Note: Descriptions are shown in the official language in which they were submitted.
BODYSUIT WITH INTEGRATED LINING STRUCTURE
AND METHOD OF MANUFACTURE
FIELD
The disclosed embodiments are generally directed to bodysuits, and more
particularly to
bodysuits with integrated lining structures and methods of manufacture.
BACKGROUND
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
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.
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
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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.
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.
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
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:
FIG. 1 is a front view of a bodysuit according to one embodiment;
FIG. 2 is a rear view of the bodysuit of FIG. 1;
FIG. 3 is a front view of a bodysuit according to another embodiment;
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;
FIG. 5 is a front view of an interior of a bodysuit according to one
embodiment;
FIG. 6 is a rear view of the bodysuit of FIG. 5;
FIG. 7 illustrates an outer shell front panel and a first inner lining front
panel of a
bodysuit according to some embodiments;
FIG. 8 illustrates an outer shell rear panel and a first inner lining rear
panel of the
bodysuit of FIG. 7;
FIG. 9 is a side view of the bodysuit of FIG. 5;
FIG. 10 is an top view of the interior of the bodysuit of FIG. 1;
FIG. 11 is top view of a second inner lining of a bodysuit according to some
embodiments;
FIG. 12 shows a third inner lining of a bodysuit according to some
embodiments;
FIGS. 13-15 illustrate attachment of first, second and third inner linings of
a bodysuit;
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FIGS. 16A and 16B illustrate front and rear fragmentary views of a bodysuit
according to
one embodiment;
FIGS. 17A and 17B illustrate construction of a leg opening bend back according
to one
embodiment;
FIGS. 18A and 18B illustrate attachment of second and third inner linings to
the leg
opening bend back of FIGS. 17A and 17B;
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;
FIG. 20 is a cross sectional side view of a crotch region of a bodysuit; and
FIG. 21 is a table listing types of fabrics and fabric treatments.
DETAILED DESCRIPTION
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.
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
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=
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.
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.
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.
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.
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
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excretions. Such visible excretions may cause embarrassment and/or undue
distress to the
wearer.
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.
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.
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
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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.
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.
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.
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,
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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.
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.
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.
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.
As shown in FIG. 7, a length Li 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 I4 of the rear panel 106b of
the first inner lining in
some embodiments.
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.
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As will be appreciated, the length Li 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.
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.
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.
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.
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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.
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.
As shown in FIG. 15, the front seams 108a, 114a may be spaced a distance Dl of
at least
about 0.25 inches from one another. For example, the seams 108a, 114a may be
spaced a
distance Dl 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 DI 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 DI, D2 may be about 0.375 inches. In other embodiments,
the distances
Dl, D2 may be different from one another.
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
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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.
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.
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.
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.
In some embodiments, a single inner lining may have a weight of between about
3.7
oz./yd2 to about 7.2 oz./yd2. In some embodiments, a single inner lining may
have a weight of
between about 7 oz./yd2 to about 14.6 oz./yd2. 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./yd2 to about 24.9oz/yd2.
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./yd2 to about 7.2 oz./yd2 or
between about 7
oz./yd2 to about 14.6 oz./yd2. 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./yd2, with a combined weight of about 4 oz./yd2. The weight of the
individual layers also may
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be different. For example, a first layer may have a weight of about 1.5
oz./yd2 and a second
layer may have a weight of about 2.5 oz./yd2, with a combined weight of about
4 oz./yd2.
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.
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.
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.
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
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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.
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.
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.
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.
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
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.
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.
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
5376834.1 12
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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.
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.
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.
5376834.1 13
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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.
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.
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/m2), more
particularly greater than
about 800 gm/m2, and more particularly greater than about 1054 gm/m2. 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.
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.
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
5376834.1 14
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may include a woven or non-woven fabric having, elongation test results
comparable to the
Darlington fabrics listed in Table A (see FIG. 21).
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 , 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, MA under
the name TX1540.
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.
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 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.
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.
5376834.1 15
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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 .
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 (PT1-E) 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 (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.
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 cm2up 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 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.
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
5376834.1 16
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polymer sealants and adhesives. Seams can also be sealed with seam tape such
as Worthen
Industries (Nashua, NH) Tape 375-4, using a Pfaff seam sealing machine.
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.
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).
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.
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.
5376834.1 17
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=
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.
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.
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.
What is claimed is:
=
5376834.1 18
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