BACKGROUND OF THE INVENTION

[001] Prior support systems for pregnant women have been bellybands or belt type of systems. Bellybands have generally just been seamless tubes of fabric that typically just provide coverage, and cannot provide adequate support. Prior leggings manufactured for pregnant woman have used this type of seamless knit support system. On the other hand, maternity belts are much more draconian, bulky and cumbersome to a woman when compared to more comfortable clothing options. A new type of support is needed that overcomes the above- mentioned shortcomings associated with the prior art systems.

TECHNICAL FIELD

[002] The technical field relates to maternity clothing, and more particularly to leggings worn by pregnant women that provide support.

SUMMARY OF THE INVENTION

[003] Various embodiments of systems and methods for the maternity clothing are disclosed. The revolutionary garment that is disclosed herein is fit precisely to a woman’s evolving body shape. Using a bonded film support band or panels, instead of traditional seamless shapewear, produces far superior leggings or maternity wear in terms of support, strength and comfort. By adding a bonded front band or panel, the legging provides the support of a medical maternity belt, (without the bulk) with the comfort and clean sleek look of a performance legging. By adding a bonded back band or panel, the garment supports the wearers back and releases any strain to the lower back muscles

[004] In one aspect of this invention, the maternity legging has support material cut and bonded onto the fabric.

[005] In another aspect of the invention, the support band or panels may be bonded on the interior or exterior of the leggings with no stitching, so the adhesion of the bonded band or panels is substantially smooth, flat and unnoticeable. In another variation the bonded support panels are reinforced with stitching or reinforcement tape. [006] In another aspect of the invention, a back panel of the support band functions as an anchor to the front support panel. The back panel stabilizes the back to release any strain to the lower back muscles. The configuration of the support band is applied to a variety of clothing such as dresses, pants, shorts, and the like.

[007] In another aspect of the invention, the front and back panel are incorporated into a continuous belt that surrounds the wearer. The exact shape of the front and back panel of the support band are designed to provide maximum support and comfort, while avoiding placing pressure in undesirable areas, such as the bladder for example.

[008] In another aspect of the invention, the folded edge of the waistband may be bonded to create a completely smooth and seamless effect with no stitching.

[009] In another aspect of the invention, a method for manufacturing clothing, particularly maternity clothing or apparel is provided. The method includes bonding support panels or bands to the front or back or both of leggings or apparel.

[0010] In another aspect of the invention, the film for the interior or exterior support bands are TPU (Thermoplastic Polyurethane) based.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] While the present invention is amenable to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. The inventions of this disclosure are better understood in conjunction with these drawings and detailed description of the preferred embodiments.

[0012] It should be understood, however, that the drawings and detailed descriptions are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the present invention as defined by the appended claims.

[0013] Figures 1- 3 represent a front, back and side view respectively of one embodiment of the leggings of the invention.

[0014] Figures 4-6 represents represent a front, back and side view respectively of another embodiment of the leggings of the invention. [0015] Figures 7-9 represents represent a front, back and side view respectively of another embodiment of the leggings of the invention

[0016] Figures 10-11 represents a front and back view respectively of an embodiment of a dress incorporating the support band of the invention.

[0017] Figures 12-13 represents a front and back view respectively of an embodiment of a bodysuit and/or top incorporating the support band of the invention.

DETAILED DESCRIPTION

[0018] The above figures are better understood in connection with the following detailed description of the preferred embodiments. With reference to Figs. 1-9, there are illustrated therein certain embodiments of the interior portion of the maternity legging. While the following embodiments are directed toward a maternity legging, the support band described herein can be applied to a variety of garments. The support band of the present invention, and the method of manufacturing garments described herein does not apply only to leggings generally or maternity leggings specifically but can also apply to any type of pants or article of clothing such as dresses, leotards, swimwear, etc. For example, the support band can be applied to any type of pants or other garment in which support of the belly or back is desired.

[0019] STRUCTURE OF THE SUPPORT BAND:

[0020] Referring to Figs. 1-3, the maternity legging 10 has support band 12 cut and bonded onto the fabric, (rather than knitted in). Support band 12 may be arranged in a variety of configurations (and referred to generally throughout as“support band” 12). The Figures show the location generally of the support band 12 indicated with cross-hatching or dotted areas. By way of example only, support band 12 may be a single bonded piece (as shown) or support band 12 may be comprised of multiple individual pieces or panels that are bonded in various locations around the waist area of the legging. Further, the support band 12 may extend in a contiguous or continuous bond around the circumference of the waist or abdomen or the support band 12 may be bonded as multiple individual pieces connected at the sides 18 or individual pieces that are not connected to each other (such as in Figs. 4-6). For example, the support band 12 may consist of a back panel 14 and front panel 16 only leaving the sides 18 free of bonded material or film (Fig. 4-6). Alternatively, the support band 12 may consist of a front panel and back panel connected by way of side pieces.

[0021] Bonding, as opposed to other attachment methods, gives the ability to engineer the size of the support band perfectly. Bonding is the process of attaching two or more fabrics together using an adhesive film (hereafter referred to as“film”) that is activated when heat, time and pressure are applied to it. Bonding can be created by means known in the art, typically heat press machines or belt laminators. Bonding differs from stitching in that no sewing threads are required as adhesive replaces the sewing thread. In the present invention, bonding is used to create discreet and well defined reinforcements on specific areas of the garment or legging. This allows for the garment to be shaped to support the body as opposed to traditional sewn seams which are restrictive. An example of such a process can be found in EP 1,633,921.

[0022] In this preferred embodiment, the manufacture of the maternity legging need not be restricted by seamless knitting machines that can only create a limited shape. In certain embodiments, the support pieces that make up the support band 12 may be laser cut or die cut to the precise millimeter for the perfect amount of support and lift for the belly of the wearer of the legging 10. The support band 12, whether a singular piece or multiple pieces, is preferably bonded to the interior of the legging. The support band 12 may alternatively be bonded to the exterior of the leggings. Alternatively, the support band 12 may be attached to the legging or garment by a combination of bonding and sewing or stitching.

[0023] As shown in the Figs., in preferred embodiments manufacturing of the support band 12 provides for shaping the band to follow the natural curve of a woman from hip to groin, so when in a seated position, the wearer gets as much support as when the wearer is standing up. The innovative support does not get the bunching and excess of fabric that she would when wearing seamless knit support.

[0024] In the preferred embodiment, this shaping also helps support the womb and enable maximum freedom of movement at the hip flexors. Unlike other support garments that have compression extending all the way down to the pelvic bone (which can cause an increase in the need or urge to urinate more frequently) the placement of the front area of support band 12 in the present invention is positioned to wrap around the lower part of the belly to cradle it, but not to push against the bladder. This targeted support reduces pressure on the pelvic floor and allows for the natural growth of the belly whilst supporting strained abdominal muscles.

[0025] In certain embodiments, support band 12 is bonded on the interior or exterior of the legging with no stitching so the seams are completely or substantially smooth, flat and unnoticeable. In other embodiments, stitching is used in combination with bonding, for example stitches on the outline of the bonded material for reinforcement. The innovative design provides for more support and comfort than traditional maternity leggings or seamless support maternity leggings. This process differs from traditional cut and sew methods currently in use in maternity apparel. Laminated belt machines, flat fusing presses, and sew free machines are used to adhere films and form garment seams.

[0026] Alternatively, all or part of the bonded area(s) may be reinforced with stitching.

[0027] In certain embodiments, the front portion 16 of support band 12 may leave enough space for the changing body throughout pregnancy and beyond. The position of and film used in the bonding is specifically designed so that the bonded portion of support band 12 conforms to the body and expands with the growing belly without restricting it.

[0028] In certain embodiments, the back panel 14 of the support band 12 acts like an anchor to the front panel 16 of support band 12 and stabilizes the wearers back to release any strain to the lower back muscles. In this embodiment the back panel 14 and front panel 12 are connected to each other at the sides of the waist in the area of the hips. The back panel 14 of the support band 12 may be curved lower at the center back to protect and support the coccyx, and may curve up and around to the gluteus minimus and medius and may further curve around to the abdominal obliques.

[0029] In certain embodiments, the back panel 14 helps enormously with posture by redistributing the weight of the belly by gently pulling the front panel 16 of the support band 12 back so as to lift the wearer’s belly so that the weight of the belly is not all carried at the front of the belly. This structure functions to releases tension and pressure from the weight of the pregnant belly to give energy back to the wearer.

[0030] The bonding process and film used to form the support band 12 need not be uniform throughout the entire support band 12. For example, the front panel 16 may be bonded with different film than the back panel 14 to provide different properties at the various locations of the leggings. Many configurations are possible by varying the shape and location of the support band 12 and varying the film, fabric and/or bonding technique in specific areas of the support band 12. For example, in certain embodiments, the back panel 14 of the support band 12 is bonded with a stronger and less flexible, less elastic (i.e. firmer) reinforcement film or material, while the front panel 16 is bonded with a film that produces a supportive yet more flexible, less firmer area than the back panel 14. In this embodiment, the back panel 14 is connected to the front panel 16 at the sides of the hip area using an active stitch to connect the edges of the back panel 14 to the edges of the front panel 16. Other stitches or attachments may be used. The edges may be bonded or fused together. Alternatively, the edges of the front panel 16 and back panel 14 may be connected via an intermediate side panel (not shown). In these configurations, the stronger, less flexible back panel 14 anchors and support the more flexible front panel 16 of the support band 12. This configuration of the support band 12 functions to alleviate pregnancy discomfort.

[0031] With reference to Figs. 4-6, another embodiment of the leggings 10 is shown. Figs. 4-6 show an embodiment where the band 12 bonded to the leggings 10 as two separate panels (front panel 16 and back panel 14). In this embodiment the panels 14 and 16 are not connected to each other at sides 18.

[0032] With reference to Figures 7-9, another embodiment of the leggings 10 is shown. Figs. 7-9 show an embodiment where the band 12 bonded to the leggings 10 as a two panel embodiment (front 16 and back 14). In this embodiment the panels 14 and 16 are connected to each other at sides 18. The shape of the panels extend to the top of the waist band 20.

[0033] TOP OF WAISTBAND:

[0034] In certain embodiments, the edge of the waistband 20 may be folded and bonded to create a completely smooth and seamless effect with no stitching. The film or material used in the bonding of the waistband 20 may preferably have a flexibility and recovery to adapt to a changing belly size. The contour of the waistband may be specifically shaped at the front to accommodate a growing belly and to offer gentle support while enabling the legging to stay in place. The contour at the center back area of the waistband may be sculpted lower for maximum freedom of movement without bunching. [0035] FILMS FOR THE SUPPORT BANDS:

[0036] The film used in the bonding for the support bands 12 is chosen to be advantageous where a high degree of movement is required, and extended comfort is demanded. The types, thickness, elasticity and recovery of films (i.e. glues or adhesives) all impact the final properties of the bonded material. Additionally, the films come in many different thicknesses, which will change the elasticity and firmness of the film. There are generally three variables to the bonding process as well, specifically the heat, time and pressure applied by the bonding machine. In certain embodiments, the films used by the innovative leggings are TPU based (Thermoplastic Polyurethane) versus tradition bonding films which are PU (Polyurethane) based. This gives the film and its bonded substrate significant stretch and recovery with less fatigue.

[0037] In certain embodiments, the PBT 510 that is used is 2 ply of the film extruded yielding a lOmil thickness. The two ply helps in the maternity range with the increased demand on modulus (stretch & recovery). In certain embodiments, the back panel 14 film is PBT 510, while the front panel 16 film is a different film designed to produce a more elastic front panel 16 as compared to the back panel. In certain embodiment the film is perforated. Perforated film includes tiny holes across the surface of the film to create extra breathability to the finished product.

[0038] It is important for a maternity garment to have excellent stretch and recovery without a breaking of the film in the bonded areas of the garment. The TPU based films offer that property to the finished garment. Breathability is another notable aspect of this film. In certain embodiments, the back-panel film may be perforated with tiny holes to create breathability and flexibility. Combined with the interior and exterior fabrics, the bonded area wicks sweat away from the skin significantly and noticeably faster through air channels created by the perforations. This leaves the wearer cool, dry and comfortable.

[0039] The bond strength of these films after fusing may be 68oz / 2305.5gf, or in the range of 60oz / 2000gf - 70oz / 2500gf, or in the range of 40oz / 1500gf - 80oz / 3000gf, and after washing 25 times the bonding strength may be 60oz / 2034.3gf, or in the range of 60oz / 2000gf - 70oz / 2500gf, or in the range of 40oz / 1500gf - 80oz / 3000gf.

[0040] In preferred embodiments, the front panel 16 and back panel 14 utilize different films in the bonding process. For example, the front panel 16 is bonded using a lighter film, with reinforcement tape film around the top and bottom. And the back panel 14 is bonded using perforated PBT 510 (available from Chargeurs Fashion Technologies).

[0041] SUPPORT BAND FABRIC:

[0042] Various types of fabrics can be used to produce the bonded support band 12. In certain embodiments, the same fabric used in the legging can be used as the fabric in the bonding to create the support band. The same fabric may be lighter or heavier than the fabric used in the legging or apparel.

[0043] In other embodiments, the support band fabric used in bonding provides for cooling properties. Pregnant women get very hot and itchy on their skin. Mild itching is common in pregnancy because of the increased blood supply to the skin. As pregnancy progresses and the baby grows, the skin of the abdomen is stretched and this may also feel itchy.

[0044] Preferably the fabric is bonded on the internal side of the leggings or garment. In some embodiments the fabric on the inside of the legging has minerals permanently blended in the compound which is cool to the touch and transfers heat quickly to the outside. The type of polyester used in this fabric shows higher Q-max value than regular polyester by up to 30%. Q- max value measures energy transfer from body to fabric. This has the effect to quickly transport sweat and moisture off the skin and away from the body, thereby having a cooling effect on the wearer.

[0045] Using the specialized fabric instead of regular PET for the interior body fabric increases the heat transfer exponentially due to channels and a wide surface area which helps with quick absorption of sweat and makes the fabric very fast drying. As a result, the wearer stays cool and dry when wearing the leggings, which is particularly important in a maternity garment but may also be beneficial to any garment in which support is desired.

[0046] In certain embodiments, minerals in the yarn may diffuse light and therefore UV protection is increased by up to 12% compared to regular polyester. In the preferred embodiment, the front panel 16 and back panel 14 utilize a lighter- weight version of the exterior legging fabric

[0047] STITCHING: [0048] In certain embodiments, stitching on the garment 10 may be created using a Merrow ACTIVESEAM. Far stronger than Flatlock, the ACTIVES EAM class of stitches is tougher and may last longer than alternatives. With more than twice the stretch built into the seam, garments can be designed in new ways and will fit the human body better without restricting athletic movement. When compared to a 6-thread Flatlock seam with identical thread, fabric, and SPI, the ACTIVESEAM can be more than 30% stronger and have the ability to stretch (linear travel) 100% further. The ACTIVESEAM is a low-profile seam, soft on the inside and tough on the outside.

[0049] Stitching can also be used in parts of the bonding area to provide reinforcement to the bonded area. Alternatively, the bonded area can be reinforced using seam reinforcement tape on all or part of the borders of the bonding.

[0050] LEGGING FABRIC:

[0051] The fabric used in the leggings 10 (or other article of clothing) may be comprised of a variety of materials. In certain embodiments, the fabric that is used in the leggings 10 is a knit fabric that has elasticity. The mechanical property of the elastic modulus allows the creation of garments that have excellent elasticity combined with good compression. In certain embodiments, this may allow for the leggings to conform to the body to stretch and grow with a pregnant woman’s changing shape. At the same time the elastic modulus holds and supports the body so the wearer feels hugged and cocooned without feeling constricted.

[0052] In certain embodiments, the fabric has excellent recovery, which may make the garment very versatile so that a woman 40 weeks pregnant can wear it and then a woman not pregnant can also wear it as the fabric recovers completely. The recovery properties enable the legging 10 to bend, stretch and adapt to the wearer’s movements with no worry of strain on the garment or fear of it losing its form.

[0053] In certain embodiments, the fabric is free cut so it will not fray. This removes the necessity of putting a seam on the ankle 22 of the legging which is important for maternity leggings as women’s ankles swell when pregnant. Thus, in certain embodiments, the leggings do not constrict the ankle and leave marks on the skin or cause pain to the wearer.

[0054] CLOTHING APPAREL [0055] As indicated above, the support band 12 of the invention has been primarily described with respect to leggings. The support band 12, and the method of manufacturing leggings with the support band, however, can be incorporated into any article of clothing in which support is desired in the back and belly area. Non limiting examples include dresses, leotards, bodysuits, shorts etc.

[0056] With reference now to Figures 10 and 11 there is disclosed the front and back views respectively of one embodiment of a knit dress 30 with a support band 12 incorporated. The position of the front panel 16 and back panel 14 are shown. The support band 12 is bonded as described above with regard to the leggings 10.

[0057] Figs. 12 and 13 show the front and back views respectively of another embodiment of the support band 12 incorporated into a bodysuit and/or top (shown generally as 40). The position of the front panel 16 and back panel 14 are shown. The support band 12 is bonded as described above with regard to the leggings 10.

[0058] Although the embodiments above have been described in considerable detail, numerous variations and modifications will become apparent to those skilled in the art once the above disclosure is fully appreciated. It is intended that the following claims be interpreted to embrace all such variations and modifications.