SHIRT COLLAR SUPPORT AND METHODS THEREFOR

BACKGROUND

Shirt collars in general lack support throughout to maintain structure, shape, and form of a pressed appearance. With wear, a shirt collar inevitably and easily begins to lose support, shape, and form, causing unwanted effects on the collar such as wrinkling, curling, widening, spreading, or an uneven distribution.

Previous solutions most commonly used on shirt collars are designed to hold form of only the front tips of a collar (e.g., collar stays) and lack providing support elsewhere. Previous solutions less commonly used on shirt collars are designed to provide shape, form, or stabilization throughout the entire collar but are all external devices, some being multi-piece, and require manual insertion at the inside the collar and alignment prior to each wear.

A need exists for an internal collar support/structure device sewn or otherwise disposed inside the fabrics and seams of a collar/collar leaf at the manufacturer, with the device providing support and aiding in maintaining structure, shape, and form throughout a shirt collar, as well as reducing time for pressing.

SUMMARY

This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.

In embodiments, a collar support device may be either a single piece or multi-piece device to be sewn or disposed in between the fabrics that makeup a collar/collar leaf. Conceptually, these devices may be configured as non-removable and to be sewn into the collar at the manufacturer as an additional step in the construction of a shirt, or any other wearable garment having a collar, or may be removable/replaceable in the pockets of the collar/collar leaf in which they are disposed. Collar support devices may be used in various applications to support and aid in maintaining structure, shape, and/or form throughout a collar/collar leaf, as well reducing time for pressing such as after laundering or wear. Collar support devices are applicable to any shirt or costume or wearable garment with a collar for any gender as well as for any style.

Collar support devices may be designed to be either of the following examples. First, a single piece device may be formfitting and may be placed or disposed throughout the entirety or majority of the fabrics and/or seams of a collar/collar leaf with or without additional ease of folding flexibility which may be targeted in the two back curving areas of the collar/collar leaf. Conceptually, this additional ease of folding flexibility in targeted areas may be achieved with the materials composition of which the device is made or by precision holes cut-out of the material or a weaving material composition. The cut-outs or weavings may be of any geometrical shape and/or orientation. Second, a multi-piece device may be formfitting to be placed throughout the majority of the fabrics and/or seams of a collar/collar leaf with additional ease of folding flexibility targeted in the two back curving areas of the collar/collar leaf. Conceptually, this additional ease of folding flexibility in targeted areas may be achieved by excluding placement of device body portions in these areas to leave gaps.

Further features and advantages, as well as the structure and operation of various examples, are described in detail below with reference to the accompanying drawings. It is noted that the ideas and techniques are not limited to the specific examples described herein. Such examples are presented herein for illustrative purposes only. Additional examples will be apparent to persons skilled in the relevant art(s) based on the teachings contained herein.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated herein and form a part of the specification, illustrate embodiments of the present application and, together with the description, further serve to explain the principles of the embodiments and to enable a person skilled in the pertinent art to make and use the embodiments.

FIG. 1A illustrates a side view of the single piece collar support device shaped to the general shape of an example embodiment.

FIG. 1B illustrates a front view of the single piece collar support device shaped to the general shape of an example embodiment.

FIG. 1C illustrates an aerial view of the single piece collar support device shaped to the general shape of an example embodiment.

FIG. 2A illustrates a side view of a collared shirt folded upward. The single piece collar support device is illustrated by shaded coloring and placed throughout the general region where the device would be sewn into the fabrics of the collar according to an example embodiment.

FIG. 2B illustrates a back view of a collared shirt folded upward. The single piece collar support device is illustrated by shaded coloring and placed throughout the general region where the device would be sewn into the fabrics of the collar according to an example embodiment.

FIG. 2C illustrates a front view of a collared shirt folded upward. The single piece collar support device is illustrated by shaded coloring and placed throughout the general region where the device would be sewn into the fabrics of the collar according to an example embodiment.

FIG. 3A illustrates a side view of the multi-piece collar support device shaped to the general shape of an example embodiment. The shape of the device is illustrated similarly to a collar being folded upward.

FIG. 3B illustrates a front view of the multi-piece collar support device shaped to the general shape of an example embodiment. The shape of the device is illustrated similarly to a collar being folded upward.

FIG. 3C illustrates an aerial view of the multi-piece collar support device shaped to the general shape of an example embodiment. The shape of the device is illustrated similarly to a collar being folded upward.

FIG. 4A illustrates a side view of a collared shirt folded upward. The multi-piece collar support device is illustrated by shaded coloring and placed throughout the general regions where the device would be sewn into the fabrics of the collar according to an example embodiment.

FIG. 4B illustrates a back view of a collared shirt folded upward. The multi-piece collar support device is illustrated by shaded coloring and placed throughout the general regions where the device would be sewn into the fabrics of the collar according to an example embodiment.

FIG. 4C illustrates a front view of a collared shirt folded upward. The multi-piece collar support device is illustrated by shaded coloring and placed throughout the general regions where the device would be sewn into the fabrics of the collar according to an example embodiment.

FIG. 5A illustrates a formation of a collar from two separate portions of material, according to an example embodiment.

FIG. 5B illustrates a formation of a collar from two conjoined portions of material, according to an example embodiment.

FIG. 6A illustrates disposing of a collar support device with respect to an initially-formed pocket at one edge of a collar, according to an example embodiment.

FIG. 6B illustrates disposing of a collar support device with respect to an initially-formed pocket at another edge of a collar, according to an example embodiment.

FIG. 7A illustrates disposing of a collar support device with respect to an initially-formed pocket at one edge of a collar, according to an example embodiment.

FIG. 7B illustrates disposing of a collar support device with respect to an initially-formed pocket at another edge of a collar, according to an example embodiment.

FIG. 8 illustrates a disposed collar support device with respect to a completely-formed pocket of a collar of an article of clothing, according to an example embodiment.

FIG. 9 illustrates a disposed collar support device with respect to a completely-formed pocket of a collar of an article of clothing, according to an example embodiment.

FIG. 10 illustrates a flowchart for of forming an article of clothing with a collar support device, according to an example embodiment.

FIG. 11 illustrates plots of a Fourier transform infrared spectroscopy (FTIR) in the attenuated total reflectance (ATR) mode for a silicone-based collar support device material, according to an example embodiment.

FIG. 12 illustrates plots of differential scanning calorimetry (DSC) for a silicone-based collar support device material, according to an example embodiment.

FIG. 13 shows plots of a thermogravimetric analysis (TGA) for a silicone-based collar support device material, according to an example embodiment.

The features and advantages of embodiments will become more apparent from the detailed description set forth below when taken in conjunction with the drawings, in which like reference characters identify corresponding elements throughout. In the drawings, like reference numbers generally indicate identical, functionally similar, and/or structurally similar elements. The drawing in which an element first appears is indicated by the leftmost digit(s) in the corresponding reference number.

DETAILED DESCRIPTION

Below are more detailed conceptual descriptions and illustrative embodiments of collar support/structure devices which are not intended to limit the scope of the embodiments herein. The summarized concepts mentioned above, and in greater detail below, may be implemented in any number of ways, and the disclosed concepts should not be and are not to be limited to any particular manner of implementation. Provided examples of implementations and applications are for illustrative purposes, and the scope of the present patent application is not limited to the disclosed embodiments, but also encompasses combinations of the disclosed embodiments, as well as modifications to the disclosed embodiments.

I. Introduction

The following detailed description discloses numerous embodiments. The scope of the present patent application is not limited to the disclosed embodiments, but also encompasses combinations of the disclosed embodiments, as well as modifications to the disclosed embodiments.

References in the specification to “one embodiment,” “an embodiment,” “an example embodiment,” etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to effect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.

In the discussion, unless otherwise stated, adjectives such as “substantially,” “approximately,” and “about” modifying a condition or relationship characteristic of a feature or features of an embodiment of the disclosure, are understood to mean that the condition or characteristic is defined to be within tolerances that are acceptable for operation of the embodiment for an application for which it is intended.

Furthermore, it should be understood that spatial descriptions (e.g., “above,” “below,” “up,” “left,” “right,” “down,” “top,” “bottom,” “vertical,” “horizontal,” etc.) used herein are for purposes of illustration only, and that practical implementations of the structures and drawings described herein can be spatially arranged in any orientation or manner. Additionally, the drawings may not be provided to scale, and orientations or organization of elements of the drawings may vary in embodiments.

Numerous exemplary embodiments are described as follows. It is noted that any section/subsection headings provided herein are not intended to be limiting. Embodiments are described throughout this document, and any type of embodiment may be included under any section/subsection. Furthermore, embodiments disclosed in any section/subsection may be combined with any other embodiments described in the same section/subsection and/or a different section/subsection in any manner.

Section II below describes example embodiments for collar support/structure devices. Section III below describes additional examples and advantages, and Section IV provides some concluding remarks.

II. Example Embodiments for Collar Support/Structure Devices

Single piece and multi-piece collar support/structure devices utilize durable and flexible materials and are configured to support and aid in maintaining structure, shape, and form throughout a shirt collar, as well reducing time for pressing. The design and location of collar support/structure devices may be formfitting and sewn inside the fabrics and seams of the collar in a pocket. Collar support/structure devices are disposed (e.g., placed) into collars of garments as non-removable devices in permanently sealed pockets, and are also disposed into collars of garments as removable devices in pockets that are not permanently sealed. Collar support/structure devices may be configured to substantially conform to shapes of collars in the pockets, and may vary in thickness in proportion to material of the collars. Single piece devices optionally include portions having increased flexibility via cut-outs, thinner material, and woven inserts. Methods of forming articles of clothing having collar support/structure devices are also performed, according to embodiments herein.

A collar, or collar leaf, as described, is typically worn for a garment as folded down and is separate from the base, or stand (when a base or stand is part of the garment), which rises up from the garment and supports the collar/collar leaf and attaches the collar/collar leaf to the garment. As a non-limiting, illustrative example, the collar/collar leaf may be popped up to rise above the base or stand so that a tie may be tied for wearing, and after the knot of the tie is formed, the collar/collar leaf is then folded down to cover the portion of the tie that encircles the neck of the wearer around the base or stand. Embodiments herein are directed to collar support/structure devices disposed into collars/collar leaves for wearable garments. That is, the embodiments described provide for support, continuity of form, and consistency in structure for collars/collar leaves while still allowing enough flexibility to avoid creasing when a garment is folded or hanging and discomfort during garment wear.

Collar support/structure devices described for the embodiments herein may be composed of a flexible and/or malleable material or composition of materials such as but not limited to non-metallic, semi-metallic, interfacing mesh, interfacing weaving, plastic, paper, fabric, poly(dimethylsiloxane) (PDMS), silicone, polyurethane, rubber, wire, memory, synthetic, organic, composite, etc., including any combination of materials. Both the body of the device and cut-outs or weavings mentioned in above Summary may take any geometric formfitting shapes, such as but not limited to the illustrations and descriptions below as well as rectangular, angled, hemispherical, circular, horizontal, vertical, elliptical, or some combination thereof. The device body and cut-outs or weavings would be durable enough to withstand continual use of washes, wears, and pressings. Device bodies/portions and cut-outs or weavings may comprise a plurality of dimensions in thickness, length, and width of any size in various embodiments. Manufacturing and application of specific collars/collar leaves may dictate size and dimensions for best characteristics of formfitting, aesthetics, and durability.

While collar support/structure devices are described herein as collar support, this should be understood as a naming convention devices for brevity and consistency of description. That is, collar support devices may be synonymous with collar structure devices.

FIG. 1A illustrates a side view of a single piece collar support device 100A shaped to the general shape of an example embodiment. The shape of single piece collar support device 100A is illustrated similarly to a curved collar/collar leaf folded upward from a base or stand as would be attached to a wearable garment, such as but without limitation, a collar/collar leaf of a dress shirt, a blouse, etc.

Single piece collar support device 100A includes a device body 102. Device body 102 may be a contiguous body of material(s) that form a shape substantially corresponding to a collar leaf that attaches to a base/stand of a garment. Device body 102 includes a bottom edge 104, a top edge 106, a right front edge 108, and a left front edge 110.

As noted above, device body 102 may be composed of a flexible material or composition of materials such as but not limited to non-metallic, semi-metallic, interfacing mesh, interfacing weaving, plastic, paper, fabric, silicon-based material(s), polyurethane, rubber, wire, memory, synthetic, organic, composite, etc., including any combination of materials. In embodiments, materials comprising device body 102 may be selected for, without limitation, one or more of durability, flexibility, the ability to maintain or return to an original form, a resistance to creasing, temperature tolerances (e.g., high heat during pressing of garments), ease of formation for shapes in desired dimensions, and/or the like. For example, a material, such as a silicon-based material, that combines each of these characteristics may comprise device body 102 in whole or in part. Additionally, device body 102 may be formed according to custom molding (e.g., via injection molding), form cutting from material sheets, etc.

As illustrated, device body 102 also includes horizontal cut-outs 112a and horizontal cut-outs 112b. In accordance with some embodiments, horizontal cut-outs 112a and/or horizontal cut-outs 112b may be configured to provide additional collar folding flexibility and support in the areas of their locations, such as is illustrated in the two back curving areas of FIG. 1A. For instance, and without limitation, folded or hanging garments with collars may benefit from extra flexibility in areas shown for horizontal cut-outs 112a and horizontal cut-outs 112b in FIG. 1A where collars may be deformed when garments are folded or where collars may be otherwise stressed from hangars while hanging. In embodiments, horizontal cut-outs 112a and/or horizontal cut-outs 112b may be formed by cutting or stamping, while in other embodiments, horizontal cut-outs 112a and/or horizontal cut-outs 112b may represent empty spaces created by forms used to create device body 102.

FIG. 1B illustrates a front view of a single piece collar support device 100B, of an example embodiment, which may correspond to an embodiment of single piece collar support device 100A. The shape of single piece collar support device 100B is also illustrated similarly to a curved collar/collar leaf folded upward from a base or stand as would be attached to a wearable garment, as also illustrated for single piece collar support device 100A described above.

Single piece collar support device 100B includes device body 102 of FIG. 1A for illustrative consistency. As noted above, device body 102 may be a contiguous body of material(s) that form a shape substantially corresponding to a collar leaf that attaches to a base/stand, and includes bottom edge 104, top edge 106, right front edge 108, and left front edge 110. As described for FIG. 1A, device body 102 may be composed of a flexible material or composition of materials.

Also exemplarily illustrated for single piece collar support device 100B in FIG. 1B are horizontal cut-outs 112a and/or horizontal cut-outs 112b located at the two back curving areas of device body 102 which, in accordance with embodiments, may provide additional collar leaf folding flexibility and support in these areas.

In some embodiments, horizontal cut-outs 112a and/or horizontal cut-outs 112b may comprise at least one cut-out portion 114 which may be mesh or weavings of material in or attached to device body 102. While for horizontal cut-outs 112a and horizontal cut-outs 112b six cut-out portions 114 each are illustrated in a horizontal and rectangular layout according to the illustrated embodiment, different numbers, sizes, locations, and shapes are contemplated herein for other embodiments.

FIG. 1C illustrates a view from above a single piece collar support device 100C of an example embodiment, which may correspond to an embodiment of single piece collar support device 100A and/or single piece collar support device 100B. The shape of the single piece collar support device 100C is also illustrated similarly to a curved collar/collar leaf folded upward from a base or stand as would be attached to a wearable garment.

Single piece collar support device 100C includes device body 102 of FIG. 1A (and FIG. 1B) for illustrative consistency. As noted above, device body 102 may be a contiguous body of material(s) that form a shape substantially corresponding to a collar leaf that attaches to a base/stand, and includes bottom edge 104, top edge 106, right front edge 108, and left front edge 110. As described for FIGS. 1A and 1B, device body 102 may be composed of a flexible material or composition of materials. Also illustrated in FIG. 1C are horizontal cut-outs 112a and horizontal cut-outs 112b, as described above.

FIG. 1C also illustrates a material thickness 116 of device body 102. In embodiments, material thickness 116 may be substantially uniform throughout contiguous portions of device body 102, for device bodies 102 with or without horizontal cut-outs 112a and horizontal cut-outs 112b. In other embodiments, material thickness 116 may vary along device body 102. For example, a first thickness value for material thickness 116 may be used beginning at front right edge 108 and front left edge 110 where the thickness value changes along device body 102 as a center back portion 118 is approached. In some example, the material thickness value may decrease as center back portion 118 is approached, or vice versa. In some embodiments, the thickness value of material thickness 116 may vary, or may also vary, between bottom edge 104 and top edge 106.

Similarly, the thickness value for material thickness 118 may vary according to the material of the garment and/or collar to which it is applied. In embodiments, device body 102 may have material thickness 116 that is proportional to a fabric thickness of a fabric of the collar/collar leaf according to a proportion factor. As an illustrative, non-limiting example, a relatively thicker collar/collar leaf fabric may be paired with a correspondingly thicker device body 102, while a relatively thinner fabric collar/collar leaf may be paired with a correspondingly thinner device body 102.

It should be understood that in cases for which horizontal cut-outs 112a and horizontal cut-outs 112b are present as recessed portions, e.g., already having material thickness less than device body 102, such recessed portions may be correspondingly adjusted based on the proportion factor, or may not be correspondingly adjusted.

FIGS. 2A, 2B, and 2C will now be described. FIG. 2A illustrates an example of application for an article of clothing 200A having a collar support device disposed therein, according to one embodiment. This illustration of article of clothing 200A exemplarily shows a side view of a collar/collar leaf 204, of a garment 202, which is folded upward from a base 206.

In the illustrated embodiment, a single piece collar support device (i.e., single piece collar support device 100A, 100B, and/or 100C as shown in FIGS. 1A, 1B, and/or 1C, respectively) is shown as being placed or disposed throughout the general region where the device would be sewn into the fabrics of collar/collar leaf 204 of garment 202 and formfitting or approximately formfitting to seams 212 of collar/collar leaf 204 above the thicker fabric of base 206. FIG. 2A is shown as a see-through view through the fabrics of garment 202, e.g., at collar/collar leaf 204, illustrating for descriptive purposes the entirety of the single piece collar support device (100A, 100B, 100C) including the exemplary cut-out portions (e.g., horizontal cut-outs 112a and/or horizontal cut-outs 112b described above).

Seams 212 of collar/collar leaf 204 may be at the edge of the fabric that comprises collar/collar leaf 204, or approximately at the edge, as would be understood by one of skill in the relevant art(s). For instance, seams 212 may be made at a distance 208, e.g., a minimal or approximately minimal distance, from a front edge of collar/collar leaf 204 (e.g., right front edge 108, as shown in FIGS. 1A, 1B, and 1C) and distance 210, e.g., a minimal or approximately minimal distance, from a bottom edge of collar/collar leaf 204 (e.g., bottom edge 104, as shown in FIGS. 1A, 1B, and 1C) to substantially conform, in a formfitting manner, to the single piece collar support device (100A, 100B, 100C), as illustrated in FIG. 2A. Seams 212 may be configured to form a pocket into which the single piece collar support device is placed or disposed. In embodiments, as described in further detail below, one or more of seams 212 may be a fold or crease in the fabric of collar/collar leaf 204 to form a portion of the pocket into which the single piece collar support device is placed or disposed without departing from the spirit and scope of the embodiments described herein.

In some embodiments, seams 212 may be formed at/through the edges of the single piece collar support device (100A, 100B, 100C) in addition to the fabric of collar/collar leaf 204 of garment 202.

FIG. 2B illustrates an example of application for an article of clothing 200B having a single piece collar support device (e.g., 100A, 100B, 100C) disposed therein, according to one embodiment. Article of clothing 200B may be an embodiment of article of clothing 200A of FIG. 2A. The illustration of article of clothing 200B exemplarily shows a back view of collar/collar leaf 204, of garment 202, which is folded upward from base 206.

In the illustrated embodiment, the single piece collar support device (100A, 100B, 100C) is shown as being placed or disposed throughout the general region where the device would be sewn into the fabrics of collar/collar leaf 204 of garment 202 and formfitting or approximately formfitting to seams 212 of collar/collar leaf 204 above the thicker fabric of base 206. FIG. 2B is shown as a see-through view through the fabrics of garment 202, e.g., at collar/collar leaf 204, illustrating for descriptive purposes the entirety of the single piece collar support device (100A, 100B, 100C) including the exemplary cut-out portions (e.g., horizontal cut-outs 112a and/or horizontal cut-outs 112b described above).

As shown, the single piece collar support device (100A, 100B, 100C) conforms to substantially the entire length of the back of collar/collar leaf 204, including the back portion thereof illustrated in FIG. 2B for garment 202.

FIG. 2C illustrates an example of application for an article of clothing 200C having a single piece collar support device (e.g., 100A, 100B, 100C) disposed therein, according to one embodiment. Article of clothing 200C may be an embodiment of article of clothing 200A of FIG. 2A and/or article of clothing 200B of FIG. 2B. The illustration of article of clothing 200B exemplarily shows a front view of collar/collar leaf 204, of garment 202, which is folded upward from base 206.

In the illustrated embodiment, the single piece collar support device (100A, 100B, 100C) is shown as being placed or disposed throughout the general region where the device would be sewn into the fabrics of collar/collar leaf 204 of garment 202 and formfitting or approximately formfitting to seams 212 of collar/collar leaf 204 above the thicker fabric of base 206. FIG. 2C is shown as a see-through view through the fabrics of garment 202, e.g., at collar/collar leaf 204, illustrating for descriptive purposes the entirety of the single piece collar support device (100A, 100B, 100C) including the exemplary cut-out portions (e.g., horizontal cut-outs 112a and/or horizontal cut-outs 112b described above).

As shown, the single piece collar support device (100A, 100B, 100C) conforms to substantially the entire lengths of the front portions of collar/collar leaf 204, including the left front and right front portions thereof illustrated in FIG. 2B for garment 202.

It should be noted that the single piece collar support device (100A, 100B, 100C) shown for garment 202 in FIGS. 2A-2C conforms substantially, or approximately, to collar/collar leaf 204 in size and shape across the longitudinal lengths and the widths of collar/collar leaf 204. In embodiments, such conformance includes conforming, or substantially conforming, to the front corners of collar/collar leaf 204 in the pocket formed therein by seams 212.

Multi-piece collar support devices are now described. For example, FIG. 3A illustrates a side view of a multi-piece collar support device 300A shaped to the general shape of an example embodiment. The shape of multi-piece collar support device 300A is illustrated similarly to a curved collar/collar leaf folded upward from a base or stand as would be attached to a wearable garment, such as but without limitation, a collar/collar leaf of a dress shirt, a blouse, etc.

Multi-piece collar support device 300A includes a device body comprised of multiple body portions: body portion 302, body portion 304, and body portion 306 (collectively “body portions 302, 304, 306”). Body portions 302, 304, 306 may form a noncontiguous body of material(s) that form a shape substantially corresponding to a collar leaf that attaches to a base/stand of a garment. Body portion 302 includes a bottom edge 310, a top edge 308, a front edge 312, and a gap edge 314. Similarly, body portion 304 is shown as having a bottom edge, a top edge, a front edge, and a gap edge (not labeled for illustrative clarity and brevity) where this gap edge borders a gap (or space) between body portion 302 and body portion 306. In embodiments, body portion 304 may be a mirror image of body portion 302 where a gap edge thereof borders a gap (or space) between body portion 304 and body portion 306; body portion 302 and body portion 304 may be front body portions for illustrative purposes and conceptualization of multi-piece collar support device 300A. For illustrative purposes and conceptualization, body portion 306 may be a back body portion that includes a bottom edge and a top edge, as well as a left gap edge and a right gap edge (not labeled for brevity and illustrative clarity) which border gaps between body portion 306, and body portion 302 and body portion 304.

Multi-piece collar support device 300A as shown is a three-piece device that includes two gaps: a right gap 316a and a left gap 316b. Right gap 316a and left gap 316b may be located at portions of a collar/collar leaf needing additional flexibility during wear of a garment or during storage of the garment. With reference to the embodiments described above for FIGS. 1A-1C and FIGS. 2A-2C, right gap 316a and left gap 316b may be similarly located as horizontal cut-outs 112a and horizontal cut-outs 112b, and may be used for multi-piece collar support devices in lieu of cut-out portions.

For instance, in multi-piece collar support device 300A, right gap 316a and left gap 316b may be configured to provide additional collar folding flexibility in the areas of their locations, such as is illustrated in the two back curving areas of FIG. 3A which right gap 316a and left gap 316b span. For instance, and without limitation, folded or hanging garments with collars may benefit from extra flexibility in areas shown for right gap 316a and left gap 316b in FIG. 3A where collars may be deformed when garments are folded or where collars may be otherwise stressed from hangars while hanging.

In embodiments, each, or one or more, of body portions 302, 304, 306 may comprise a material(s) as similarly described above for device body 102. For instance, body portions 302, 304, 306 may be composed of a flexible material or composition of materials such as but not limited to non-metallic, semi-metallic, interfacing mesh, interfacing weaving, plastic, paper, fabric, silicon-based material(s), polyurethane, rubber, wire, memory, synthetic, organic, composite, etc., including any combination of materials. Likewise, in embodiments, materials comprising body portions 302, 304, 306 may be selected for, without limitation, one or more of durability, flexibility, the ability to maintain or return to an original form, a resistance to creasing, temperature tolerances (e.g., high heat during pressing of garments), ease of formation for shapes in desired dimensions, and/or the like. For example, a material, such as a silicon-based material, that combines each of these characteristics may comprise body portions 302, 304, 306 in whole or in part. Additionally, body portions 302, 304, 306 may be formed according to custom molding (e.g., via injection molding), form cutting from material sheets, etc.

While exemplarily illustrated in FIG. 3A as a multi-piece collar support device comprising three pieces, multi-piece collar support device 300A is not so limited and any number of pieces, e.g., greater than two, may be used in various embodiments, where the number of gaps therebetween is equal to the number of pieces plus one. It is also contemplated herein that right gap 316a and left gap 316b are of approximately equal size between their respective, adjacent body portions 302, 304, 306. Moreover, the combined longitudinal length of body portions 302, 304, 306, right gap 316a, and left gap 316b of multi-piece collar support device 300A is approximately equal to a longitudinal length of a collar/collar leaf in which multi-piece collar support device 300A is placed/disposed, thereby providing support for shape and structure of such a collar/collar leaf while also providing flexibility thereto.

FIG. 3B illustrates a front view of a multi-piece collar support device 300B, of an example embodiment, which may correspond to an embodiment of multi-piece collar support device 300A. The shape of multi-piece collar support device 300B is also illustrated similarly to a curved collar/collar leaf folded upward from a base or stand as would be attached to a wearable garment, as also illustrated for multi-piece collar support device 300A described above.

Multi-piece collar support device 300B includes body portions 302, 304, 306 of FIG. 3A for illustrative consistency. As noted above, body portions 302, 304, 306 may be a non-contiguous body of material(s) that form a shape substantially corresponding to a collar leaf that attaches to a base/stand, and may include edges as described for body portions 302, 304, 306 for FIG. 3A. Likewise, body portions 302, 304, 306 may be composed of a flexible material or composition of materials as noted for FIG. 3A.

Also exemplarily illustrated for multi-piece collar support device 300B in FIG. 3B are right gap 316a and left gap 316b located at the two back curving areas between body portions 302, 304, 306 which, in accordance with embodiments, may provide additional collar/collar leaf folding flexibility in these areas while also allowing body portions 302, 304, 306 to provide support substantially throughout the collar/collar leaf.

FIG. 3C illustrates a view from above a multi-piece collar support device 300C of an example embodiment, which may correspond to an embodiment of multi-piece collar support device 300A and/or multi-piece collar support device 300B. The shape of multi-piece collar support device 300C is also illustrated similarly to a curved collar/collar leaf folded upward from a base or stand as would be attached to a wearable garment.

Multi-piece collar support device 300C includes body portions 302, 304, 306 (of FIG. 1A and FIG. 1B) for illustrative consistency. As noted above, body portions 302, 304, 306 may be a non-contiguous body of material(s) that form a shape substantially corresponding to a collar leaf that attaches to a base/stand, and may include edges as described for body portions 302, 304, 306 for FIG. 3A and FIG. 3B. Likewise, body portions 302, 304, 306 may be composed of a flexible material or composition of materials as noted for FIG. 3A and FIG. 3B.

FIG. 3C also illustrates a material thickness 318 of device body portions 302, 304, 306. In embodiments, material thickness 318 may be substantially uniform throughout the non-contiguous body portions 302, 304, 306. In other embodiments, material thickness 318 may vary along body portions 302, 304, 306. For example, a first thickness value for material thickness 318 may be used beginning at front right edge 312 of body portion 302 and the corresponding front left edge of body portion 304 where the thickness value changes along these device body portions as their respective gap edges are approached. In some examples, the material thickness value may decrease from front to back, or vice versa, and the material thickness 318 may uniformly progress also through body portion 306 as a center back portion 320 of body portion 306 is approached. In some embodiments, the thickness value of material thickness 318 may vary between bottom edges and top edges of body portions 302, 304, 306.

Similarly, the thickness value for material thickness 318 may vary according to the material of the garment and/or collar to which it is applied. In embodiments, body portions 302, 304, 306 may have material thickness 318 that is proportional to a fabric thickness of a fabric of the collar/collar leaf according to a proportion factor. As an illustrative, non-limiting example, a relatively thicker collar/collar leaf fabric may be paired with correspondingly thicker body portions 302, 304, 306, while a relatively thinner fabric collar/collar leaf may be paired with correspondingly thinner body portions 302, 304, 306.

Embodiments herein also contemplate different sizes for right gap 316a and left gap 316b. For instance, embodiments may require that right gap 316a and left gap 316b be of a size such that body portions 302, 304, 306 do not touch during wear and/or storage of a garment in which body portions 302, 304, 306 are placed/disposed in a collar/collar leaf thereof. In some embodiments, a size for right gap 316a and left gap 316b may be used such that portions of the collar/collar leaf corresponding thereto are large enough that the flexing or deforming of the collar/collar leaf is not limited to a specific, relatively small or localized area (which may cause undue stress or creasing of the collar/collar leaf). However, a gap size may also be selected as small enough that the support for and structure of the collar/collar leaf is not compromised. For instance, a range of sizes for right gap 316a and left gap 316b may be between approximately 0.75 inches and 1.5 inches, although other sizes are also contemplated herein. Furthermore, sizes for right gap 316a and left gap 316b may vary based on collar/collar leaf length, thickness of material(s) of the collar/collar leaf, thickness of material(s) of body portions 302, 304, 306, and/or the like. While not so limited, embodiments herein also contemplate that sizes for right gap 316a and left gap 316b are approximately equal.

FIGS. 4A, 4B, and 4C will now be described. FIG. 4A illustrates an example of application for an article of clothing 400A having a collar support device disposed therein, according to one embodiment. This illustration of article of clothing 400A exemplarily shows a side view of a collar/collar leaf 404, of a garment 402, which is folded upward from a base 406.

In the illustrated embodiment, a multi-piece collar support device (i.e., multi-piece collar support device 300A, 300B, and/or 300C as shown in FIGS. 3A, 3B, and/or 3C, respectively) is shown as being placed or disposed substantially throughout the general regions where the device would be sewn into the fabrics of collar/collar leaf 404 of garment 402 and formfitting or approximately formfitting to seams 412 of collar/collar leaf 404 above the thicker fabric of base 406. FIG. 4A is shown as a see-through view through the fabrics of garment 402, e.g., at collar/collar leaf 404, illustrating for descriptive purposes the entirety of the multi-piece collar support device (300A, 300B, 300C) including the exemplary gaps between the body portions thereof (e.g., right gap 316a and left gap 316b described above).

Seams 412 of collar/collar leaf 404 may be at the edges of the fabric that comprises collar/collar leaf 404, or approximately at the edges, as would be understood by one of skill in the relevant art(s). For instance, seams 412 may be made at a distance 408, e.g., a minimal or approximately minimal distance, from a front edge of collar/collar leaf 404 and distance 410, e.g., a minimal or approximately minimal distance, from a bottom edge of collar/collar leaf 204 to substantially conform, in a formfitting manner, to the multi-piece collar support device (300A, 300B, 300C), as illustrated in FIG. 4A. Additionally, seams 412 may be formed along gap edges of body portions 302, 304, 306 in some embodiments. Seams 412 may be configured to form a pocket(s) into which the multi-piece collar support device is placed or disposed. In embodiments, as described in further detail below, one or more of seams 412 may be a fold or crease in the fabric of collar/collar leaf 404 to form a portion of the pocket(s) into which the multi-piece collar support device is placed or disposed without departing from the spirit and scope of the embodiments described herein. For instance, a pocket for each body portion of a multi-piece collar support device may be formed into which corresponding body portions are placed or disposed (as shown in FIG. 4A), or a single pocket may be formed into which each body portion of the multi-piece collar support device is placed or disposed. In embodiments for a single pocket, ones of seams 412 that run vertically between top and bottom edges of collar/collar leaf 404 along the gap edges of body portions 302, 304, 306 and the edges of right gap 316a and left gap 316b may not be formed.

In some embodiments, seams 412 may be formed at/through the edges of multi-piece collar support device (300A, 300B, 300C), e.g., at/through one or more of body portions 302, 304, 306, in addition to the fabric of collar/collar leaf 204 of garment 402.

FIG. 4B illustrates an example of application for an article of clothing 400B having a multi-piece collar support device (e.g., 300A, 300B, 300C) disposed therein, according to one embodiment. Article of clothing 400B may be an embodiment of article of clothing 400A of FIG. 4A. The illustration of article of clothing 400B exemplarily shows a back view of collar/collar leaf 404, of garment 402, which is folded upward from base 406.

In the illustrated embodiment, the single piece collar support device (300A, 300B, 300C) is shown as being placed or disposed throughout the general regions where the device would be sewn into the fabrics of collar/collar leaf 404 of garment 402 and formfitting or approximately formfitting to seams 412 of collar/collar leaf 404 above the thicker fabric of base 406. FIG. 4B is shown as a see-through view through the fabrics of garment 402, e.g., at collar/collar leaf 404, illustrating for descriptive purposes the entirety of the multi-piece collar support device (300A, 300B, 300C) including the exemplary gaps between the body portions thereof (e.g., right gap 316a and left gap 316b described above).

As shown, the multi-piece collar support device (300A, 300B, 300C) conforms to substantially the entire length of the back of collar/collar leaf 304, including the back portion thereof illustrated in FIG. 4B for garment 402.

FIG. 4C illustrates an example of application for an article of clothing 400C having a multi-piece collar support device (e.g., 300A, 300B, 300C) disposed therein, according to one embodiment. Article of clothing 400C may be an embodiment of article of clothing 400A of FIG. 4A and/or article of clothing 400B of FIG. 4B. The illustration of article of clothing 400B exemplarily shows a front view of collar/collar leaf 404, of garment 402, which is folded upward from base 406.

In the illustrated embodiment, the multi-piece collar support device (300A, 300B, 300C) is shown as being placed or disposed throughout the general regions where the device would be sewn into the fabrics of collar/collar leaf 404 of garment 402 and formfitting or approximately formfitting to seams 412 of collar/collar leaf 404 above the thicker fabric of base 406. FIG. 4C is shown as a see-through view through the fabrics of garment 402, e.g., at collar/collar leaf 404, illustrating for descriptive purposes the entirety of the single piece collar support device (300A, 300B, 300C) including the exemplary gaps (e.g., right gap 316a and left gap 316b described above).

As shown, the a multi-piece collar support device (300A, 300B, 300C) conforms to substantially the entire lengths of the front portions of collar/collar leaf 404, including the left front and right front portions thereof illustrated in FIG. 4B for garment 402.

It should be noted that the a multi-piece collar support device (300A, 300B, 300C) shown for garment 302 in FIGS. 3A-3C conforms substantially, or approximately, to collar/collar leaf 304 in size and shape across the longitudinal lengths and the widths of collar/collar leaf 304 (e.g., based on the combined longitudinal lengths of body portions 302, 304, 306, right gap 316a, and left gap 316b). In embodiments, such conformance includes conforming, or substantially conforming, to the front corners of collar/collar leaf 404 in the pocket(s) formed therein by seams 412.

FIGS. 5A and 5B are now described. In FIG. 5A, a formation of a collar 500A from two separate portions of material is shown, according to one embodiment. Collar 500A may be referred to as a collar leaf in embodiments, as described herein, and may be an embodiment of collars/collar leaves described above.

The formation of collar 500A may be performed by joining a first collar portion 502 with a second collar portion 504. Joining may be performed by various means such as, but not limited to, sewing to form seams, adhesives, interlocking groove and ridge mechanism, hook-and-eye fasteners, zippers, magnetic strips, and/or the like. Joining may be performed along a top edge 506 of first collar portion 502 and a top edge 508 of second collar portion 504.

Each of top edge 506 and top edge 508 described may have a longitudinal length L2 approximately based on the size of the desired collar/collar leaf. As shown, a bottom edge 510 of first collar portion 502 and a bottom edge 512 of second collar portion 504 may each have a longitudinal length L1 approximately proportional to length L2, based on the collar/collar leaf desired. First collar portion 502 and second collar portion 504 may be of the same, or approximately the same, size and shape, according to embodiments, such that a uniform collar/collar leaf is formed by the joining of thereof.

Each of first collar portion 502 and second collar portion 504 as described may have a front width W1 and center width Wn which may be the same, similar, or different based on the design of collar 500A. In embodiments, e.g., as shown in FIG. 5A, the width of collar 500A may vary between W1 and Wn according to the shape desired.

The formation of collar 500A shown in FIG. 5A may comprise an initial formation of a pocket therein into which a collar support device may be placed or deposed.

In FIG. 5B, a formation of a collar 500B from two conjoined portions of material is shown, according to one embodiment. Collar 500B may be referred to as a collar leaf in embodiments, as described herein, and may be an embodiment of collars/collar leaves described above.

The formation of collar 500B may be performed by folding or creasing a single collar piece 514 to form a first collar portion 514 and a second collar portion 516, that are conjoined and separated by a boundary 520 (e.g., a crease or fold) having length L2. The creation of boundary 520 from single collar piece 514 may also create a top edge of collar 500B corresponding to boundary 520.

As shown, a bottom edge 522 of first collar portion 516 and a bottom edge 524 of second collar portion 518 may each have a longitudinal length L1 approximately proportional to length L2, based on the collar/collar leaf desired. First collar portion 516 and second collar portion 518 may be of the same, or approximately the same, size and shape, according to embodiments, such that a uniform collar/collar leaf is formed from the folding/creasing of single collar piece 514, as shown in FIG. 5B.

Each of first collar portion 516 and second collar portion 518 as described may have front width W1 and center width Wn which may be the same, similar, or different based on the design of collar 500B. In embodiments, e.g., as shown in FIG. 5B, the width of collar 500B may vary between W1 and Wn according to the shape desired.

The formation of collar 500B shown in FIG. 5B may comprise an initial formation of a pocket therein into which a collar support device may be placed or deposed.

In FIG. 6A, a collar 600A having a disposed collar support device with respect to an initially-formed pocket at one edge of collar 600A is shown, according to one embodiment. Collar 600A may be referred to as a collar leaf in embodiments, as described herein, and may be an embodiment of collars/collar leaves described above. Collar 600A may be an embodiment of either of collar 500A of FIG. 5A or collar 500B of FIG. 5B described above.

For example, collar 600A may be formed from two separate portions of material as described for collar 500A, or from two conjoined portions of material as described for collar 500B. Collar 600A may include a top edge 602 formed according to either of the joining of top edge 506 with top edge 508 of FIG. 5A, or boundary 520 of FIG. 5B. In embodiments, as noted above, such operations may comprise the initialization of formation of a pocket into which a collar support device 604 may be placed or disposed.

In embodiments, collar support device 604 may be any collar support device as described herein, and while a single piece collar support device is shown for collar support device 604, multi-piece collar support devices are also contemplated in other embodiments. In such other embodiments, the initial formation of the pocket(s) may also include additional joining of first and second collar portions (e.g., as described with respect to FIGS. 5A-5B) along the axis of, and between, widths W1 to Wn. These additional joinings may be performed to form seams, or equivalents, as described above for seams 412 illustrated in FIGS. 4A-4C.

Collar 600A may be folded or closed according to an operation 606 such that the bottom edges of collar 600A are brought together. Operation 606 may be performed either before or after collar support device 604 is placed/disposed on collar 600A.

In FIG. 6B, a collar 600B having a disposed collar support device with respect to an initially-formed pocket at one edge of collar 600B is shown, according to one embodiment. Collar 600B may be referred to as a collar leaf in embodiments, as described herein, and may be an embodiment of collars/collar leaves described above. Collar 600B may be an embodiment of either of collar 500A of FIG. 5A or collar 500B of FIG. 5B described above, with variations described as follows.

For collar 500A of FIG. 5A and collar 500B of FIG. 5B described above, collar portions are joined at the top edge of collar 500A and collar 500B respectively. However, embodiments herein also contemplate formation of collars/collar leaves along a top edge thereof. In these embodiments, separate collar portions may be joined, as described herein, or conjoined portions may be formed from a single piece of fabric by folding or creasing, where the joining or folding/creasing is performed for top edges of the collar/collar leaf. For instance, as shown for collar 600B of FIG. 6B, a first collar portion 608 and a second collar portion 610 of collar 600B may have a shared edge at an adjoinment 612 that is formed along the top edges of first collar portion 608 and second collar portion 610 either by attaching first collar portion 608 and second collar portion 640 as described for FIG. 5A or by folding/creasing a single piece of fabric as described for FIG. 5B.

Accordingly, as similarly described for FIG. 6A, a collar support device 614 may be placed or disposed on collar 600B. With respect to collar FIG. 6B, however, collar 600B may be folded or closed according to an operation 616 such that the top edges of collar 600B are brought together. Operation 616 may be performed either before or after collar support device 614 is placed/disposed on collar 600B.

Turning now to FIGS. 7A and 7B, further formations of collars/collar leaves having collar support devices in pockets are illustrated with collars/collar leaves shown as being folded down from a base (not shown) as would be configured for normal wear of a garment to which the collars/collar leaves are attached.

In FIG. 7A, a disposing diagram 700A for a collar support device with respect to an initially-formed pocket at one edge of a collar is shown, according to an example embodiment. For instance, a collar support device 702 is shown in diagram 700A that is disposed via a disposing operation 704 into a pocket 706 of a collar/collar leaf 708.

As shown, pocket 706 of a collar/collar leaf 708 is initially formed at a top edge 710 by a seam 712, and is further formed by additional seams 714 at right front and left front edges of collar/collar leaf 708. Accordingly, three edges of pocket 706 are formed, in FIG. 7A, into which collar support device 702 is placed or disposed.

In embodiments, collar support device 702 may be placed or disposed into pocket 706 prior to seams 714 being formed. Moreover, in embodiments, seam 712 may be a fold or crease or the like as described above in lieu of, or in addition to, a threaded joining. In still other embodiments, seams 714 and seam 712 may be created in a single operation, e.g., sequentially, to initially form pocket 706 prior to disposing operation 704 being performed.

In FIG. 7B, a disposing diagram 700B for a collar support device with respect to an initially-formed pocket at another edge of a collar is shown, according to an example embodiment. For instance, a collar support device 702 is shown in diagram 700B that is disposed via a disposing operation 716 into a pocket 718 of a collar/collar leaf 720.

As shown, pocket 718 of a collar/collar leaf 720 is initially formed at a bottom edge 722 by a seam 724, and is further formed by additional seams 726 at right front and left front edges of collar/collar leaf 720. Accordingly, three edges of pocket 718 are formed, in FIG. 7B, into which collar support device 702 is placed or disposed.

In embodiments, collar support device 702 may be placed or disposed into pocket 718 prior to seams 726 being formed. Moreover, in embodiments, seam 724 may be a fold or crease or the like as described above in lieu of, or in addition to, a threaded joining. In still other embodiments, seams 726 and seam 724 may be created in a single operation, e.g., sequentially, to initially form pocket 718 prior to disposing operation 716 being performed.

With respect to FIGS. 7A and 7B, disposing operation 704 and disposing operation 716 may be enabled by one or more of a size(s) of the openings to pocket 706 and pocket 718, respectively (such that collar support device 702 may be disposed therein) and/or an amount of rigidity/resistance to folding of the material comprising collar support device 702.

In FIG. 8, an article of clothing 800 having a collar support device disposed in a completed pocket of a collar/collar leaf is shown, according an example embodiment. FIG. 8 illustrates a collar/collar leaf having a collar support device in a pocket with the collar/collar leaf shown as being folded down from a base (not shown) as would be configured for normal wear of a garment to which the collars/collar leaves are attached.

For instance, article of clothing 800 as shown comprises a collar/collar leaf 802 having a collar support device 804 disposed in a pocket 806 thereof. Pocket 806 is illustrated as being completed by being bordered on each edge by a completed seam 808. As an illustrative example, article of clothing 800 may be an embodiment of collar/collar leaf 708 of FIG. 7A or of collar/collar leaf 720 of FIG. 7B in which the unfinished side of pocket 706 or the unfinished side of pocket 718 has been completed by a seam. That is, article of clothing 800 may represent completion of disposing operation 704 and the addition of a seam to the bottom edge of collar/collar leaf 708 from FIG. 7A, or may represent completion of disposing operation 716 and the addition of a seam to the top edge of collar/collar leaf 720 from FIG. 7B.

In embodiments, completed seam 808 may comprise a fold or crease at the top edge or the bottom edge of collar/collar leaf 802 in lieu of, or in addition to, a corresponding portion of completed seam 808, as described above herein.

In FIG. 9, an article of clothing 900 having a collar support device disposed in a completed pocket of a collar/collar leaf is shown, according an example embodiment. FIG. 9 illustrates a collar/collar leaf having a collar support device in a pocket with the collar/collar leaf shown as being folded down from a base (not shown) as would be configured for normal wear of a garment to which the collars/collar leaves are attached.

For instance, article of clothing 900 as shown comprises a collar/collar leaf 902 having a collar support device 904 disposed in a pocket 906 thereof. Pocket 906 is illustrated as being completed by being bordered on three of four edges by a seam 908 where a top edge 910 is attached to a base (not shown) at its outer-facing portion. As an illustrative example, article of clothing 900 may be an embodiment of collar/collar leaf 720 of FIG. 7B in which the unfinished side of pocket 718 is not closed a seam. To this end, in embodiments where collar/collar leaf 902 is formed as described in FIG. 6B, first collar portion 608 in FIG. 6B may correspond to an outer-facing collar portion of collar/collar leaf 902 where first collar portion 608, and not second collar portion 610 (i.e., the inner-facing collar portion), is connected to the base structure that attaches the collar/collar leaf to the garment.

In other words, the inner-facing collar portion of collar/collar leaf 902 remains unattached to the outer-facing collar portion and unattached to the base, such that collar support device 904 may disposed into pocket 906 and remain encapsulated thereby, while collar support device 904 may be removed from pocket 906 and later be re-disposed or replaced with a different collar support device. Or, put another way, article of clothing 900 may represent completion of disposing operation 716 for collar support device 702 into collar/collar leaf 720 from FIG. 7B without entirely sealing collar support device 702 into pocket 718.

In embodiments, seam 908 may comprise a fold or crease at the bottom edge of collar/collar leaf 902 in lieu of, or in addition to, a corresponding portion of seam 908, as described above herein.

As described above, embodiments herein contemplate the formation of collars/collar leaves for articles of clothing (e.g., garments) having collar support devices disposed therein for additional support and flexibility.

Turning now to FIG. 10, a flowchart 1000 for of forming an article of clothing with a collar support device is shown, according to an example embodiment. Flowchart 1000 may be performed according to one or more operations and/or embodiments herein, e.g., to form articles of clothing having collar support devices disposed in pockets thereof. Flow chart 1000 is described as follows and begins with step 1002.

In step 1002, a first portion of a collar and a second portion of the collar are received. For instance, a first portion and a second portion of collar/collar leaf material may be received as illustrated in FIG. 5A and/or FIG. 5B. In FIG. 5A, a first collar portion 502 and separate a second collar portion 504 are received for formation of a collar/collar leaf. In FIG. 5B, a first collar portion 516 and a conjoined second collar portion 518 (as part of single collar piece 514) are received for formation of a collar/collar leaf. The receiving of the first portion of a collar and the second portion of the collar may be performed according either of these embodiments, or according any other embodiments and/or equivalents described herein.

In step 1004, formation of a pocket in the collar at a first edge of the collar is initialized. For example, referring again to FIG. 5A and FIG. 5B, the first and second collar portions may be joined by creating a seam, or the like, through top edge 506 and top edge 508 (e.g., as in FIG. 5A), or single collar piece 514 may be folded or creased at boundary 520 (e.g., as in FIG. 5A). In either embodiment, the first and second collar portions may be formed/joined to initialize creation of a pocket for the collar/collar leaf. As described herein, some embodiments provide for initialization of pocket formation to be performed on a bottom edge(s) of a collar/collar leaf (e.g., as in FIG. 6B) which allows for disposing of a collar support device via a top edge of the collar/collar leaf (e.g., as in FIG. 7B).

In step 1006, a collar support device that is configured to maintain at least one of a shape or a form of the collar, and that is congruently shaped with respect to the first portion or the second portion, is received. For instance, a single- or multi-piece collar support device as described herein may be received for addition to or disposition in a collar/collar leaf (e.g., as in FIGS. 6A-6B and 7A-7B). As described herein, collar support devices may be configured to maintain shapes and/or forms of collars/collar leaves, and to provide flexibility, in addition to extra flexibility in certain portions. Collar support devices may also be congruently shaped in pockets formed in collars/collar leaves and substantially fill such pockets. For example, each of the Figures described above exemplarily show collar support devices, both single- and multi-piece collar support devices, having such characteristics. In embodiments for multi-piece collar support devices, gaps may additionally comprise such devices such that the multi-piece collar support devices substantially fill and conform to the shapes of collars/collar leaves while the gaps provide areas of extra flexibility.

In step 1008, the collar support device is disposed in the pocket as initially formed. For example, collar support devices may be disposed or placed into pockets initially or partially formed in collars/collar leaves (e.g., as in FIGS. 6A-6B and 7A-7B (disposing operation 704 and disposing operation 716)). Collar support devices may be placed or disposed by hand or by machine techniques, in embodiments, and may be disposed at any time during formation of a pocket prior to completion thereof (e.g., subsequent to an operation such as seam forming or folding/creasing performed on at least one edge of a collar/collar leaf). In some embodiments, collar support devices may be disposed after an initial formation operation but before subsequent formation operations.

The material composition of the described collar support devices provides for sufficient rigidity to enable these devices to be disposed in pockets that are initialized or partially formed with three of four edges closed, as exemplarily shown in FIGS. 7A-7B, although it should be noted that embodiments herein also contemplate disposing collar support devices when an open edge of a pocket corresponds to right or left front edge.

In step 1010, formation of the pocket is completed, where the pocket as completely formed contains the collar support device within and is approximately filled by the collar support device. For instance, FIGS. 9 and 10 show completed pockets of collars/collar leaves where the disposed collar support devices are contained within the pockets, and the pockets are substantially filled by the collar support devices as they conform to the shape of the pockets and the collars/collar leaves illustrated. In some embodiments, a completed pocket may have all edges thereof closed along the edges of the collar/collar leaf (as in FIG. 8), while in other embodiments a completed pocket may comprise three of four edges being closed with the final edge has a portion of material thereof that is attached to a base at an outer-facing side of the collar/collar leaf thus providing an open pocket that enables collar support devices to be removed and replaced while the open portion is located on an inner-facing side of the collar/collar leaf on the inside and under the downward fold of the collar/collar leaf from the base.

III. Embodiments for Additional Examples and Advantages

In embodiments, one or more of the steps or operations of any operation, process, and/or method described herein may not be performed. Moreover, steps or operations in addition to or in lieu of those in any operation, process, and/or method described herein may be performed. Further, in examples, one or more operations/steps of any operation, process, and/or method described herein may be performed out of order, in an alternate sequence, or partially (or completely) concurrently with each other or with other operations/steps.

As described herein, pockets may be formed using seams, but embodiments are not so limited and pocket formation may also comprise the use/application of interlocking groove and ridge mechanisms, hook-and-eye fasteners, zippers, magnetic strips, and/or the like.

In the current state of the art, collar stays are made of stiff plastic materials, or metal, that rigidly conform for a specific, straight shape in order to prevent corners of collars from being folded, creased, or otherwise deformed. Additionally, collar stays are only applied to the front corners of collars. The embodiments herein provide for materials, e.g., silicone-based materials, which provide support and structural shape, conforming to substantially an entire collar/collar leaf, while also allowing flexibility throughout the entire collar/collar leaf. Furthermore, the embodiments herein for collar support devices also provide for additional flexibility at specific locations of the entire collar/collar leaf.

Similarly, the use of additional layers of garment material/fabric in collars/collar leaves is different from the described embodiments. First, the embodiments herein provide for a different combination of flexibility and support via materials with characteristics that improve the performance of the described collar support devices, and described collar support devices are included in pockets formed in collars/collar leaves. Moreover, embodiments provide for removable and replaceable collar support devices, which cannot be performed with garment materials/fabrics to substantially conform to and fill pockets in collars/collar leaves (while still providing improved support, resistance to creasing, and flexibility). Still further, the embodiments herein do not require the use of wires, stiffening solutions, or adhesives unlike additional fabric layers, and the described embodiments do not require that collar support devices have seams formed such that the seams are in or through (e.g., perforate) the material of the collar support devices themselves.

Current solutions for support and structural maintenance of garments focus on the base or stand that attach collars to garments. In stark contrast, the collar support devices in the described embodiments provide support and structure substantially throughout the collar/collar leaf itself rather than the base/stand.

While the described embodiments provide for collar support devices, e.g., for collars/collar leaves that are attached to a base or a stand of a shirt, other applications of support devices are also contemplated herein for different types of collars/collar leaves, different types of garments, and different parts of garments, e.g., cuffs, waist bands, garment portions including buttons and/or button holes, etc.

Turning now to material properties for collar support devices, various properties and characteristics are described above. Provided below are additional descriptions of example properties and characteristics.

Garment materials, e.g., for collared shirts, may range in thickness from very thin (e.g., approximately 0.17 mm) to very thick (e.g., approximately 0.4 mm). As noted herein, collar support device materials may be used that correlate to garment fabric thicknesses. For instance, a collar support device with less thickness may be used for a thinner garment material, while a collar support device with more thickness may be used for a thicker garment material. The garment material thickness examples provided above may have an approximate average thickness of about 0.28-0.29 mm, and in such cases a collar support device thickness of approximately 1.0 mm may be used (although the described embodiments are not so limited and different embodiments allow for variation in this thickness value).

Materials for collar support devices may have an average tensile strength (e.g., at a load of 50 lbs with a constant speed of 20 in/min) of approximately 1,280 psi (with a standard deviation of about 50), and may have an ultimate elongation of approximately 544% (with a standard deviation of about 16), at approximately 23° C. and 50% relative humidity. Materials for collar support devices may have an average tear strength under similar conditions of approximately 96.5 lbf/in (with a standard deviation of about 4.5). Additionally, materials for collar support devices may have an average specific gravity and density of approximately 1.18 (e.g., density in g/cubic cm), in embodiments.

FIG. 11 shows plots 1100 of a Fourier transform infrared spectroscopy (FTIR) in the attenuated total reflectance (ATR) mode for an example, silicone-based collar support device material.

FIG. 12 shows plots 1200 of differential scanning calorimetry (DSC) for an example, silicone-based collar support device material. DSC measures the temperature and heat flow associated with transitions in materials as a function of time and temperature. Plots 1200 represent DSC results for an example, silicone-based collar support device material heated from −80° C. to 50° C. and control cooled to −80° C. at 10° C./min in a nitrogen purge.

FIG. 13 shows plots 1300 of a thermogravimetric analysis (TGA) for an example, silicone-based collar support device material. TGA is a thermal analysis technique that measures the amount and rate of change in the weight of a material as a function of temperature or time in a controlled atmosphere.

IV. Conclusion

While various embodiments of the disclosed subject matter have been described above, it should be understood that they have been presented by way of example only, and not limitation. It will be understood by those skilled in the relevant art(s) that various changes in form and details may be made therein without departing from the spirit and scope of the embodiments as defined in the appended claims. Accordingly, the breadth and scope of the disclosed subject matter should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents.

SHIRT COLLAR SUPPORT AND METHODS THEREFOR

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