherein the base portion positioned
to correspond with the front crotch area of the waist and crotch
region of the wearer has a relatively looser tension relative to
all other sections of the base layer.
9. The base layer of claim 1, wherein the durable portion of the
waist section is positioned to correspond with a buttocks area of
the waist and crotch region of the wearer.
10. The base layer of claim 1, wherein the compressive portion of
the waist section is positioned at least one of (i) along each
lateral side of the waist section and (ii) to extend at least
partially around a periphery of the waist section to correspond
with a waistline of the waist and crotch region of the wearer.
11. The base layer of claim 1, wherein the mesh portion of the
upper leg section is positioned to extend at least one of (i) along
a front portion of a knee of the thigh and knee region of the
wearer, (ii) along a rear portion of the knee of the thigh and knee
region of the wearer, and (iii) around at least a portion of a
periphery of a thigh of the thigh and knee region of the
wearer.
12. The base layer of claim 1, wherein the compressive portion of
the lower leg section is positioned to extend along at least one of
(i) a shin of the shin and calf region of the wearer and (ii) a
calf of the shin and calf region of the wearer.
13. The base layer of claim 1, wherein the lower leg section
includes a foot section positioned to receive and enclose around a
foot of the wearer.
14. The base layer of claim 13, wherein the foot section includes
the compressive portion positioned to extend around at least a
portion of a periphery of the foot of the wearer.
15. The base layer of claim 13, wherein the foot section includes
the durable portion positioned to correspond with at least a
portion of a bottom of the foot of the wearer.
16. The base layer of claim 13, wherein the foot section includes
the mesh portion positioned to correspond with at least a portion
of a top of the foot of the wearer.
17. A garment, comprising: a base layer including: a first section
positioned to correspond with and receive a waist and crotch region
of a wearer; a second section positioned to correspond with and
receive a thigh and knee region of the wearer; and a third section
positioned to correspond with and receive a shin and calf region of
the wearer, wherein each of the first section, the second section,
and the third section includes a plurality of zones manufactured
from a first material, each of the plurality of zones having
different material characteristics; and a shell layer defining an
internal cavity configured to receive the base layer, the shell
layer at least partially manufactured from a second material having
a greater durability than the base layer.
18. The garment of claim 17, wherein the first section, the second
section, and the third leg section form a continuous and seamless
layer manufactured from the first material.
19. A base layer of a garment, comprising: a plurality of sections
positioned to correspond with and receive respective anatomical
regions of a wearer; wherein the plurality of sections form a
continuous and seamless layer; and wherein each of the plurality of
sections includes a plurality of portions having different material
characteristics.
20. The garment of claim 19, wherein the base layer is at least one
of an undershirt, a sleeveless shirt, a short-sleeve shirt, a
long-sleeve shirt, briefs, shorts, pants, a jumpsuit, a full-length
tight, a unitard, a singlet, and a leotard, and wherein the
material characteristics include at least one of (i) a thread count
or threads-per-inch, (ii) courses per inch, (iii) wales per inch,
(iv) a warp thread density or ends-per-inch, (v) a weft thread
density or picks-per-inch, (vi) a fabric density, and (vii) a
fabric thickness.
Description
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Patent Application No. 62/416,825, filed Nov. 3, 2016, which is
incorporated herein by reference in its entirety.
BACKGROUND
[0002] Traditional garments include a plurality of fabric pieces
that are sewn together or otherwise coupled to form the article of
clothing. Such coupling forms seams within the garment that may be
irritable to the wearer, affect the properties of the garment, as
well as limit the performance of the garment.
SUMMARY
[0003] One embodiment relates to a base layer of a garment. The
base layer includes a waist section, an upper leg section, and a
lower leg section. The waist section is positioned to correspond
with and receive a waist and crotch region of a wearer. The waist
section includes a base portion, a mesh portion, a compressive
portion, and a durable portion. The upper leg section is positioned
to correspond with and receive a thigh and knee region of the
wearer. The upper leg section includes the base portion and the
mesh portion. The lower leg section is positioned to correspond
with and receive a shin and calf region of the wearer. The lower
leg section includes the base portion and the compressive
portion.
[0004] Another embodiment relates to a garment. The garment
includes a base layer and a shell layer. The base layer includes a
first section, a second section, and a third section. The first
section is positioned to correspond with and receive a waist and
crotch region of a wearer. The second section is positioned to
correspond with and receive a thigh and knee region of the wearer.
The third section is positioned to correspond with and receive a
shin and calf region of the wearer. Each of the first section, the
second section, and the third section includes a plurality of zones
manufactured from a first material. Each of the plurality of zones
has different material characteristics. The shell layer defines an
internal cavity configured to receive the base layer. The shell
layer is at least partially manufactured from a second material
having a greater durability than the base layer.
[0005] Still another embodiment relates to a base layer of a
garment. The base layer includes a plurality of sections positioned
to correspond with and receive respective anatomical regions of a
wearer. The plurality of sections form a continuous and seamless
layer. Each of the plurality of sections includes a plurality of
portions having different material characteristics.
[0006] Yet another embodiment relates to a method for manufacturing
a base layer of a garment. The method include providing yarn and
knitting the yarn to form a seamless, three-dimensional layer. The
seamless, three-dimensional layer includes a plurality of sections
positioned to correspond with and receive respective anatomical
regions of a wearer. Each of the plurality of sections includes a
plurality of portions having different material characteristics.
The material characteristics include at least one of (i) a thread
count or threads-per-inch, (ii) courses per inch (CPI), (iii) wales
per inch (WPI), (iv) a warp thread density or ends-per-inch, (v) a
weft thread density or picks-per-inch, (vi) a fabric density, and
(vii) a fabric thickness.
[0007] The foregoing summary is illustrative only and is not
intended to be in any way limiting. In addition to the illustrative
aspects, embodiments, and features described above, further
aspects, embodiments, and features will become apparent by
reference to the drawings and the following detailed
description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The drawings are provided to illustrate example embodiments
described herein and are not intended to limit the scope of the
disclosure. Throughout the drawings, reference numbers may be
re-used to indicate general correspondence between referenced
elements.
[0009] FIG. 1 is a front view of a base layer of a garment,
according to an example embodiment;
[0010] FIG. 2 is a side view of the base layer of FIG. 1, according
to an example embodiment;
[0011] FIG. 3 is a rear view of the base layer of FIG. 1, according
to an example embodiment;
[0012] FIG. 4 is a front, left perspective view of a shell layer of
a garment, according to an example embodiment;
[0013] FIG. 5 is a rear, right perspective view of the shell layer
of FIG. 4, according to an example embodiment;
[0014] FIG. 6 is a front view of a base layer of a garment,
according to another example embodiment;
[0015] FIG. 7 is a side view of the base layer of FIG. 6, according
to an example embodiment; and
[0016] FIG. 8 is a rear view of the base layer of FIG. 6, according
to an example embodiment.
DETAILED DESCRIPTION
[0017] Various aspects of the disclosure will now be described with
regard to certain examples and embodiments, which are intended to
illustrate but not to limit the disclosure. Nothing in this
disclosure is intended to imply that any particular feature or
characteristic of the disclosed embodiments is essential. The scope
of protection is defined by the claims that follow this description
and not by any particular embodiment described herein. Before
turning to the figures, which illustrate example embodiments in
detail, it should be understood that the application is not limited
to the details or methodology set forth in the description or
illustrated in the figures. It should also be understood that the
terminology is for the purpose of description only and should not
be regarded as limiting.
[0018] Embodiments herein generally relate to articles and/or base
layers that can provide one or more of ease of dressing, improved
movement and flexibility, improved ventilation, improved comfort,
improved interaction with other products (e.g., a shell layer,
boots, knee pads, etc.), etc. Such articles and/or base layers may
be used in a number of activities, including without limitation:
sports and athletics, including extreme sports and traditional
sports; military and combat activity; law enforcement; outdoor
activities such as camping, hiking, and climbing; automotive and
cycling activities, including auto racing, motorcycle riding and
racing, motocross, bicycling such as BMX, etc.; equestrian and
rodeo; while operating recreational vehicles including ATVs,
snowmobiles, side-by-sides, and other off-road vehicles; to name
just a few. The articles and/or base layers and methods for
manufacturing and/or using the same provide various improvements
not present in existing articles and/or base layers. Further
details are provided herein.
[0019] According to an example embodiment, a base layer of a
garment includes a plurality of sections that are arranged (e.g.,
knitted, woven, sewn, etc.) from a single material (e.g., a single
spool of yarn, etc.) to form a single, continuous, seamless,
three-dimensional layer. The plurality of sections of the base
layer may include a plurality of different portions (e.g., base
portions, mesh portions, compressive portions, durable portions,
etc.) having differing material characteristics (e.g., thread count
or threads-per-inch, warp thread density or ends-per-inch, weft
thread density or picks-per-inch, fabric density, fabric thickness,
etc.). The material characteristics of the various portions may
provide specific material properties (e.g., strength, durability,
elasticity, mechanical ease, ventilation, joint articulation, etc.)
in desired locations of the base layer (e.g., to correspond with
certain anatomical regions of the wearer of the base layer,
etc.).
[0020] According to the example embodiment shown in FIGS. 1-5, a
garment includes an outer layer, shown as shell layer 2, and an
inner layer, shown as base layer 10. According to an example
embodiment, the garment is a motocross racepant. In other
embodiments, the garment is a snowmobile pant, an ATV pant, or
another type of pant used for action sports. In still other
embodiments, the garment is another type of article (e.g., used for
action sports including motocross, race car driving, etc.; used for
athletics including football, baseball, hockey, track and field,
etc.; etc.). In some embodiments, the garment may additionally or
alternatively be or include a sleeveless shirt, a short-sleeve
shirt, a long-sleeve shirt, shorts, pants, a jumpsuit, a jacket,
and/or still another article of clothing.
[0021] According to the example embodiment shown in FIGS. 4 and 5,
the shell layer 2 includes a plurality of panels that are at least
one of arranged, molded, sewn, shaped, formed, cut, and tailored to
form a pant. In an alternative embodiment, the plurality of panels
of the shell layer 2 are at least one of arranged, molded, sewn,
shaped, formed, cut, and tailored to form another type of pant, a
sleeveless shirt, a short-sleeve shirt, a long-sleeve shirt,
briefs, shorts, pants, a jumpsuit, a jacket, or still another
article of clothing. The size of the shell layer 2 may be varied to
fit various wearers. For example, the plurality of panels of the
shell layer 2 may be at least one of arranged, molded, sewn,
shaped, formed, cut, and tailored to fit men, women, both men and
women, or children. According to an example embodiment, the
plurality of panels of the shell layer 2 are manufactured from at
least two different materials. In some embodiments, the plurality
of panels of the shell layer 2 are manufactured from three distinct
materials. In other embodiments, the plurality of panels of the
shell layer 2 are manufactured from four or more distinct
materials.
[0022] According to an example embodiment, the shell layer 2
includes a first plurality of panels or stretch fabric panels, and
a second plurality of panels or rigid panels. According to an
example embodiment, the stretch fabric panels of the shell layer 2
are manufactured from a first fabric material, and the rigid panels
are manufactured from a second different material. According to an
example embodiment, the stretch fabric panels are selectively
positioned about the shell layer 2 (e.g., between the rigid panels,
etc.) to facilitate independent movement of each of the rigid
panels relative to one another (e.g., each of the rigid panels
moves independently, etc.). According to an example embodiment, the
interaction between the stretch fabric panels and the rigid panels
facilitates natural movement of a wearer's body such that as a
wearer moves, the front side and the rear side of the shell layer 2
do not sheer away from each other (e.g., which may cause discomfort
and restriction in movement, etc.). In one embodiment, at least one
of the stretch fabric panels is manufactured from a first stretch
fabric material and at least one of the stretch fabric panels is
manufactured from a second different stretch fabric material. For
example, at least one of the stretch fabric panels may be
manufactured from a stretch fabric material and at least one of the
stretch fabric panels may be manufactured from a stretch mesh
fabric material and/or a mesh fabric material. The different
stretch fabric materials may differ in one or more characteristics
including elasticity, ventilation, abrasion resistance, heat
resistance, penetration resistance, and the like. The stretch mesh
fabric and/or the mesh fabric material may be used in areas of the
shell layer 2 to facilitate air to flow into and out of the shell
layer 2 of the garment (e.g., to provide a cooling effect to the
wearer of the shell layer 2, etc.). According to an example
embodiment, the stretch fabric material is more durable (e.g.,
tougher, stronger, heavier, etc.) than the stretch mesh fabric
material. In other embodiments, the stretch fabric panels are
manufactured from a single stretch fabric material. In an
alternative embodiment, the stretch fabric panels are manufactured
from a nominal stretch material (e.g., denim, a material having
more stretch than a rigid fabric material, a material having less
stretch that a stretch fabric material, etc.).
[0023] According to an example embodiment, the rigid panels of the
shell layer 2 are manufactured to be durable, protective (e.g.,
heat resistant, abrasion resistant, penetration resistant, etc.),
and/or structure giving. In one embodiment, at least one of the
rigid panels is manufactured from a first rigid material and at
least one of the rigid panels is manufactured from a second
different rigid material. The first rigid material and the second
rigid material may differ in one or more characteristics including
abrasion resistance, penetration resistance, heat resistance,
elasticity, and/or other material properties of the rigid
materials. For example, at least one of the rigid panels may be
manufactured from an abrasion resistant material and at least one
of the rigid panels may be manufactured from a heat resistant
material. The abrasion resistant material may be used in desired
areas of the shell layer 2 (e.g., a thigh area, a shin area, etc.)
to shield desired anatomical regions of the wearer from dirt,
rocks, and/or other debris that may hit the wearer during use
(e.g., while riding a dirt bike, etc.). The abrasion resistant
material may include 900D fabric, ballistic nylon, a heavy duty
poly-fabric, Kevlar, carbon fiber, plastic, and/or leather, among
other possible abrasion resistant materials. The heat resistant
material may be used in desired areas of the shell layer 2 (e.g.,
inner leg area, etc.) to shield desired anatomical regions of the
wearer from heat emitted by components (e.g., an engine, engine
components, exhaust components, etc.) of a vehicle (e.g., a dirt
bike, an ATV, a snowmobile, etc.) being driven by the wearer of the
garment (e.g., the shell layer 2 and/or the base layer 10, etc.).
The heat resistant material may include leather, Therma-fleece heat
resistant fabric, and/or Kevlar, among other possible heat
resistant materials. In other embodiments, the rigid panels are
manufactured from a single rigid material. In an alternative
embodiment, the rigid panels are manufactured from a fabric
material.
[0024] According to an example embodiment, the independent movement
of the rigid panels allows the rigid panels to work independent of
each other, thereby providing a greater degree of comfort and less
restriction (e.g., while walking, sitting, riding, etc.) without
sacrificing the intended function of the shell layer 2, which is to
provide protection to the wearer (e.g., a motocross rider, a
snowmobile rider, an ATV rider, etc.) from debris and/or heat while
driving a vehicle (e.g., a dirt bike, etc.). In some embodiments,
the rigid panels are configured (e.g., aerodynamically shaped,
formed, etc.) to reduce drag forces experienced by a wearer of the
shell layer 2 (e.g., while traveling at increased speeds, etc.). In
some embodiments, the rigid panels are woven or otherwise
manufactured from a hard and/or durable material (e.g., carbon
fiber, Kevlar, 900D fabric, etc.). In other embodiments, the rigid
panels are formed (e.g., molded, etc.) from a non-woven material
(e.g., plastic, etc.). According to an example embodiment, the
shell layer 2 (e.g., the rigid panels, etc.) is at least partially
manufactured from a material having a greater durability than the
base layer 10.
[0025] As shown in FIGS. 4 and 5, the shell layer 2 includes a
first section or waist section, a second section, shown as right
leg section 6, and a third section, shown as left leg section 8. As
shown in FIG. 4, the waist section, the right leg section 6, and
the left leg section 8 of the shell layer 2 cooperatively define an
internal cavity, shown as cavity 4. More details regarding the
shell layer 2 may be found in International Application No.
PCT/US2016/062317, filed on Nov. 16, 2016, which is incorporated
herein by reference in its entirety.
[0026] According to an example embodiment, the cavity 4 of the
shell layer 2 is configured to receive the base layer 10. In one
embodiment, the shell layer 2 and the base layer 10 are individual
components of the garment (e.g., the base layer 10 is not coupled
or attached to the shell layer 2, etc.). In an alternative
embodiment, the base layer 10 is disposed within and coupled (e.g.,
sewn; attached; releasably coupled with hook and loop fasteners,
clips, hooks, buttons; etc.) to the shell layer 2. According to an
example embodiment, the base layer 10 covers seams formed between
the stretch fabric panels and the rigid panels (e.g., such that the
seams, the stretch fabric panels, and/or the rigid panels do not
come into contact with the wearer, providing increased comfort,
reducing chaffing and/or scratching, etc.). In other embodiments,
the base layer 10 covers the rigid panels and/or the seams to
prevent discomfort and/or chaffing. In some embodiments, the base
layer 10 is configured to provide ventilation to the wearer of the
garment. In some embodiments, the base layer 10 is configured to
provide warmth and/or protection from wind.
[0027] According to the example embodiment shown in FIGS. 1-3, the
base layer 10 includes a plurality of sections that are at least
one of arranged, knitted, woven, molded, sewn, shaped, formed, cut,
and tailored to form a pant (e.g., a full-length tight, etc.). In
an alternative embodiment, the plurality of section of the base
layer 10 are at least one of arranged, knitted, woven, molded,
sewn, shaped, formed, cut, and tailored to form another type of
pant, an undershirt, a sleeveless shirt, a short-sleeve shirt, a
long-sleeve shirt, briefs, shorts, pants, a jumpsuit, a unitard, a
singlet, a leotard, or still another article of clothing. The size
of the base layer 10 may be varied to fit various wearers. For
example, the plurality of sections of the base layer 10 may be at
least one of arranged, knitted, woven, molded, sewn, shaped,
formed, cut, and tailored to fit men, women, both men and women, or
children. According to an example embodiment, the plurality of
sections of the base layer 10 (i) are positioned to correspond with
and receive respective anatomical regions of a wearer of the base
layer 10, (ii) form a continuous and seamless layer, and/or (iii)
include a plurality of portions or zones having different material
characteristics (e.g., thread count or threads-per-inch (TPI),
courses per inch (CPI), wales per inch (WPI), warp thread density
or ends-per-inch (EPI), weft thread density or picks-per-inch
(PPI), fabric density, thickness, etc.).
[0028] As shown in FIGS. 1-3, the base layer 10 includes a first
section, shown as waist section 12, a second section, shown as
upper leg section 14, and a third section, shown as lower leg
section 16. The lower leg section 16 includes a fourth section,
shown as foot section 18. In other embodiments, the base layer 10
does not include one or more of the waist section 12, the upper leg
section 14, the lower leg section 16, and/or the foot section 18
(e.g., just the waist section 12, the upper leg section 14, and the
lower leg section 16; just the waist section 12 and the upper leg
section 14; just the lower leg section 16 and the foot section 18;
etc.). The waist section 12 is positioned and formed to correspond
with and receive a waist, buttocks, and crotch region of a wearer
of the base layer 10. The upper leg section 14 is positioned and
formed to correspond with and receive a thigh and knee region of a
wearer of the base layer 10. The lower leg section 16 is positioned
and formed to correspond with and receive a shin and calf region of
a wearer of the base layer 10. The foot section 18 is positioned
and formed to correspond with and receive (e.g., enclose around,
etc.) a foot of a wearer of the base layer 10. The upper leg
section 14, the lower leg section 16, and/or the foot section 18
cooperatively form a pair of legs of the base layer 10 that extend
from the waist section 12.
[0029] According to an example embodiment, the base layer 10 is
configured to be a skintight and/or a one piece layer. In one
embodiment, the waist section 12, the upper leg section 14, the
lower leg section 16, and/or the foot section 18 form a continuous
and seamless layer (e.g., a unitary, seamless, and
three-dimensional (3D) layer, etc.). The continuous and seamless
layer maybe manufactured from a single, uniform material. According
to an example embodiment, the base layer 10 is manufactured using a
3D knitting machine that forms (e.g., knits, etc.) the base layer
10 from the single material (e.g., yarn, fabric, thread, etc.). In
one embodiment, the single material includes multi-constituent yarn
(e.g., Cordura.RTM. yarn, 95% Cordura.RTM. nylon and 5% elastane,
etc.). By way of example, the yarn may be or include 160D/68F
(80D/34F 2 ply air-textured yarn (ATY)) with Lycra 40 denier (den)
covering yarn. In other embodiments, a different type of yarn,
thread, and/or fabric is used. The base layer 10 may advantageously
provide the durability of nylon and the comfort of cotton, be
strong yet lightweight, have exceptional abrasion resistance, have
high tensile and/or tear strengths for lasting performance, and/or
provide excellent temperature and moisture management. The base
layer 10 may also advantageously prevent the need to put on
multiple undergarments (e.g., socks, compression shorts, a jock
strap, etc.) as the multiple undergarments may be integrally formed
within the base layer 10 (e.g., providing ease of dressing,
etc.).
[0030] According to an example embodiment, the continuous and
seamless structure of the base layer 10 provides various advantages
relative to traditional garments that are cut and sewn or otherwise
coupled together. By way of example, without seams, patterns and
designs of the base layer 10 remain uninterrupted across the entire
garment (e.g., front-to-back, down-the-legs, etc.). 3D knitting may
allow the base layer 10 to be reproduced exactly as intended (e.g.,
minimizes and/or eliminates manufacturing defects associated with
traditional garments, each base layer 10 is produced based on
digitally programmed data such that item-to-item and batch-to-batch
quality remains consistent, etc.). Labor-intensive cutting and
sewing processes may be eliminated, and the amount of scrap
material thrown away after cutting out each part of a garment may
be entirely eliminated (e.g., by knitting a base layer 10 with only
the required amount of yarn, etc.). The base layer 10 may also have
superior comfort by eliminating irritable seams. The base layer 10
may additionally have superior stretch and mobility by eliminating
seams that would otherwise interfere with the natural elasticity of
knits. The seamless one-piece construction of the base layer 10 may
also facilitate evenly distributing stress throughout the base
layer 10, preventing localized pressure points which may cause
discomfort. Further, the seamless one-piece construction of the
base layer 10 may facilitate incorporating articulated joints in
desired areas of the base layer 10 (e.g., in a knee area, in an
elbow area, etc.) to further improve stretch and mobility of the
base layer 10.
[0031] In alternative embodiments, the waist section 12, the upper
leg section 14, the lower leg section 16, and/or the foot section
18 are manufactured as two or more (e.g., two, three, four, etc.)
individual sections and thereafter joined together (e.g., sewn
together, etc.). By way of example, (i) the waist section 12 and
the upper leg section 14 may be manufactured as a first continuous
portion (e.g., shorts, 3/4 pants, etc.) of the base layer 10 and
(ii) the lower leg section 16 and/or the foot section 18 may be
manufactured as a second continuous portion (e.g., a long sock, a
tube sock, etc.) of the base layer 10. By way of another example,
(i) the waist section 12, the upper leg section 14, and the lower
leg section 16 may be manufactured as a first continuous portion
(e.g., pants, etc.) of the base layer 10 and (ii) the foot section
18 may be manufactured as a second continuous portion (e.g., an
ankle sock, etc.) of the base layer 10. By way of yet another
example, (i) a first half of the base layer 10 (e.g., a front half,
a right half, etc. of the waist section 12, the upper leg section
14, the lower leg section 16, and/or the foot section 18) may be
manufactured as a first continuous portion of the base layer 10 and
(ii) an opposing second half of the base layer 10 (e.g., a rear
half, a left half, etc. of the waist section 12, the upper leg
section 14, the lower leg section 16, and/or the foot section 18)
may be manufactured as a second continuous portion of the base
layer 10. The first continuous portion and the second continuous
portion may thereafter be coupled (e.g., sewn, using a flat lock
stitch, etc.) to form the base layer 10.
[0032] According to an example embodiment, each of the waist
section 12, the upper leg section 14, the lower leg section 16,
and/or the foot section 18 includes a plurality of portions
manufactured (e.g., woven, knitted, felted, otherwise arranged into
a structure that forms fabric, etc.) from the same material (e.g.,
the multi-constituent yarn, Cordura.RTM. yarn, etc.). Each of the
plurality of portions of the waist section 12, the upper leg
section 14, the lower leg section 16, and/or the foot section 18
have different material characteristics (e.g., TPI, CPI, WPI, EPI,
PPI, fabric density, fabric thickness, etc.), according to an
example embodiment. The different material characteristics may
facilitate providing various portions having specific material
properties (e.g., strength, durability, elasticity, mechanical
ease, ventilation, joint articulation, etc.) at desired locations
of the base layer 10.
[0033] A shown in FIGS. 1-3, the waist section 12, the upper leg
section 14, the lower leg section 16, and the foot section 18 of
the base layer 10 include a first plurality of portions, shown as
base zones 20, a second plurality of portions, shown as compressive
zones 40, a third plurality of portions, shown as mesh zones 60,
and a fourth plurality of portions, shown as durable zones 80.
According to an example embodiment, the compressive zones 40 are
configured to facilitate providing a tight-fitting (e.g.,
skin-tight, etc.) base layer 10 that conforms to the body structure
of the wearer of the base layer 10 (e.g., in desired anatomical
regions, etc.). According to an example embodiment, the mesh zones
60 have a mesh structure that defines a plurality of apertures that
facilitate ventilation (e.g., air flow into and out of the base
layer 10, in desired anatomical regions, allows the base layer 10
to "breath," etc.). In one embodiment, the plurality of apertures
are formed during the manufacturing process (e.g., the plurality of
apertures are integrated into the base layer 10 during the knitting
process, etc.). In an alternative embodiment, the plurality of
apertures are formed after the base layer 10 is completed (e.g.,
the plurality of apertures are cut out of the base layer 10, etc.).
In one embodiment, the plurality of apertures have a diameter of
about 2 millimeters (mm). In other embodiments, the plurality of
apertures have a different diameter (e.g., 1/4 mm, 1/2 mm, 1 mm, 3
mm, 5 mm, etc.). According to an example embodiment, the durable
zones 80 have a greater durability relative to the other portions
of the base layer 10 to provide increased protection (e.g.,
abrasion resistance, penetration resistance, heat resistance,
impact resistance, etc.) to the wearer of the base layer 10 (e.g.,
in desired anatomical regions, etc.). By way of example, the
durable zones 80 may include a plurality of localized portions that
have much higher thread count than adjacent portions of the durable
zones 80, creating a pattern (e.g., a pattern of rectangles, etc.)
that provides the increased durability.
[0034] The various portions (e.g., the base zones 20, the
compressive zones 40, the mesh zones 60, the durable zones 80,
etc.) of the base layer 10 may include a plurality of fibers that
are woven, knitted, felted, or otherwise arranged into a structure
that forms the base layer 10. The plurality of fibers may include a
single constituent material (e.g., cotton, nylon, polyester,
spandex, another elastane material, another synthetic material,
another natural material, etc.) or may include a blend of multiple
constituent materials (e.g., Cordura.RTM. nylon and elastane,
etc.). The base layer 10 may include a fabric having a certain
degree of elastic stretch, where the fabric elongates when a force
is applied due to deformation (e.g., elastic deformation, etc.) of
the fibers themselves (e.g., deformation within the elastic region
of the fibers when a force or a stress below the yield strength of
the fibers is applied, etc.). The fibers may resist the force and
return the fabric to the pre-stretch state when the force is
released.
[0035] The various portions of the base layer 10 may have a certain
degree of mechanical ease (i.e., mechanical give), where the fabric
elongates when a force is applied due to movement of the fibers
within the structure of the various portions. The mechanical ease
of the fabric may vary based on the arrangement of the fibers
within the structure of the various portions (e.g., warp and weft
density, weave, etc.) and the conditions under which the fabric was
produced (e.g., speed of weaving, warp insertion rate, warp and
weft tension, etc.). In one embodiment, the mechanical ease does
not resist pull in the same way (e.g., does not have the same type
of rebound, does not have the same pull profile of rebound, etc.)
as the elastic stretch associated with the fibers themselves.
Rather, the mechanical ease allows the fibers that make up the
fabric to move in and out of the empty spaces between the
fibers.
[0036] The elongation of the fabric (e.g., due to the mechanical
ease, due to the elastic deformation of the fibers themselves, due
to the both the mechanical ease and the elastic deformation of the
fibers themselves, etc.) may be quantified in terms of a stretch
factor. The stretch factor may be equal to the pre-stretched
dimension of the fabric subtracted from the stretched dimension of
the fabric (e.g., with a force applied that produces sub-yield
strength stresses, etc.), with the resulting quantity thereafter
divided by the pre-stretched dimension of the fabric.
[0037] One or more portions of the base layer 10 (e.g., the base
zones 20, the compressive zones 40, the mesh zones 60, etc.) may
have both mechanical ease and elastic stretch or primarily only
elastic stretch while other portions of the base layer 10 (e.g.,
the durable zones 80, etc.) may have primarily only mechanical
ease. In some embodiments, one or more portions of the base layer
10 (e.g., the base zones 20, the compressive zones 40, the mesh
zones 60, etc.) have a greater degree of elastic stretch than
mechanical ease while other portions of the base layer 10 (e.g.,
the durable zones 80, etc.) have a greater degree of mechanical
ease than elastic stretch. In some embodiments, one or more
portions of the base layer 10 (e.g., the base zones 20, the
compressive zones 40, the mesh zones 60, etc.) have a stretch
factor at least equal to a threshold (e.g., more than zero percent,
at least 5%, at least 10%, at least 25%, at least 50%, at least
100%, etc.) in one or both directions (e.g., lateral and/or
longitudinal, along x-axis and/or y-axis, etc.), while other
portions of the base layer 10 (e.g., the durable zones 80, etc.)
have a stretch factor of less than the threshold (e.g., zero
percent, less than 5%, less than 10%, less than 25%, less than 50%,
less than 100%, etc.) in one or both directions (e.g., lateral
and/or longitudinal, along x-axis and/or y-axis, etc.).
[0038] In some embodiments, the base zones 20, the compressive
zones 40, the mesh zones 60, and/or the durable zones 80 have
isotropic (e.g., symmetrical, identical, etc.) stretch properties
(e.g., four-ways stretch, uniform stretch characteristics, etc.).
By way of example, the base zones 20, the compressive zones 40, the
mesh zones 60, and/or the durable zones 80 may have a mechanical
ease and/or an elastic stretch that is independent of the direction
of an applied force (e.g., stretches the same in a lateral
direction as a longitudinal direction, etc.). In some embodiments,
the base zones 20, the compressive zones 40, the mesh zones 60,
and/or the durable zones 80 have anisotropic (e.g., asymmetrical,
etc.) stretch properties (e.g., may have properties that vary with
direction, etc.). By way of example, the base zones 20, the
compressive zones 40, the mesh zones 60, and/or the durable zones
80 may have at least one of a mechanical ease and an elastic
stretch that varies based on the direction of an applied force. For
example, the compressive zones 40 may have an elastic stretch that
is greater in a first direction (e.g., a cross-grain direction,
etc.) than in a second direction (e.g., a grain direction, etc.).
The first direction may be angularly offset relative to (e.g.,
perpendicular to, etc.) the second direction. The first direction
(i.e., the direction along which the greater amount of elastic
stretch occurs) may define a primary stretch direction of the
fabric. Portions of the base layer 10 having a primary stretch
direction may have elastic stretch that occurs primarily in a
single direction. This characteristic can be observed by physical
manipulation of the fabric in both the first and second
directions.
[0039] According to an example embodiment shown in FIGS. 1-3, (i)
the waist section 12 includes one or more portions of the base
zones 20, the compressive zones 40, the mesh zones 60, and the
durable zones 80, (ii) the upper leg section 14 includes one or
more portions of the base zones 20 and the mesh zones 60, (iii) the
lower leg section 16 includes one or more portions of the base
zones 20 and the compressive zones 40, and (iv) the foot section 18
includes one or more portions of the compressive zones 40, the mesh
zones 60, and the durable zones 80. In other embodiments, the waist
section 12, the upper leg section 14, the lower leg section 16,
and/or the foot section 18 include different zones and/or more or
fewer zones of those that are shown. It should be understood that
the number, position, and/or the type of the various zones of the
waist section 12, the upper leg section 14, the lower leg section
16, and/or the foot section 18 shown in FIGS. 1-3 are for
illustrative purposes. Therefore, the number, type, and/or
placement of the various zones of the base layer 10 may be
different than what is shown in FIGS. 1-3.
[0040] As shown in FIGS. 1 and 2, the base zones 20 of the waist
section 12 include a first base portion, shown as left waist base
zone 22, a second base portion, shown as right waist base zone 24,
and a third base portion, shown as central waist base zone 30. As
shown in FIG. 1, the left waist base zone 22 is selectively
positioned about the base layer 10 so as to correspond in location
to a left anterior area of the waist, buttocks, and crotch region
of the wearer of the base layer 10. As shown in FIGS. 1 and 2, the
right waist base zone 24 is selectively positioned about the base
layer 10 so as to correspond in location to a right anterior area
of the waist, buttocks, and crotch region of the wearer of the base
layer 10. As shown in FIG. 1, the central waist base zone 30 is
selectively positioned about the base layer 10 so as to correspond
in location to the front crotch area of the waist, buttocks, and
crotch region of the wearer of the base layer 10. According to an
example embodiment, the central waist base zone 30 has a relatively
looser tension relative to all other portions of the base layer 10.
In some embodiments, the central waist base zone 30 defines a
cavity (e.g., a sleeve, a pocket, etc.) configured to receive a
protective cup to facilitate protecting the front crotch area of
the wearer of the base layer 10 from impacts thereto.
[0041] As shown in FIGS. 1-3, the compressive zones 40 of the waist
section 12 include a first compressive portion, shown as left waist
compressive zone 42, a second compressive portion, shown as right
waist compressive zone 44, and a third compressive portion, shown
as waistline compressive zone 50. As shown in FIGS. 1 and 3, the
left waist compressive zone 42 is selectively positioned about the
base layer 10 so as to correspond in location to the left lateral
side of the waist, buttocks, and crotch region of the wearer of the
base layer 10. As shown in FIGS. 1-3, the right waist compressive
zone 44 is selectively positioned about the base layer 10 so as to
correspond in location to the right lateral side of the waist,
buttocks, and crotch region of the wearer of the base layer 10.
Therefore, the left waist compressive zone 42 and the right waist
compressive zone 44 may be positioned along each lateral side of
the waist section 12 of the base layer 10. In some embodiments, the
left waist compressive zone 42 and/or the right waist compressive
zone 44 define a cavity (e.g., a sleeve, a pocket, etc.) configured
to receive a protective pad to facilitate protecting the left
and/or right lateral sides of the wearer of the base layer 10 from
impacts thereto.
[0042] As shown in FIGS. 1-3, the waistline compressive zone 50 is
selectively positioned about the base layer 10 so as to correspond
in location to the waistline of the waist, buttocks, and crotch
region of the wearer of the base layer 10. Therefore, the waistline
compressive zone 50 may be positioned to extend at least partially
around a periphery of the waist section 12 of the base layer 10. In
some embodiments, the waistline compressive zone 50 is coupled
(e.g., attached, sewn, etc.) to the waist section 12 after the base
layer 10 is manufactured (e.g., 3D knitted, etc.). By way of
example, the waistline compressive zone 50 may be or include an
elastic band coupled to the base layer 10 and configured to
facilitate securing the base layer 10 around the waist of the
wearer.
[0043] As shown in FIGS. 1-3, the mesh zones 60 of the waist
section 12 include a first mesh portion, shown as waist mesh zone
70. The waist mesh zone 70 is selectively positioned about the base
layer 10 to at least one of (i) surround the front crotch area of
the waist, buttocks, and crotch region of the wearer such that the
central waist base zone 30 is at least partially surrounded by the
waist mesh zone 70, (ii) extend along a midline of a posterior
buttocks area of the waist, buttocks, and crotch region of the
wearer, and (iii) extend at least partially around a periphery of
the waist section 12 to correspond with the waistline of the waist,
buttocks, and crotch region of the wearer.
[0044] As shown in FIGS. 2 and 3, the durable zones 80 of the waist
section 12 include a first durable portion, shown as left buttocks
durable zone 82, and a second durable portion, shown as right
buttocks durable zone 84. As shown in FIG. 3, the left buttocks
durable zone 82 is selectively positioned about the base layer 10
so as to correspond in location to a left posterior buttocks area
of the waist, buttocks, and crotch region of the wearer of the base
layer 10. As shown in FIGS. 2 and 3, the right buttocks durable
zone 84 is selectively positioned about the base layer 10 so as to
correspond in location to a right posterior buttocks area of the
waist, buttocks, and crotch region of the wearer of the base layer
10. The waist mesh zone 70 extending along the midline of the
posterior buttocks area of the waist, buttocks, and crotch region
of the wearer may thereby separate the left buttocks durable zone
82 from the right buttocks durable zone 84. In some embodiments,
the left buttocks durable zone 82 and/or the right buttocks durable
zone 84 define a cavity (e.g., a sleeve, a pocket, etc.) configured
to receive a protective pad to further facilitate protecting the
left and/or right buttocks area of the wearer of the base layer 10
from impacts thereto.
[0045] As shown in FIGS. 1-3, the base zones 20 of the upper leg
section 14 include a fourth base portion, shown as left upper leg
base zone 26, and a fifth base portion, shown as right upper leg
base zone 28. The left upper leg base zone 26 and the right upper
leg base zone 28 are selectively positioned about the base layer 10
so as to correspond in location to at least one of an upper
posterior leg area (e.g., rear of a wearer's thigh, hamstrings,
back of knee, etc.), an upper medial leg area (e.g., inner thigh,
inner knee, etc.), an upper lateral leg area (e.g., exterior thigh,
exterior knee, etc.), and/or an upper anterior leg area (e.g.,
front of a wearer's thigh, front of knee, etc.) of the thigh and
knee region of a wearer of the base layer 10.
[0046] As shown in FIGS. 1-3, the mesh zones 60 of the upper leg
section 14 include a second mesh portion, shown as left thigh mesh
zone 62, a third mesh portion, shown as right thigh mesh zone 64, a
fourth mesh portion, shown as left anterior knee mesh zone 66, a
fifth mesh portion, shown as right anterior knee mesh zone 68, a
sixth mesh portion, shown as left posterior knee mesh zone 72, and
a seventh mesh portion, shown as right posterior knee mesh zone 74.
As show in FIGS. 1-3, the left thigh mesh zone 62 and the right
thigh mesh zone 64 are selectively positioned about the base layer
10 so as to correspond in location to at least one of an upper
posterior leg area (e.g., rear of a wearer's thigh, etc.), an upper
medial leg area (e.g., inner thigh, etc.), an upper lateral leg
area (e.g., exterior thigh, etc.), and/or an upper anterior leg
area (e.g., front of a wearer's thigh, etc.) of the thigh and knee
region of a wearer of the base layer 10 such that the left thigh
mesh zone 62 and the right thigh mesh zone 64 extend around at
least a portion of a periphery of a thigh (e.g., the left thigh,
the right thing, etc.) of the thigh and knee region of the
wearer.
[0047] As shown in FIGS. 1 and 2, the left anterior knee mesh zone
66 and the right anterior knee mesh zone 68 are selectively
positioned about the base layer 10 so as to correspond in location
to an upper anterior leg area (e.g., front of the wearer's knee,
etc.) of the thigh and knee region of a wearer of the base layer 10
such that the left anterior knee mesh zone 66 and the right
anterior knee mesh zone 68 extend along an anterior area (e.g., a
front area, etc.) of a knee of the thigh and knee region of the
wearer. As shown in FIGS. 2 and 3, the left posterior knee mesh
zone 72 and the right posterior knee mesh zone 74 are selectively
positioned about the base layer 10 so as to correspond in location
to an upper posterior leg area (e.g., rear of the wearer's knee,
etc.) of the thigh and knee region of a wearer of the base layer 10
such that the left posterior knee mesh zone 72 and the right
posterior knee mesh zone 74 extend along a posterior area (e.g., a
rear area, etc.) of the knee of the thigh and knee region of the
wearer. According to an example embodiment, the mesh zones 60 of
the upper leg section 14 (e.g., the left thigh mesh zone 62, the
right thigh mesh zone 64, the left anterior knee mesh zone 66, the
right anterior knee mesh zone 68, the left posterior knee mesh zone
72, the right posterior knee mesh zone 74, etc.) are positioned to
increase the comfort of the wearer when the wearer is wearing a
knee brace by increasing the airflow into and out of the thigh and
knee region where the knee brace may be coupled.
[0048] As shown in FIGS. 1-3, the base zones 20 of the lower leg
section 16 include a sixth base portion, shown as left lateral
lower leg base zone 32, a seventh base portion, shown as left
medial lower leg base zone 34, an eighth base portion, shown as
right lateral lower leg base zone 36, and a ninth base portion,
shown as right medial lower leg base zone 38. The left lateral
lower leg base zone 32, the left medial lower leg base zone 34, the
right lateral lower leg base zone 36, and the right medial lower
leg base zone 38 are selectively positioned about the base layer 10
so as to correspond in location to at least one of a lower
posterior leg area (e.g., a calf area of the wearer, etc.), a lower
medial leg area (e.g., an inner calf and shin area of the wearer,
etc.), a lower lateral leg area (e.g., an exterior calf and shin
area of the wearer, etc.), and/or a lower anterior leg area (e.g.,
a shin area of the wearer, etc.) of the shin and calf region of a
wearer of the base layer 10.
[0049] As shown in FIGS. 1-3, the compressive zones 40 of the lower
leg section 16 include a fourth compressive portion, shown as left
shin compressive zone 46, a fifth compressive portion, shown as
right shin compressive zone 48, a sixth compressive portion, shown
as left calf compressive zone 52, and a seventh compressive
portion, shown as right calf compressive zone 54. As shown in FIGS.
1 and 2, the left shin compressive zone 46 and the right shin
compressive zone 48 are selectively positioned about the base layer
10 so as to correspond in location to a lower anterior leg area
(e.g., front of the wearer's lower leg, etc.) of the shin and calf
region of a wearer of the base layer 10 such that the left shin
compressive zone 46 and the right shin compressive zone 48 extend
along an anterior area (e.g., a front area, etc.) or a shin of the
shin and calf region of the wearer. As shown in FIGS. 2 and 3, the
left calf compressive zone 52 and the right calf compressive zone
54 are selectively positioned about the base layer 10 so as to
correspond in location to a lower posterior leg area (e.g., rear of
the wearer's lower leg, etc.) of the shin and calf region of a
wearer of the base layer 10 such that the left calf compressive
zone 52 and the right calf compressive zone 54 extend along a
posterior area (e.g., a rear area, etc.) or a calf of the shin and
calf region of the wearer. According to an example embodiment, the
compressive zones 40 of the lower leg section 16 (e.g., the left
shin compressive zone 46, the right shin compressive zone 48, the
left calf compressive zone 52, the right calf compressive zone 54,
etc.) are positioned to prevent the lower leg section 16 of the
base layer 10 from riding up the legs of the wearer of the base
layer 10. The compressive zones 40 of the lower leg section 16 may
be positioned and/or configured to facilitate a wearer of the base
layer 10 with easily putting on and taking off a pair of boots
(e.g., motocross boots, snowmobile boots, snowboarding boots,
skiing boots, etc.).
[0050] As shown in FIGS. 1-3, the compressive zones 40 of the foot
section 18 include an eighth compressive portion, shown as left
foot compressive zone 56, and a ninth compressive portion, shown as
right foot compressive zone 58. The left foot compressive zone 56
and the right foot compressive zone 58 are selectively positioned
about the base layer 10 so as to extend around at least a portion
of a periphery of each foot of the wearer. According to an example
embodiment, the compressive zones 40 of the foot section 18 (e.g.,
the left foot compressive zone 56, the right foot compressive zone
58, etc.) are positioned to secure the foot section 18 to the feet
of the wearer of the base layer 10 (e.g., prevent the foot section
18 from inadvertently pulling off of the feet as the wearer removes
footwear, etc.).
[0051] As shown in FIGS. 1 and 2, the mesh zones 60 of the foot
section 18 include an eighth mesh portion, shown as left foot mesh
zone 76, and a ninth mesh portion, shown as right foot mesh zone
78. The left foot mesh zone 76 and the right foot mesh zone 78 are
selectively positioned about the base layer 10 so as to correspond
in location to a top portion of the feet of a wearer of the base
layer 10 such that the left foot mesh zone 76 and the right foot
mesh zone 78 extend along the top of a respective foot of the
wearer. According to an example embodiment, the left foot mesh zone
76 and the right foot mesh zone 78 are positioned to provide
increased ventilation to the feet of the wearer (e.g., within
footwear such as boots, shoes, etc.).
[0052] As shown in FIGS. 1-3, the durable zones 80 of the foot
section 18 include a third durable portion, shown as left ankle
durable zone 86, a fourth durable portion, shown as right ankle
durable zone 88, a fifth durable portion, shown as left heel
durable zone 92, a sixth durable portion, shown as right heel
durable zone 94, a seventh durable portion, shown as left toes
durable zone 96, and an eighth durable portion, shown as right toes
durable zone 98. As shown in FIGS. 2 and 3, the left ankle durable
zone 86 and the right ankle durable zone 88 are selectively
positioned about the base layer 10 so as to correspond in location
to the ankles of a wearer of the base layer 10. The left heel
durable zone 92 and the right heel durable zone 94 are selectively
positioned about the base layer 10 so as to correspond in location
to the heels of a wearer of the base layer 10. As shown in FIGS.
1-3, the left toes durable zone 96 and the right toes durable zone
98 are selectively positioned about the base layer 10 so as to
correspond in location to the toes of a wearer of the base layer
10. According to an example embodiment, the left ankle durable zone
86, the right ankle durable zone 88, the left heel durable zone 92,
the right heel durable zone 94, the left toes durable zone 96,
and/or the right toes durable zone 98 are positioned to prevent
wear (e.g., rips, holes, etc.) to the foot section 18 and/or the
feet of the wearer (e.g., skin irritation, rashes, blisters, etc.
on the heels, ankles, toes, bottom portion, etc. of the feet)
during use (e.g., highly active use, while riding a dirt bike, as
the feet shift within footwear, etc.). As shown in FIGS. 1-3, the
foot section 18 includes grip portions, shown as grip zones 90. The
grip zones 90 may be configured to provide a wearer with grip while
not wearing footwear (e.g., boots, shoes, etc.) to provide better
traction and/or prevent a wearer's feet from moving within
footwear.
[0053] According to an example embodiment, the base zones 20, the
compressive zones 40, the mesh zones 60, and the durable zones 80
have different material characteristics relative to each other
(e.g., TPI, CPI, WPI, EPI, PPI, fabric density, fabric thickness,
etc. of the base zones 20, the compressive zones 40, the mesh zones
60, and the durable zones 80 all can be different). By way of
example, the base zones 20 (e.g., the left waist base zone 22, the
right waist base zone 24, the left upper leg base zone 26, the
right upper leg base zone 28, the central waist base zone 30, the
left lateral lower leg base zone 32, the left medial lower leg base
zone 34, the right lateral lower leg base zone 36, the right medial
lower leg base zone 38, etc.) may have first material
characteristics (e.g., a first CPI, a first WPI, etc.). For
example, in some embodiments the zone one material can have a CPI
of between about 45-58, of about 50-54, or of about 52 (or any sub
value or sub range therein, inclusive of endpoints). In some
embodiments, zone 1 material can have a WPI of about 15-27, of
about 19-23, or about 21 (or any sub value or sub range therein,
inclusive of endpoints). The compressive zones 40 (e.g., the left
waist compressive zone 42, the right waist compressive zone 44, the
left shin compressive zone 46, the right shin compressive zone 48,
the left calf compressive zone 52, the right calf compressive zone
54, the left foot compressive zone 56, the right foot compressive
zone 58, etc.) may have second material characteristics (e.g., a
second CPI, a second WPI, etc.). For example, in some embodiments
the zone 2 material can have a CPI of between about 30-42, of about
34-38, or of about 36 (or any sub value or sub range therein,
inclusive of endpoints). In some embodiments, zone 2 material can
have a WPI of about 20-32, of about 24-28, or about 26 (or any sub
value or sub range therein, inclusive of endpoints). The mesh zones
60 (e.g., the left thigh mesh zone 62, the right thigh mesh zone
64, the left anterior knee mesh zone 66, the right anterior knee
mesh zone 68, the waist mesh zone 70, the left posterior knee mesh
zone 72, the right posterior knee mesh zone 74, the left foot mesh
zone 76, the right foot mesh zone 78, etc.) may have third material
characteristics (e.g., a third CPI, a third WPI, etc.). For
example, in some embodiments the zone 3 material can have a CPI of
between about 30-42, of about 34-38, or of about 36 (or any sub
value or sub range therein, inclusive of endpoints). In some
embodiments, zone 3 material can have a WPI of about 20-32, of
about 24-28, or about 26 (or any sub value or sub range therein,
inclusive of endpoints). The durable zones 80 (e.g., the left
buttocks durable zone 82, the right buttocks durable zone 84, the
left ankle durable zone 86, the right ankle durable zone 88, the
left heel durable zone 92, the right heel durable zone 94, the left
toes durable zone 96, the right toes durable zone 98, etc.) may
have fourth material characteristics (e.g., a fourth CPI, a fourth
WPI, etc.). For example, in some embodiments the zone 4 material
can have a CPI of between about 48-60, of about 52-56, or of about
54 (or any sub value or sub range therein, inclusive of endpoints).
In some embodiments, zone 4 material can have a WPI of about 23-35,
of about 27-31, or about 29 (or any sub value or sub range therein,
inclusive of endpoints). According to an example embodiment, the
first material characteristics, the second material
characteristics, the third material characteristics, and the fourth
material characteristics are all different. By way of example, the
durable zones 80 may have the highest tread count (e.g., highest
thread density, etc.) to provide the inherent durability. By way of
another example, the mesh zones 60 may have the lowest thread count
(e.g., lowest thread density, etc.) to provide the loose, mesh
structure. By way of example, one or more zones of the base layer
10 (e.g., the base zones 20, etc.) may have a construction of about
40 CPI by about 31 WPI. It should be understood that not all of the
zones described have to be different in some or all of their
characteristics relative to each other. Some characteristics can be
the same, while others differ. For example, 2 or 3 can be similar
in one or more of the various characteristics and parameters
described here. In some embodiments, the various zone materials can
have a weight of between 320-350 g/m2, or 330-340 g/m2, or about
335 g/m2, for example.
[0054] According to the example embodiment shown in FIGS. 6-8, a
second base layer, shown as base layer 100, includes a plurality of
sections that are at least one of arranged, knitted, woven, molded,
sewn, shaped, formed, cut, and tailored to form a long-sleeve
shirt. According to an example embodiment, the base layer 100 is a
motocross base layer configured to be worn underneath a motocross
jersey. In other embodiments, the base layer 100 is a snowmobile
shirt, an ATV shirt, a bicycling shirt, or another type of shirt
used for athletics (e.g., running, sports, action sports, etc.). In
an alternative embodiment, the plurality of sections are at least
one of arranged, knitted, woven, molded, sewn, shaped, formed, cut,
and tailored to form another type of shirt such as a short-sleeve
shirts, a sleeve-less shirt, a tank-top, or still another article
of clothing. The size of the base layer 100 may be varied to fit
various wearers. For example, the plurality of sections of the base
layer 100 may be at least one of arranged, knitted, woven, molded,
sewn, shaped, formed, cut, and tailored to fit men, women, both men
and women, or children. According to an example embodiment, the
plurality of sections of the base layer 100 (i) are positioned to
correspond with and receive respective anatomical regions of a
wearer of the base layer 100, (ii) form a continuous and seamless
layer, and/or (iii) include a plurality of portions or zones having
different material characteristics (e.g., TPI, CPI, WPI, warp
thread density or EPI, weft thread density or PPI, fabric density,
thickness, etc.).
[0055] As shown in FIGS. 6-8, the base layer 100 includes a first
section, shown as torso section 112, a second section, shown as
left sleeve section 114, and a third section, shown as right sleeve
section 116. The torso section 112 is positioned and formed so as
to correspond with and receive a torso, waist, neck, and/or
shoulders of a wearer of the base layer 100. The left sleeve
section 114 and the right sleeve section 116 are positioned and
formed so as to correspond with and receive at least a portion of a
length of each arm of a wearer of the base layer 100. According to
the example embodiment shown in FIGS. 6-8, the left sleeve section
114 and the right sleeve section 116 include long-sleeves. In other
embodiments, the left sleeve section 114 and the right sleeve
section 116 include short-sleeves. In an alternative embodiment,
the base layer 100 does not include the left sleeve section 114 and
the right sleeve section 116. According to an example embodiment,
the torso section 112, the left sleeve section 114, and the right
sleeve section 116 are formed to receive a specific sized person
(e.g., an extra-small, a small, a medium, a large, an extra-large
person, etc.).
[0056] According to an example embodiment, the base layer 100 is
configured to be a skintight and/or a one piece layer. In one
embodiment, the torso section 112, the left sleeve section 114,
and/or the right sleeve section 116 form a continuous and seamless
layer (e.g., a unitary, seamless, and three-dimensional (3D) layer,
etc.). The continuous and seamless layer maybe manufactured from a
single, uniform material. According to an example embodiment, the
base layer 100 is manufactured using a 3D knitting machine that
forms (e.g., knits, etc.) the base layer 100 from the single
material (e.g., yarn, fabric, thread, etc.). In one embodiment, the
single material includes a multi-constituent yarn (e.g.,
Cordura.RTM. yarn, 95% Cordura.RTM. nylon and 5% elastane, etc.).
By way of example, the yarn may be or include 160D/68F (80D/34F 2
ply air-textured yarn (ATY)) with Lycra 40 denier (den) covering
yarn. In other embodiments, a different type of yarn, thread,
and/or fabric is used. In alternative embodiments, the torso
section 112, the left sleeve section 114, and/or the right sleeve
section 116 are manufactured as two or more (e.g., two, three,
etc.) individual sections and thereafter joined together (e.g.,
sewn together, etc.).
[0057] According to an example embodiment, each of the torso
section 112, the left sleeve section 114, and/or the right sleeve
section 116 includes a plurality of portions manufactured (e.g.,
woven, knitted, felted, otherwise arranged into a structure that
forms fabric, etc.) from the same material (e.g., the
multi-constituent yarn, Cordura.RTM. yarn, etc.). Each of the
plurality of portions of the torso section 112, the left sleeve
section 114, and/or the right sleeve section 116 have different
material characteristics (e.g., TPI, CPI, WPI, EPI, PPI, fabric
density, fabric thickness, etc.), according to an example
embodiment. The different material characteristics may facilitate
providing various portions having specific material properties
(e.g., strength, durability, elasticity, ventilation, joint
articulation, etc.) at desired locations of the base layer 100.
[0058] A shown in FIGS. 6-8, the torso section 112, the left sleeve
section 114, and the right sleeve section 116 of the base layer 100
include a first plurality of portions, shown as base zones 120, a
second plurality of portions, shown as compressive zones 140, a
third plurality of portions, shown as mesh zones 160, and a fourth
plurality of portions, shown as durable zones 180. According to an
example embodiment, the compressive zones 140 are configured to
facilitate providing a tight-fitting (e.g., skin-tight, etc.) base
layer 100 that conforms to the body structure of the wearer of the
base layer 100 (e.g., in desired anatomical regions, etc.).
According to an example embodiment, the mesh zones 160 have a mesh
structure that defines a plurality of apertures that facilitate
ventilation (e.g., air flow into and out of the base layer 100, in
desired anatomical regions, allow the base layer 100 to "breath,"
etc.). According to an example embodiment, the durable zones 180
have a greater durability relative to the other portions of the
base layer 100 to provide increased protection (e.g., abrasion
resistance, penetration resistance, heat resistance, etc.) to the
wearer of the base layer 100 (e.g., in desired anatomical regions,
etc.). The base zones 120, the compressive zones 140, the mesh
zones 160, and/or the durable zones 180 of the base layer 100 may
have similar material characteristics and/or properties as the base
zones 20, the compressive zones 40, the mesh zones 60, and/or the
durable zones 80 of the base layer 10 (e.g., TPI, CPI, WPI, EPI,
PPI, fabric density, fabric thickness, strength, durability,
elasticity, mechanical ease, ventilation, joint articulation,
etc.).
[0059] According to an example embodiment shown in FIGS. 6-8, (i)
the torso section 112 includes one or more portions of the base
zones 120, the compressive zones 140, and the mesh zones 160, and
(ii) the left sleeve section 114 and the right sleeve section 116
include one or more portions of the base zones 120, the mesh zones
160, and the durable zones 180. In other embodiments, the torso
section 112, the left sleeve section 114, and/or the right sleeve
section 116 include different zones and/or more or fewer zones of
those that are shown. It should be understood that the number,
position, and/or the type of the various zones of the torso section
112, the left sleeve section 114, and/or the right sleeve section
116 shown in FIGS. 6-8 are for illustrative purposes. Therefore,
the number, type, and/or placement of the various zones of the base
layer 100 may be different than what is shown in FIGS. 6-8.
[0060] As shown in FIGS. 6 and 8, the base zones 120 of the torso
section 112 include a first base portion, shown as torso base zone
122. The torso base zone 122 is selectively positioned about the
base layer 100 so as to correspond in location to a torso, neck,
and/or shoulders of the wearer of the base layer 100. As shown in
FIGS. 6-8, the compressive zones 140 of the torso section 112
include a compressive portion, shown as torso compressive zone 142.
The torso compressive zone 142 is selectively positioned about the
base layer 100 so as to correspond in location to the torso,
shoulders, and/or waist of the wearer of the base layer 100 (e.g.,
such that the base layer 100 is tight-fitting, etc.). As shown in
FIGS. 6-8, the mesh zones 160 of the torso section 112 include a
first mesh portion, shown as lateral torso mesh zones 162, and a
second mesh portion, shown as rear torso mesh zones 168. The
lateral torso mesh zones 162 are selectively positioned about the
base layer 100 so as to correspond in location to the lateral areas
of the torso of the wearer of the base layer 100. The rear torso
mesh zones 168 are selectively positioned about the base layer 100
so as to correspond in location to the rear of the torso (e.g., the
back, etc.) of the wearer of the base layer 100.
[0061] As shown in FIGS. 6-8, the base zones 120 of the left sleeve
section 114 and the right sleeve section 116 include a second base
portion, shown as left sleeve base zone 124, and a third base
portion, shown as right sleeve base zone 126, respectively. The
left sleeve base zone 124 and the right sleeve base zone 126 are
selectively positioned about the base layer 100 so as to correspond
in location to at least a portion of a length of each arm of the
wearer of the base layer 100. As shown in FIGS. 6 and 8, the mesh
zones 160 of the left sleeve section 114 and the right sleeve
section 116 include a third mesh portion, shown as left underarm
mesh zone 164, and a fourth mesh portion, shown as right underarm
mesh zone 166, respectively. The left underarm mesh zone 164 and
the right underarm mesh zone 166 are selectively positioned about
the base layer 100 so as to correspond in location to an armpit
area of each arm of the wearer of the base layer 100.
[0062] As shown in FIG. 7, the durable zones 180 of the left sleeve
section 114 include a first durable portion, shown as left elbow
durable zone 182, and a second durable portion, shown as left wrist
durable zone 184. As shown in FIGS. 7-8, the durable zones 180 of
the right sleeve section 116 include a third durable portion, shown
as right elbow durable zone 186, and a fourth durable portion,
shown as right wrist durable zone 188. The left elbow durable zone
182, the left wrist durable zone 184, the right elbow durable zone
186, and the right wrist durable zone 188 are selectively
positioned about the base layer 100 so as to correspond in location
to the elbows and wrists of the wearer of the base layer 100.
[0063] It is important to note that the construction and
arrangement of the elements of the systems, methods, and
apparatuses as shown in the example embodiments are illustrative
only. Although only a few embodiments of the present disclosure
have been described in detail, those skilled in the art who review
this disclosure will readily appreciate that many modifications are
possible (e.g., variations in sizes, dimensions, structures, shapes
and proportions of the various elements, values of parameters,
mounting arrangements, use of materials, colors, orientations,
etc.) without materially departing from the novel teachings and
advantages of the subject matter recited. For example, elements
shown as integrally formed may be constructed of multiple parts or
elements. It should be noted that the elements and/or assemblies of
the enclosure may be constructed from any of a wide variety of
materials that provide sufficient strength or durability, in any of
a wide variety of colors, textures, and combinations.
[0064] Embodiments have been described in connection with the
accompanying drawings. However, it should be understood that the
figures are not drawn to scale. Distances, angles, shapes, etc. are
merely illustrative and do not necessarily bear an exact
relationship to actual dimensions and layout of the articles that
are illustrated. In addition, the foregoing embodiments have been
described at a level of detail to allow one of ordinary skill in
the art to make and use the articles, parts, different materials,
etc. described herein. A wide variety of variation is possible.
Articles, materials, elements, and/or steps can be altered, added,
removed, or rearranged. While certain embodiments have been
explicitly described, other embodiments will become apparent to
those of ordinary skill in the art based on this disclosure.
[0065] Conditional language used herein, such as, among others,
"can," "could," "might," "may," "e.g.," and the like, unless
specifically stated otherwise, or otherwise understood within the
context as used, is generally intended to convey that certain
embodiments include, while other embodiments do not include,
certain features, elements and/or states. Thus, such conditional
language is not generally intended to imply that features, elements
and/or configurations are in any way required for one or more
embodiments. The terms "comprising," "including," "having," and the
like are synonymous and are used inclusively, in an open-ended
fashion, and do not exclude additional elements, features, acts,
operations, and so forth. The term "consisting essentially of" can
be used anywhere where the terms comprising, including, containing
or having are used herein, but consistent essentially of is
intended to mean that the claim scope covers or is limited to the
specified materials or steps recited and those that do not
materially affect the basic and novel characteristic(s) of the
claimed invention. Also, the term "consisting of" can be used
anywhere where the terms comprising, including, containing or
having are used herein, but consistent of excludes any element,
step, or ingredient not specified in a given claim where it is
used.
[0066] Also, the term "or" is used in its inclusive sense (and not
in its exclusive sense) so that when used, for example, to connect
a list of elements, the term "or" means one, some, or all of the
elements in the list. Conjunctive language such as the phrase "at
least one of X, Y, and Z," unless specifically stated otherwise, is
otherwise understood with the context as used in general to convey
that an item, term, etc. may be either X, Y, Z, X and Y, X and Z, Y
and Z, or X, Y, and Z (i.e., any combination of X, Y, and Z). Thus,
such conjunctive language is not generally intended to imply that
certain embodiments require at least one of X, at least one of Y,
and at least one of Z to each be present, unless otherwise
indicated.
[0067] Additionally, in the subject description, the word "example"
and "exemplary" are used to mean serving as an example, instance,
or illustration. Any embodiment or design described herein as
"exemplary" is not necessarily to be construed as preferred or
advantageous over other embodiments or designs. Rather, use of the
word exemplary is intended to present concepts in a concrete
manner. Accordingly, all such modifications are intended to be
included within the scope of the present inventions. Other
substitutions, modifications, changes, and omissions may be made in
the design, operating conditions, and arrangement of the preferred
and other exemplary embodiments without departing from scope of the
present disclosure or from the spirit of the appended claims.
* * * * *