U.S. patent application number 15/978784 was filed with the patent office on 2018-11-29 for bodysuit with integrated lining structure and method of manufacture.
This patent application is currently assigned to Moonrise Sisters, Inc.. The applicant listed for this patent is Moonrise Sisters, Inc.. Invention is credited to Hongjoo Sun, Daniel M. Wyner.
Application Number | 20180338548 15/978784 |
Document ID | / |
Family ID | 64400172 |
Filed Date | 2018-11-29 |
United States Patent
Application |
20180338548 |
Kind Code |
A1 |
Wyner; Daniel M. ; et
al. |
November 29, 2018 |
BODYSUIT WITH INTEGRATED LINING STRUCTURE AND METHOD OF
MANUFACTURE
Abstract
In some embodiments, a bodysuit includes an outer shell with
front and rear panel and a first inner lining with front and rear
panels. Each of the front and rear panels of the first inner lining
extends from above a waistline of the bodysuit to a seam at a
respective side of a crotch region. The bodysuit may include a
second inner lining attached to the front and rear panels of the
first inner lining at first and second seams, the first and second
seams located at first and second sides of the crotch region. The
bodysuit also may include a third inner lining positioned on top of
and attached to the second inner lining. Attachment of the first
inner lining to the second inner lining and the second inner lining
to the third inner lining may be accomplished via inner seams not
visible on an exterior of the bodysuit.
Inventors: |
Wyner; Daniel M.; (North
Scituate, RI) ; Sun; Hongjoo; (New York, NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Moonrise Sisters, Inc. |
New York |
NY |
US |
|
|
Assignee: |
Moonrise Sisters, Inc.
New York
NY
|
Family ID: |
64400172 |
Appl. No.: |
15/978784 |
Filed: |
May 14, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62510252 |
May 23, 2017 |
|
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A41D 27/02 20130101;
A41B 2400/60 20130101; A41B 11/14 20130101; A41D 13/0017
20130101 |
International
Class: |
A41D 13/00 20060101
A41D013/00 |
Claims
1. A bodysuit comprising: an outer shell having a front panel and a
rear panel; a first inner lining attached to the outer shell, the
first inner lining having a front panel and a rear panel, the front
panel of the first inner lining extending from above a waistline of
the outer shell front panel to a first seam and the rear panel of
the first inner lining extending from above a waistline of the
outer shell rear panel to a second seam, wherein the first seam is
located at a first side of a crotch region of the bodysuit and the
second seam is located at a second, opposite side of the crotch
region of the bodysuit; and a second inner lining attached to the
first inner lining at the first and second seams.
2. The bodysuit of claim 1, wherein the first and second seams are
not joined to either of the front and rear panels of the outer
shell.
3. The bodysuit of claim 1, wherein the first seam is located on a
front side of the crotch region and the second seam is located on a
rear side of the crotch region.
4. The bodysuit of claim 3, wherein the second inner lining extends
rearwardly through the crotch region from the first seam to the
second seam.
5. The bodysuit of claim 1, further comprising a third lining
positioned on an inner side of and attached to the second inner
lining;
6. The bodysuit of claim 1, wherein: the front panel of the first
inner lining extends from a neckline of the front panel of the
outer shell to the first seam; and the rear panel of the first
inner lining extends from a neckline of the rear panel of the outer
shell to the second seam.
7. The bodysuit of claim 1, wherein a length of the front panel of
the first inner lining is different than a length of the rear panel
of the first inner lining.
8. The bodysuit of claim 1, wherein the second inner lining has a
substantially hourglass shape.
9. The bodysuit of claim 5, wherein the third inner lining has a
substantially hourglass shape.
10. The bodysuit of claim 5, wherein the third inner lining is
smaller than the second inner lining.
11. The bodysuit of claim 10, wherein: a front side of the third
inner lining is attached to a front side of the second inner lining
at a third seam; and a rear side of the third inner lining is
attached to a rear side of the second inner lining at a fourth
seam.
12. The bodysuit of claim 11, wherein the third seam is adjacent to
the first seam and the fourth seam is adjacent to the second
seam.
13. The bodysuit of claim 11, wherein the third seam is
longitudinally spaced from the first seam by a distance of at least
about 0.25 inches.
14. The bodysuit of claim 13, wherein the second seam is
longitudinally spaced from the fourth seam by a distance of at
least about 0.25 inches.
15. The bodysuit of claim 10, wherein a first side of the third
inner lining is spaced from a first side of the second inner lining
by a distance of at least about 0.125 inches.
16. (canceled)
17. (canceled)
18. The bodysuit of claim 1, wherein the second inner lining is a
barrier layer.
19. (canceled)
20. The bodysuit of claim 5, wherein the third inner lining is
formed of an absorbent material.
21. The bodysuit of claim 20, wherein the third inner lining is
arrange to absorb up to about 50 mL of fluid.
22. (canceled)
23. The bodysuit of claim 1, wherein the front panel of the first
inner lining is attached to the outer shell at a fifth seam located
on a first side of the bodysuit and at a sixth seam located on a
second, opposite side of the bodysuit.
24. A method of constructing a bodysuit having an outer shell with
front and rear panels; attaching a front panel of a first inner
lining to a front panel of an outer shell of the bodysuit and
attaching a rear panel of the first inner lining to a rear panel of
the outer shell, wherein the front panel of the first inner lining
extends from a portion above a waistline of the outer shell to a
first seam and the rear panel of the first inner lining extends
from a portion above the waistline of the outer shell to a second
seam, the first seam defining a first edge of a crotch region of
the bodysuit and the second seam defining a second edge of the
crotch region; and attaching a second inner lining to the front and
rear panels of the first inner lining at the first and second
seams.
25.-28. (canceled)
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. .sctn.
119(e) to U.S. Provisional Application No. U.S. 62/510,252,
entitled "BODYSUIT WITH INTEGRATED LINING STRUCTURE AND METHOD OF
MANUFACTURE" and filed May 23, 2017, the contents of which are
incorporated herein by reference in its entirety.
FIELD
[0002] The disclosed embodiments are generally directed to
bodysuits, and more particularly to bodysuits with integrated
lining structures and methods of manufacture.
BACKGROUND
[0003] Bodysuits are articles of clothing that are worn by female
and males, such as dancers, swimmers, cyclists, yogis and gymnasts.
Typically, the bodysuit covers at least the torso, portions of the
back, the buttocks and the crotch of the wearer, with openings for
the neck, arms, and legs. In some instances, the bodysuit may
include sleeves and/or legs.
SUMMARY
[0004] In one embodiment, a bodysuit includes an outer shell having
a front panel and a rear panel, a first inner lining attached to
the outer shell, the first inner lining having a front panel and a
rear panel, the front panel of the first inner lining extending
from above a waistline of the outer shell front panel to a first
seam and the rear panel of the first inner lining extending from
above a waistline of the outer shell rear panel to a second seam,
wherein the first seam is located at a first side of a crotch
region of the bodysuit and the second seam is located at a second,
opposite side of the crotch region of the bodysuit, and a second
inner lining attached to the first inner lining at the first and
second seams.
[0005] In another embodiment, a method of constructing a bodysuit
having an outer shell with front and rear panels is disclosed. The
method includes attaching a front panel of a first inner lining to
a front panel of an outer shell of the bodysuit and attaching a
rear panel of the first inner lining to a rear panel of the outer
shell, wherein the front panel of the first inner lining extends
from a portion above a waistline of the outer shell to a first seam
and the rear panel of the first inner lining extends from a portion
above the waistline of the outer shell to a second seam, the first
seam defining a first edge of a crotch region of the bodysuit and
the second seam defining a second edge of the crotch region, and
attaching a second inner lining to the front and rear panels of the
first inner lining at the first and second seams.
[0006] It should be appreciated that the foregoing concepts, and
additional concepts discussed below, may be arranged in any
suitable combination, as the present disclosure is not limited in
this respect.
[0007] The foregoing and other aspects, embodiments, and features
of the present teachings can be more fully understood from the
following description in conjunction with the accompanying
drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0008] The accompanying drawings are not intended to be drawn to
scale. In the drawings, each identical or nearly identical
component that is illustrated in various figures is represented by
a like numeral. For purposes of clarity, not every component may be
labeled in every drawing. In the drawings:
[0009] FIG. 1 is a front view of a bodysuit according to one
embodiment;
[0010] FIG. 2 is a rear view of the bodysuit of FIG. 1;
[0011] FIG. 3 is a front view of a bodysuit according to another
embodiment;
[0012] FIG. 4 is an interior view of a bodysuit prior to final
assembly, with front and rear panels attached only in a crotch
region of the bodysuit;
[0013] FIG. 5 is a front view of an interior of a bodysuit
according to one embodiment;
[0014] FIG. 6 is a rear view of the bodysuit of FIG. 5;
[0015] FIG. 7 illustrates an outer shell front panel and a first
inner lining front panel of a bodysuit according to some
embodiments;
[0016] FIG. 8 illustrates an outer shell rear panel and a first
inner lining rear panel of the bodysuit of FIG. 7;
[0017] FIG. 9 is a side view of the bodysuit of FIG. 5;
[0018] FIG. 10 is an top view of the interior of the bodysuit of
FIG. 1;
[0019] FIG. 11 is top view of a second inner lining of a bodysuit
according to some embodiments;
[0020] FIG. 12 shows a third inner lining of a bodysuit according
to some embodiments;
[0021] FIGS. 13-15 illustrate attachment of first, second and third
inner linings of a bodysuit;
[0022] FIGS. 16A and 16B illustrate front and rear fragmentary
views of a bodysuit according to one embodiment;
[0023] FIGS. 17A and 17B illustrate construction of a leg opening
bend back according to one embodiment;
[0024] FIGS. 18A and 18B illustrate attachment of second and third
inner linings to the leg opening bend back of FIGS. 17A and
17B;
[0025] FIGS. 19A and 19B are enlarged cross sectional views of
second and third inner linings attached to a leg opening bend back
according to some embodiments;
[0026] FIG. 20 is a cross sectional side view of a crotch region of
a bodysuit; and
[0027] FIG. 21 is a table listing types of fabrics and fabric
treatments.
DETAILED DESCRIPTION
[0028] Bodysuits are articles of clothing that may be worn to be
form fitting and highlight a wearer's muscle definition and
skeletal alignment, and to allow for unencumbered movement and
comfort. For purposes herein, a bodysuit may include a leotard, a
unitard, a swimsuit, a biketard, or similar garments. Bodysuits may
be used in various athletic activities, such as for dance, yoga,
pilates, running, swimming, and gymnastics. Bodysuits are typically
worn without any additional garments over or underneath the
bodysuit. In some embodiments, the bodysuit can cover the body like
a second skin and provide modesty. Typically, a bodysuit covers at
least the torso, a portion of the back, the buttocks and the crotch
of the wearer, and has openings for the neck, arms and legs.
Bodysuits also may include one or more sleeves of varying lengths
and/or one or more pant legs of varying lengths.
[0029] Typically, a bodysuit includes an outer layer made of any
one of a variety of synthetic and non-synthetic materials (e.g.,
nylon, polyester and cotton) with fibers (e.g., spandex, lycra,
rubber or elastane) that allow the outer layer to stretch to
varying degrees. The outer layer is typically constructed of front
and back panels that are secured to one another on each side via a
seam that may be stitched, welded or bonded. The front and back
panels also may be secured to one another via a single seam that is
stitched, welded or bonded in or adjacent to the crotch region. In
some embodiments, the crotch region of the outer shell may be
formed via at least a portion of the front panel and/or at least a
portion of the rear panel. For example, a portion of the front
panel may extend from the front of the garment, through the crotch
region, and be attached to the rear panel via a seam at a rear of
the crotch region. In some embodiments, the leg, arm and neck
openings may be finished with decorative stitching, binding or
elastics, and/or straps.
[0030] For purposes herein, the crotch region may include a portion
of the bodysuit, such as a portion of the outer shell or one of the
inner linings, that extends between the leg openings and is
adjacent to a crotch of the wearer when the bodysuit is being worn.
For example, for female wearers, the crotch region may be a portion
of the bodysuit that is positionable over the wearer's vulva,
pudendal cleft and mons pubis. In some embodiments, the crotch
region is located between the leg holes of the bodysuit and extends
upwardly toward the front of the bodysuit and rearwardly toward the
rear of the bodysuit. In some embodiments, the crotch region may be
substantially hourglass in shape.
[0031] A bodysuit also may include an inner lining that covers,
supports and/or protects the whole torso or portions thereof. An
inner lining typically includes a single layer that is attached to
the uppermost edges of the front of the outer shell, such as from
the neckline, and laterally connected to the side seam(s). The
inner lining also may be connected to the leg openings and reward
under the crotch and towards the buttocks, where the inner lining
is stitched to the seam at the rear end of the crotch region. The
lining may be made of a material with a similar stretch to that of
the outer shell. Typically, bodysuits do not have a lining attached
to the rear of the bodysuit, unless there is a flaw in the outer
layer.
[0032] The female body from time to time excretes or can excrete
bodily fluids, like vaginal discharge, menstrual flow and/or urine.
While wearing a traditional bodysuit, the wearer may experience a
variety of anxieties and embarrassments from visible undergarments,
sanitary napkins, tampon strings and/or incontinence diapers. For
example, because bodysuits are typically form fitting, they are not
discrete and may highlight the additional undergarment and/or other
sanitary product worn under the bodysuit. The additional
undergarment and/or sanitary product also may add bulk and not be
the same shape as the bodysuit or the wearer, thus signaling to the
public that the wearer is protecting against the possibility of
excreting fluids.
[0033] Additionally, because excretions may occur at any unforeseen
time, the wearer of the bodysuit may not be prepared and therefore
may have an accident. Wetness and/or blood may become visible on
the outer layer(s) of the traditional bodysuit. The wearer also may
wet or bleed through the bodysuit and any undergarment and/or
sanitary product used to control excretions. Such visible
excretions may cause embarrassment and/or undue distress to the
wearer.
[0034] The inventors have recognized that advantages may be
realized by providing a bodysuit with one or more inner linings
that are capable of absorbing and/or blocking the permeation of
excretions without the use of an undergarment, overgarment or other
sanitary product. For example, in some embodiments, the inner
layers may reduce or even eliminate the need for the wearer to use
an undergarment or other sanitary product to protect against
menstruation, incontinence, or other female excretion. The
inventors have further recognized that advantages may be realized
if such bodysuits are not distinguishable from typical bodysuits
such that the wearer may not be identified as someone protecting
against incontinence, menstrual flow or other menstrual discharge.
For example, in some embodiments, the bodysuit does not include
visible seams in a crotch region of the outer shell where the one
or more protective inner linings may be present and attached to one
another. As will be appreciated, the inner seams of the inner
linings also may be located at other portions of the bodysuit, such
as near the waist of the bodysuit, the inner seams not being
visible near the waist of the outer shell.
[0035] To that end, embodiments disclosed herein include a bodysuit
with an outer shell and one or more inner linings arranged to
absorb and/or block the permeation of excretions, the one or more
inner linings not being visible from the exterior of the bodysuit.
In some embodiments, the bodysuit includes an outer shell with
front and rear panels. The bodysuit also may include a first inner
lining that has front and rear panels, each of the panels of the
first inner lining extending from above a waistline of the outer
shell to a seam that may be at a first or second end of the crotch
region. For example, the front panel of the first inner lining may
extend all the way from the neckline of the bodysuit to a seam
defining the front end of the crotch region. In such embodiments,
the first inner lining may be attached to the outer shell only at
the neckline and at one or more seams on a side of the
bodysuit.
[0036] The bodysuit also may include a second inner lining that
extends from the seam at the front of the crotch region to the seam
at the rear of the crotch region. The second inner lining may be
formed in the shape of the crotch region, such as having a
substantially hourglass shape. For example, the second inner lining
may be wider at the top and bottom than in a central region. In
some embodiments, the second inner lining is attached to the first
inner lining at the seams at the front and rear edges of the crotch
region. The bodysuit also may include a third inner lining that is
placed on top of and is attachable to the second inner lining. In
some embodiments, the third inner lining may have the same shape as
the second inner lining, and crotch region, but be smaller than the
second inner lining. In some embodiments, by having a third lining
that is smaller than the second lining, fluids absorbed by the
third lining may not be transferred to the outer shell (e.g., via
the second lining). In these embodiments, attachment between the
second and first inner linings and between the second and third
inner linings may be accomplished via inner seams that are not
attached to the outer shell. In some embodiments, the third inner
lining may include one or more layers.
[0037] In these embodiments, each of the first, second and third
inner linings may have a body contacting surface. In some
embodiments, one or more of the inner linings may be arranged to
absorb and/or wick fluids. In some embodiments, at least one of the
inner linings acts as a barrier layer that may minimize or prevent
excretions from passing through to the outer shell. In some
embodiments, the barrier layer may be stain releasing so that the
bodysuit is not permanently damaged during an accident. In some
embodiments, the layers may be formed of a stretchable
material.
[0038] Turning now to the figures, FIGS. 1 and 2 show a bodysuit
100 according to embodiments of the present disclosure. As shown in
these views, the bodysuit may have an outer shell with a front
panel 102a and a rear panel 102b. In some embodiments, the front
and rear panels 102a, 102b are secured to one another via seams 104
located at opposite sides of the bodysuit 100, and via a rear outer
seam 105 located adjacent to the crotch region of the bodysuit. As
will be appreciated in view of the above, at least a portion of the
front panel 102a may form the crotch region of the outer shell of
the bodysuit. The front and rear panels 102a, 102b also may be
secured to one another along the top edge of the neckline 107a,
107b. In some embodiments, the rear outer seam 105 is not visible
in the inside of the bodysuit. As will be appreciated, such a seam
105 may be obstructed by the one or more inner linings inside the
bodysuit 100. As shown in FIGS. 1 and 2, other than then rear outer
seam 105, neither the front or rear panels 102a, 102b of the outer
shell include seams visible on the outside of the garment, such as
in the crotch region, where one or more inner linings are attached
to one another.
[0039] As will be appreciated, the outer shell of the bodysuit may
have any suitable configuration. For example, as shown in FIGS. 1
and 2, the bodysuit may have sleeves. In other embodiments, as
shown in FIG. 3, the bodysuit also may be sleeveless. In some
embodiments, the bodysuit may cover the legs, or at least a portion
of the legs. As will be appreciated, in such embodiments, the one
or more inner linings may be adjusted in size to accommodate the
size and shape of the outer shell.
[0040] As shown in FIGS. 4-6, in some embodiments, the bodysuit may
include two or more inner linings. As will be described, the inner
linings may be attached to one another and to the outer shell. In
some embodiments, the inner linings may have different protective
characteristics, such as for absorbing, wicking, and/or blocking
transmission of fluids.
[0041] In some embodiments, as shown in FIGS. 4-10 and 13, the
bodysuit includes a first inner lining having a front panel 106a
and a rear panel 106b. In some embodiments, the first inner lining
may extend from above a waistline of the respective panel of the
outer shell to a edge of the crotch region 111. In this regard, the
first inner lining may be arranged to not extend into the crotch
region of the bodysuit.
[0042] As shown in FIGS. 4-6, in some embodiments, the crotch
region may be defined by a front seam 108a at a front edge of the
crotch region and a rear seam 108b at a rear edge of the crotch
region. As will be described, the first and second inner linings
106a, 106b, 110 may be joined to one another via the front and rear
seams 108a, 108b. As will be appreciated from the above, the front
and rear seams 108a, 108b may be visible from the interior of the
bodysuit but not visible on the exterior of the bodysuit.
[0043] As shown in FIG. 7, a length L1 of the front panel 102a of
the outer shell may be longer than a length L2 of the front panel
106a of the first inner lining of the bodysuit. In such
embodiments, the front panel of the first inner lining may end at
or above a crotch region of the bodysuit. As shown in FIG. 8, and
similar to the front panels, a length L3 of the rear panel 102b of
the outer shell may be longer than a length L4 of the rear panel
106b of the first inner lining in some embodiments.
[0044] As shown in FIGS. 7 and 8, the first inner lining may be
formed in a shape similar to that of the outer shell. For example,
the front and rear panels of the first inner lining have similarly
shaped neck openings and silhouettes. As shown in these views, the
front and rear panels 106a, 106b of the first inner lining need not
include each of the features of the front and rear panels 102a,
102b of the outer shell. For example, as shown in these views, the
front and rear panels 106a, 106b of the first inner lining do not
have sleeve portions.
[0045] As will be appreciated, the length L1 of the front panel
102a of the outer shell need not be the same as the length L3 of
the rear panel of the outer shell. In a similar fashion, the length
L2 of the front panel 106a of the first inner lining may be
different than the length L4 of the rear panel 106b of the first
inner lining. As will be further appreciated, the front and rear
panels 106a, 106b of the first inner lining may be formed of the
same material or may be formed of different materials. For example,
the front panel of the inner lining may be formed of a material
that is arranged to wick fluids, while the rear panel of the inner
lining may be formed of a stretchable material with no protective
features.
[0046] In some embodiments, as shown in FIG. 9, the front and rear
panels 106a, 106b of the first inner lining are secured to the
front and rear panels 102a, 102b of the outer shell at seams 104
located on opposite sides of the bodysuit. As shown in FIGS. 4-6,
The first inner lining 102a, 102b also may be secured at a neckline
107a of a front of the bodysuit and a neckline 107b of the rear of
the bodysuit.
[0047] As shown in FIGS. 4-6, 9-10 and 14, the bodysuit 100 also
includes a second inner lining 110 positioned in the crotch region
of the bodysuit. In some embodiments, as shown in these views, the
second inner lining 110 is attached to the front panel 106a of the
first inner lining at the front seam 108a and to the rear panel
106b of the first inner lining at the rear seam 108b. In such
embodiments, the second inner may extend along the crotch region
111 of the bodysuit.
[0048] As shown in FIGS. 4 and 10-11, the second inner lining 110
may have a substantially hourglass shape, with front and rear
portions of the second inner lining 110 being wider than a central
portion. For purposes herein, the front portion of the second inner
lining is the portion of the second inner lining that is positioned
towards the front of the bodysuit when the bodysuit is worn by the
user, and the rear portion is the portion positioned towards the
rear of the bodysuit. As shown in these views, the front portion of
the second inner lining 110 need not be the same size (e.g., the
same width) as the rear portion of the second inner lining 110. For
example, as shown in FIG. 11, a rear portion of the second inner
lining 110 may be wider than the front portion. In some
embodiments, the second inner lining may be the same size as the
crotch region of the outer shell. In other embodiments, the second
inner lining may be larger than the crotch region. As will be
appreciated, the shape and size of the second inner lining may vary
based on the shape and size of the crotch region of the outer
shell.
[0049] As also shown in FIGS. 4-6 and 9-10, the bodysuit also may
include a third inner lining 112. As with the second inner lining,
the third inner lining 112 is also arranged to be positioned in the
crotch region of the bodysuit. As shown in FIG. 10, the third inner
lining 112 is attached to the second inner lining via front 114a
and rear 114b seams. In some embodiments, the second inner lining
is flatlocked on top of the first inner lining at the front and
rear seams 108a, 108b. As with other embodiments, the front and
rear seams 114a, 114b are positioned toward a front and rear of the
garment, respectively, when the garment is worn by the wearer. In
some embodiments, the second and third inner linings 110, 112 may
be attached (see stitching 115 in FIG. 10) on top of a leg opening
116 bend back.
[0050] In some embodiments, as shown in FIGS. 4-6, and 9-10, the
third inner lining is smaller than the second inner lining. In some
embodiments, by having the third inner lining be smaller than the
second inner lining, fluids absorbed by the third inner lining may
not be transferred to the outer shell. In such embodiments, the
front seam 108a attaching the second inner lining 110 to the first
inner lining 106a is spaced from the front seam 114a attaching the
third inner lining 112 to the second inner lining 110. In a similar
fashion, the rear seam 108b attaching the second inner lining 110
to the first inner lining 106a may be spaced from the rear seam
114b attaching the third inner lining 112 to the second inner
lining 110. As will be appreciated, the respective front seams
108a, 114a and rear seams 108b, 114b may be longitudinally spaced
from one another.
[0051] As shown in FIG. 15, the front seams 108a, 114a may be
spaced a distance D1 of at least about 0.25 inches from one
another. For example, the seams 108a, 114a may be spaced a distance
D1 of between about 0.25 inches and about 1 inch. In a similar
fashion, the rear seams 108b, 114b may be spaced a distance D2 of
at least about 0.25 inches from one another. For example, the seams
108b, 114b may be spaced a distance D2 of between about 0.25 inches
and about 1 inch. As will be appreciated, the distance D1 between
the first seams 108a, 114a and the distance D2 between the rear
seams 108b, 114b may be the same in some embodiments. For example,
the distances D1, D2 may be about 0.375 inches. In other
embodiments, the distances D1, D2 may be different from one
another.
[0052] As also shown in FIG. 15, a side of the third inner lining
112 may be spaced from a side of the second inner lining 110. For
example, in some embodiments, the side of the third inner lining
may be spaced a distance D3 of at least about 0.125 inches. For
example, the side of the third lining may be spaced a distance D3
of between about 0.125 inches and 0.375 inches. For example, in
some embodiments, the distance D3 between the second and third
inner linings 110, 112 may be about 0.25 inches.
[0053] In some embodiments, the third inner lining has a
substantially hourglass shape, with the front and rear portions of
the third inner lining 112 being wider than a width of a central
portion of the third inner lining. As with the above, the front
portion of the third inner lining may be narrower than the rear
portion. As will be appreciated, the shape and size of the third
inner lining may vary based on the shape and size of the crotch
region of the outer shell.
[0054] As also shown in FIGS. 4-6 and 9-10, the third inner lining
112 may have a similar shape as the second inner lining 110. As
will be appreciated, the third inner lining need not have the same
shape as the second inner lining. For example, the third inner
lining may have a substantially rectangular shape while the second
inner lining has a substantially hourglass shape.
[0055] In some embodiments, the third inner lining 112 may include
one or more layers of material. For example, as shown in FIG. 12,
in some embodiments, the third inner lining 112 may include first
and second layers 118a, 118b. In some embodiments, the first and
second layers may be stitched to one another around a periphery of
each layer. As will be appreciated, although the third inner lining
112 is shown as having two layers in this embodiment, the third
inner lining also may have more than two layers in other
embodiments.
[0056] In some embodiments, a single inner lining may have a weight
of between about 3.7 oz./yd.sup.2 to about 7.2 oz./yd.sup.2. In
some embodiments, a single inner lining may have a weight of
between about 7 oz./yd.sup.2 to about 14.6 oz./yd.sup.2. In some
embodiments, the combined weight of the inner linings (e.g., of the
first, second and third inner linings) may be between about 9.5
oz./yd.sup.2 to about 24.9 oz/yd.sup.2.
[0057] In embodiments in which an inner lining includes more than
one layers, such as the third inner lining 112 having first and
second layers 118a, 118b (see FIG. 12), the combined weight of the
layers may be the same as the weight of a single layer. For
example, the weight of the third inner lining with only a single
layer, or the combined weight of a third inner lining having first
and second layers, may be between about 3.7 oz./yd.sup.2 to about
7.2 oz./yd.sup.2 or between about 7 oz./yd.sup.2 to about 14.6
oz./yd.sup.2. In embodiments having more than one layers, the
weight of each layer may be the same. For example, each of the
first and second layers may weigh about 2 oz./yd.sup.2, with a
combined weight of about 4 oz./yd.sup.2. The weight of the
individual layers also may be different. For example, a first layer
may have a weight of about 1.5 oz./yd.sup.2 and a second layer may
have a weight of about 2.5 oz./yd.sup.2, with a combined weight of
about 4 oz./yd.sup.2.
[0058] FIGS. 13-19 illustrate the construction of a bodysuit
according to embodiments of the present disclosure. As shown in
FIG. 13, front and rear panels 106a, 106b of the first inner lining
may be cut shorter than the front and rear panels 102, 102b of the
outer shell. As with other embodiments, the front and rear panels
106a, 106b of the first inner lining may be cut so that the front
and rear panels 106a 106b do not extend to the crotch region 111 of
the bodysuit. As shown in FIG. 13, the crotch region 111 of the
bodysuit may include a region that is substantially hourglass in
shape and that extends between the legs of a wearer, adjacent a
wearer's crotch.
[0059] As shown in FIG. 14, a second inner lining 110 may be cut in
the general shape of the crotch region of the outer shell so that
it may be stitched to the first inner lining and ultimately to the
outer shell. As shown in FIG. 14, the second inner lining 110 may
be attached to the front and rear panels 106a, 106b of the first
inner lining at front and rear seams 108a, 108b. As will be
appreciated, the first inner lining may be stitched, bonded, welded
or otherwise attached to the second inner lining at the front and
rear seams 108a, 108b. In some embodiments, the second inner lining
110 may be flatlocked to the first inner lining 106a, 106b at the
front and rear seams 108a, 108b.
[0060] Next, as shown in FIG. 15, a third inner lining 112 may be
cut for attachment to the second inner lining. In some embodiments,
the third inner lining 112 may include a single layer. In other
embodiments, two or more layers may be cut and stitched together at
the peripheral edges to form the third inner lining 112. In some
embodiments, the third inner lining is placed on top of and
attached to the second inner lining 110. In some embodiments, the
third inner lining 112 may be stitched to the second inner lining
110 at a front seam 114a and rear seam 114b. For example, the third
inner lining 112 may be coverstitched to the second inner lining at
flatlock seam 114a and at flatlock seam 114b. As shown in these
views, each of the flatlock seams extends generally horizontally
across the third inner lining. In some embodiments, the third inner
lining is not yet attached to the second inner lining at one or
more side portions.
[0061] Although the seams 114a, 114b are described as being
flatlocked, it will be appreciated that the third inner lining 112
may be attached to the second inner lining 110 via other suitable
methods. For example, the third inner lining may be welded, or
otherwise bonded to the second inner lining. Other suitable methods
also may be used to join the second and third inner linings.
[0062] FIGS. 16A and 16B show front and rear interior views of the
bodysuit with the first, second and third inner linings attached to
one another. As also shown in this view, the front and rear panels
106a, 106b of the first inner lining have been stitched to the
outer shell via side seams 104.
[0063] FIGS. 17A and 17B illustrate construction of the leg opening
bend back. As shown in these views, the leg opening bend back may
be stitched together via seam 120. During such construction, the
second and third inner linings 110, 112 may be moved aside and out
of the way.
[0064] Next, as shown in FIGS. 18A, and 18B, the second and third
inner linings 110, 112 may be stitched on top of the bend back at
seam 122. As will be appreciated in view of FIGS. 18A and 18B, the
second and third inner linings 110, 112 may be attached to the bend
back at respective side portions of each inner lining.
[0065] In embodiments in which the third inner lining has more than
one layer, the second inner lining may be secured in between the
sub-layers of the third lining, along the outer edge. The second
inner lining may then be secured to the primary lining and to the
outer shell
[0066] FIGS. 19A and 19B illustrate the attachment of the second
and third inner linings 110, 112 to the leg opening bend back. As
shown in these views, the second inner lining 110 is stitched on
top of the bend back (see 126). The third inner lining 112 is
stitched on top of the second inner lining 110 and the bend back
(see 128) to complete the three layers of stitching in the leg
opening of the crotch region.
[0067] FIG. 20 illustrates a side view of the linings in the crotch
region of the bodysuit. As shown in this view, the crotch region
111 includes the outer shell 102a of the leg opening bend back. As
will be appreciated, the bend back stitching may come into contact
with the skin. In this regard, the bend back stitching may be
covered by the second inner lining to prevent staining and wetness
to the outer sell. In some embodiments, the second inner lining 110
comes into contact with the outer shell, as the second inner lining
is placed in between the outer shell and the third inner lining.
The crotch region also may include the third inner lining, which
has a body-contacting side and is visible to the wearer.
[0068] Although embodiments have been shown and described in which
the first inner lining extends to a crotch region, with the second
inner lining being attached to the first inner lining and extending
in the crotch region, the bodysuit may have other arrangements in
other embodiments. For example, the front panel of the first inner
lining may extend from a first position above a waist of the
bodysuit to a second position above the crotch region and below the
waist. In a similar fashion, the rear panel of the first inner
lining may extend from a third position above a waist of the
bodysuit to a fourth position above the crotch region and below the
waist. In such embodiments, the second inner lining may be attached
to the front and rear panels at the second and fourth positions
above the crotch region. In this regard, the second inner lining
may be connected to the first inner lining and extend from the
second position above the front crotch region, through the crotch
region, and to the rear of the bodysuit to the fourth position
above the rear crotch region. In such embodiments, the second inner
lining may be larger than the crotch region.
[0069] As will be appreciated, the inner linings may have any
suitable properties and be formed of any suitable materials. In
some embodiments, the second inner lining may be formed of a
stretchable material, such as like nylon, cotton, thermoplastic
urethane, spandex, polyester, lycra, elastane or a combination
thereof. The second inner lining also may be formed of other
similar stretchable materials. As will be described, the second
inner lining may have unique properties that prevent moisture from
leaking to the outer shell, is stain releasing, antibacterial
and/or breathable. In some embodiments, the third inner lining may
be formed of a stretchable materials like nylon, spandex, cotton,
polyester, lycra, elastane, thermoplastic urethane, or combinations
thereof. The third layer also may be formed of other similar
stretchable materials. As will be described, the third lining may
have unique properties that are absorbent, breathable, wicking, or
combinations thereof. Although each of the first, second and third
inner linings are described as having certain properties, it will
be appreciated that these linings may have other possible
properties in other embodiments.
[0070] In some embodiments, the first, second and third inner
linings may be connected to one another via stitching, bonding, or
welding, and using a variety of appropriate materials. In some
embodiments, such a constructions does not compromise the stretch
properties of the bodysuit. Such a construction also may not negate
the desired property or properties of the inner linings. For
example, one or more of the inner linings may be wicking,
absorbing, blocking, and/or releasing.
[0071] In some embodiments, suitable materials for one or more
linings, such as a body-contacting lining, includes, but are not
limited to: polyolefin, polyamide, polyester and combination
thereof. In such embodiments, the materials may have inherently
stain-resisting fibers. For purposes herein, "stain releasing,"
means both stain-resistant materials and stain-releasing materials,
including those that have been treated to be stain resistant or
stain releasing. The linings also may include any suitable fabric
that has been treated with a stain releasing finish (such as the
Darlington finishes listed in Table A (see FIG. 21). Such linings
also may include an inherently stain-releasing material such as
microfiber or a microfiber blend including different materials that
can be treated to have even greater stain-releasing
capabilities.
[0072] In some embodiments, one or more linings (e.g., the second
or third inner linings) may be formed of a relatively dark material
color that can assist in masking stains.
[0073] In some embodiments, one or more linings, such as the third
inner lining, may include a material capable of absorbing fluids,
and of releasing the absorbed fluids under certain conditions, such
as during a laundry cycle. The moisture-absorbent lining may
include an absorbency of greater than about 300 grams/square meter
(gm/m.sup.2), more particularly greater than about 800 gm/m.sup.2,
and more particularly greater than about 1054 gm/m.sup.2. For
example, in some embodiments, the third inner lining may be capable
of absorbing up to about 50 mL of fluid. Suitable materials for a
moisture absorbent lining include, but are not limited to, woven or
non-woven microfiber or polymer knits, fabrics formed using
hydrophilic fibers, absorbent or superabsorbent foams, fibers or
powders. In some embodiments, any knit, absorbent knit, woven,
nonwoven or polymeric material that has reservoir properties due to
air gaps or voids can be used as the moisture absorbing liner.
Examples of such materials include, but are not limited to,
needlebar knit fabrics, foams, nonwovens, and the like.
[0074] In some embodiments, the moisture-absorbent lining can
include a knitted fabric that has been treated to have hydrophilic
properties. In some embodiments, the yarn from which the fabric is
made can be treated prior to knitting to be hydrophilic. In some
embodiments, the yarn and knitted fabric can both be treated to be
hydrophilic.
[0075] In some embodiments, a barrier lining, such as the second
inner lining, includes any material or combination of materials
that prevent or minimize transmission of fluid through the barrier
layer. In some embodiments, such a material or combination of
materials does not adversely affect the feel and/or hand of the
garment. In some embodiments, the barrier lining may include a
woven or non-woven fabric having elongation test results comparable
to the Darlington fabrics listed in Table A (see FIG. 21).
[0076] In some embodiments, the barrier lining may be formed of a
material including, but not limited to, a fabric laminated to a
polymer film. The polymer film may comprise a thickness of less
than or equal to about 15 microns, more particularly less than or
equal to about 10 microns, and more particularly less than or equal
to about 5 microns. Suitable materials for the polymer film may
include, but not be limited to, copolyether-esters, thermoplastic
elastomers (TPEs) such as HYTREL.RTM., nylons and polyolefins.
Other soft elastic TPEs may be used if they have sufficient
softness and pliability to be used in a bodysuit. The poly film may
be laminated in a 2-ply or 3-ply configuration, or be free-hanging
and sewn between other layers, such as between an absorbent lining
and an outer layer. Other suitable polymer materials may include a
highly moisture transmitting monolithic polyurethane film sold by
Omniflex Inc., Greenfield, Mass. under the name TX1540.
[0077] Other suitable materials for the barrier lining may include,
but are not limited to, a 2-ply laminate polymer film protected by
another layer that is not bonded to the film, as this arrangement
allows for a softer feel in the finished garment. The
film/composite material may optionally be subjected to a
hydrophobic (water-repellent) treatment to enhance the barrier
properties without negatively impacting the hand of the material.
In still another embodiment, the barrier film or composite may be
stretched or pressed with heat and/or pressure into the surrounding
layers to enhance feel. These stretch or heat and pressure
treatments also have the advantage of creating small fissures that
enhance breathability.
[0078] Other suitable materials for barrier lining may include a
hydrophobic fabric that may be inherently hydrophobic, or which may
be treated to make it hydrophobic. Suitable fabrics for treating
with such hydrophobic coatings include, but are not limited to,
relatively tight knitted, nonwoven or woven fabrics. Suitable
hydrophobic materials for treating the fabric include, but are not
limited to, polymers such as silicone, polyurethane and
combinations thereof. In many embodiments, it is desirable to use
elastic polymers for this purpose, such as LYCRA.RTM. and blends
thereof. In some embodiments, the hydrophobic treated knitted,
nonwoven or woven material may contain microfibers, as this creates
a more tortuous path for any fluid to penetrate.
[0079] In some embodiments, if the material used to form the
barrier layer is nonwoven, the use of a meltblown nonwoven material
may be used, since it also provides a tortuous path for fluids.
Multiple nonwoven, knitted or woven materials may also be combined
in any number of layers. Several or all layers may be treated with
hydrophobic treatment or made of inherently hydrophobic
material(s). Embodiments using such treated (non-film) materials
may provide greater breathability than may be achieved with a film
barrier. One exemplary barrier layer is an elastic meltblown
nonwoven material made from a copolyether-ester polymer similar to
the product previously sold by Kimberly-Clark under the brand name
DEMIQUE.RTM..
[0080] In some embodiments, the barrier lining may include a
microporous polymer film. Suitable microporous polymer films may
include, but are not limited to, urethane films,
polytetrafluoroethytene (PTFE) films, polyolefin films, and
combinations thereof. One such microporous urethane film is sold by
Porvair PLC, Norfolk, UK. Other microporous PIPE films are
available under the product name GORE-TEX.RTM. (W. L. Gore &
Associates, Inc., Newark, Del.). Such microporous films can be used
in any combination of layers, either laminated or unlaminated, and
can be treated with a hydrophobic water repellent treatment, or
filled with a substance such as oil, to keep the pores from
becoming contaminated. In some embodiments, the polymer film may be
stretchable.
[0081] In some embodiments, a lining may include a single layer of
fabric that has a first surface that is stain resistant
(inherently, or as a result of being treated with a stain resistant
treatment, as described above) and moisture-absorbent, and a second
surface that is hydrophobic. The first surface can be capable of
absorbing an amount of fluid between about 0.1 milliliters ("ml")
and about 50 ml of fluid within as little as 95 cm.sup.2 up to the
entire surface area of the undergarment, and more particularly
between about 3 ml and about 15 ml fluid. The second, opposite
surface of the layer can be treated to be hydrophobic (as described
above) and to prevent or minimize the transmission of the absorbed
fluids. The second surface may be treated with a conventional
durable water-repellent (DWR) treatment (such as ZEPEL.RTM. or
other treatments) and/or it may be saturated or impregnated with a
hydrophobic polymer (such as silicone or urethane). The hydrophobic
polymer fills the gaps in the fabric, and may be applied by dip and
squeeze, knife over roll, spray, gravure, or other methods. The
fabric used may be, for example, a knit and with the stretch
characteristics described above. The fabric may also include the
use of microfiber.
[0082] In some embodiments, bonding of the seams may be done
without stitching using tape or adhesive seams, or using sealants
over the stitched seams. Suitable materials may include elastic
polymer sealants and adhesives. Seams can also be sealed with seam
tape such as Worthen Industries (Nashua, N.H.) Tape 375-4, using a
Pfaff seam sealing machine.
[0083] In some embodiments, stitching of the seams may be done with
thread that is non-wicking. In some embodiments, the non-wicking
thread may be used to minimize fluid from wicking along the thread
in stitched seams. In some embodiments, the thread may be
stretchable. The thread also may have other properties. For
example, the thread may be hydrophilic or treated to be
hydrophilic. The thread also may be hydrophobic or treated to be
hydrophobic.
[0084] Although embodiments have been shown and described for a
bodysuit, it will be appreciated that the same inner lining
construction may be used in other garments. For example, the inner
linings may be used in an undergarment. In such an example, the
undergarment may include an outer shell, a first inner lining that
extends from the upper portion of the undergarment (e.g., a waist
area of the undergarment) to a crotch seam. As with other
embodiments, a second inner lining may extend from a front crotch
seam to a rear crotch seam and be formed in the shape of the crotch
region. A third inner lining may be attached to a top of the second
inner lining. The third inner lining may have the same shape as the
second inner lining but be smaller in size. The inner lining
construction may be used in other garments in other embodiments.
For example, the inner linings may be incorporated into a pair of
pants (e.g., leggings).
[0085] While the present teachings have been described in
conjunction with various embodiments and examples, it is not
intended that the present teachings be limited to such embodiments
or examples. On the contrary, the present teachings encompass
various alternatives, modifications, and equivalents, as will be
appreciated by those of skill in the art. Accordingly, the
foregoing description and drawings are by way of example only.
[0086] Various aspects of the present invention may be used alone,
in combination, or in a variety of arrangements not specifically
discussed in the embodiments described in the foregoing and is
therefore not limited in its application to the details and
arrangement of components set forth in the foregoing description or
illustrated in the drawings. For example, aspects described in one
embodiment may be combined in any manner with aspects described in
other embodiments.
[0087] Also, the invention may be embodied as a method, of which an
example has been provided. The acts performed as part of the method
may be ordered in any suitable way. Accordingly, embodiments may be
constructed in which acts are performed in an order different than
illustrated, which may include performing some acts simultaneously,
even though shown as sequential acts in illustrative
embodiments.
[0088] Use of ordinal terms such as "first," "second," "third,"
etc., in the claims to modify a claim element does not by itself
connote any priority, precedence, or order of one claim element
over another or the temporal order in which acts of a method are
performed, but are used merely as labels to distinguish one claim
element having a certain name from another element having a same
name (but for use of the ordinal term) to distinguish the claim
elements.
[0089] Also, the phraseology and terminology used herein is for the
purpose of description and should not be regarded as limiting. The
use of "including," "comprising," or "having," "containing,"
"involving," and variations thereof herein, is meant to encompass
the items listed thereafter and equivalents thereof as well as
additional items.
* * * * *