Patent Application
20240415204
Conventional men's undergarments, such a men's briefs, are uncomfortable for the wearer as they exhibit low breathability. Further, presence of seams in undergarments exacerbates wearer discomfort. Moreover, conventional men's undergarments lack the ability to conform to one or more of the wearer's body parts, for example, the wearer's genitals.
The accompanying figures, where like reference numerals refer to identical or functionally similar elements throughout the separate views, together with the detailed description below, are incorporated in and form part of the specification, and serve to further illustrate embodiments of concepts that include the claimed invention and explain various principles and advantages of those embodiments.
Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of embodiments.
The apparatus and method components have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments so as not to obscure the description with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.
The embodiments described herein are related to a brief for a male wearer. More particularly, the embodiments described herein are related to a method for manufacturing a brief. The brief provides for a pouch to enclose genitals of a male wearer. The pouch provides improved breathability to the wearer's genitals.
In one aspect, a method for manufacturing a brief for a male wearer is described. The method includes using a stretchable fabric defining a first leg portion, a second leg portion, and a crotch portion integrally and contiguously extending between the first leg portion and the second leg portion. The method includes placing the stretchable fabric into a die assembly such that the crotch portion sits between a core and a cavity of the die assembly. Further, the method includes mating the core with the cavity to cause the core to push a section of the crotch portion into the cavity such that the section is stretched from a non-stretched state to a stretched state with respect to a remaining section of the crotch portion. The section includes a synthetic compound. The method includes applying heat and pressure at the section to cause a volume of the synthetic compound to melt while retaining the section in the stretched state. Further, the method includes cooling the section while retaining the section in the stretched state such that a melted volume of the synthetic compound is infused or incorporated into a remainder of the section and solidified therewithin. The infusion or the incorporation and the solidification cause the section of the crotch portion to acquire a shape as that acquired in the stretched state and be retained in the shape to form a pouch seamlessly integrated with the remaining section of the crotch portion. The pouch is configured to enclose genitals of the male wearer when the brief is worn by the male wearer.
In another aspect, a brief for a male wearer is described. The brief includes a stretchable fabric including a satin weave synthetic composite fabric with elongated nano fibres. The stretchable fabric defines a first leg portion, a second leg portion, and a crotch portion integrally and contiguously extending between the first leg portion and the second leg portion. The crotch portion defines a pouch to enclose genitals of the male wearer when the brief is worn by the male wearer. The pouch is formed by a section of the crotch portion that is stretched outwardly to a stretched state to define a bulge with respect to a remaining section of the crotch portion. The pouch is seamlessly integral with the remaining section of the crotch portion. Each of the remaining section of the crotch portion, the first leg portion, and the second leg portion, defines first holes and the pouch defines second holes. The first holes define a diameter in a range of 0.01 millimetres (mm) to 0.024 mm in between warp and filament yarn, and the second holes define a diameter in a range of 0.025 mm to 0.05 mm in between warp and filament yarn.
Reference will now be made in detail to specific embodiments or features, examples of which are illustrated in the accompanying drawings. Generally, corresponding reference numbers may be used throughout the drawings to refer to the same or corresponding parts, for example, 1, 1′, 1″, 101 and 201 could refer to one or more comparable components used in the same and/or different depicted embodiments.
Referring to
The brief 100 includes a first panel 112 (which is a front panel of the brief 100) and a second panel 116 (which is a rear panel of the brief 100). In an embodiment, each of the first panel 112 and the second panel 116 is made from the same fabric material. Alternatively, in an embodiment, the first panel 112 and the second panel 116 are made from different fabric materials. As an example, at least one of the first panel 112 and the second panel 116 includes, but is not limited to, a fabric which includes a satin weave synthetic composite fabric having elongated nano fibres. The fabric forming each of the first panel 112 and the second panel 116 is a stretchable fabric that enables the brief 100 to adjust and conform to a body structure of the male wearer 104. For the purposes of the present disclosure, the first panel 112 is referred to as a first stretchable fabric 120. Similarly, the second panel 116 is referred to as a second stretchable fabric 124.
In further detail, the first stretchable fabric 120 defines a first leg portion 128, a second leg portion 132, and a first crotch portion 136 integrally and contiguously extending between the first leg portion 128 and the second leg portion 132. Similar portions are available in the second stretchable fabric 124, as well. The first crotch portion 136 defines the pouch 108 to enclose the genitals of the male wearer 104 when the brief 100 is worn by the male wearer 104. To this end, the first crotch portion 136 defines a first section 140 and a second section 144. In this regard, reference is also made to
As is viewed from various views of the brief 100 in
According to some embodiments, the first holes define a diameter anywhere in a first range of 0.01 mm to 0.024 mm in between warp and filament yarn. According to some embodiments, the second holes define a diameter anywhere in a second range of 0.025 mm to 0.05 mm in between warp and filament yarn. In some examples, the lower limit of 0.025 mm of the second range for the second holes of the pouch 108 is optimal for application in men's garments that are related to sports activities, while the upper limit of 0.05 mm of the second range for the second holes of the pouch 108 is optimal for application in men's garments such as a recovery underwear.
With the relatively larger second holes in the pouch 108, the second holes serve as aeration holes of the pouch 108 that allows relatively more air to pass across the fabric matrix of the pouch 108 when the brief 100 is worn by the male wearer 104. This makes the pouch 108 (formed by the second section 144) more breathable than the first section 140 and/or also more breathable than other portions of the first stretchable fabric 120 and, in some embodiments, optionally additionally, the second stretchable fabric 124. Apart from providing greater breathability, the larger, second holes also provide for lowering humidity and improved heat dissipation from a groin area of the male wearer 104, thus enabling the wearer's genitals to remain at an optimal temperature range. While the bulge, BU, defined by the pouch 108 provides adequate space for the wearer's genitals to be accommodated within the brief 100, the bulge, BU, also appropriately supports the wearer's genitals, in turn promoting wearer comfort and sperm health.
In some embodiments, one or more of the first stretchable fabric 120 and the second stretchable fabric 124 (or the satin weave synthetic composite fabric of one or more of the first stretchable fabric 120 and the second stretchable fabric 124) is formed from a polyamide weave transformed into a satin weave and thinned out. Moreover, in some embodiments, one or more of the first stretchable fabric 120 and the second stretchable fabric 124, with the satin weave synthetic composite fabric, includes elongated nano fibres having a length anywhere between ten (10) to hundred (100) microns. In some embodiments, the satin weave synthetic composite fabric of one or more of the first stretchable fabric 120 and the second stretchable fabric 124 includes polyester. Further, in some embodiments, the first crotch portion 136 includes a synthetic compound, associated with the polyester. In one example, the synthetic compound takes up to fifteen percent (15%) of the weight in the first stretchable fabric 120 or in the brief 100. In some embodiments, a portion (for example, a non-synthetic part) of the brief 100, which is devoid of the synthetic compound, takes up to eighty five percent (85%) of the weight in the first stretchable fabric 120 or in the brief 100.
As an example, both the first section 140 and the second section 144 (and understandably the second section 144′) include the synthetic compound. However, it will be appreciated that the pouch 108 (or the second section 144 formed by the second section 144′) includes a melted, infused, and solidified volume of the synthetic compound. The solidified volume of the synthetic compound enables the pouch 108 to be retained in the stretched state, with the bulge, BU. A manner in which the synthetic compound is melted, infused, and solidified, will be described later in the present description. In some embodiments, the synthetic compound includes or corresponds to polyethylene terephthalate (PET).
With continued reference to
In some embodiments, one or more of the first stretchable fabric 120 and the second stretchable fabric 124 is a synthetic composite fabric of approximately eighty six percent (86%) Creora® Polyamide and approximately fourteen percent (14%) Spandex® or Lyrca®. The term ‘approximately’, as used here, accounts for tolerances when manufacturing the brief 100. In some embodiments, one or more of the first stretchable fabric 120 and the second stretchable fabric 124 includes elongated nano fibres making up each corresponding thread and which allows for greater strength and stretch recovery of the corresponding fabric. In some embodiments, one or more of the first stretchable fabric 120 and the second stretchable fabric 124 is made using a conventional polyamide weave that is transformed to a satin weaved and thinned out, as described above. In some embodiments, one or more of the first stretchable fabric 120 and the second stretchable fabric 124 has a thickness anywhere within the range of 0.0045-0.0048 millimetres (mm).
Referring to
At block 902, a base fabric 184 (for example, a relatively enlarged flat piece of stretchable fabric) (see
At block 904, the first stretchable fabric 120 is placed into a die assembly 196 (see
With reference to
At block 906, the die assembly 196 is operated to mate the core 208 with the cavity 200. During the mating of the core 208 with the cavity 200, the core 208 passes through the through-slot 224 such that the core 208 is able to ingress or enter into the cavity 200 (see direction, A,
When operating the die assembly 196 for mating the core 208 with the cavity 200 or prior to the mating the core 208 with the cavity 200, one of the first support part 212 and the second support part 216 is moved (see direction, B,
With reference to
At block 908, once the core 208 fully enters into the cavity 200 and is mated with the cavity 200 (referred to as a ‘mated state’ of the core 208), the core 208 exerts pressure against the cavity 200 such that the pressure is transferred and thus applied to the second section 144′ received between the core 208 and the cavity 200. This pressure application causes the second section 144′ to sit snugly and/or tightly within the cavity 200 (see
In some embodiments, the heat is supplied to the second section 144 through the core 208. To this end, and as an example, the core 208 includes features, such as one or more heating elements 236 that convert any supplied energy, at least in part, into heat, and through which heat is applied and/or imparted to the second section 144′. As an example, a source from where energy is supplied for the production of heat at the core 208 corresponds to any heat source, for example, an electrical heat source (not shown). In some embodiments, heat application is uniform about a body 240 of the core 208. In so doing, a physical state (for example, an initial solid state) of the synthetic compound, present in and across the second section 144′ of the first crotch portion 136, is uniformly altered or melted. In other words, a temperature at an outer surface 244 of the core 208 is varied evenly across an expanse of said outer surface 244 of the core 208. In so doing, a phase change of the synthetic compound in and across the second section 144′ of the first crotch portion 136 is attained uniformly throughout the second section 144. In some embodiments, the temperature is evenly varied at the outer surface 244 of the core 208 by having the heating elements 236 evenly distributed across the expanse of the outer surface 244 of the core 208. Although not limited, the second section 144′ is retained in the stretched state for an entire duration of the melting of the synthetic compound.
In some embodiments, a temperature value during an application of the heat is anywhere between 330.2 degrees fahrenheit to 402 degrees fahrenheit. In some embodiments, a pressure value during an application of the pressure is anywhere between 3.899 pounds per square inch to 7.024 pounds per square inch. In some embodiments, the heat is applied for a period of at least 10.05 seconds from start and up to a maximum of 13.03 seconds. In some embodiments, the pressure is applied for a period of at least 10.05 seconds from start and up to a maximum of 13.03 seconds. In some embodiments, the period for heat and pressure application is same when they are applied simultaneously. In some embodiments, the period for each of the heat and the pressure application varies or changes within or with respect to the ranges provided above according to a material of the first stretchable fabric 120. The method proceeds to block 910.
At block 910, after the heat and pressure have been applied in accordance with the ranges provided above, the heat application is halted and the operation switches to the cool the second section 144′ such that the volume of the synthetic compound that is melted (referred to as a ‘melted volume 260’) (see
The solidification enables the pouch 108 to be retained in said shape, for example, with the bulge, BU. Further, the pouch 108, as formed from the same fabric as that of the first crotch portion 136, is seamlessly merged and/or integrated with the remaining section or with the first section 140 of the first crotch portion 136. This is beneficial over cases where a different fabric piece is applied and which is stitched to the first crotch portion 136 to form a pouch, similar to the pouch 108, as stitching a different fabric externally to any section of the first crotch portion 136 inevitably defines a seam (for example, a suture-based seam) at the first crotch portion 136. During use by the male wearer 104, such suture-based seams are observed to undesirably cause chaffing of a skin of the male wearer 104. The method ends at block 910, although a variety of other processes are contemplatable by someone skilled in the art in subsequence to block 910.
In some embodiments, the cooling is performed while retaining the second section 144′ in the stretched state. At this point, ‘retaining the second section 144 in the stretched state’ means that the either the core 208 continues to be in the mated state with the cavity 200 to keep the second section 144′ in the stretched state, or, that the core 208 moves away from the cavity 200 to an unmated state but the second section 144′ continues to remain in the stretched state owing to the heat and pressure applied to the second section 144′ at block 908 and/or owing to the melting of the synthetic compound at the second section 144′ at block 908.
In some embodiments, cooling is provided by natural convection. For example, natural convention includes the allowance of a natural flow of air across the second section 144′ (for example, immediately) after the melting of the synthetic compound or immediately after the period for which the heat and/or the pressure is applied. In some embodiments, the solidification of the synthetic compound incorporated into the second section 144′ takes about thirty (30) seconds. Additionally, or optionally, cooling is provided by one or more additional systems associated with the die assembly 196. As an example, the core 208 includes cooling channels 248 through which a cooled fluid, such as cooled air, is passed and transferred (or applied) to the second section 144′ such that the volume of the synthetic compound that is melted (or the melted volume) is solidified, while retaining the second section 144′ in the stretched state and thus turning the same into the second section 144 and/or the pouch 108.
In some embodiments, the second section 144′ is stretched from the non-stretched state to the stretched state to increase sizes of holes defined in the second section 144 (or in the fabric matrix of the second section 144) from relatively smaller hole sizes to relatively larger hole sizes. As an example, holes in the second section 144 are switched from being the first holes to the second holes-more specifically, as the second section 144′ is stretched to the stretched state, diameter of the holes in the second section 144′ moves from being anywhere between 0.01 mm to 0.024 mm in between warp and filament yarn to anywhere between 0.025 mm to 0.05 mm in between warp and filament yarn. Also, when the melted volume of the synthetic compound is infused or incorporated into the second section 144′ (or into the remainder of the second section 144′) and solidified therewithin, the larger sizes of holes, as achieved in the stretched state of the second section 144 or as achieved in the second section 144, are retained so, without returning to the hole size they were in when in the non-stretched state.
Referring to
Moreover, the first crotch periphery 156 and the second crotch periphery 180 are also overlapped with each other and a third adhesive volume (not shown but is similar to the first adhesive volume 252) is used between the first crotch periphery 156 and the second crotch periphery 180 to fuse and join the first crotch periphery 156 with the second crotch periphery 180. This enables the formation of a third suture-less and seamless joint 268 of the brief 100. In so doing, and with the first stretchable fabric 120 and the second stretchable fabric 124 being heat pressed (for example, the base fabric 184 (see
In the foregoing specification, specific embodiments have been described. However, one of ordinary skill in the art appreciates that various modifications and changes can be made without departing from the scope of the invention as set forth in the claims below. Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of present teachings.
The benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential features or elements of any or all the claims. The invention is defined solely by the appended claims including any amendments made during the pendency of this application and all equivalents of those claims as issued.
Moreover, in this document, relational terms such as first and second, top and bottom, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms “comprises,” “comprising,” “has”, “having,” “includes”, “including,” “contains”, “containing” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises, has, includes, contains a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element preceded by “comprises . . . a”, “has . . . a”, “includes . . . a”, “contains . . . a” does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises, has, includes, contains the element. The terms “a” and “an” are defined as one or more unless explicitly stated otherwise herein. The terms “substantially”, “essentially”, “approximately”, “about” or any other version thereof, are defined as being close to as understood by one of ordinary skill in the art, and in one non-limiting embodiment the term is defined to be within 10%, in another embodiment within 5%, in another embodiment within 1% and in another embodiment within 0.5%. The term “coupled” as used herein is defined as connected, although not necessarily directly and not necessarily mechanically. A device or structure that is “configured” in a certain way is configured in at least that way but may also be configured in ways that are not listed.
The Abstract of the Disclosure is provided to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description, it can be seen that various features are grouped together in various embodiments for the purpose of streamlining the description. This method is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separately claimed subject matter.
| Number | Date | Country | Kind |
|---|---|---|---|
| 3116915 | Apr 2021 | CA | national |
The present application is a continuation-in-part of U.S. Non-Provisional application Ser. No. 17/246,215, filed Apr. 30, 2021, entitled “SEAMLESS MALE GARMENT”, which claims priority from U.S. Provisional Application No. 63/018,175, filed Apr. 30, 2020, entitled “SEAMLESS MALE GARMENT”, both of which are incorporated by reference herein in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63018175 | Apr 2020 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 17246215 | Apr 2021 | US |
| Child | 18821426 | US |
