Note: Descriptions are shown in the official language in which they were submitted.
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UNDERGARMENT
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application
No.
60/724,176, filed on October 6, 2005. The content of the provisional
application is hereby
incorporated by reference.
BACKGROUND
[0002] The present invention relates to undergarments, and more particularly
to men's and
women's seamless undergarments.
[0003) Undergarments, more commonly known as underwear and having multiple
configurations such as boxers, briefs, bikini cut, etc., are commonly worn
under the clothing to
support the wearer's body under his or her clothes, as well as to provide a
more comfortable
garment between the wearer's skin and his or her clothes. Recently, strides
have been taken to
increase the comfort of undergarments for both men and women, including using
softer fabrics
and removing the tags from the undergarments to prevent irntation.
[0004] Another feature of undergarments that has been changed to increase both
the comfort
of the wearer as well as the appearance of the garment is to reduce the number
of seams on the
garment. The seams can also cause irntation to the user, as well as detracting
from the
appearance of the garment by disrupting the contour of the garment with
respect to the body of
the wearer. A challenge presented in producing seamless undergarments is that
the seamless
undergarment is essentially formed from a tube, and yet must conform to the
contoured body of
the wearer to ensure a comfortable fit. It is thus desirable to provide an
undergarment with
increased comfort and support for the user, as well as improved aesthetic
appearance of the
garment.
SUMMARY
[0005] In one embodiment, the invention provides an undergarment. The
undergarment
comprises a front panel composed of a first stitch pattern, a rear panel
composed of a second
stitch pattern, a waistband formed at the top of the front and rear panels, a
leg band formed at the
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bottom of the front and rear panels, and an interface. The interface is formed
between the front
and rear panels and generally extends at least partially between the waistband
and the leg band
on a side of the undergarment. The interface interleaves at least a portion of
the front panel with
at least a portion of the rear panel.
[0006] In another embodiment, the invention provides a method of manufacturing
an
undergarment. The method comprises the steps of stitching a front panel
composed of a first
stitch pattern, stitching a rear panel composed of a second stitch pattern,
stitching a waistband
formed at the top of the front and rear panels, stitching a leg band formed at
the bottom of the
front and rear panels, and stitching an interface. The method further
comprises the step of
forming the interface between the front and rear panels and generally
extending the interface at
least partially between the waistband and the leg band on a side of the
undergarment. The
method further comprises the step of interleaving the interface with at least
a portion of the front
panel with at least a portion of the rear panel.
[0007] In another embodiment, the invention provides an undergarment
comprising a front
panel composed of a first stitch pattern, a rear panel composed of a second
stitch pattern, a
waistband and a leg band. The waistband is formed at the top of the front and
rear panels. The
waistband includes a first waistband portion and a second waistband portion.
The first waistband
portion is formed between the second waistband portion and the front and rear
panels. The
second waistband portion has a higher modulus of elasticity than the first
waistband portion. The
leg band is formed at the bottom of the front and rear panels. The leg band
includes a first leg
band portion and a second leg band portion. The first leg band portion is
formed between the
second leg band portion and the front and rear panels. The second leg band
portion has a higher
modulus of elasticity than the first leg band portion.
[0008] In another embodiment, the invention provides a method of manufacturing
an
undergarment. The method comprises the steps of stitching a front panel
composed of a first
stitch pattern, stitching a rear panel composed of a second stitch pattern,
stitching a waistband
and stitching a leg band. The method further comprises the step of stitching
the waistband
formed at the top of the front and rear panels, the waistband including a
first waistband portion
and a second waistband portion. The method further includes the step of
forming the first
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waistband portion between the second waistband portion and the front and rear
panels. The
method further comprises the step of forming the second waistband portion with
a higher
modulus of elasticity than the first waistband portion. The method further
comprises the step of
stitching a leg band formed at the bottom of the front and rear panels, the
leg band including a
first leg band portion and a second leg band portion. The method further
comprises the step of
forming the first leg band portion between the second leg band portion and the
front and rear
panels. The method further includes the step of forming the second leg band
portion to have a
higher modulus of elasticity than the first leg band portion.
[0009] Other features and advantages of the invention will become apparent to
those skilled
in the art upon review of the following detailed description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Fig. 1 is a front view of an undergarment according to the present
invention;
[0011] Fig. 2 is an enlarged front view of the waistband of the undergarment
of Fig. l;
[0012] Fig. 3 is an enlarged front view of the leg band of the undergarment of
Fig. 1;
[0013] Fig. 4 is a rear view of the undergarment of Fig. 1;
[0014] Fig. S is a side view of the undergarment of Fig. 1;
[0015] Fig. 6 is a front view of an alternate embodiment of an undergarment
according to the
present invention;
[0016] Fig. 7 is a rear view of the undergarment of Fig. 6;
[0017] Fig. 8 is a front view of an alternate embodiment of an undergarment
according to the
present invention;
[0018] Fig. 9 is a rear view of the undergarment of Fig. 8;
[0019] Fig. 10 is a front view of an alternate embodiment of an undergarment
according to
the present invention; and
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[0020] Fig. 11 is a rear view of the undergarment of Fig. 10.
[0021] Before one embodiment ofthe invention is explained in detail, it is to
be understood
that the invention is not limited in its application to the details of
construction and the
arrangements of the components set forth in the following description or
illustrated in the
drawings. The invention is capable of other embodiments and of being practiced
or being carried
out in various ways. Also, it is understood that the phraseology and
terminology used herein is
for the purpose of description and should not be regarded as limiting. The use
of "including,"
"having," and "comprising" and variations thereof herein is meant to encompass
the items listed
thereafter and equivalents thereof as well as additional items.
DETAILED DESCRIPTION
[0022] Fig. 1 illustrates an undergarment 14 embodying aspects of the present
invention.
The undergarment 14 comprises various zones of stitching that will be
described in detail below.
The undergarment 14 includes a first front panel 18 and a second front panel
22. The first and
second front panels 18, 22 are composed of the same stitch pattern. In the
illustrated
embodiment, a 4x 1 mock rib stitch is used in the first and second front
panels 18, 22, though it is
understood that other stitches could be used. The rib stitch results in
vertical ribs 24 evenly
spaced about the first and second panels 18, 22.
[0023] The 4x 1 mock rib stitch results in an evenly ribbed outer surface of
the panels 18, 22,
and an inner surface (i.e., the surface that rests against the skin of the
person wearing the
undergarment 14) that has the look and feel of terry cloth. Thus, the inner
surface is soft and can
absorb any moisture on the skin, and the outer surface of the panels 18, 22 is
aesthetically
pleasing and provides a smooth, contoured fit. In addition, the terry cloth
effect of the rib stitch
allows air to circulate between the body of the wearer and the fabric by
keeping the fabric from
making 100% contact with the body of the wearer, increasing the comfort of the
wearer.
[0024] Positioned between the first and second front panels 18, 22 is a pouch
area 26. The
pouch area 26 includes sections of varying stitch types. Along the perimeter
of the pouch area
26 is an area of reduced stretch stitching 30. The reduced stretch stitching
30 provides a
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transition between the front panels 18, 22 and the pouch area 26 such that no
ripples or bunching
occurs at the transition point between the panels 18, 22 and the pouch area
26.
[0025] A pouch 34 is constructed of a jersey stitch to provide a roomy cavity.
Releasing the
stitching of the pouch such as by using the jersey stitch creates the cavity
in the pouch 34 for
increased comfort of the wearer. The 4x1 mock rib stitch of the front panels
18, 22 assists in
displacing the jersey stitch fabric to create the cavity. The reduced stretch
stitching 30 also
provides support to the pouch 34. Above the pouch 34 is an area of alternating
lxl fine mesh
stitching 38. In the illustrated embodiment, ornamental stitches 42 are also
provided in the
pouch area 26 to improve the aesthetic appearance of the undergarment 14.
[0026] A waistband 46 is formed at the top of the front panels 18, 22. With
reference to Fig.
2, the waistband 46 encircles the top of the undergarment 14 and includes a
first portion 50 and a
second gripping portion 54. The first and second portions 50, 54 are similar
in that they both are
constructed of a 1x1 mock rib stitch utilizing cotton, nylon, and spandex
strands within the
stitches. The first portion 50, which constitutes the lower portion of the
waistband 46, is stitched
using threads containing 66% cotton, 26% nylon, and 8% spandex. The second
portion 54,
which constitutes the top of the waistband 46 and is smaller in width than the
first portion 50, is
stitched using threads containing 53% cotton, 37% nylon, and 10% spandex.
[0027] The increased percentages of nylon and spandex in the second portion 54
increases
the modulus of elasticity of the second portion 54 with respect to the first
portion S0. The higher
modulus of elasticity creates a cupping effect on the edge of the band,
allowing the waistband 46
to pull in more towards the body, and increases the gripping strength of the
second portion 54
with respect to the wearer's body. The configuration of the waistband 46 thus
anchors the
undergarment 14 into position on the wearer's body without pinching or digging
into the skin of
the wearer. The increased grip reduces the likelihood that the waistband 46
can roll down upon
itself when the undergarment 14 is worn by the wearer. It is understood that
the specific
construction of the threads used in the waistband 46 can vary from the
embodiment discussed
above and still fall within the scope of the invention, so long as at least
one of the first and
second portions S0, 54 results in an increased grip strength with respect to
the other of the first
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and second portions 50, 54 to provide a cupping effect of the waistband 46
against the body of
the wearer.
[0028] A leg band 58 is formed at the bottom of each of the front panels 18,
22. As best
illustrated in Fig. 3, each leg band 58 includes first and second portions 62,
66 that are
constructed and function in the same way as the first and second portions 50,
54 of the waistband
46 discussed above. The second portion 66 includes the increased percentages
of nylon and
spandex, as discussed above with respect to the second portion 54, thereby
increasing its
modulus of elasticity, and thus its grip strength. The increased grip strength
results in a leg band
58 that more comfortably grips the leg of the wearer, with less bunching and
rolling of the
undergarment 14 on the wearer's leg. The design of the leg band 58 also
provides more comfort
to the user by reducing the likelihood of the undergarment 14 riding up the
leg of the wearer.
Ornamental stitches 70 are located above the leg band 58 to create a visibly
pleasing transition
between the stitching of the front panels 18, 22 and the stitching of the leg
bands 58.
[0029] Fig. 4 illustrates a rear view of the undergarment 14. As illustrated
in Fig. 4, the
undergarment 14 also includes first and second rear panels 74, 78. The same
type of stitch, i.e.,
the 4x 1 mock rib stitch that is used in the front panels 18, 22, is used for
the rear panels 74, 78,
resulting in vertical ribs 82. However, the length of the stitches forming the
ribs 82 is longer and
looser than the stitch used to form the ribs 24 such that the ribs 82 of the
rear panels 74, 78 are
slightly contoured, whereas the ribs 24 are substantially flat. The slight
excess of material
created by the longer, looser stitches in the vertical direction results in
the contour of the ribs 82.
The longer, looser stitch, and thus the contour, accommodates the contoured
rear end of the
wearer to maintain a smooth and supportive fit.
[0030] Between the rear panels 74, 78 is a central portion 86. The central
portion 86
includes an area 90 constructed of a 1x1 fine mesh stitch on either side of a
center strip 94. The
1x1 fme mesh stitch provides a smooth transition between the rear panels 74,
78 and the center
strip 94 such that no rippling or bunching occurs. The center strip 94 is
constructed of a
modified stitch pattern that exhibits reduced stretching in the vertical
direction compared to the
rear panels 74, 78.
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[0031] In general, it is desired to maximize the stretching properties of the
fabric in some
zones of the undergarment 14 so that the undergarment 14 can comfortably move
with the
wearer as the wearer's body moves. Varying the length of the stitching in
different zones of the
undergarment varies the stretching properties in those zones to achieve a
better fit and more
comfort for the three dimensional shape of the wearer's body. However, the
area of the body
against which the center strip 94 rests is an area that exhibits little or no
stretching in the vertical
direction, even during bending and other movement by the wearer, due to the
anatomy of the
wearer. Thus, the center strip 94 is constructed to have reduced vertical
stretching.
[0032] A support panel 98, also constructed of the 4x1 mock rib stitching, is
coupled to the
front and rear panels 18, 22, 74, 78. The support panel 98 is constructed
separately from the
remainder of the undergarment 14, as will be discussed in more detail below,
and the stitching is
configured to allow for sculpting of the undergarment 14 to the rear end of
the wearer without
causing pinching or digging.
[0033] Fig. 5 illustrates the interface between the shorter, flat 4x 1 mock
rib stitch forming
the ribs 24, and the longer, contoured 4x1 mock rib stitch forming the ribs
82. The interface
includes a zig-zag portion 102 that interleaves portions of the front panel 18
with portions of the
rear panel 78. The interface is three dimensional due to the difference in
stitch length between
the front and rear panels 18, 78. The interleaving of the front and rear
panels 18, 78 allows for a
seamless, comfortable fit, and results in a front portion F that is shorter in
height, and thus sits
lower on the wearer's body, than a rear portion R of the undergarment, as
viewed from the side.
The difference in height between the front F and the rear R allows the
undergarment 14 to
conform comfortably to the wearer's body in all positions of movement, rest,
and stretching.
[0034] The interleaving of the front and rear panels 18, 78 also provides a
smooth, less
abrupt transition between the shorter, tighter stitch of the front panel 18
and the longer, looser
stitch of the rear panel 78 such that no rippling or bunching occurs. Such
rippling or bunching
not only could detract from the overall appearance of the undergarment 14, but
could irntate the
wearer or cause the undergarment 14 to bunch or move in a way uncomfortable to
the wearer, as
well as decrease the support of the wearer's body. It is understood that while
a substantially Z-
shaped zig-zag pattern is illustrated and described above, other interface
configurations are
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possible (e.g. sinusoidal, trapezoidal, stepped, etc.) that would provide for
a smooth transition
between the front and rear panels 18, 78.
[0035] The undergarment 14 with the features described above is constructed to
have a
virtually seamless design. In known undergarment configurations, the
undergarment is
constructed from multiple panels of cloth that must be stitched together,
creating seams at
various points on the undergarment. These seams are not only distracting
visually, but also can
cause discomfort to the user. In other known undergarment configurations,
abrupt transitions
between various stitch types result in seams or virtual seams due to rippling
and bunching.
[0036] The undergarment 14 described above is constructed using a machine
known as a
SANTONI Seamless knitting machine, a piece of equipment well known to one of
ordinary skill
in the art. Using the SANTONI machine, the undergarment 14 is largely created
in a single
process, out of one panel of material. The exception to this is the support
panel 98, which is
created separately and is sewn to the remainder of the undergarment 14
resulting in seams 106
(shown in Figs. 1 and 4). The support panel 98 is sewn in separately to
increase the support to
the inner thighs of the wearer of the undergarment 14.
[0037] The remaining zones of the undergarment 14 are constructed from
beginning to end
by the SANTONI machine, which can be programmed to vary the stitch type and
stitch length in
different zones of the undergarment. As discussed above, some of the zones of
the undergarment
14 are constructed to provide smooth transitions between stitch zones having
different
constructions to provide an undergarment that is both aesthetically and
functionally pleasing.
[0038] Figs. 6 and 7 illustrate another embodiment of a women's undergarment
of the
present invention. Similar reference numbers are used to identify similar
elements as previously
described. Undergarment 110 has a first front panel 18 and a second front
panel 22. The first
and second front panels 18, 22 are composed of the same stitch pattern (e.g.,
a stitch pattern
forming a matte appearance). An alternate stitch pattern between the front
panels 18, 22 creates
a central front 114. Ornamental stitches 42 are also provided to improve the
aesthetic
appearance of the undergarment 110. A waistband 46 is formed at the top of the
front panels 18,
22. The waistband 46 encircles the top of the undergarment 110 and includes a
first portion 50
and a second gripping portion 54. A leg band 158 is formed at the bottom of
each of the front
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panels 18, 22. The undergarment 110 also includes first and second rear panels
74, 78. Between
the rear panels is a central portion 86 having a reduced vertical stretch
compared to the rear
panels 74, 78. The first and second rear panels are composed of the same
stitch pattern (e.g., a
stitch pattern forming a shear appearance). Zig-zag portions 102 interleave
portions of the front
panels 18, 22 with portions of the rear panels 74, 78 to blend the different
stitch patterns.
[0039] Figs. 8 and 9 illustrate an additional embodiment of a women's
undergarment of the
present invention. Similar reference numbers are used to identify similar
elements as previously
described. Undergarment 118 has a first front panel 18 and a second front
panel 22. The first
and second front panels 18, 22 are composed of the same stitch pattern (e.g.,
a stitch pattern
forming a matte appearance). An alternate stitch pattern between the front
panels 18, 22 creates
a central front 114. Ornamental stitches 42 are also provided to improve the
aesthetic
appearance of the undergarment 118. A waistband 46 is formed at the top of the
front panels 18,
22. The waistband 46 encircles the top of the undergarment 118 and includes a
first portion 50
and a second gripping portion 54. A leg band 158 is formed at the bottom of
each of the front
panels 18, 22. The undergarment 118 also includes first and second rear panels
74, 78. Between
the rear panels is a central portion 86 having a reduced vertical stretch
compared to the rear
panels 74, 78. The first and second rear panels are composed of the same
stitch pattern (e.g., a
stitch pattern forming a shear appearance). Zig-zag portions 102 interleave
portions of the front
panels 18, 22 with portions of the rear panels 74, 78 to blend the different
stitch patterns.
[0040] Figs. 10 and 11 illustrate another embodiment of an undergarment of the
present
invention. Similar reference numbers are used to identify similar elements as
previously
described. Undergarment 122 has a first front panel 18 and a second front
panel 22. The first
and second front panels 18, 22 are composed of the same stitch pattern (e.g.,
a stitch pattern
forming a matte appearance). An alternate stitch pattern between the front
panels 18, 22 creates
a central front 114. Ornamental stitches 42 are also provided to improve the
aesthetic
appearance of the undergarment 122. A waistband 46 is formed at the top of the
front panels 18,
22. The waistband 46 encircles the top of the undergarment 122 and includes a
first portion 50
and a second gripping portion 54. A leg band 58 is formed at the bottom of
each of the front
panels 18, 22. The leg band 58 has includes a first and second portions 62, 66
that are
constructed and function in the same way as the first and second portions S0,
54 of the waistband
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46 of Figs. 1-5. The undergarment 122 also includes first and second rear
panels 74, 78.
Between the rear panels is a central portion 86 having a reduced vertical
stretch compared to the
rear panels 74, 78. The first and second rear panels are composed of the same
stitch pattern (e.g.,
a stitch pattern forming a shear appearance). Zig-zag portions 102 interleave
portions of the
front panels 18, 22 with portions of the rear panel 74, 78 to blend the
different stitch patterns. A
support panel 98 is coupled to the front and rear panels 18, 22, 74, 78
resulting in seams 106.
[0041] All of the components discussed in detail above work together to
achieve a common
goal: a better fitting, more comfortable undergarment that supports and moves
comfortably with
the body of the wearer sculpted from an essentially tube shaped garment. The
sculpted silhouette
results from the stitching patterns utilized to create the undergarment. The
features discussed
above also result in an undergarment that is smooth and visually attractive,
comfortably
following the contour of the wearer's body. The features of the undergarment
discussed above
are applicable to all styles of undergarments, including but not limited to
briefs, boxers, low rise,
a high-waist brief, a french cut brief, a triangle bikini, a hip brief, and
the like. It is also
understood that the specific thread compositions and the specific stitch types
used above can be
varied and still fall within the scope of the invention and should not be
interpreted as limiting the
invention to any one thread composition or combination of stitch types.
[0042] Various features and advantages of the invention are set forth in the
following claims
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