US20220400780A1

US20220400780A1 - Article of clothing and manufacturing method thereof

Info

Publication number: US20220400780A1
Application number: US17/765,729
Authority: US
Inventors: Zhenqiang LIU
Original assignee: Regina Miracle International Group Ltd
Current assignee: Regina Miracle International Group Ltd
Priority date: 2019-10-31
Filing date: 2020-10-30
Publication date: 2022-12-22
Also published as: CN114222508A; CN114222508B; WO2021081893A1; EP4051040A1; EP4051040A4; CN118216730A; WO2021083340A1

Abstract

An article of clothing includes a first fabric layer having an inner surface and an outer surface. The article of clothing also includes a second fabric layer having an inner surface and an outer surface. The article of clothing further includes a silicone layer embedded with at least one of the inner surface of the first fabric layer and the inner surface of the second fabric layer, and thereby joining the first fabric layer and the second fabric layer. The article of clothing includes a first zone of a first thickness and a second zone of a second thickness. The first thickness is greater than the second thickness, and the first zone is disposed along an edge of the article of clothing while the second zone is disposed further away from the edge than the first zone.

Description

FIELD OF THE PRESENT DISCLOSURE

The present disclosure relates generally to articles of clothing, and in particular, to an article of clothing having one or more elastic portions to allow for expansion and contraction thereof.

BACKGROUND

Various garments, such as bras, T-shirts, pants, etc., incorporate elastic portions, for example around neck portion or in shoulder portion thereof. These elastic portions are capable of expanding and contracting, and thus may aid with supporting the garment against the body of a wearer. Conventionally, in order to allow for such expansion and contraction of the elastic portions, rubber material has been employed. The rubber material is often sewn or adhered to the portions of the garments that are to be made elastic. To wear or remove the garment, force is applied to the elastic portions, and the rubber material allows the elastic portions to expand to moderate elongations. Once the applied force to the elastic portions is removed, the rubber material causes the elastic portions to regain their original shape from the expanded state, thus providing a snug fit against the body of the wearer.
However, typical rubber material tends to lose its elastic properties after repeated stretching over a period of time. Once the rubber material losses its elastic properties, the elastic portions of the garment be likely to get loose, with limited or no expanding and contracting capabilities. Therefore, the garment after multiple uses may not be able to provide consistent expansion and/or contraction as desired by the wearer. Such garments often become unfit to be used, unless the rubber material is replaced with a new rubber material. Further, these garments utilizing rubber material for providing elasticity are prone to yellowing. Some garments may utilize thermoplastic materials which provide better elastic properties compared to traditional rubber. However, if such garments are subjected to high temperatures, such as high temperature washing and pressing or ironing, they may lose their elastic properties.
Accordingly, there is a need of article of clothing with elastic portions which can retain elastic properties even after repeated and prolonged usage, and can withstand high temperatures, leading to an increase in overall life span of the garments.

SUMMARY

In one aspect, an article of clothing is disclosed. The article of clothing comprises a first fabric layer having an inner surface and an outer surface. The article of clothing also comprises a second fabric layer having an inner surface and an outer surface. The article of clothing further comprises a silicone layer embedded with at least one of the inner surface of the first fabric layer and the inner surface of the second fabric layer, and thereby joining the first fabric layer and the second fabric layer.
In one embodiment, the silicone layer joins the inner surface of the first fabric layer and the inner surface of the second fabric layer. In another embodiment, the silicone layer joins the inner surface of the first fabric layer and the outer surface of the second fabric layer.
In one or more embodiments, the first fabric layer and the second fabric layer are portions of a first panel, and wherein the first fabric layer and the second fabric layer are defined by folding of the first panel. In some embodiments, the article of clothing further comprises a second panel. Herein, the first panel and the second panel are joined together.
In one or more embodiments, the article of clothing further comprises a folded panel joined to the outer surface of the first fabric layer and the outer surface of the second fabric layer.
In one or more embodiments, the silicone layer is composed of a first component and a second component. Herein, the first component comprises one or more of hydrogenated silicone oil, additives and catalysts, and the second component comprises one or more of vinyl silicone oil and silica.
In one or more embodiments, the silicone layer comprises a pattern that includes a plurality of openings, each of the openings defining a region of absence of silicone.
In one or more embodiments, the silicone layer comprises a pattern that includes regions of presence of silicone and regions of absence of silicone.
In one or more embodiments, the silicone layer comprises two or more zones, and at least one of the zones has a thickness that is different from a thickness of at least one of the rest of the zones.
In one or more embodiments, the silicone layer comprises a first zone of a first thickness and a second zone of a second thickness, and the first thickness is greater than the second thickness.
In one or more embodiments, the first zone is disposed along an edge of the article of clothing and the second zone is disposed further away from the edge than the first zone
In one or more embodiments, at least one of the first zone and the second zone is of one of the following shapes: strip shape, wave shape, dot shape, and mesh shape.
In one or more embodiments, at least one of the first zone and the second zone comprises a pattern that includes a plurality of openings, each of the openings defining a region of absence of silicone.
In one or more embodiments, at least some of the plurality of openings are of one of the following shapes: diamond shape, circular shape, and oval shape.
In one or more embodiments, at least one of the first zone and the second zone comprises a pattern that includes regions of presence of silicone and regions of absence of silicone.
The aforementioned article of clothing may be one of a brassiere, a sports bra, an undergarment, a sports pant, a sportswear, a casual dress, and a T-shirt.
In another aspect, a method of manufacturing an article of clothing is disclosed. The method comprises providing a first panel with a first fabric layer and a second fabric layer, the first fabric layer having an inner surface and an outer surface, and the second fabric layer having an inner surface and an outer surface. The method further comprises placing a template with a cut-out onto at least one of the inner surface of the first fabric layer and the inner surface of the second fabric layer. The method further comprises pouring silicone material into the cut-out of the template. The method further comprises pressing the first fabric layer and the second fabric layer together, thereby forming a silicone layer embedded with at least one of the inner surface of the first fabric layer and the inner surface of the second fabric layer, and joining the first fabric layer and the second fabric layer.
In one or more embodiments, the first fabric layer and the second fabric layer are pressed together at room temperature.
In one or more embodiments, the first fabric layer and the second fabric layer are hot-pressed together.
In one or more embodiments, the method further comprises curing the silicone material at a temperature in the range of 50 to 150 degree Celsius.
In one or more embodiments, the method further comprises curing the silicone material for a period in the range of 5 to 60 minutes.
In one or more embodiments, the method further comprises scrapping the extra poured silicone material from the cut-out of the template, to form the silicone layer in the shape of the cut-out of the template.
In one or more embodiments, the first panel is folded to define the first fabric layer and the second fabric layer therein.
In one or more embodiments, the method further comprises providing a second panel; and joining the first panel and the second panel.
In one or more embodiments, the method further comprises providing a folded panel; and joining the folded panel to the outer surface of the first fabric layer and the outer surface of the second fabric layer.
In one or more embodiments, the method further comprises preparing the silicone material by mixing a first component and a second component, the first component comprising one or more of hydrogenated silicone oil, additives and catalysts, and the second component comprising one or more of vinyl silicone oil and silica.
In yet another aspect, an article of clothing is disclosed. The article of clothing comprises a body structure. The article of clothing also comprises one or more elastic portions formed along one or more edges of the body structure. The one or more elastic portions comprises a first fabric layer having an inner surface and an outer surface; and a second fabric layer having an inner surface and an outer surface. The one or more elastic portions further comprises a silicone layer embedded with at least one of the inner surface of the first fabric layer and the inner surface of the second fabric layer, and thereby joining the first fabric layer and the second fabric layer.
In one or more embodiments, the article of clothing further comprises a first panel and a second panel. Herein, the first fabric layer and the second fabric layer are portions of the first panel. Further, the first panel and the second panel are joined together.
In one or more embodiments, the first fabric layer and the second fabric layer are defined by folding of the first panel.
In one or more embodiments, the silicone layer comprises a first zone of a first thickness and a second zone of a second thickness, and the first thickness is greater than the second thickness.
In one or more embodiments, the first zone is disposed along at least one of the one or more edges of the body structure and the second zone is disposed further away than the first zone from the at least one of the one or more edges of the body structure.
In yet another aspect, a brasserie is disclosed. The brasserie comprises a cup region and a body structure. The body structure comprises a first fabric layer having an inner surface and an outer surface; and a second fabric layer having an inner surface and an outer surface. The brasserie comprises one or more elastic portions formed along one or more edges of the body structure. The one or more elastic portions comprises a silicone layer embedded with at least one of the inner surface of the first fabric layer and the inner surface of the second fabric layer, and thereby joining the first fabric layer and the second fabric layer.
In one or more embodiments, the one or more elastic portions are formed along a lower edge of the body structure.
In one or more embodiments, the thermoplastic strip is secured to the second portion of the outer fabric layer by hot-pressing technique.
In one or more embodiments, the silicone layer comprises a first zone of a first thickness and a second zone of a second thickness, and the first thickness is greater than the second thickness.
In one or more embodiments, the first zone is disposed along at least one of the one or more edges of the body structure and the second zone is disposed further away than the first zone from the at least one of the one or more edges of the body structure.
In yet another aspect, a sports bra is disclosed. The sports bra comprises a cup region and a body structure. The body structure comprises a first fabric layer having an inner surface and an outer surface; and a second fabric layer having an inner surface and an outer surface. The sports bra comprises one or more elastic portions formed along one or more edges of the body structure. The one or more elastic portions comprises a silicone layer embedded with at least one of the inner surface of the first fabric layer and the inner surface of the second fabric layer, and thereby joining the first fabric layer and the second fabric layer.
In one or more embodiments, the one or more elastic portions are formed along a lower edge of the body structure.
In one or more embodiments, the one or more elastic portions are formed along strap portions of the body structure.
In one or more embodiments, the first fabric layer and the second fabric layer are defined by folding of the first panel along the one or more edges.
In one or more embodiments, the silicone layer comprises a first zone of a first thickness and a second zone of a second thickness, and the first thickness is greater than the second thickness.
In one or more embodiments, the first zone is disposed along at least one of the one or more edges of the body structure and the second zone is disposed further away than the first zone from the at least one of the one or more edges of the body structure.
In yet another aspect, a side wing for a brassiere is disclosed. The side wing comprises a first fabric layer having an inner surface and an outer surface, a second fabric layer having an inner surface and an outer surface, and a silicone layer embedded with at least one of the inner surface of the first fabric layer and the inner surface of the second fabric layer, and thereby joining the first fabric layer and the second fabric layer.
In one embodiment, the silicone layer joins the inner surface of the first fabric layer and the inner surface of the second fabric layer. In another embodiment, the silicone layer joins the inner surface of the first fabric layer and the outer surface of the second fabric layer.
In one or more embodiments, the first fabric layer and the second fabric layer are portions of a first panel, and wherein the first fabric layer and the second fabric layer are defined by folding of the first panel. In some embodiments, the article of clothing further comprises a second panel. Herein, the first panel and the second panel are joined together.
In one or more embodiments, the article of clothing further comprises a folded panel joined to the outer surface of the first fabric layer and the outer surface of the second fabric layer.
In one or more embodiments, the silicone layer is composed of a first component and a second component. Herein, the first component comprises one or more of hydrogenated silicone oil, additives and catalysts, and the second component comprises one or more of vinyl silicone oil and silica.
In one or more embodiments, the silicone layer comprises a first zone of a first thickness and a second zone of a second thickness, and the first thickness is greater than the second thickness.
In one or more embodiments, the first zone is disposed along an edge of the body structure and the second zone is disposed further away from the edge than the first zone.
In one or more embodiments, at least one of the first zone and the second zone is of one of the following shapes: strip shape, wave shape, dot shape, and mesh shape.
In one or more embodiments, at least one of the first zone and the second zone comprises a pattern that includes a plurality of openings, each of the openings defining a region of absence of silicone.
In one or more embodiments, at least some of the plurality of openings are of one of the following shapes: diamond shape, circular shape, and oval shape.
In another aspect, a method of manufacturing an article of clothing is disclosed. The method comprises providing a first panel with a first fabric layer and a second fabric layer, the first fabric layer having an inner surface and an outer surface, and the second fabric layer having an inner surface and an outer surface. The method further comprises repeating two or more times the following steps: placing a template with a cut-out onto at least one of the inner surface of the first fabric layer and the inner surface of the second fabric layer; pouring silicone material into the cut-out of the template; and allowing the silicone material to cure. The method further comprises pressing the first fabric layer and the second fabric layer together, thereby forming a silicone layer embedded with at least one of the inner surface of the first fabric layer and the inner surface of the second fabric layer, and joining the first fabric layer and the second fabric layer. In some embodiments, the method further comprises scrapping the extra poured silicone material from the cut-out of the template after the step of pouring silicone material into the cut-out of the template and before allowing the silicone material to cure.
The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of example embodiments of the present disclosure, reference is now made to the following descriptions taken in connection with the accompanying drawings in which:

FIG. 1 illustrates a front diagrammatic view of a brassiere, in accordance with an embodiment of the present disclosure;

FIG. 2 illustrates a diagrammatic view of a side wing of the brassiere of FIG. 1 ;

FIG. 3 illustrates a section view of the side wing of FIG. 2 taken along section AA′;

FIGS. 4-8 illustrate various stages involved in forming of a silicone layer, in accordance with one or more embodiments of the present disclosure;

FIGS. 10-16 illustrate various configurations of a first panel incorporating the silicone layer, in accordance with one or more embodiments of the present disclosure;

FIG. 17 illustrates a front diagrammatic view of a brassiere, in accordance with another embodiment of the present disclosure;

FIGS. 18-19 illustrate diagrammatic views of a side wing of the brassiere of FIG. 17 ;

FIG. 20 illustrates a section view of the side wing of FIGS. 18-19 taken along section BB′;

FIG. 21 illustrates a front diagrammatic view of a brassiere, in accordance with yet another embodiment of the present disclosure;

FIG. 22 illustrates a diagrammatic view of a side wing of the brassiere of FIG. 21 ;

FIG. 23 illustrates a section view of the side wing of FIG. 21 taken along section CC′;

FIG. 24 illustrates a front diagrammatic view of a brassiere, in accordance with yet another embodiment of the present disclosure;

FIG. 25 illustrates a diagrammatic view of a side wing of the brassiere of FIG. 24 ;

FIG. 26 illustrates a section view of the side wing of FIG. 25 taken along section DD′;

FIGS. 27-28 illustrate layered views of a side wing of a brassiere, in accordance with different embodiments of the present disclosure; and

FIGS. 29-40 illustrate diagrammatic view of different articles of clothing incorporating the silicone layer, in accordance with various embodiments of the present disclosure.

FIG. 41 illustrates a diagrammatic view of a side wing of the brassiere of FIG. 1 ;

FIG. 42 illustrates a section view of the side wing of FIG. 41 taken along section EE′;

FIG. 43 illustrates a diagrammatic view of a side wing of the brassiere of FIG. 1 ;

FIG. 44 illustrates a section view of the side wing of FIG. 43 taken along section FF′;

DETAILED DESCRIPTION

In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present disclosure. It will be apparent, however, to one skilled in the art that the present disclosure can be practiced without these specific details. In other instances, apparatuses and methods are shown in block diagram form only in order to avoid obscuring the present disclosure.
Reference in this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. The appearance of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Further, the terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item. Moreover, various features are described which may be exhibited by some embodiments and not by others. Similarly, various requirements are described which may be requirements for some embodiments but not for other embodiments.
The embodiments are described herein for illustrative purposes and are subject to many variations. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but are intended to cover the application or implementation without departing from the spirit or the scope of the present disclosure. Further, it is to be understood that the phraseology and terminology employed herein are for the purpose of the description and should not be regarded as limiting. Any heading utilized within this description is for convenience only and has no legal or limiting effect.
Where there is reference to the word “layer” it is to be understood that it may have its common definition and, but not limited to that the layer could consist of one panel or may have regions that are defined by two or more panels that are joined and that may each be of a different characteristic (e.g. color, thickness, material, orientation, size).
Referring to the accompanied drawings, FIG. 1 illustrates a diagrammatic view an article of clothing (generally referred by the numeral 100), in accordance with one or more embodiments of the present disclosure. In the present illustration, the article of clothing 100 has been shown to be a brassiere; however, for the purposes of the present disclosure, the article of clothing 100 may be any garment to be worn by a wearer. For example, the article of clothing 100 may be, but not limited to, a bra top, a sports top, a pantie, a T-shirt, a pant, and the like. The article of clothing 100 includes a body structure 102 which defines shape and purpose of the article of clothing 100. In the exemplary article of clothing 100 of FIG. 1 , the body structure 102 includes a pair of bra cups, with a first bra cup 104 a and a second bra cup 104 b. A center gore 106 is extending between and connects the first bra cup 104 a and the second bra cup 104 b. A pair of straps, including a first strap 108 a and a second strap 108 b are attached to peripheries of the first bra cup 104 a and the second bra cup 104 b, respectively. Further, a pair of side wings, including a first side wing 110 a and a second side wing 110 b are attached to the peripheries of the first bra cup 104 a and the second bra cup 104 b, respectively. In one or more examples, one or more fasteners 112 may be provided with one or more of the first side wing 110 a and the second side wing 110 b. It may be contemplated that the pair of straps 108 a and 108 b support the article of clothing 100 on shoulders of the wearer, while the pair of side wings 110 a and 110 b support the article of clothing 100 around a torso of the wearer. In some examples, the pair of straps 108 a and 108 b may not be provided and only the pair of side wings 110 a and 110 b may support the article of clothing 100 on the wearer.
As illustrated in FIG. 1 , the body structure 102 provides one or more edges, including an edge 114. In the illustrated examples, the edge 114 is shown to be extending along a bottom of one or both of the pair of side wings 110 a and 110 b of the body structure 102, in the article of clothing 100. For such cases, the edge 114 has been, sometimes, interchangeably referred to as “bottom edge 114” without any limitations. It may be understood that although the edge 114 is shown to be extending along the bottom of the body structure 102; in other examples, the edge 114 may be any other edge, such as, a side edge or a top edge, of the body structure 102 without any limitations. According to an embodiment of the present disclosure, the article of clothing 100 includes an elastic portion 120 formed along and co-extensive with the edge 114 of the body structure 102. The elastic portion 120 may be extending along the entire length of the edge 114 of the body structure 102. In some examples, the article of clothing 100 may have multiple elastic portions 120 formed along various edges thereof. Herein, the elastic portion 120 allows the article of clothing 100 to expand and contract. It may be understood that the body structure 102 provides the external appearance to the article of clothing 100 and the incorporated elastic portions 120 allow the article of clothing 100 to be worn and removed conveniently.
FIG. 2 illustrates one of the side wings, for example side wing 110 a of the article of clothing 100; and FIG. 3 illustrates a section view of the side wing 110 a taken along the section AA′ as shown in FIG. 2 . As depicted, the article of clothing 100, or particularly the side wing 110 a therein, includes a first fabric layer 122 and a second fabric layer 124. Herein, the first fabric layer 122 and the second fabric layer 124 are portions of a single panel 126 which is a single piece, hereinafter referred to as “first panel.” In one embodiment, as illustrated, the first fabric layer 122 and the second fabric layer 124 are defined by folding of the first panel 126. In the illustrated example, the first panel 126 is folded once at fold 128 a to define the first fabric layer 122 and the second fabric layer 124, and is further folded at fold 128 b to be joined back to the first fabric layer 122. In another example (not illustrated), the first fabric layer 122 and the second fabric layer 124 may be separate pieces and placed as one on the other to define two layers of the first panel 126. In general, the second fabric layer 124 in the present example is disposed below the first fabric layer 122. Herein, the first fabric layer 122 has an inner surface 122 a and an outer surface 122 b; and also the second fabric layer 124 has an inner surface 124 a and an outer surface 124 b. In the present configuration of the first panel 126, the inner surface 122 a of the first fabric layer 122 and the inner surface 124 a of the second fabric layer 124 are facing each other.
According to an embodiment, the article of clothing 100, or herein the first panel 126, includes a silicone layer 140 embedded with at least one of the inner surface 122 a of the first fabric layer 122 and the inner surface 124 a of the second fabric layer 124. In the present example, the silicone layer 140 is embedded with at least one of the inner surface 122 a of the first fabric layer 122 and the inner surface 124 a of the second fabric layer 124 at or near the fold 128 a. As shown, the silicone layer 140 is sandwiched between the inner surface 122 a of the first fabric layer 122 and the inner surface 124 a of the second fabric layer 124. In particular, the silicone layer 140 is embedded with the inner surface 122 a of the first fabric layer 122 and the inner surface 124 a of the second fabric layer 124; i.e., the silicone layer 140 is embedded with the textile material of the first fabric layer 122 and the second fabric layer 124. Herein, the silicone layer 140 provides the elasticity to the first panel 126 at or near the fold 128 a. The silicone layer 140 further acts as the adhesive, and thereby the silicone layer 140 joins the first fabric layer 122 and the second fabric layer 124 at or near the fold 128 a, without the need of or in the absence of any additional adhesive. In an embodiment, the first panel 126 is provided with a layer 142 of adhesive for joining the loose edges of the first panel at the fold 128 b. In some other embodiments, the layer 142 provided at the other fold 128 b may also be a silicone layer, in place of the adhesive layer, with the silicone layer 142 acting as the adhesive.
The present disclosure further provides a method of manufacturing the article of clothing 100, or a part or a component of the article of clothing 100, such as the side wing 110 a as illustrated in FIG. 3 . Herein, the method includes providing the first panel 126. As illustrated in FIG. 4 , the first panel 126 is in the form of a piece of suitable textile material. Herein, the first panel 126 is laid flat on a flat surface, such as the flat surface 144. The method further includes placing a template 146 onto the first panel 126. The template 146 includes a cut-out 148 formed in the required shape of the silicone layer to be formed. The template 146 is placed onto the first panel 126. As discussed above, the first panel 126 is folded to define the first fabric layer and the second fabric layer. Thus, the template 146 can be considered to be placed on one of the following: the inner surface of the first fabric layer and the inner surface of the second fabric layer.
The method further includes pouring silicone material into the cut-out 148 of the template 146. The silicone material is poured or applied manually or by machine in liquid form or gel form. In some embodiments, the silicone material is prepared by mixing two components, a first component and a second component, with the first component preferably including one or more of hydrogenated silicone oil, additives and catalysts, and the second component preferably including one or more of vinyl silicone oil and silica. In some examples, the silicone material may be Polysiloxane rubber (SiR), as known in the art. Further, as illustrated in FIG. 5 , the method further includes scrapping the extra poured silicone material from the cut-out 148 of the template 146, to form the silicone layer in the shape of the cut-out 148. As shown, the scrapping of the extra poured silicone material may be done by using a knife 150 or the like. Thereafter, the template 146 may be removed, to leave a layer of silicone material on the first panel 126.
Subsequently, as illustrated in FIG. 6 , the first panel 126 is folded to define the first fabric layer and the second fabric layer, with the first fabric layer having an inner surface and an outer surface and the second fabric layer having an inner surface and an outer surface, as discussed above. As shown better in FIG. 7 , the layer of silicone material is disposed between the inner surface 122 a of the first fabric layer 122 and the inner surface 124 a of the second fabric layer 124. Herein, the layer of silicone material is substantially embedded with the inner surface 122 a of the first fabric layer 122 and the inner surface 124 a of the second fabric layer 124.
As illustrated in FIG. 8 , the method further includes pressing the first fabric layer 122 and the second fabric layer 124 together, thereby forming the silicone layer 140 embedded with the inner surface 122 a of the first fabric layer 122 and the inner surface 134 a of the second fabric layer 124. In this step, the first fabric layer 122 and the second fabric layer 124 are joined together by pressing, using a press 152. In one example, the first fabric layer 122 and the second fabric layer 124 are pressed together at room temperature. In another example, the first fabric layer 122 and the second fabric layer 124 are hot-pressed together. It will be appreciated that the pressing together of the first fabric layer 122 and the second fabric layer 124 generally occurs before curing of the silicone material therebetween, and forming of the silicone layer 140 as described above. The silicone material is allowed to cure at room temperature or under heat in a drying oven. The silicone material is cured at a temperature in the range of 50 to 150 degree Celsius. The method further comprises curing the silicone material for a period in the range of 5 to 60 minutes. As may be appreciated, longer curing time will be required if curing is at room temperature. Further, actual curing time will also depend on the thickness of the silicone layer to be formed. Typical thickness of the silicone layer to be formed is 0.1 to 1.5 mm.
During the curing process, the silicone material will penetrate into the fabric, and upon curing and pressing the outer and inner layers of the fabric enclosing the silicone layer Thus, the layers will be adhered to each other, without the need of an adhesive. FIG. 9 illustrates an exemplary first panel 126 as formed with the silicone layer 140 embedded with the inner surface 122 a of the first fabric layer 122 and the inner surface 134 a of the second fabric layer 124 therein. FIGS. 10-16 illustrate other possible configurations of the first panel 126 that could be formed by the method as described above in reference to FIGS. 4-8 . In some examples, the article of clothing 100 further includes a second panel, such as a back panel in the brassiere (not shown). In such example, the first panel and the second panel are joined together.
FIG. 10 illustrates an arrangement 1000 of the various layers for forming the first panel 126 when pressed, in accordance with an embodiment of the present disclosure. As shown in FIG. 10 , the first fabric layer 122 and the second fabric layer 124 are portions of a fabric sheet, and are defined by folding of the fabric sheet along a folded region 1002. Also as may be seen, the fabric sheet is further folded along a folded region 1004, such that the inner surface 122 a of the first fabric layer 122 is facing the outer surface 124 b of the second fabric layer 124 at their respective free ends 1006 a and 1006 b. The silicone layer 140 is disposed proximal to the folded region 1002 between the inner surface 122 a of the first fabric layer 122 and the inner surface 124 a of the second fabric layer 124. Further, an adhesive layer 1008 is provided proximal to the folded region 1004 between the inner surface 122 a of the first fabric layer 122 and the outer surface 124 b of the second fabric layer 124. In some examples, the layer 1008 provided at the fold 1004 may also be a silicone layer in place of the adhesive layer, with the silicone layer 1008 acting as the adhesive.
FIG. 11 illustrates an arrangement 1100 of the various layers for forming the first panel 126 when pressed, in accordance with another embodiment of the present disclosure. As shown in FIG. 11 , the first fabric layer 122 and the second fabric layer 124 are portions of the fabric sheet, and are defined by folding of the fabric sheet along a folded region 1102 and a folded region 1104, such that the inner surface 122 a of the first fabric layer 122 is facing the inner surface 124 a of the second fabric layer 124. The silicone layer 140 is disposed proximal to the folded region 1102 between the inner surface 122 a of the first fabric layer 122 and the inner surface 124 a of the second fabric layer 124. Further, the adhesive layer 1106 is provided proximal to the folded region 1104 between the inner surface 122 a of the first fabric layer 122 and the inner surface 124 a of the second fabric layer 124.
FIG. 12 illustrates an arrangement 1200 of the various layers for forming the first panel 126 when pressed, in accordance with yet another embodiment of the present disclosure. As shown in FIG. 12 , similar to the arrangement 1200, the first fabric layer 122 and the second fabric layer 124 are portions of the fabric sheet, and are defined by folding of the fabric sheet along a folded region 1202. The fabric sheet is further folded along a folded region 1204, such that the inner surface 122 a of the first fabric layer 122 is facing the outer surface 124 b of the second fabric layer 124 at their respective free ends 1204 a and 1204 b. The silicone layer 140 is disposed proximal to the folded region 1202 between the inner surface 122 a of the first fabric layer 122 and the inner surface 124 a of the second fabric layer 124. Further, a rubber layer 1206 is provided proximal to the folded region 1204 between the inner surface 122 a of the first fabric layer 122 and the outer surface 124 b of the second fabric layer 124. An adhesive layer 112 is present on either side of the rubber layer 1206 to adhere the rubber layer 1206 to the first fabric layer 122 and the second fabric layer 124 respectively.
FIG. 13 illustrates an arrangement 1300 of the various layers for forming the first panel 126 when pressed, in accordance with yet another embodiment of the present disclosure. As shown in FIG. 13 , the first fabric layer 122 and the second fabric layer 124 are portions of the fabric sheet, and are defined by folding of the fabric sheet along a folded region 1302, such that the inner surface 122 a of the first fabric layer 122 is facing the inner surface 124 a of the second fabric layer 124. The silicone layer 140 is disposed proximal to the folded region 1302 between the inner surface 122 a of the first fabric layer 122 and the inner surface 124 a of the second fabric layer 124. Further, a folded panel 1304 is provided which is to be joined to the outer surface 122 b of the first fabric layer 122 and the outer surface 124 b of the second fabric layer 124.
FIG. 14 illustrates an arrangement 1400 of the various layers for forming the first panel 126 when pressed, in accordance with yet another embodiment of the present disclosure. As shown in FIG. 14 , the first fabric layer 122 and the second fabric layer 124 are portions of the fabric sheet, and are defined by folding of the fabric sheet along a folded region 1402 and a folded region 1404, such that the inner surface 122 a of the first fabric layer 122 is facing the inner surface 124 a of the second fabric layer 124. Free ends (not shown) of the fabric sheet may be joined together by ultrasonic welding process or the like, to complete a loop. Silicone layers 140 are disposed proximal to each or one of the folded region 1402 and the folded region 1404 between the inner surface 122 a of the first fabric layer 122 and the inner surface 124 a of the second fabric layer 124.
FIG. 15 illustrates an arrangement 1500 of the various layers for forming the first panel 126 when pressed, in accordance with yet another embodiment of the present disclosure. As shown in FIG. 15 , the first fabric layer 122 and the second fabric layer 124 are portions of the fabric sheet, and are defined by folding of the fabric sheet along a folded region 1502 and a folded region 1504, such that the inner surface 122 a of the first fabric layer 122 is facing the inner surface 124 a of the second fabric layer 124. The silicone layer 140 is disposed proximal to the folded region 1502 between the inner surface 122 a of the first fabric layer 122 and the inner surface 124 a of the second fabric layer 124. Further, another silicone layer 1506 is provided proximal to the folded region 1504.
FIG. 16 illustrates an arrangement 1600 of the various layers for forming the first panel 126 when pressed, in accordance with yet another embodiment of the present disclosure. As shown in FIG. 16 , the first fabric layer 122 and the second fabric layer 124 are portions of the fabric sheet, and are defined by folding of the fabric sheet along a folded region 1602, such that the inner surface 122 a of the first fabric layer 122 is facing the inner surface 124 a of the second fabric layer 124. The silicone layer 140 is disposed proximal to the folded region 1602 between the inner surface 122 a of the first fabric layer 122 and the inner surface 124 a of the second fabric layer 124. Further, another silicone layer 1606 is provided proximal to free ends 1604 a and 1604 b between the inner surface 122 a of the first fabric layer 122 and the inner surface 124 a of the second fabric layer 124.
FIG. 17 illustrates a configuration for the article of clothing, in particular a brassiere 1700, in accordance with another embodiment of the present disclosure. As shown, the brassiere 1700 includes a cup region and a body structure. The brassiere 1700 is substantially similar to the brassiere 100 of FIG. 1 . Herein, the shaded region represents the silicone layer 1702. As may be seen, the silicone layer 1702 has a different shape and size as compared to the silicone layer 140 of FIG. 1 . Herein, the silicone layer 1702 substantially cover the lower region of side wing 1704 and not just the lower edge thereof. FIGS. 18 and 19 illustrate the side wing 1704 of the brassiere 1700. As shown in FIG. 18 , the silicone layer 1702 substantially covers the side wing 1704 at lower region 1706 thereof, with upper region 1708 not having the silicone layer 1702. Thus, the layers of the side wing 1704 in the lower region 1706 are adhered together via the silicone layer 1702, while the layers of the side wing 1704 in the upper region 1708 are not, as may be seen from FIGS. 18 and 19 respectively. FIG. 20 illustrates a section view of the side wing 1704 taken along a section BB′ as shown in FIG. 19 . As shown, the silicone layer 1702 is formed at the lower region 1706 embedded between a first fabric layer 1710 and a second fabric layer 1712 thereof. The silicone layer 1702 is located between the first fabric layer 1710 and the second fabric layer 1712, and is represented by the shaded region shown in FIGS. 17 to 19 . The upper region 1708, where silicone layer is absent, has the layers 1710 and 1712 remaining loose relative to each other which provides better comfort for the wearer, when the brassiere 1700 is worn. The upper region 1708, where silicone layer is absent, may span the whole of the upper edge, or may, as illustrated in FIGS. 17 to 19 , span only a portion of the upper edge.
FIG. 21 illustrates a configuration for the article of clothing, in particular a brassiere 2100, in accordance with another embodiment of the present disclosure. The brassiere 2100 is substantially similar to the brassiere 100 of FIG. 1 . Herein, the shaded region represents the silicone layers 2102. As may be seen, the silicone layers 2102 are disposed along most of the edges of brassiere 2100 and not just the lower edge (as in brassiere 100 of FIG. 1 ). FIG. 22 illustrates the side wing 2104 of the brassiere 2100. FIG. 23 illustrates a section view of the side wing 2104 taken along a section CC′ as shown in FIG. 22 . As shown in FIG. 22 , the silicone layer 2102 are formed along upper, lower and side edges of the side wing 2104.
FIG. 24 illustrates a configuration for the article of clothing, in particular a brassiere 2400, in accordance with another embodiment of the present disclosure. The brassiere 2400 is substantially similar to the brassiere 2100 of FIG. 21 . Herein, the shaded region represents the silicone layers 2402 in side wing 2404 of the brassiere 2400. As may be seen, the silicone layers 2402 are disposed along most of the edges of brassiere 2100. FIG. 25 illustrates the side wing 2404 of the brassiere 2400. FIG. 26 illustrates a section view of the side wing 2404 taken along a section DD′ as shown in FIG. 25 . As shown in FIG. 25 , the silicone layer 2402 are formed along upper, lower and side edges of the side wing 2404. Herein, the fabric layers are folded twice at the edges, and the silicone layers 2402 are formed along the edges, such that at each edge, the silicone layer 2402 is located between a folded portion of the first fabric layer and a folded portion of the second fabric layer (as best seen from FIG. 26 ).
FIG. 27 illustrates layered view of a side wing 2700 according to another embodiment. In the exemplary embodiment, as shown in FIG. 27 , silicone layers 2702 may be applied in a pattern that includes a plurality of elongated channels extending transversely. The elongated channels defined a region of absence of the silicone layer 2702. FIG. 28 illustrates layered view of a side wing 2800 according to yet another embodiment. In the exemplary embodiment, as shown in FIG. 28 , silicone layers 2802 may be applied in a pattern that includes a plurality of diamond shaped openings defining a region of absence of silicone layer. It may be understood that the any suitable pattern may be utilized that facilitates a strong bonding between the inner layer and the outer layer or between the first fabric layer and the second fabric layer, and also provide desired air permeability and stretchability. Also, the openings may be of any suitable shape, such as circular, oval, rhombus, or any other suitable shape. In some embodiments, the silicone layer may comprise or may be applied in a pattern that includes regions of presence of silicone and regions of absence of silicone. The regions where silicone is absent may correspond to the openings of the pattern. The other regions, i.e., regions other than the openings, are where silicone is present in the pattern. The pattern may be a repeating pattern, or may be an irregular pattern.
FIGS. 29-40 illustrate different articles of clothing, and some of their different views. In most of these figures, the shaded regions represent the locations where the silicone layers are located between a first fabric layer and a second fabric layer. FIG. 29 provides a brassiere 2900 with silicone layers 2902 spanning substantial part of the side wings thereof. FIG. 30 provides a front view of a sports bra 3000 and FIG. 31 provides a back view of the sports bra 3000. As shown, silicone layers 3002 spans part of lower region as well as edges along upper region in the front of the sports bra 3000. Silicone layer (not shown) may also be formed along lower edge of the sports bra 3000. FIG. 32 provides a front view of a sports bra 3200 and FIG. 33 provides a back view of the sports bra 3200. As shown, silicone layers 3202 span part of edges in upper region in the front of the sports bra 3200 and along straps at back of the sports bra 3200. FIG. 34 provides back view of a sports bra 3400 with silicone layer 3402 formed along all edges thereof, while FIG. 35 provides back view of a sports bra 3500 with silicone layer 3502 formed along all portion of edges thereof. FIG. 36 provides front view of a bra 3600 with silicone layer 3602 (shown in wavy lines) formed along upper edges thereof, while FIG. 37 provides back view of the bra 3600. FIG. 38 illustrates an underwear 3800 with the silicone layer 3802 formed along upper edge thereof. FIG. 39 illustrates a pant 3900 with the silicone layer 3902 formed along lower edges thereof. FIG. 40 illustrates a T-shirt 4000 with the silicone layer 4002 formed along lower edge thereof. In all such examples, and in all of the examples and embodiments described in the foregoing, the silicone layer is located between a first fabric layer and a second fabric layer, and is embedded with at least one of the inner surface of the first fabric layer and the inner surface of the second fabric layer and thereby joining the first and second fabric layers. In some embodiments, the first fabric layer and the second fabric layer are portions of a first panel, and the folding of the first panel defines the first fabric layer and the second fabric layer.
In accordance with some or more embodiments of the present disclosure, the silicone layer may comprise two or more zones, and all such zones may have different thicknesses, or at least one of such zones may be of a thickness that is different from the thickness of at least one or more of the rest of the zones. As an example, FIG. 41 illustrates the side wing 110 a or 110 b of the brassiere 100 of FIG. 1 in accordance with an embodiment of the present disclosure. FIG. 42 illustrates a section view of the side wing taken along a section EE′ as shown in FIG. 41 . In the exemplary embodiment as shown in FIG. 41 and FIG. 42 , the silicone layer comprises two zones, namely a first zone 4102 and a second zone 4112. As can be seen, the two zones have different thicknesses. In the exemplary embodiment as shown, the first zone 4102 has a thickness that is greater than the thickness of the second zone 4112. The thicker first zone 4102 provides better support and stronger resilient force than the thinner second zone 4112, and is generally disposed at regions where support or enhanced support is required. For example, as shown in FIG. 41 and FIG. 42 , the first zone 4102 is disposed along an edge of the article of clothing, or an edge of the side wing of the brassiere 100. The second zone 4112 can be disposed at any other parts of the article of clothing or any other parts of the side wing of the brassiere 100. In the exemplary embodiment as shown, the second zone 4112 is disposed further away from the edge than the first zone 4102. It will be appreciated that it is not necessary that the first zone is disposed along an edge; it can be disposed at any part of the article of clothing as desired.
FIG. 43 illustrates the side wing 110 a or 110 b of the brassiere 100 of FIG. 1 in accordance with another embodiment. FIG. 44 illustrates a section view of the side wing taken along a section FF′ as shown in FIG. 43 . In the exemplary embodiment as shown in FIG. 43 and FIG. 44 , the silicone layer comprises two zones, namely a first zone 4302 and a second zone 4312. The first zone 4302 has a thickness that is greater than the thickness of the second zone 4312. In addition, in the exemplary embodiment as shown, the second zone 4312 comprises or is applied in a pattern with a plurality of openings, each opening defining a region of absence of silicone. The other regions of the pattern, i.e., regions other than the openings, are where silicone is present. The openings as shown in FIG. 43 and FIG. 44 are of diamond shape. However, any suitable shape may be utilized, such as circular, oval, rhombus or any other suitable shape. Also, any suitable pattern may be utilized that facilitates an adequate bonding between the inner layer and the outer layer or between the first fabric layer and the second fabric layer, and also provide desired air permeability and stretchability. The pattern may be a repeating pattern, or may be an irregular pattern.
In the embodiments as shown in FIG. 41 to FIG. 44 , the first zone and/or the second zone can be of any suitable shape. For example, it can be of strip shape, wave shape, dot shape, mesh shape, or any other suitable shape.
In manufacturing, silicone layer may be applied in a pattern through, for example, screen printing technique. Silicone layer comprising two or more zones of different thicknesses may be applied using suitable mold. Alternatively, silicone layer comprising two or more zones of different thicknesses may be applied through repeating two or more times the following steps to produce the thicker zone or zones: placing template on the fabric layer, pouring silicone material into the cut-out of the template corresponding to the thicker zone or zones, scrapping the extra poured silicone material from the cut-out of the template and allowing the silicone material to cure; and followed by pressing the first fabric layer and the second fabric layer together to thereby form the silicone layer that is embedded with at least one of the inner surface of the first fabric layer and the inner surface of the second fabric layer and join the first fabric layer and the second fabric layer.
In general, typical thickness of the silicone layer according to the present disclosure is 0.1 to 1.5 mm. Where there are, for example, two zones of the silicone layer with different thicknesses, typical thickness of the first zone which has a greater thickness is 0.35 to 0.6 mm, while typical thickness of the second zone which has a smaller thickness is 0.15 to 0.35 mm.
Although some of the embodiments described in the foregoing are related to side wings or brassieres, it will be appreciated that the features and concepts described are applicable to any article of clothing, including but not limited to a brassiere, a sports bra, an undergarment, a sports pant, a sportswear, a casual dress, and a T-shirt.
The silicone layer as formed provides the one or more elastic portions in the various articles of clothing as described above. After curing, the silicone layer is resistant to high temperature and hence the assembly of outer and inner layers enclosing silicone (or elastic portion) could be subject to hot pressing or hot molding, for example to produce the there-dimensional cup shape. The shape of the cured silicone layer, and hence the part providing adhering and elastic recovery properties, is defined by the template, and can be adjusted to suit any required shape. The silicone layer is preferably planar, but may also be curved depending on the template. It may be appreciated that by appropriately choosing the composition making up the silicone material, the hardness and softness of the silicone layer (formed after curing) can be controlled and so it can also be applied so as to provide support in regions requiring support, such as the lower region below the two cup regions as illustrated in FIG. 30 .
The embodiments and methods described in the foregoing focused on the use of a silicone layer being embedded with at least one of the inner surface of the first fabric layer and the inner surface of the second fabric layer, and thereby joining the first fabric layer and the second fabric layer. Apart from using silicone, the following may also be used: silicone rubber, natural rubber adhesive, polyamide resin adhesive, or 1-component-polyurethane adhesive.
The foregoing descriptions of specific embodiments of the present disclosure have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present disclosure to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The exemplary embodiment was chosen and described in order to best explain the principles of the present disclosure and its practical application, to thereby enable others skilled in the art to best utilize the present disclosure and various embodiments with various modifications as are suited to the particular use contemplated.

Claims

1. An article of clothing comprising:

a first fabric layer having an inner surface and an outer surface;

a second fabric layer having an inner surface and an outer surface; and

a silicone layer embedded with at least one of the inner surface of the first fabric layer and the inner surface of the second fabric layer, and thereby joining the first fabric layer and the second fabric layer.

2. The article of clothing of claim 1, wherein the silicone layer joins the inner surface of the first fabric layer and the inner surface of the second fabric layer.

3. The article of clothing of claim 1, wherein the silicone layer joins the inner surface of the first fabric layer and the outer surface of the second fabric layer.

4. The article of clothing of claim 1, wherein the first fabric layer and the second fabric layer are portions of a first panel, and wherein the first fabric layer and the second fabric layer are defined by folding of the first panel.

5. The article of clothing of claim 4 further comprising a second panel, wherein the first panel and the second panel are joined together.

6. The article of clothing of claim 4 further comprising a folded panel joined to the outer surface of the first fabric layer and the outer surface of the second fabric layer.

7. The article of clothing of claim 1, wherein the silicone layer is composed of a first component and a second component, the first component comprising one or more of hydrogenated silicone oil, additives and catalysts, and the second component comprising one or more of vinyl silicone oil and silica.

8. The article of clothing of claim 1, wherein the silicone layer comprises a pattern that includes a plurality of openings, each of the openings defining a region of absence of silicone.

9. The article of clothing of claim 1, wherein the silicone layer comprises a pattern that includes regions of presence of silicone and regions of absence of silicone.

10. (canceled)

11. The article of clothing of claim 1, wherein the silicone layer comprises a first zone of a first thickness and a second zone of a second thickness, and the first thickness is greater than the second thickness.

12. The article of clothing of claim 11, wherein the first zone is disposed along an edge of the article of clothing and the second zone is disposed further away from the edge than the first zone.

13. The article of clothing of claim 11, wherein at least one of the first zone and the second zone is of one of the following shapes: strip shape, wave shape, dot shape, and mesh shape.

14. The article of clothing of claim 11, wherein at least one of the first zone and the second zone comprises a pattern that includes a plurality of openings, each of the openings defining a region of absence of silicone.

15. The article of clothing of claim 14, wherein at least some of the plurality of openings are of one of the following shapes: diamond shape, circular shape, and oval shape.

16. (canceled)

17. The article of clothing of claim 1 is one of a brassiere, a sports bra, an undergarment, a sports pant, a sportswear, a casual dress, and a T-shirt.

18-50. (canceled)

51. The article of clothing of claim 1, wherein the article of clothing comprises:

a body structure; and

an elastic portion formed along an edge of the body structure, the elastic portion comprising the first fabric layer, the second fabric layer, and the silicone layer.

52. The article of clothing of claim 51, wherein the first fabric layer and the second fabric layer are portions of a first panel, and the first fabric layer and the second fabric layer are defined by folding of the first panel along the edge.

53. The article of clothing of claim 51, wherein the elastic portion is formed along a lower edge of the body structure.

54. The article of clothing of claim 51, wherein the elastic portion is formed along a lower edge of a side wing of a brassiere.