US20180279694A1

US20180279694A1 - Base layer of a garment

Info

Publication number: US20180279694A1
Application number: US15/802,317
Authority: US
Inventors: Jake Theno; David Durham; Jillian Miranda; Tom Burgher; Lindsay Mellen
Original assignee: Fox Head Inc
Current assignee: Fox Head Inc
Priority date: 2016-11-03
Filing date: 2017-11-02
Publication date: 2018-10-04
Also published as: GB2572503A; GB201907863D0; WO2018083545A3; EP3534737A2; EP3534737A4; WO2018083545A2

Abstract

A base layer of a garment includes a waist section, an upper leg section, and a lower leg section. The waist section is positioned to correspond with and receive a waist and crotch region of a wearer. The waist section includes a base portion, a mesh portion, a compressive portion, and a durable portion. The upper leg section is positioned to correspond with and receive a thigh and knee region of the wearer. The upper leg section includes the base portion and the mesh portion. The lower leg section is positioned to correspond with and receive a shin and calf region of the wearer. The lower leg section includes the base portion and the compressive portion.

Description

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application No. 62/416,825, filed Nov. 3, 2016, which is incorporated herein by reference in its entirety.

BACKGROUND

Traditional garments include a plurality of fabric pieces that are sewn together or otherwise coupled to form the article of clothing. Such coupling forms seams within the garment that may be irritable to the wearer, affect the properties of the garment, as well as limit the performance of the garment.

SUMMARY

One embodiment relates to a base layer of a garment. The base layer includes a waist section, an upper leg section, and a lower leg section. The waist section is positioned to correspond with and receive a waist and crotch region of a wearer. The waist section includes a base portion, a mesh portion, a compressive portion, and a durable portion. The upper leg section is positioned to correspond with and receive a thigh and knee region of the wearer. The upper leg section includes the base portion and the mesh portion. The lower leg section is positioned to correspond with and receive a shin and calf region of the wearer. The lower leg section includes the base portion and the compressive portion.
Another embodiment relates to a garment. The garment includes a base layer and a shell layer. The base layer includes a first section, a second section, and a third section. The first section is positioned to correspond with and receive a waist and crotch region of a wearer. The second section is positioned to correspond with and receive a thigh and knee region of the wearer. The third section is positioned to correspond with and receive a shin and calf region of the wearer. Each of the first section, the second section, and the third section includes a plurality of zones manufactured from a first material. Each of the plurality of zones has different material characteristics. The shell layer defines an internal cavity configured to receive the base layer. The shell layer is at least partially manufactured from a second material having a greater durability than the base layer.
Still another embodiment relates to a base layer of a garment. The base layer includes a plurality of sections positioned to correspond with and receive respective anatomical regions of a wearer. The plurality of sections form a continuous and seamless layer. Each of the plurality of sections includes a plurality of portions having different material characteristics.
Yet another embodiment relates to a method for manufacturing a base layer of a garment. The method include providing yarn and knitting the yarn to form a seamless, three-dimensional layer. The seamless, three-dimensional layer includes a plurality of sections positioned to correspond with and receive respective anatomical regions of a wearer. Each of the plurality of sections includes a plurality of portions having different material characteristics. The material characteristics include at least one of (i) a thread count or threads-per-inch, (ii) courses per inch (CPI), (iii) wales per inch (WPI), (iv) a warp thread density or ends-per-inch, (v) a weft thread density or picks-per-inch, (vi) a fabric density, and (vii) a fabric thickness.
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

The drawings are provided to illustrate example embodiments described herein and are not intended to limit the scope of the disclosure. Throughout the drawings, reference numbers may be re-used to indicate general correspondence between referenced elements.

FIG. 1 is a front view of a base layer of a garment, according to an example embodiment;

FIG. 2 is a side view of the base layer of FIG. 1, according to an example embodiment;

FIG. 3 is a rear view of the base layer of FIG. 1, according to an example embodiment;

FIG. 4 is a front, left perspective view of a shell layer of a garment, according to an example embodiment;

FIG. 5 is a rear, right perspective view of the shell layer of FIG. 4, according to an example embodiment;

FIG. 6 is a front view of a base layer of a garment, according to another example embodiment;

FIG. 7 is a side view of the base layer of FIG. 6, according to an example embodiment; and

FIG. 8 is a rear view of the base layer of FIG. 6, according to an example embodiment.

DETAILED DESCRIPTION

Various aspects of the disclosure will now be described with regard to certain examples and embodiments, which are intended to illustrate but not to limit the disclosure. Nothing in this disclosure is intended to imply that any particular feature or characteristic of the disclosed embodiments is essential. The scope of protection is defined by the claims that follow this description and not by any particular embodiment described herein. Before turning to the figures, which illustrate example embodiments in detail, it should be understood that the application is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology is for the purpose of description only and should not be regarded as limiting.
Embodiments herein generally relate to articles and/or base layers that can provide one or more of ease of dressing, improved movement and flexibility, improved ventilation, improved comfort, improved interaction with other products (e.g., a shell layer, boots, knee pads, etc.), etc. Such articles and/or base layers may be used in a number of activities, including without limitation: sports and athletics, including extreme sports and traditional sports; military and combat activity; law enforcement; outdoor activities such as camping, hiking, and climbing; automotive and cycling activities, including auto racing, motorcycle riding and racing, motocross, bicycling such as BMX, etc.; equestrian and rodeo; while operating recreational vehicles including ATVs, snowmobiles, side-by-sides, and other off-road vehicles; to name just a few. The articles and/or base layers and methods for manufacturing and/or using the same provide various improvements not present in existing articles and/or base layers. Further details are provided herein.
According to an example embodiment, a base layer of a garment includes a plurality of sections that are arranged (e.g., knitted, woven, sewn, etc.) from a single material (e.g., a single spool of yarn, etc.) to form a single, continuous, seamless, three-dimensional layer. The plurality of sections of the base layer may include a plurality of different portions (e.g., base portions, mesh portions, compressive portions, durable portions, etc.) having differing material characteristics (e.g., thread count or threads-per-inch, warp thread density or ends-per-inch, weft thread density or picks-per-inch, fabric density, fabric thickness, etc.). The material characteristics of the various portions may provide specific material properties (e.g., strength, durability, elasticity, mechanical ease, ventilation, joint articulation, etc.) in desired locations of the base layer (e.g., to correspond with certain anatomical regions of the wearer of the base layer, etc.).
According to the example embodiment shown in FIGS. 1-5, a garment includes an outer layer, shown as shell layer 2, and an inner layer, shown as base layer 10. According to an example embodiment, the garment is a motocross racepant. In other embodiments, the garment is a snowmobile pant, an ATV pant, or another type of pant used for action sports. In still other embodiments, the garment is another type of article (e.g., used for action sports including motocross, race car driving, etc.; used for athletics including football, baseball, hockey, track and field, etc.; etc.). In some embodiments, the garment may additionally or alternatively be or include a sleeveless shirt, a short-sleeve shirt, a long-sleeve shirt, shorts, pants, a jumpsuit, a jacket, and/or still another article of clothing.
According to the example embodiment shown in FIGS. 4 and 5, the shell layer 2 includes a plurality of panels that are at least one of arranged, molded, sewn, shaped, formed, cut, and tailored to form a pant. In an alternative embodiment, the plurality of panels of the shell layer 2 are at least one of arranged, molded, sewn, shaped, formed, cut, and tailored to form another type of pant, a sleeveless shirt, a short-sleeve shirt, a long-sleeve shirt, briefs, shorts, pants, a jumpsuit, a jacket, or still another article of clothing. The size of the shell layer 2 may be varied to fit various wearers. For example, the plurality of panels of the shell layer 2 may be at least one of arranged, molded, sewn, shaped, formed, cut, and tailored to fit men, women, both men and women, or children. According to an example embodiment, the plurality of panels of the shell layer 2 are manufactured from at least two different materials. In some embodiments, the plurality of panels of the shell layer 2 are manufactured from three distinct materials. In other embodiments, the plurality of panels of the shell layer 2 are manufactured from four or more distinct materials.
According to an example embodiment, the shell layer 2 includes a first plurality of panels or stretch fabric panels, and a second plurality of panels or rigid panels. According to an example embodiment, the stretch fabric panels of the shell layer 2 are manufactured from a first fabric material, and the rigid panels are manufactured from a second different material. According to an example embodiment, the stretch fabric panels are selectively positioned about the shell layer 2 (e.g., between the rigid panels, etc.) to facilitate independent movement of each of the rigid panels relative to one another (e.g., each of the rigid panels moves independently, etc.). According to an example embodiment, the interaction between the stretch fabric panels and the rigid panels facilitates natural movement of a wearer's body such that as a wearer moves, the front side and the rear side of the shell layer 2 do not sheer away from each other (e.g., which may cause discomfort and restriction in movement, etc.). In one embodiment, at least one of the stretch fabric panels is manufactured from a first stretch fabric material and at least one of the stretch fabric panels is manufactured from a second different stretch fabric material. For example, at least one of the stretch fabric panels may be manufactured from a stretch fabric material and at least one of the stretch fabric panels may be manufactured from a stretch mesh fabric material and/or a mesh fabric material. The different stretch fabric materials may differ in one or more characteristics including elasticity, ventilation, abrasion resistance, heat resistance, penetration resistance, and the like. The stretch mesh fabric and/or the mesh fabric material may be used in areas of the shell layer 2 to facilitate air to flow into and out of the shell layer 2 of the garment (e.g., to provide a cooling effect to the wearer of the shell layer 2, etc.). According to an example embodiment, the stretch fabric material is more durable (e.g., tougher, stronger, heavier, etc.) than the stretch mesh fabric material. In other embodiments, the stretch fabric panels are manufactured from a single stretch fabric material. In an alternative embodiment, the stretch fabric panels are manufactured from a nominal stretch material (e.g., denim, a material having more stretch than a rigid fabric material, a material having less stretch that a stretch fabric material, etc.).
According to an example embodiment, the rigid panels of the shell layer 2 are manufactured to be durable, protective (e.g., heat resistant, abrasion resistant, penetration resistant, etc.), and/or structure giving. In one embodiment, at least one of the rigid panels is manufactured from a first rigid material and at least one of the rigid panels is manufactured from a second different rigid material. The first rigid material and the second rigid material may differ in one or more characteristics including abrasion resistance, penetration resistance, heat resistance, elasticity, and/or other material properties of the rigid materials. For example, at least one of the rigid panels may be manufactured from an abrasion resistant material and at least one of the rigid panels may be manufactured from a heat resistant material. The abrasion resistant material may be used in desired areas of the shell layer 2 (e.g., a thigh area, a shin area, etc.) to shield desired anatomical regions of the wearer from dirt, rocks, and/or other debris that may hit the wearer during use (e.g., while riding a dirt bike, etc.). The abrasion resistant material may include 900D fabric, ballistic nylon, a heavy duty poly-fabric, Kevlar, carbon fiber, plastic, and/or leather, among other possible abrasion resistant materials. The heat resistant material may be used in desired areas of the shell layer 2 (e.g., inner leg area, etc.) to shield desired anatomical regions of the wearer from heat emitted by components (e.g., an engine, engine components, exhaust components, etc.) of a vehicle (e.g., a dirt bike, an ATV, a snowmobile, etc.) being driven by the wearer of the garment (e.g., the shell layer 2 and/or the base layer 10, etc.). The heat resistant material may include leather, Therma-fleece heat resistant fabric, and/or Kevlar, among other possible heat resistant materials. In other embodiments, the rigid panels are manufactured from a single rigid material. In an alternative embodiment, the rigid panels are manufactured from a fabric material.
According to an example embodiment, the independent movement of the rigid panels allows the rigid panels to work independent of each other, thereby providing a greater degree of comfort and less restriction (e.g., while walking, sitting, riding, etc.) without sacrificing the intended function of the shell layer 2, which is to provide protection to the wearer (e.g., a motocross rider, a snowmobile rider, an ATV rider, etc.) from debris and/or heat while driving a vehicle (e.g., a dirt bike, etc.). In some embodiments, the rigid panels are configured (e.g., aerodynamically shaped, formed, etc.) to reduce drag forces experienced by a wearer of the shell layer 2 (e.g., while traveling at increased speeds, etc.). In some embodiments, the rigid panels are woven or otherwise manufactured from a hard and/or durable material (e.g., carbon fiber, Kevlar, 900D fabric, etc.). In other embodiments, the rigid panels are formed (e.g., molded, etc.) from a non-woven material (e.g., plastic, etc.). According to an example embodiment, the shell layer 2 (e.g., the rigid panels, etc.) is at least partially manufactured from a material having a greater durability than the base layer 10.
As shown in FIGS. 4 and 5, the shell layer 2 includes a first section or waist section, a second section, shown as right leg section 6, and a third section, shown as left leg section 8. As shown in FIG. 4, the waist section, the right leg section 6, and the left leg section 8 of the shell layer 2 cooperatively define an internal cavity, shown as cavity 4. More details regarding the shell layer 2 may be found in International Application No. PCT/US2016/062317, filed on Nov. 16, 2016, which is incorporated herein by reference in its entirety.
According to an example embodiment, the cavity 4 of the shell layer 2 is configured to receive the base layer 10. In one embodiment, the shell layer 2 and the base layer 10 are individual components of the garment (e.g., the base layer 10 is not coupled or attached to the shell layer 2, etc.). In an alternative embodiment, the base layer 10 is disposed within and coupled (e.g., sewn; attached; releasably coupled with hook and loop fasteners, clips, hooks, buttons; etc.) to the shell layer 2. According to an example embodiment, the base layer 10 covers seams formed between the stretch fabric panels and the rigid panels (e.g., such that the seams, the stretch fabric panels, and/or the rigid panels do not come into contact with the wearer, providing increased comfort, reducing chaffing and/or scratching, etc.). In other embodiments, the base layer 10 covers the rigid panels and/or the seams to prevent discomfort and/or chaffing. In some embodiments, the base layer 10 is configured to provide ventilation to the wearer of the garment. In some embodiments, the base layer 10 is configured to provide warmth and/or protection from wind.
According to the example embodiment shown in FIGS. 1-3, the base layer 10 includes a plurality of sections that are at least one of arranged, knitted, woven, molded, sewn, shaped, formed, cut, and tailored to form a pant (e.g., a full-length tight, etc.). In an alternative embodiment, the plurality of section of the base layer 10 are at least one of arranged, knitted, woven, molded, sewn, shaped, formed, cut, and tailored to form another type of pant, an undershirt, a sleeveless shirt, a short-sleeve shirt, a long-sleeve shirt, briefs, shorts, pants, a jumpsuit, a unitard, a singlet, a leotard, or still another article of clothing. The size of the base layer 10 may be varied to fit various wearers. For example, the plurality of sections of the base layer 10 may be at least one of arranged, knitted, woven, molded, sewn, shaped, formed, cut, and tailored to fit men, women, both men and women, or children. According to an example embodiment, the plurality of sections of the base layer 10 (i) are positioned to correspond with and receive respective anatomical regions of a wearer of the base layer 10, (ii) form a continuous and seamless layer, and/or (iii) include a plurality of portions or zones having different material characteristics (e.g., thread count or threads-per-inch (TPI), courses per inch (CPI), wales per inch (WPI), warp thread density or ends-per-inch (EPI), weft thread density or picks-per-inch (PPI), fabric density, thickness, etc.).
As shown in FIGS. 1-3, the base layer 10 includes a first section, shown as waist section 12, a second section, shown as upper leg section 14, and a third section, shown as lower leg section 16. The lower leg section 16 includes a fourth section, shown as foot section 18. In other embodiments, the base layer 10 does not include one or more of the waist section 12, the upper leg section 14, the lower leg section 16, and/or the foot section 18 (e.g., just the waist section 12, the upper leg section 14, and the lower leg section 16; just the waist section 12 and the upper leg section 14; just the lower leg section 16 and the foot section 18; etc.). The waist section 12 is positioned and formed to correspond with and receive a waist, buttocks, and crotch region of a wearer of the base layer 10. The upper leg section 14 is positioned and formed to correspond with and receive a thigh and knee region of a wearer of the base layer 10. The lower leg section 16 is positioned and formed to correspond with and receive a shin and calf region of a wearer of the base layer 10. The foot section 18 is positioned and formed to correspond with and receive (e.g., enclose around, etc.) a foot of a wearer of the base layer 10. The upper leg section 14, the lower leg section 16, and/or the foot section 18 cooperatively form a pair of legs of the base layer 10 that extend from the waist section 12.
According to an example embodiment, the base layer 10 is configured to be a skintight and/or a one piece layer. In one embodiment, the waist section 12, the upper leg section 14, the lower leg section 16, and/or the foot section 18 form a continuous and seamless layer (e.g., a unitary, seamless, and three-dimensional (3D) layer, etc.). The continuous and seamless layer maybe manufactured from a single, uniform material. According to an example embodiment, the base layer 10 is manufactured using a 3D knitting machine that forms (e.g., knits, etc.) the base layer 10 from the single material (e.g., yarn, fabric, thread, etc.). In one embodiment, the single material includes multi-constituent yarn (e.g., Cordura® yarn, 95% Cordura® nylon and 5% elastane, etc.). By way of example, the yarn may be or include 160D/68F (80D/34F 2 ply air-textured yarn (ATY)) with Lycra 40 denier (den) covering yarn. In other embodiments, a different type of yarn, thread, and/or fabric is used. The base layer 10 may advantageously provide the durability of nylon and the comfort of cotton, be strong yet lightweight, have exceptional abrasion resistance, have high tensile and/or tear strengths for lasting performance, and/or provide excellent temperature and moisture management. The base layer 10 may also advantageously prevent the need to put on multiple undergarments (e.g., socks, compression shorts, a jock strap, etc.) as the multiple undergarments may be integrally formed within the base layer 10 (e.g., providing ease of dressing, etc.).
According to an example embodiment, the continuous and seamless structure of the base layer 10 provides various advantages relative to traditional garments that are cut and sewn or otherwise coupled together. By way of example, without seams, patterns and designs of the base layer 10 remain uninterrupted across the entire garment (e.g., front-to-back, down-the-legs, etc.). 3D knitting may allow the base layer 10 to be reproduced exactly as intended (e.g., minimizes and/or eliminates manufacturing defects associated with traditional garments, each base layer 10 is produced based on digitally programmed data such that item-to-item and batch-to-batch quality remains consistent, etc.). Labor-intensive cutting and sewing processes may be eliminated, and the amount of scrap material thrown away after cutting out each part of a garment may be entirely eliminated (e.g., by knitting a base layer 10 with only the required amount of yarn, etc.). The base layer 10 may also have superior comfort by eliminating irritable seams. The base layer 10 may additionally have superior stretch and mobility by eliminating seams that would otherwise interfere with the natural elasticity of knits. The seamless one-piece construction of the base layer 10 may also facilitate evenly distributing stress throughout the base layer 10, preventing localized pressure points which may cause discomfort. Further, the seamless one-piece construction of the base layer 10 may facilitate incorporating articulated joints in desired areas of the base layer 10 (e.g., in a knee area, in an elbow area, etc.) to further improve stretch and mobility of the base layer 10.
In alternative embodiments, the waist section 12, the upper leg section 14, the lower leg section 16, and/or the foot section 18 are manufactured as two or more (e.g., two, three, four, etc.) individual sections and thereafter joined together (e.g., sewn together, etc.). By way of example, (i) the waist section 12 and the upper leg section 14 may be manufactured as a first continuous portion (e.g., shorts, ¾ pants, etc.) of the base layer 10 and (ii) the lower leg section 16 and/or the foot section 18 may be manufactured as a second continuous portion (e.g., a long sock, a tube sock, etc.) of the base layer 10. By way of another example, (i) the waist section 12, the upper leg section 14, and the lower leg section 16 may be manufactured as a first continuous portion (e.g., pants, etc.) of the base layer 10 and (ii) the foot section 18 may be manufactured as a second continuous portion (e.g., an ankle sock, etc.) of the base layer 10. By way of yet another example, (i) a first half of the base layer 10 (e.g., a front half, a right half, etc. of the waist section 12, the upper leg section 14, the lower leg section 16, and/or the foot section 18) may be manufactured as a first continuous portion of the base layer 10 and (ii) an opposing second half of the base layer 10 (e.g., a rear half, a left half, etc. of the waist section 12, the upper leg section 14, the lower leg section 16, and/or the foot section 18) may be manufactured as a second continuous portion of the base layer 10. The first continuous portion and the second continuous portion may thereafter be coupled (e.g., sewn, using a flat lock stitch, etc.) to form the base layer 10.
According to an example embodiment, each of the waist section 12, the upper leg section 14, the lower leg section 16, and/or the foot section 18 includes a plurality of portions manufactured (e.g., woven, knitted, felted, otherwise arranged into a structure that forms fabric, etc.) from the same material (e.g., the multi-constituent yarn, Cordura® yarn, etc.). Each of the plurality of portions of the waist section 12, the upper leg section 14, the lower leg section 16, and/or the foot section 18 have different material characteristics (e.g., TPI, CPI, WPI, EPI, PPI, fabric density, fabric thickness, etc.), according to an example embodiment. The different material characteristics may facilitate providing various portions having specific material properties (e.g., strength, durability, elasticity, mechanical ease, ventilation, joint articulation, etc.) at desired locations of the base layer 10.
A shown in FIGS. 1-3, the waist section 12, the upper leg section 14, the lower leg section 16, and the foot section 18 of the base layer 10 include a first plurality of portions, shown as base zones 20, a second plurality of portions, shown as compressive zones 40, a third plurality of portions, shown as mesh zones 60, and a fourth plurality of portions, shown as durable zones 80. According to an example embodiment, the compressive zones 40 are configured to facilitate providing a tight-fitting (e.g., skin-tight, etc.) base layer 10 that conforms to the body structure of the wearer of the base layer 10 (e.g., in desired anatomical regions, etc.). According to an example embodiment, the mesh zones 60 have a mesh structure that defines a plurality of apertures that facilitate ventilation (e.g., air flow into and out of the base layer 10, in desired anatomical regions, allows the base layer 10 to “breath,” etc.). In one embodiment, the plurality of apertures are formed during the manufacturing process (e.g., the plurality of apertures are integrated into the base layer 10 during the knitting process, etc.). In an alternative embodiment, the plurality of apertures are formed after the base layer 10 is completed (e.g., the plurality of apertures are cut out of the base layer 10, etc.). In one embodiment, the plurality of apertures have a diameter of about 2 millimeters (mm). In other embodiments, the plurality of apertures have a different diameter (e.g., ¼ mm, ½ mm, 1 mm, 3 mm, 5 mm, etc.). According to an example embodiment, the durable zones 80 have a greater durability relative to the other portions of the base layer 10 to provide increased protection (e.g., abrasion resistance, penetration resistance, heat resistance, impact resistance, etc.) to the wearer of the base layer 10 (e.g., in desired anatomical regions, etc.). By way of example, the durable zones 80 may include a plurality of localized portions that have much higher thread count than adjacent portions of the durable zones 80, creating a pattern (e.g., a pattern of rectangles, etc.) that provides the increased durability.
The various portions (e.g., the base zones 20, the compressive zones 40, the mesh zones 60, the durable zones 80, etc.) of the base layer 10 may include a plurality of fibers that are woven, knitted, felted, or otherwise arranged into a structure that forms the base layer 10. The plurality of fibers may include a single constituent material (e.g., cotton, nylon, polyester, spandex, another elastane material, another synthetic material, another natural material, etc.) or may include a blend of multiple constituent materials (e.g., Cordura® nylon and elastane, etc.). The base layer 10 may include a fabric having a certain degree of elastic stretch, where the fabric elongates when a force is applied due to deformation (e.g., elastic deformation, etc.) of the fibers themselves (e.g., deformation within the elastic region of the fibers when a force or a stress below the yield strength of the fibers is applied, etc.). The fibers may resist the force and return the fabric to the pre-stretch state when the force is released.
The various portions of the base layer 10 may have a certain degree of mechanical ease (i.e., mechanical give), where the fabric elongates when a force is applied due to movement of the fibers within the structure of the various portions. The mechanical ease of the fabric may vary based on the arrangement of the fibers within the structure of the various portions (e.g., warp and weft density, weave, etc.) and the conditions under which the fabric was produced (e.g., speed of weaving, warp insertion rate, warp and weft tension, etc.). In one embodiment, the mechanical ease does not resist pull in the same way (e.g., does not have the same type of rebound, does not have the same pull profile of rebound, etc.) as the elastic stretch associated with the fibers themselves. Rather, the mechanical ease allows the fibers that make up the fabric to move in and out of the empty spaces between the fibers.
The elongation of the fabric (e.g., due to the mechanical ease, due to the elastic deformation of the fibers themselves, due to the both the mechanical ease and the elastic deformation of the fibers themselves, etc.) may be quantified in terms of a stretch factor. The stretch factor may be equal to the pre-stretched dimension of the fabric subtracted from the stretched dimension of the fabric (e.g., with a force applied that produces sub-yield strength stresses, etc.), with the resulting quantity thereafter divided by the pre-stretched dimension of the fabric.
One or more portions of the base layer 10 (e.g., the base zones 20, the compressive zones 40, the mesh zones 60, etc.) may have both mechanical ease and elastic stretch or primarily only elastic stretch while other portions of the base layer 10 (e.g., the durable zones 80, etc.) may have primarily only mechanical ease. In some embodiments, one or more portions of the base layer 10 (e.g., the base zones 20, the compressive zones 40, the mesh zones 60, etc.) have a greater degree of elastic stretch than mechanical ease while other portions of the base layer 10 (e.g., the durable zones 80, etc.) have a greater degree of mechanical ease than elastic stretch. In some embodiments, one or more portions of the base layer 10 (e.g., the base zones 20, the compressive zones 40, the mesh zones 60, etc.) have a stretch factor at least equal to a threshold (e.g., more than zero percent, at least 5%, at least 10%, at least 25%, at least 50%, at least 100%, etc.) in one or both directions (e.g., lateral and/or longitudinal, along x-axis and/or y-axis, etc.), while other portions of the base layer 10 (e.g., the durable zones 80, etc.) have a stretch factor of less than the threshold (e.g., zero percent, less than 5%, less than 10%, less than 25%, less than 50%, less than 100%, etc.) in one or both directions (e.g., lateral and/or longitudinal, along x-axis and/or y-axis, etc.).
In some embodiments, the base zones 20, the compressive zones 40, the mesh zones 60, and/or the durable zones 80 have isotropic (e.g., symmetrical, identical, etc.) stretch properties (e.g., four-ways stretch, uniform stretch characteristics, etc.). By way of example, the base zones 20, the compressive zones 40, the mesh zones 60, and/or the durable zones 80 may have a mechanical ease and/or an elastic stretch that is independent of the direction of an applied force (e.g., stretches the same in a lateral direction as a longitudinal direction, etc.). In some embodiments, the base zones 20, the compressive zones 40, the mesh zones 60, and/or the durable zones 80 have anisotropic (e.g., asymmetrical, etc.) stretch properties (e.g., may have properties that vary with direction, etc.). By way of example, the base zones 20, the compressive zones 40, the mesh zones 60, and/or the durable zones 80 may have at least one of a mechanical ease and an elastic stretch that varies based on the direction of an applied force. For example, the compressive zones 40 may have an elastic stretch that is greater in a first direction (e.g., a cross-grain direction, etc.) than in a second direction (e.g., a grain direction, etc.). The first direction may be angularly offset relative to (e.g., perpendicular to, etc.) the second direction. The first direction (i.e., the direction along which the greater amount of elastic stretch occurs) may define a primary stretch direction of the fabric. Portions of the base layer 10 having a primary stretch direction may have elastic stretch that occurs primarily in a single direction. This characteristic can be observed by physical manipulation of the fabric in both the first and second directions.
According to an example embodiment shown in FIGS. 1-3, (i) the waist section 12 includes one or more portions of the base zones 20, the compressive zones 40, the mesh zones 60, and the durable zones 80, (ii) the upper leg section 14 includes one or more portions of the base zones 20 and the mesh zones 60, (iii) the lower leg section 16 includes one or more portions of the base zones 20 and the compressive zones 40, and (iv) the foot section 18 includes one or more portions of the compressive zones 40, the mesh zones 60, and the durable zones 80. In other embodiments, the waist section 12, the upper leg section 14, the lower leg section 16, and/or the foot section 18 include different zones and/or more or fewer zones of those that are shown. It should be understood that the number, position, and/or the type of the various zones of the waist section 12, the upper leg section 14, the lower leg section 16, and/or the foot section 18 shown in FIGS. 1-3 are for illustrative purposes. Therefore, the number, type, and/or placement of the various zones of the base layer 10 may be different than what is shown in FIGS. 1-3.
As shown in FIGS. 1 and 2, the base zones 20 of the waist section 12 include a first base portion, shown as left waist base zone 22, a second base portion, shown as right waist base zone 24, and a third base portion, shown as central waist base zone 30. As shown in FIG. 1, the left waist base zone 22 is selectively positioned about the base layer 10 so as to correspond in location to a left anterior area of the waist, buttocks, and crotch region of the wearer of the base layer 10. As shown in FIGS. 1 and 2, the right waist base zone 24 is selectively positioned about the base layer 10 so as to correspond in location to a right anterior area of the waist, buttocks, and crotch region of the wearer of the base layer 10. As shown in FIG. 1, the central waist base zone 30 is selectively positioned about the base layer 10 so as to correspond in location to the front crotch area of the waist, buttocks, and crotch region of the wearer of the base layer 10. According to an example embodiment, the central waist base zone 30 has a relatively looser tension relative to all other portions of the base layer 10. In some embodiments, the central waist base zone 30 defines a cavity (e.g., a sleeve, a pocket, etc.) configured to receive a protective cup to facilitate protecting the front crotch area of the wearer of the base layer 10 from impacts thereto.
As shown in FIGS. 1-3, the compressive zones 40 of the waist section 12 include a first compressive portion, shown as left waist compressive zone 42, a second compressive portion, shown as right waist compressive zone 44, and a third compressive portion, shown as waistline compressive zone 50. As shown in FIGS. 1 and 3, the left waist compressive zone 42 is selectively positioned about the base layer 10 so as to correspond in location to the left lateral side of the waist, buttocks, and crotch region of the wearer of the base layer 10. As shown in FIGS. 1-3, the right waist compressive zone 44 is selectively positioned about the base layer 10 so as to correspond in location to the right lateral side of the waist, buttocks, and crotch region of the wearer of the base layer 10. Therefore, the left waist compressive zone 42 and the right waist compressive zone 44 may be positioned along each lateral side of the waist section 12 of the base layer 10. In some embodiments, the left waist compressive zone 42 and/or the right waist compressive zone 44 define a cavity (e.g., a sleeve, a pocket, etc.) configured to receive a protective pad to facilitate protecting the left and/or right lateral sides of the wearer of the base layer 10 from impacts thereto.
As shown in FIGS. 1-3, the waistline compressive zone 50 is selectively positioned about the base layer 10 so as to correspond in location to the waistline of the waist, buttocks, and crotch region of the wearer of the base layer 10. Therefore, the waistline compressive zone 50 may be positioned to extend at least partially around a periphery of the waist section 12 of the base layer 10. In some embodiments, the waistline compressive zone 50 is coupled (e.g., attached, sewn, etc.) to the waist section 12 after the base layer 10 is manufactured (e.g., 3D knitted, etc.). By way of example, the waistline compressive zone 50 may be or include an elastic band coupled to the base layer 10 and configured to facilitate securing the base layer 10 around the waist of the wearer.
As shown in FIGS. 1-3, the mesh zones 60 of the waist section 12 include a first mesh portion, shown as waist mesh zone 70. The waist mesh zone 70 is selectively positioned about the base layer 10 to at least one of (i) surround the front crotch area of the waist, buttocks, and crotch region of the wearer such that the central waist base zone 30 is at least partially surrounded by the waist mesh zone 70, (ii) extend along a midline of a posterior buttocks area of the waist, buttocks, and crotch region of the wearer, and (iii) extend at least partially around a periphery of the waist section 12 to correspond with the waistline of the waist, buttocks, and crotch region of the wearer.
As shown in FIGS. 2 and 3, the durable zones 80 of the waist section 12 include a first durable portion, shown as left buttocks durable zone 82, and a second durable portion, shown as right buttocks durable zone 84. As shown in FIG. 3, the left buttocks durable zone 82 is selectively positioned about the base layer 10 so as to correspond in location to a left posterior buttocks area of the waist, buttocks, and crotch region of the wearer of the base layer 10. As shown in FIGS. 2 and 3, the right buttocks durable zone 84 is selectively positioned about the base layer 10 so as to correspond in location to a right posterior buttocks area of the waist, buttocks, and crotch region of the wearer of the base layer 10. The waist mesh zone 70 extending along the midline of the posterior buttocks area of the waist, buttocks, and crotch region of the wearer may thereby separate the left buttocks durable zone 82 from the right buttocks durable zone 84. In some embodiments, the left buttocks durable zone 82 and/or the right buttocks durable zone 84 define a cavity (e.g., a sleeve, a pocket, etc.) configured to receive a protective pad to further facilitate protecting the left and/or right buttocks area of the wearer of the base layer 10 from impacts thereto.
As shown in FIGS. 1-3, the base zones 20 of the upper leg section 14 include a fourth base portion, shown as left upper leg base zone 26, and a fifth base portion, shown as right upper leg base zone 28. The left upper leg base zone 26 and the right upper leg base zone 28 are selectively positioned about the base layer 10 so as to correspond in location to at least one of an upper posterior leg area (e.g., rear of a wearer's thigh, hamstrings, back of knee, etc.), an upper medial leg area (e.g., inner thigh, inner knee, etc.), an upper lateral leg area (e.g., exterior thigh, exterior knee, etc.), and/or an upper anterior leg area (e.g., front of a wearer's thigh, front of knee, etc.) of the thigh and knee region of a wearer of the base layer 10.
As shown in FIGS. 1-3, the mesh zones 60 of the upper leg section 14 include a second mesh portion, shown as left thigh mesh zone 62, a third mesh portion, shown as right thigh mesh zone 64, a fourth mesh portion, shown as left anterior knee mesh zone 66, a fifth mesh portion, shown as right anterior knee mesh zone 68, a sixth mesh portion, shown as left posterior knee mesh zone 72, and a seventh mesh portion, shown as right posterior knee mesh zone 74. As show in FIGS. 1-3, the left thigh mesh zone 62 and the right thigh mesh zone 64 are selectively positioned about the base layer 10 so as to correspond in location to at least one of an upper posterior leg area (e.g., rear of a wearer's thigh, etc.), an upper medial leg area (e.g., inner thigh, etc.), an upper lateral leg area (e.g., exterior thigh, etc.), and/or an upper anterior leg area (e.g., front of a wearer's thigh, etc.) of the thigh and knee region of a wearer of the base layer 10 such that the left thigh mesh zone 62 and the right thigh mesh zone 64 extend around at least a portion of a periphery of a thigh (e.g., the left thigh, the right thing, etc.) of the thigh and knee region of the wearer.
As shown in FIGS. 1 and 2, the left anterior knee mesh zone 66 and the right anterior knee mesh zone 68 are selectively positioned about the base layer 10 so as to correspond in location to an upper anterior leg area (e.g., front of the wearer's knee, etc.) of the thigh and knee region of a wearer of the base layer 10 such that the left anterior knee mesh zone 66 and the right anterior knee mesh zone 68 extend along an anterior area (e.g., a front area, etc.) of a knee of the thigh and knee region of the wearer. As shown in FIGS. 2 and 3, the left posterior knee mesh zone 72 and the right posterior knee mesh zone 74 are selectively positioned about the base layer 10 so as to correspond in location to an upper posterior leg area (e.g., rear of the wearer's knee, etc.) of the thigh and knee region of a wearer of the base layer 10 such that the left posterior knee mesh zone 72 and the right posterior knee mesh zone 74 extend along a posterior area (e.g., a rear area, etc.) of the knee of the thigh and knee region of the wearer. According to an example embodiment, the mesh zones 60 of the upper leg section 14 (e.g., the left thigh mesh zone 62, the right thigh mesh zone 64, the left anterior knee mesh zone 66, the right anterior knee mesh zone 68, the left posterior knee mesh zone 72, the right posterior knee mesh zone 74, etc.) are positioned to increase the comfort of the wearer when the wearer is wearing a knee brace by increasing the airflow into and out of the thigh and knee region where the knee brace may be coupled.
As shown in FIGS. 1-3, the base zones 20 of the lower leg section 16 include a sixth base portion, shown as left lateral lower leg base zone 32, a seventh base portion, shown as left medial lower leg base zone 34, an eighth base portion, shown as right lateral lower leg base zone 36, and a ninth base portion, shown as right medial lower leg base zone 38. The left lateral lower leg base zone 32, the left medial lower leg base zone 34, the right lateral lower leg base zone 36, and the right medial lower leg base zone 38 are selectively positioned about the base layer 10 so as to correspond in location to at least one of a lower posterior leg area (e.g., a calf area of the wearer, etc.), a lower medial leg area (e.g., an inner calf and shin area of the wearer, etc.), a lower lateral leg area (e.g., an exterior calf and shin area of the wearer, etc.), and/or a lower anterior leg area (e.g., a shin area of the wearer, etc.) of the shin and calf region of a wearer of the base layer 10.
As shown in FIGS. 1-3, the compressive zones 40 of the lower leg section 16 include a fourth compressive portion, shown as left shin compressive zone 46, a fifth compressive portion, shown as right shin compressive zone 48, a sixth compressive portion, shown as left calf compressive zone 52, and a seventh compressive portion, shown as right calf compressive zone 54. As shown in FIGS. 1 and 2, the left shin compressive zone 46 and the right shin compressive zone 48 are selectively positioned about the base layer 10 so as to correspond in location to a lower anterior leg area (e.g., front of the wearer's lower leg, etc.) of the shin and calf region of a wearer of the base layer 10 such that the left shin compressive zone 46 and the right shin compressive zone 48 extend along an anterior area (e.g., a front area, etc.) or a shin of the shin and calf region of the wearer. As shown in FIGS. 2 and 3, the left calf compressive zone 52 and the right calf compressive zone 54 are selectively positioned about the base layer 10 so as to correspond in location to a lower posterior leg area (e.g., rear of the wearer's lower leg, etc.) of the shin and calf region of a wearer of the base layer 10 such that the left calf compressive zone 52 and the right calf compressive zone 54 extend along a posterior area (e.g., a rear area, etc.) or a calf of the shin and calf region of the wearer. According to an example embodiment, the compressive zones 40 of the lower leg section 16 (e.g., the left shin compressive zone 46, the right shin compressive zone 48, the left calf compressive zone 52, the right calf compressive zone 54, etc.) are positioned to prevent the lower leg section 16 of the base layer 10 from riding up the legs of the wearer of the base layer 10. The compressive zones 40 of the lower leg section 16 may be positioned and/or configured to facilitate a wearer of the base layer 10 with easily putting on and taking off a pair of boots (e.g., motocross boots, snowmobile boots, snowboarding boots, skiing boots, etc.).
As shown in FIGS. 1-3, the compressive zones 40 of the foot section 18 include an eighth compressive portion, shown as left foot compressive zone 56, and a ninth compressive portion, shown as right foot compressive zone 58. The left foot compressive zone 56 and the right foot compressive zone 58 are selectively positioned about the base layer 10 so as to extend around at least a portion of a periphery of each foot of the wearer. According to an example embodiment, the compressive zones 40 of the foot section 18 (e.g., the left foot compressive zone 56, the right foot compressive zone 58, etc.) are positioned to secure the foot section 18 to the feet of the wearer of the base layer 10 (e.g., prevent the foot section 18 from inadvertently pulling off of the feet as the wearer removes footwear, etc.).
As shown in FIGS. 1 and 2, the mesh zones 60 of the foot section 18 include an eighth mesh portion, shown as left foot mesh zone 76, and a ninth mesh portion, shown as right foot mesh zone 78. The left foot mesh zone 76 and the right foot mesh zone 78 are selectively positioned about the base layer 10 so as to correspond in location to a top portion of the feet of a wearer of the base layer 10 such that the left foot mesh zone 76 and the right foot mesh zone 78 extend along the top of a respective foot of the wearer. According to an example embodiment, the left foot mesh zone 76 and the right foot mesh zone 78 are positioned to provide increased ventilation to the feet of the wearer (e.g., within footwear such as boots, shoes, etc.).
As shown in FIGS. 1-3, the durable zones 80 of the foot section 18 include a third durable portion, shown as left ankle durable zone 86, a fourth durable portion, shown as right ankle durable zone 88, a fifth durable portion, shown as left heel durable zone 92, a sixth durable portion, shown as right heel durable zone 94, a seventh durable portion, shown as left toes durable zone 96, and an eighth durable portion, shown as right toes durable zone 98. As shown in FIGS. 2 and 3, the left ankle durable zone 86 and the right ankle durable zone 88 are selectively positioned about the base layer 10 so as to correspond in location to the ankles of a wearer of the base layer 10. The left heel durable zone 92 and the right heel durable zone 94 are selectively positioned about the base layer 10 so as to correspond in location to the heels of a wearer of the base layer 10. As shown in FIGS. 1-3, the left toes durable zone 96 and the right toes durable zone 98 are selectively positioned about the base layer 10 so as to correspond in location to the toes of a wearer of the base layer 10. According to an example embodiment, the left ankle durable zone 86, the right ankle durable zone 88, the left heel durable zone 92, the right heel durable zone 94, the left toes durable zone 96, and/or the right toes durable zone 98 are positioned to prevent wear (e.g., rips, holes, etc.) to the foot section 18 and/or the feet of the wearer (e.g., skin irritation, rashes, blisters, etc. on the heels, ankles, toes, bottom portion, etc. of the feet) during use (e.g., highly active use, while riding a dirt bike, as the feet shift within footwear, etc.). As shown in FIGS. 1-3, the foot section 18 includes grip portions, shown as grip zones 90. The grip zones 90 may be configured to provide a wearer with grip while not wearing footwear (e.g., boots, shoes, etc.) to provide better traction and/or prevent a wearer's feet from moving within footwear.
According to an example embodiment, the base zones 20, the compressive zones 40, the mesh zones 60, and the durable zones 80 have different material characteristics relative to each other (e.g., TPI, CPI, WPI, EPI, PPI, fabric density, fabric thickness, etc. of the base zones 20, the compressive zones 40, the mesh zones 60, and the durable zones 80 all can be different). By way of example, the base zones 20 (e.g., the left waist base zone 22, the right waist base zone 24, the left upper leg base zone 26, the right upper leg base zone 28, the central waist base zone 30, the left lateral lower leg base zone 32, the left medial lower leg base zone 34, the right lateral lower leg base zone 36, the right medial lower leg base zone 38, etc.) may have first material characteristics (e.g., a first CPI, a first WPI, etc.). For example, in some embodiments the zone one material can have a CPI of between about 45-58, of about 50-54, or of about 52 (or any sub value or sub range therein, inclusive of endpoints). In some embodiments, zone 1 material can have a WPI of about 15-27, of about 19-23, or about 21 (or any sub value or sub range therein, inclusive of endpoints). The compressive zones 40 (e.g., the left waist compressive zone 42, the right waist compressive zone 44, the left shin compressive zone 46, the right shin compressive zone 48, the left calf compressive zone 52, the right calf compressive zone 54, the left foot compressive zone 56, the right foot compressive zone 58, etc.) may have second material characteristics (e.g., a second CPI, a second WPI, etc.). For example, in some embodiments the zone 2 material can have a CPI of between about 30-42, of about 34-38, or of about 36 (or any sub value or sub range therein, inclusive of endpoints). In some embodiments, zone 2 material can have a WPI of about 20-32, of about 24-28, or about 26 (or any sub value or sub range therein, inclusive of endpoints). The mesh zones 60 (e.g., the left thigh mesh zone 62, the right thigh mesh zone 64, the left anterior knee mesh zone 66, the right anterior knee mesh zone 68, the waist mesh zone 70, the left posterior knee mesh zone 72, the right posterior knee mesh zone 74, the left foot mesh zone 76, the right foot mesh zone 78, etc.) may have third material characteristics (e.g., a third CPI, a third WPI, etc.). For example, in some embodiments the zone 3 material can have a CPI of between about 30-42, of about 34-38, or of about 36 (or any sub value or sub range therein, inclusive of endpoints). In some embodiments, zone 3 material can have a WPI of about 20-32, of about 24-28, or about 26 (or any sub value or sub range therein, inclusive of endpoints). The durable zones 80 (e.g., the left buttocks durable zone 82, the right buttocks durable zone 84, the left ankle durable zone 86, the right ankle durable zone 88, the left heel durable zone 92, the right heel durable zone 94, the left toes durable zone 96, the right toes durable zone 98, etc.) may have fourth material characteristics (e.g., a fourth CPI, a fourth WPI, etc.). For example, in some embodiments the zone 4 material can have a CPI of between about 48-60, of about 52-56, or of about 54 (or any sub value or sub range therein, inclusive of endpoints). In some embodiments, zone 4 material can have a WPI of about 23-35, of about 27-31, or about 29 (or any sub value or sub range therein, inclusive of endpoints). According to an example embodiment, the first material characteristics, the second material characteristics, the third material characteristics, and the fourth material characteristics are all different. By way of example, the durable zones 80 may have the highest tread count (e.g., highest thread density, etc.) to provide the inherent durability. By way of another example, the mesh zones 60 may have the lowest thread count (e.g., lowest thread density, etc.) to provide the loose, mesh structure. By way of example, one or more zones of the base layer 10 (e.g., the base zones 20, etc.) may have a construction of about 40 CPI by about 31 WPI. It should be understood that not all of the zones described have to be different in some or all of their characteristics relative to each other. Some characteristics can be the same, while others differ. For example, 2 or 3 can be similar in one or more of the various characteristics and parameters described here. In some embodiments, the various zone materials can have a weight of between 320-350 g/m2, or 330-340 g/m2, or about 335 g/m2, for example.
According to the example embodiment shown in FIGS. 6-8, a second base layer, shown as base layer 100, includes a plurality of sections that are at least one of arranged, knitted, woven, molded, sewn, shaped, formed, cut, and tailored to form a long-sleeve shirt. According to an example embodiment, the base layer 100 is a motocross base layer configured to be worn underneath a motocross jersey. In other embodiments, the base layer 100 is a snowmobile shirt, an ATV shirt, a bicycling shirt, or another type of shirt used for athletics (e.g., running, sports, action sports, etc.). In an alternative embodiment, the plurality of sections are at least one of arranged, knitted, woven, molded, sewn, shaped, formed, cut, and tailored to form another type of shirt such as a short-sleeve shirts, a sleeve-less shirt, a tank-top, or still another article of clothing. The size of the base layer 100 may be varied to fit various wearers. For example, the plurality of sections of the base layer 100 may be at least one of arranged, knitted, woven, molded, sewn, shaped, formed, cut, and tailored to fit men, women, both men and women, or children. According to an example embodiment, the plurality of sections of the base layer 100 (i) are positioned to correspond with and receive respective anatomical regions of a wearer of the base layer 100, (ii) form a continuous and seamless layer, and/or (iii) include a plurality of portions or zones having different material characteristics (e.g., TPI, CPI, WPI, warp thread density or EPI, weft thread density or PPI, fabric density, thickness, etc.).
As shown in FIGS. 6-8, the base layer 100 includes a first section, shown as torso section 112, a second section, shown as left sleeve section 114, and a third section, shown as right sleeve section 116. The torso section 112 is positioned and formed so as to correspond with and receive a torso, waist, neck, and/or shoulders of a wearer of the base layer 100. The left sleeve section 114 and the right sleeve section 116 are positioned and formed so as to correspond with and receive at least a portion of a length of each arm of a wearer of the base layer 100. According to the example embodiment shown in FIGS. 6-8, the left sleeve section 114 and the right sleeve section 116 include long-sleeves. In other embodiments, the left sleeve section 114 and the right sleeve section 116 include short-sleeves. In an alternative embodiment, the base layer 100 does not include the left sleeve section 114 and the right sleeve section 116. According to an example embodiment, the torso section 112, the left sleeve section 114, and the right sleeve section 116 are formed to receive a specific sized person (e.g., an extra-small, a small, a medium, a large, an extra-large person, etc.).
According to an example embodiment, the base layer 100 is configured to be a skintight and/or a one piece layer. In one embodiment, the torso section 112, the left sleeve section 114, and/or the right sleeve section 116 form a continuous and seamless layer (e.g., a unitary, seamless, and three-dimensional (3D) layer, etc.). The continuous and seamless layer maybe manufactured from a single, uniform material. According to an example embodiment, the base layer 100 is manufactured using a 3D knitting machine that forms (e.g., knits, etc.) the base layer 100 from the single material (e.g., yarn, fabric, thread, etc.). In one embodiment, the single material includes a multi-constituent yarn (e.g., Cordura® yarn, 95% Cordura® nylon and 5% elastane, etc.). By way of example, the yarn may be or include 160D/68F (80D/34F 2 ply air-textured yarn (ATY)) with Lycra 40 denier (den) covering yarn. In other embodiments, a different type of yarn, thread, and/or fabric is used. In alternative embodiments, the torso section 112, the left sleeve section 114, and/or the right sleeve section 116 are manufactured as two or more (e.g., two, three, etc.) individual sections and thereafter joined together (e.g., sewn together, etc.).
According to an example embodiment, each of the torso section 112, the left sleeve section 114, and/or the right sleeve section 116 includes a plurality of portions manufactured (e.g., woven, knitted, felted, otherwise arranged into a structure that forms fabric, etc.) from the same material (e.g., the multi-constituent yarn, Cordura® yarn, etc.). Each of the plurality of portions of the torso section 112, the left sleeve section 114, and/or the right sleeve section 116 have different material characteristics (e.g., TPI, CPI, WPI, EPI, PPI, fabric density, fabric thickness, etc.), according to an example embodiment. The different material characteristics may facilitate providing various portions having specific material properties (e.g., strength, durability, elasticity, ventilation, joint articulation, etc.) at desired locations of the base layer 100.
A shown in FIGS. 6-8, the torso section 112, the left sleeve section 114, and the right sleeve section 116 of the base layer 100 include a first plurality of portions, shown as base zones 120, a second plurality of portions, shown as compressive zones 140, a third plurality of portions, shown as mesh zones 160, and a fourth plurality of portions, shown as durable zones 180. According to an example embodiment, the compressive zones 140 are configured to facilitate providing a tight-fitting (e.g., skin-tight, etc.) base layer 100 that conforms to the body structure of the wearer of the base layer 100 (e.g., in desired anatomical regions, etc.). According to an example embodiment, the mesh zones 160 have a mesh structure that defines a plurality of apertures that facilitate ventilation (e.g., air flow into and out of the base layer 100, in desired anatomical regions, allow the base layer 100 to “breath,” etc.). According to an example embodiment, the durable zones 180 have a greater durability relative to the other portions of the base layer 100 to provide increased protection (e.g., abrasion resistance, penetration resistance, heat resistance, etc.) to the wearer of the base layer 100 (e.g., in desired anatomical regions, etc.). The base zones 120, the compressive zones 140, the mesh zones 160, and/or the durable zones 180 of the base layer 100 may have similar material characteristics and/or properties as the base zones 20, the compressive zones 40, the mesh zones 60, and/or the durable zones 80 of the base layer 10 (e.g., TPI, CPI, WPI, EPI, PPI, fabric density, fabric thickness, strength, durability, elasticity, mechanical ease, ventilation, joint articulation, etc.).
According to an example embodiment shown in FIGS. 6-8, (i) the torso section 112 includes one or more portions of the base zones 120, the compressive zones 140, and the mesh zones 160, and (ii) the left sleeve section 114 and the right sleeve section 116 include one or more portions of the base zones 120, the mesh zones 160, and the durable zones 180. In other embodiments, the torso section 112, the left sleeve section 114, and/or the right sleeve section 116 include different zones and/or more or fewer zones of those that are shown. It should be understood that the number, position, and/or the type of the various zones of the torso section 112, the left sleeve section 114, and/or the right sleeve section 116 shown in FIGS. 6-8 are for illustrative purposes. Therefore, the number, type, and/or placement of the various zones of the base layer 100 may be different than what is shown in FIGS. 6-8.
As shown in FIGS. 6 and 8, the base zones 120 of the torso section 112 include a first base portion, shown as torso base zone 122. The torso base zone 122 is selectively positioned about the base layer 100 so as to correspond in location to a torso, neck, and/or shoulders of the wearer of the base layer 100. As shown in FIGS. 6-8, the compressive zones 140 of the torso section 112 include a compressive portion, shown as torso compressive zone 142. The torso compressive zone 142 is selectively positioned about the base layer 100 so as to correspond in location to the torso, shoulders, and/or waist of the wearer of the base layer 100 (e.g., such that the base layer 100 is tight-fitting, etc.). As shown in FIGS. 6-8, the mesh zones 160 of the torso section 112 include a first mesh portion, shown as lateral torso mesh zones 162, and a second mesh portion, shown as rear torso mesh zones 168. The lateral torso mesh zones 162 are selectively positioned about the base layer 100 so as to correspond in location to the lateral areas of the torso of the wearer of the base layer 100. The rear torso mesh zones 168 are selectively positioned about the base layer 100 so as to correspond in location to the rear of the torso (e.g., the back, etc.) of the wearer of the base layer 100.
As shown in FIGS. 6-8, the base zones 120 of the left sleeve section 114 and the right sleeve section 116 include a second base portion, shown as left sleeve base zone 124, and a third base portion, shown as right sleeve base zone 126, respectively. The left sleeve base zone 124 and the right sleeve base zone 126 are selectively positioned about the base layer 100 so as to correspond in location to at least a portion of a length of each arm of the wearer of the base layer 100. As shown in FIGS. 6 and 8, the mesh zones 160 of the left sleeve section 114 and the right sleeve section 116 include a third mesh portion, shown as left underarm mesh zone 164, and a fourth mesh portion, shown as right underarm mesh zone 166, respectively. The left underarm mesh zone 164 and the right underarm mesh zone 166 are selectively positioned about the base layer 100 so as to correspond in location to an armpit area of each arm of the wearer of the base layer 100.
As shown in FIG. 7, the durable zones 180 of the left sleeve section 114 include a first durable portion, shown as left elbow durable zone 182, and a second durable portion, shown as left wrist durable zone 184. As shown in FIGS. 7-8, the durable zones 180 of the right sleeve section 116 include a third durable portion, shown as right elbow durable zone 186, and a fourth durable portion, shown as right wrist durable zone 188. The left elbow durable zone 182, the left wrist durable zone 184, the right elbow durable zone 186, and the right wrist durable zone 188 are selectively positioned about the base layer 100 so as to correspond in location to the elbows and wrists of the wearer of the base layer 100.
It is important to note that the construction and arrangement of the elements of the systems, methods, and apparatuses as shown in the example embodiments are illustrative only. Although only a few embodiments of the present disclosure have been described in detail, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements. It should be noted that the elements and/or assemblies of the enclosure may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations.
Embodiments have been described in connection with the accompanying drawings. However, it should be understood that the figures are not drawn to scale. Distances, angles, shapes, etc. are merely illustrative and do not necessarily bear an exact relationship to actual dimensions and layout of the articles that are illustrated. In addition, the foregoing embodiments have been described at a level of detail to allow one of ordinary skill in the art to make and use the articles, parts, different materials, etc. described herein. A wide variety of variation is possible. Articles, materials, elements, and/or steps can be altered, added, removed, or rearranged. While certain embodiments have been explicitly described, other embodiments will become apparent to those of ordinary skill in the art based on this disclosure.
Conditional language used herein, such as, among others, “can,” “could,” “might,” “may,” “e.g.,” and the like, unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements and/or states. Thus, such conditional language is not generally intended to imply that features, elements and/or configurations are in any way required for one or more embodiments. The terms “comprising,” “including,” “having,” and the like are synonymous and are used inclusively, in an open-ended fashion, and do not exclude additional elements, features, acts, operations, and so forth. The term “consisting essentially of” can be used anywhere where the terms comprising, including, containing or having are used herein, but consistent essentially of is intended to mean that the claim scope covers or is limited to the specified materials or steps recited and those that do not materially affect the basic and novel characteristic(s) of the claimed invention. Also, the term “consisting of” can be used anywhere where the terms comprising, including, containing or having are used herein, but consistent of excludes any element, step, or ingredient not specified in a given claim where it is used.
Also, the term “or” is used in its inclusive sense (and not in its exclusive sense) so that when used, for example, to connect a list of elements, the term “or” means one, some, or all of the elements in the list. Conjunctive language such as the phrase “at least one of X, Y, and Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to convey that an item, term, etc. may be either X, Y, Z, X and Y, X and Z, Y and Z, or X, Y, and Z (i.e., any combination of X, Y, and Z). Thus, such conjunctive language is not generally intended to imply that certain embodiments require at least one of X, at least one of Y, and at least one of Z to each be present, unless otherwise indicated.
Additionally, in the subject description, the word “example” and “exemplary” are used to mean serving as an example, instance, or illustration. Any embodiment or design described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments or designs. Rather, use of the word exemplary is intended to present concepts in a concrete manner. Accordingly, all such modifications are intended to be included within the scope of the present inventions. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the preferred and other exemplary embodiments without departing from scope of the present disclosure or from the spirit of the appended claims.

Claims

1. A base layer of a garment, comprising:

a waist section positioned to correspond with and receive a waist and crotch region of a wearer, the waist section including a base portion, a mesh portion, a compressive portion, and a durable portion;

an upper leg section positioned to correspond with and receive a thigh and knee region of the wearer, the upper leg section including the base portion and the mesh portion; and

a lower leg section positioned to correspond with and receive a shin and calf region of the wearer, the lower leg section including the base portion and the compressive portion.

2. The base layer of claim 1, wherein the waist section, the upper leg section, and the lower leg section form a unitary, seamless, and three-dimensional layer.

3. The base layer of claim 2, wherein the base portion, the mesh portion, the compressive portion, and the durable portion have different material characteristics relative to each other such that each of the base portion, the mesh portion, the compressive portion, and the durable portion has specific properties at desired locations of the base layer.

4. The base layer of claim 3, wherein the material characteristics include at least one of (i) a thread count or threads-per-inch, (ii) courses per inch, (iii) wales per inch, (iv) a warp thread density or ends-per-inch, (v) a weft thread density or picks-per-inch, (vi) a fabric density, and (vii) a fabric thickness.

5. The base layer of claim 4, wherein the base portion has a first thread count, the mesh portion has a second thread count, the compressive portion has a third thread count, and the durable portion has a fourth thread count, wherein the first thread count, the second thread count, the third thread count, and the fourth thread count are all different.

6. The base layer of claim 1, wherein the mesh portion of the waist section is positioned to at least one of (i) surround a front crotch area of the waist and crotch region of the wearer, (ii) extend along a midline of a buttocks area of the waist and crotch region of the wearer, and (iii) extend at least partially around a periphery of the waist section to correspond with a waistline of the waist and crotch region of the wearer.

7. The base layer of claim 6, wherein the base portion of the waist section is positioned to correspond with the front crotch area of the waist and crotch region of the wearer such that the base portion is at least partially surrounded by the mesh portion of the waist section.

8. The base layer of claim 7, wherein the base portion positioned to correspond with the front crotch area of the waist and crotch region of the wearer has a relatively looser tension relative to all other sections of the base layer.

9. The base layer of claim 1, wherein the durable portion of the waist section is positioned to correspond with a buttocks area of the waist and crotch region of the wearer.

10. The base layer of claim 1, wherein the compressive portion of the waist section is positioned at least one of (i) along each lateral side of the waist section and (ii) to extend at least partially around a periphery of the waist section to correspond with a waistline of the waist and crotch region of the wearer.

11. The base layer of claim 1, wherein the mesh portion of the upper leg section is positioned to extend at least one of (i) along a front portion of a knee of the thigh and knee region of the wearer, (ii) along a rear portion of the knee of the thigh and knee region of the wearer, and (iii) around at least a portion of a periphery of a thigh of the thigh and knee region of the wearer.

12. The base layer of claim 1, wherein the compressive portion of the lower leg section is positioned to extend along at least one of (i) a shin of the shin and calf region of the wearer and (ii) a calf of the shin and calf region of the wearer.

13. The base layer of claim 1, wherein the lower leg section includes a foot section positioned to receive and enclose around a foot of the wearer.

14. The base layer of claim 13, wherein the foot section includes the compressive portion positioned to extend around at least a portion of a periphery of the foot of the wearer.

15. The base layer of claim 13, wherein the foot section includes the durable portion positioned to correspond with at least a portion of a bottom of the foot of the wearer.

16. The base layer of claim 13, wherein the foot section includes the mesh portion positioned to correspond with at least a portion of a top of the foot of the wearer.

17. A garment, comprising:

a base layer including:

a first section positioned to correspond with and receive a waist and crotch region of a wearer;

a second section positioned to correspond with and receive a thigh and knee region of the wearer; and

a third section positioned to correspond with and receive a shin and calf region of the wearer, wherein each of the first section, the second section, and the third section includes a plurality of zones manufactured from a first material, each of the plurality of zones having different material characteristics; and

a shell layer defining an internal cavity configured to receive the base layer, the shell layer at least partially manufactured from a second material having a greater durability than the base layer.

18. The garment of claim 17, wherein the first section, the second section, and the third leg section form a continuous and seamless layer manufactured from the first material.

19. A base layer of a garment, comprising:

a plurality of sections positioned to correspond with and receive respective anatomical regions of a wearer;

wherein the plurality of sections form a continuous and seamless layer; and

wherein each of the plurality of sections includes a plurality of portions having different material characteristics.

20. The garment of claim 19, wherein the base layer is at least one of an undershirt, a sleeveless shirt, a short-sleeve shirt, a long-sleeve shirt, briefs, shorts, pants, a jumpsuit, a full-length tight, a unitard, a singlet, and a leotard, and wherein the material characteristics include at least one of (i) a thread count or threads-per-inch, (ii) courses per inch, (iii) wales per inch, (iv) a warp thread density or ends-per-inch, (v) a weft thread density or picks-per-inch, (vi) a fabric density, and (vii) a fabric thickness.