Garment comprising a layer of winding wire

Abstract

An article of apparel and a method of making an article of apparel, the article of apparel comprising a base layer and a thread layer defined by threads, the thread having a plurality of thread rows intersecting each other at an overlap point between two or more thread rows. In some embodiments, the wire layer may be directly bonded to the substrate layer. In some embodiments, the substrate layer and the thread layer may define a chamber or pocket of the article of apparel.

Description

Technical Field

[0001] The described embodiments generally relate to garments and methods of making garments. In particular, the described embodiments relate to garments comprising layers made by winding one or more continuous threads around anchor points. Background Art

[0002] Garments can be made from a variety of materials using a variety of techniques including weaving and knitting. People are often concerned with the durability, comfort, and / or performance characteristics of an article of clothing. This is true for clothing worn for both athletic and non-athletic activities. Suitable clothing should be durable, comfortable, and provide other beneficial properties to an individual. Therefore, there is a continuing need for innovations in garments and methods of making garments to fit individuals in a range of use situations. Summary of the invention

[0003] The first embodiment (1) of the present application relates to a clothing article comprising: a base layer; and a thread layer defined by threads, the thread layer comprising a plurality of thread rows, the thread rows crossing each other at overlapping points between two or more thread rows, wherein each thread row extends continuously across the thread layer, wherein the thread rows are not woven threads or knitted threads, wherein the thread rows are not embroidery threads sewn to the base layer, and wherein each thread row is directly connected to the surface of the base layer along at least a portion of the length of the thread layer.

[0004] In a second embodiment (2), the line layer according to the first embodiment (1) occupies a surface area defined by line boundaries on the surface of the base layer, and each line row includes a first end arranged at the line boundary and a second end arranged at the line boundary.

[0005] In the third embodiment (3), the first end and the second end of each line array according to the second embodiment (2) are directly connected to the surface of the base layer.

[0006] In a fourth embodiment (4), the line layer according to any one of embodiments (1)-(3) occupies a surface area defined by the line boundary on the surface of the base layer, and the base layer includes a peripheral edge surrounding the line boundary.

[0007] In a fifth embodiment (5), the base layer according to any one of embodiments (1)-(4) comprises a first material piece and a second material piece adjacent to the first material piece, and one or more rows of lines extend across and are directly connected to the first material piece and the second material piece.

[0008] In a sixth embodiment (6), the article of clothing according to the fifth embodiment (5) further comprises a gap between the first material panel and the second material panel, wherein one or more of the rows of threads extend across the gap.

[0009] In a seventh embodiment (7), the base layer according to any one of embodiments (1)-(4) includes a first material panel and a second material panel joined together at a seam, and one or more rows of lines extend across the seam and are directly connected to the first material panel and the second material panel.

[0010] In an eighth embodiment (8), each line array according to any one of embodiments (1)-(7) applies a compressive force on the surface of the base layer, and the compressive force is applied along an axis extending from the first end to the second end of the line array.

[0011] In a ninth embodiment (9), the article of clothing according to any one of embodiments (1)-(8) further includes a second thread layer defined by a second thread, the second thread layer including a plurality of second thread rows, the second thread rows crossing each other at overlapping points between two or more second thread rows, wherein each second thread row extends continuously across the second thread layer, wherein the second thread rows are not woven or knitted threads, wherein the second thread rows are not embroidery threads sewn to the base layer, and wherein each second thread row is directly connected to the surface of the base layer along at least a portion of the length of the second thread row.

[0012] In a tenth embodiment (10), each of the wire arrangements according to any one of embodiments (1) to (8) is directly bonded to the surface of the base layer at the periphery of the wire layer to define a pocket between the wire layer and the base layer.

[0013] In an eleventh embodiment (11), the article of clothing according to the tenth embodiment (10) further comprises an insert disposed within the pocket.

[0014] In a twelfth embodiment (12), the insert according to the eleventh embodiment (11) comprises a shin guard.

[0015] In a thirteenth embodiment (13), the substrate layer according to any one of embodiments (1) to (12) comprises a foam material.

[0016] In a fourteenth embodiment (14), a clothing article according to any one of embodiments (1) to (13) is provided, and the base layer is a first base layer arranged below the line layer, and the clothing article also includes a second base layer arranged above the line layer, and each of the line rows is directly connected to the surface of the second base layer along at least a portion of the length of the line row.

[0017] In a fifteenth embodiment (15), the base layer according to the fourteenth embodiment (14) includes a foam material, and the second base layer according to the fourteenth embodiment (14) includes a foam material.

[0018] The sixteenth embodiment (16) of the present application relates to a clothing article, which includes: a first thread layer, the first thread layer includes a first thread boundary and a first thread, the first thread defining a plurality of first thread rows, each first thread row extending from a first side of the first thread boundary to a second side of the first thread boundary, and crossing each other at overlapping points between two or more of the first thread rows; a second thread layer, the second thread layer being arranged above the first thread layer and including a second thread boundary and a second thread, the second thread defining a plurality of second thread rows, each second thread row extending from a first side of the second thread boundary to a second side of the second thread boundary, and crossing each other at overlapping points between two or more of the second thread rows; and a base layer, which is arranged between the first thread layer and the second thread layer; wherein the first thread layer, the second layer and the base layer are coupled together to form a chamber occupying a volume between the first thread layer and the second thread layer.

[0019] In the seventeenth embodiment (17), a portion of the substrate layer according to the sixteenth embodiment (16) defines a portion of the chamber.

[0020] In the eighteenth embodiment (18), the base layer, the first thread layer and the second thread layer according to the sixteenth embodiment (16) or the seventeenth embodiment (17) are attached at a seam located at the edge of the cavity.

[0021] In a nineteenth embodiment (19), the plurality of first lines according to any one of embodiments (16) to (18) are directly attached to the surface of the base layer.

[0022] In a twentieth embodiment (20), a clothing article according to any one of embodiments (16)-(19) is provided, and the base layer is a first base layer, and the clothing article also includes a second base layer arranged between the first base layer and the second line layer, and a portion of the second base layer defines a portion of the chamber.

[0023] In the twenty-first embodiment (21), the first base layer, the second base layer, the first thread layer and the second thread layer according to the twentieth embodiment (20) are attached at a seam located at the edge of the cavity.

[0024] In the twenty-second embodiment (22), the plurality of second line arrays according to the twentieth embodiment (20) or the twenty-first embodiment (21) are directly attached to the surface of the second substrate layer.

[0025] In a twenty-third embodiment (23), the chamber according to any one of embodiments (16)-(22) is filled with insulating material.

[0026] In a twenty-fourth embodiment (24), the chamber according to any one of embodiments (16)-(22) is filled with an insert.

[0027] In a twentieth embodiment (25), the chamber according to any one of embodiments (16)-(24) is a tubular chamber.

[0028] In the twenty-sixth embodiment (26), the clothing article according to the twenty-fifth embodiment (25) includes trouser legs, arm sleeves, knee sleeves, belts, elbow sleeves, ankle sleeves, wrist sleeves, collars, two-piece shirts or fully formed tubular fabrics.

[0029] The twenty-seventh embodiment (27) of the present application relates to a method for manufacturing a clothing article, the method comprising: winding a continuous thread around a plurality of anchor points on a support plate to form a thread layer, the continuous thread comprising a plurality of thread rows, each thread row extending between two corresponding anchor points; and injecting foam around at least a portion of the thread layer. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1A and 1B An article of clothing according to some embodiments is shown.

[0031] Figure 2A-2C A line layer is shown according to some embodiments.

[0032] Figure 3 is an exemplary flow chart of a method according to some embodiments.

[0033] Figure 4 A machine for producing a production line layer is shown according to some embodiments.

[0034] Figure 5 A heat press is shown according to some embodiments.

[0035] Figure 6 An article of apparel including multiple thread layers and multiple material panels is shown according to some embodiments.

[0036] Figure 7 An article of apparel including multiple thread layers and multiple material panels is shown according to some embodiments.

[0037] Figure 8 An article of apparel including multiple thread layers is shown according to some embodiments.

[0038] Fig. 9 An article of apparel including multiple thread layers is shown according to some embodiments.

[0039] Fig.10 An article of apparel including a thread layer is shown according to some embodiments.

[0040] Fig.11 An article of apparel including a thread layer defining a pocket is shown according to some embodiments.

[0041] Fig.12 A layered structure for an article of clothing is shown according to some embodiments.

[0042] Fig.13 A cross-sectional view of a layered structure for an article of clothing is shown according to some embodiments.

[0043] Fig.14A A formed material including a line pattern is shown according to some embodiments.

[0044] Fig. 14B yes Fig.14A Section view along line B-B'.

[0045] Fig.15 A molded assembly according to some embodiments is shown.

[0046] Fig.16 A line layer including a molded part is shown according to some embodiments.

[0047] Fig.17 A molded assembly according to some embodiments is shown.

[0048] Fig.18 A line layer including a molded part is shown according to some embodiments.

[0049] Fig.19 A layered structure for an article of clothing is shown according to some embodiments.

[0050] Fig. 20A A thread layer is shown on a stretched base layer according to some embodiments.

[0051] Fig. 20B Shown in a relaxed state Fig. 20A The line layer and the base layer.

[0052] Fig.21A Shows the line A-A' Fig. 20A sectional view of .

[0053] Fig. 21B Shows the line B-B' Fig. 20B sectional view of .

[0054] Fig.22A A thread layer is shown on a stretched base layer according to some embodiments.

[0055] Fig. 22B Shown in a relaxed state Fig.22A The line layer and the base layer.

[0056] Fig.23A Shows the line A-A' Fig.22A sectional view of .

[0057] Fig. 23B Shows the line B-B' Fig. 22B sectional view of . DETAILED DESCRIPTION

[0058] The present invention will now be described in detail with reference to the embodiments of the invention as illustrated in the accompanying drawings. Reference to "some embodiments", "one (one) embodiment", "embodiment", "exemplary embodiment", etc., means that the described embodiments may include specific features, structures or characteristics, but each embodiment may not necessarily include the specific features, structures or characteristics. In addition, such phrases do not necessarily refer to the same embodiment. In addition, when a specific feature, structure or characteristic is described in connection with an embodiment, it is considered to be within the knowledge of those skilled in the art to be associated with other embodiments to affect such features, structures or characteristics, whether or not explicitly described.

[0059] As used herein, references to "first," "second," "third," "fourth," etc. are not intended to indicate an order, or that earlier-numbered features are required for later-numbered features, unless otherwise specified. Furthermore, the use of "first," "second," "third," "fourth," etc. does not necessarily mean that the "first," "second," "third," "fourth," etc. features have different properties or values, unless otherwise specified.

[0060] As used herein, "thread" means a material whose length is substantially greater than its width. "Thread" can be filaments, fibers, yarns, cables, ropes, fiber bundles, tapes, ribbons, monofilaments, braids, strings, twines, and other forms of materials that can be wound and laid in a thread pattern as described herein.

[0061] Articles of clothing have many purposes. Among them, clothing can provide a unique aesthetic appearance, provide warmth or cooling properties, provide support for parts of an individual's body, and provide other performance properties, such as breathability, moisture wicking properties, compression properties. Each of these purposes, alone or in combination, provides a comfortable garment suitable for use in a variety of situations (e.g., exercise and daily activities). The characteristics of articles of clothing (e.g., the materials and components used to make the garment, and the manner in which these materials / components are made) can be varied to produce desired properties, such as durability, stiffness, weight, viscosity, texture, tactile feel, stickiness, and / or breathability.

[0062] The clothing articles described herein can be made by winding one or more continuous threads around anchor points to produce a desired thread layer or thread pattern, or can include a layer made by winding one or more continuous threads around anchor points to produce a desired thread layer or thread pattern. Winding a continuous thread around an anchor point includes: wrapping a continuous thread around a first anchor point, extending that continuous thread to a second anchor point, wrapping the continuous thread around the second anchor point, and so on. The number and position of the anchor points can be used to control the characteristics of the thread layer or thread pattern, and thus the characteristics of the clothing. Moreover, the number of times the continuous thread is wrapped from the anchor point to the anchor point can be used to control the characteristics of the thread layer or thread pattern, and thus the characteristics of the clothing.

[0063] The continuous lines of a thread layer or a thread pattern can be connected within the thread layer or the thread pattern. The connection of the continuous lines of a thread layer or a thread pattern can consolidate the layer or pattern and fix the thread line in the layer or pattern. In some embodiments, the continuous lines of the thread layer or the thread pattern can be used to control the characteristics of the thread layer or the thread pattern. In some embodiments, the continuous line can be connected to itself within the thread layer or the thread pattern. In some embodiments, the continuous line can be connected to itself at the overlapping point between different lines of the continuous line (that is, at the line row intersection). In some embodiments, different continuous lines of a thread layer or a thread pattern can be connected together. In some embodiments, different continuous lines can be connected to each other at the overlapping point between different continuous lines (that is, at the intersection between different continuous lines). Since the continuous line can be wound around the anchor point under tension, the connection of the continuous line can fix the continuous line under tension.

[0064] In some embodiments, a plurality of different continuous threads may be wound around an anchor point to form a plurality of thread layers of a thread pattern. In some embodiments, the different continuous threads may be wound in the same layout (i.e., around the same anchor point and along the same path). In some embodiments, the different continuous threads may be wound in different layouts (i.e., around one or more different anchor points and / or along different paths between one or more anchor points). In some embodiments, the different continuous threads may define different winding layers for an article of clothing or a portion thereof. In such embodiments, the different layers may provide different properties for the thread pattern and, therefore, provide different properties on the article of clothing.

[0065] The continuous thread can be wrapped around the anchor points in various arrangements to provide varying degrees of properties to the article of clothing. The number of anchor points, the location of the anchor points, the manner in which the continuous thread is wrapped around the anchor points, and / or the material of the thread wrapped around the anchor points can be used to produce clothing with desired properties, such as strength, stiffness, breathability, comfort, wear resistance, fit, texture, tactility, viscosity, and durability. The properties of the article of clothing can be altered by changing the arrangement of the anchor points and / or the manner in which the continuous thread is wrapped around the anchor points. The properties can also be altered by changing the material of the continuous thread.

[0066] In some embodiments, different thread layers or thread patterns may provide a first degree of property in one area of ​​an article of clothing and a second degree of property in a second area of ​​the article of clothing. In some embodiments, different thread layers or thread patterns may provide targeted properties for different areas of an article of clothing. In some embodiments, different thread layers or thread patterns may include rows of threads oriented in different directions to provide targeted properties to different areas of an article of clothing.

[0067] In some embodiments, winding one or more continuous threads for an article of clothing may include winding one or more threads so that the row of threads is positioned tangential to an area or zone on the garment. Threading the row of threads tangentially to the area or zone may define a boundary separating the area or zone from an adjacent area or zone.

[0068] In some embodiments, the line layer or line pattern may be attached to the surface of one or more base layers. In some embodiments, the line layer or line pattern may be directly attached to the surface of one or more base layers. In such an embodiment, the line row of the line layer or line pattern may be directly attached to the surface of the base layer. Directly attached to one or more base layers can give unique characteristics on the base layer, and therefore give the clothing article unique characteristics. For example, the direct attachment of the line layer or line pattern can give the clothing article all or part of the desired mechanical or aesthetic properties. In some embodiments, once the line pattern or line layer is removed from the anchor point, the direct attachment of the line layer or line pattern wound under tension can apply a compressive force on the surface of the base layer. The compressive force can give the desired mechanical or aesthetic properties. For example, the compressive force can give the clothing article a desired shape.

[0069] As used herein, two components (e.g., wire and fabric) described as "connected" to each other refer to that the first component and the second component are connected to each other by direct contact and / or connection between the two components, or via an adhesive or a bonding layer. Two components (e.g., wire and fabric) described as "directly connected" to each other mean that the two components are directly connected to each other via the material of the first component, the material of the second component, or both. For example, in the case where the polymer material of the wire is directly connected to the base layer using heat and / or pressure, the wire is directly connected to the base layer via the polymer material of the wire. In such an embodiment, the polymer material can be heat-melted to the base layer.

[0070] In some embodiments, a thread layer or thread pattern as described herein can form a pocket or chamber on an article of clothing. In such embodiments, the pocket or chamber can be filled with an insert or additional material, such as an insulating material.

[0071] In some embodiments, a garment article as described herein may include one or more parts molded onto a line layer or line pattern. In some embodiments, the molded parts may enclose all or part of a line layer or line pattern. In such embodiments, all or part of a line layer or line pattern may be embedded in the molded parts. In some embodiments, the molded parts may include a concave or convex surface that provides a corresponding concave or convex shape for the line layer or line pattern. In some embodiments, the concave or convex shape may help shape the garment article to fit the wearer's body.

[0072] FIG. 1 illustrates an article of clothing 100 according to some embodiments. Apparel 100 may include one or more base layers 110 and one or more thread layers, such as thread layers 120, 130, and 140. Thread layers 120, 130, 140 may be any of the exemplary thread layers described herein, such as thread layers 200, 220, and 240. In some embodiments, a thread layer, such as thread layer 120, may include multiple thread layers (e.g., thread layer 200 and thread layer 220). In such embodiments, the thread layer may be referred to as a thread pattern including multiple thread layers.

[0073] Each thread layer 120, 130, 140 (or thread pattern) can be defined by one or more threads, the one or more threads comprising a plurality of thread rows, and the plurality of thread rows cross each other at the overlapping points between two or more thread rows. Each thread of the thread layer extends continuously across the thread layer (or thread pattern). The thread rows extending continuously across the thread layer (or thread pattern) are not woven or knitted threads. Similarly, the thread rows extending continuously across the thread layer (or thread pattern) are not embroidery threads sewn to the base layer 110. Instead, as described herein, the thread rows are formed by winding the thread around the anchor point, and thus the thread layer is formed.

[0074] In some embodiments, the row of threads that extend continuously across the thread layer (or thread pattern) may extend continuously without forming a knitted structure or a woven structure between the opposite ends of the thread row. In some embodiments, the row of threads that extend continuously across the thread layer (or thread pattern) may extend continuously without forming a knitted structure or a woven structure, measured between the opposite ends of the thread row, along a distance greater than or equal to at least 90% of the length of the thread row. In some embodiments, the row of threads that extend continuously across the thread layer (or thread pattern) may extend continuously without forming an embroidery structure between the opposite ends of the thread row. In some embodiments, the row of threads that extend continuously across the thread layer (or thread pattern) may extend continuously without forming an embroidery structure, measured between the opposite ends of the thread row, along a distance greater than or equal to at least 90% of the length of the thread row.

[0075] In some embodiments, the rows of thread layers 120, 130, 140 may be attached to the surface 112 of the base layer 110 along at least a portion of the length of the row of thread layers. In some embodiments, the rows of thread layers 120, 130, 140 may be directly attached to the surface 112 of the base layer 110 along at least a portion of the length of the row of thread layers. In some embodiments, the surface 112 may be the outer surface of the base layer 110, facing away from the wearer's body during use. In some embodiments, the surface 112 may be the inner surface of the base layer 110, facing the wearer's body during use. In some embodiments, the clothing article 100 may include one or more thread layers attached (or directly attached) to the outer surface of the base layer 110 and one or more thread layers attached (or directly attached) to the inner surface of the base layer 110.

[0076] Thread layers 120, 130, 140 may be attached to different areas on surface 112 of base layer 110. Apparel 100 may include any number of thread layers (or thread patterns) attached to different areas of apparel 100. For example, Figure 6 An article of clothing 600 is illustrated that includes a first thread layer 620 attached to a first area on the article of clothing 600, a second thread layer 630 attached to a second area on the article of clothing 600, a third thread layer 640 attached to a third area on the article of clothing 600, and a fourth thread layer 650 attached to a fourth area on the article of clothing 600. In such an embodiment, thread boundaries 250 of each thread layer may define a corresponding area on the garment 100. In some embodiments, the thread layers (or thread patterns) may overlap in overlapping areas, e.g. Figure 6 Overlap area 602 is shown. Figure 7-9 Another article of clothing including multiple thread layers according to some embodiments is shown. Garment 100 may include Figure 6-9 Any line layer described in .

[0077] In some embodiments, thread layers 120, 130, 140 (or thread patterns including thread layers 120, 130, 140) may be wrapped completely around a portion of article of apparel 100 to maintain the shape of apparel 100 during use, as described herein with reference to Fig.10 As described.

[0078] In some embodiments, the line layers 120, 130, 140 (or the line patterns including the line layers 120, 130, 140) may include the Figure 15-18 The molded part 1530 or 1730.

[0079] The thread layers (or thread patterns) applied to different areas of the base layer 110 can impart desired properties to the corresponding areas. Exemplary properties include, but are not limited to, strength, support, breathability, comfort (stretchability), aesthetics, wear resistance, water resistance, texture, stickiness, and touch. In some embodiments, the material of the continuous thread used to wrap the thread layer can impart the desired properties. For example, a thread layer wrapped with hydrophobic thread can impart water resistance to specific areas on a clothing article. In some embodiments, the tension when the continuous thread is wrapped can impart the desired properties. For example, a thread wrapped with high tension can apply a high degree of compression to a specific area on a clothing article.

[0080] Each line layer 120, 130, 140 (or line pattern) can occupy a surface area defined by a line boundary 250 (e.g., boundary 250a, 250b, or 250c) on the surface 112 of the substrate layer 110. Each line row within a line layer (or line pattern) can extend continuously across the layer and include a first end disposed at the line boundary and a second end disposed at the line boundary. In some embodiments, the first end and the second end of each line row can be connected to the surface 112 of the substrate layer 110. In some embodiments, the first end and the second end of each line row can be directly connected to the surface 112 of the substrate layer 110.

[0081] In some embodiments, the thread layer or thread pattern may be visibly exposed on surface 112 of garment 100. In some embodiments, no laminate layer or supporting textile layer is disposed above the thread layer or thread pattern on surface 112 of article of apparel 100. In some embodiments, areas on article of apparel 100 that include the thread layer or thread pattern may be free of a laminate layer.

[0082] In some embodiments, the first and second ends of each row of wires that are attached or directly attached to surface 112 of base layer 110 can define the perimeter of a pocket (eg, pocket 1130 ) on garment 100 .

[0083] In some embodiments, the surface area of ​​the first thread layer (or thread pattern) and the surface area of ​​the second thread layer (or thread pattern) may partially overlap on the surface 112 of the base layer 110 in the overlapping area. In such embodiments, the first thread layer (or thread pattern) and the second thread layer (or thread pattern) may partially overlap on the garment 100. In some embodiments, the first thread layer (or thread pattern) and the second thread layer (or thread pattern) may be connected to each other at the overlapping area between the first thread layer (or thread pattern) and the second thread layer (or thread pattern). In some embodiments, the first thread layer (or thread pattern) and the second thread layer (or thread pattern) may be directly connected to each other at the overlapping area between the first thread layer (or thread pattern) and the second thread layer (or thread pattern). Figure 6 An overlapping area 602 of line layers (or line patterns) is shown in accordance with some embodiments.

[0084] In some embodiments, one or more of the line layers 120, 130, 140 (or line patterns) may occupy a surface area defined by the same line boundary as the peripheral edge 114 of the base layer 110. In such embodiments, the one or more line layers 120, 130, 140 (or line patterns) may include a surface area that occupies the entire base layer 110. In some embodiments, one or more of the line layers 120, 130, 140 (or line patterns) may occupy a surface area defined by a line boundary that is at least partially surrounded by the peripheral edge 114 of the base layer 110. In such embodiments, the peripheral edge 114 may define a surface area that at least partially includes the surface area defined by the line boundary. In some embodiments, one or more of the line layers 120, 130, 140 (or line patterns) may occupy a surface area defined by a line boundary that is surrounded by the peripheral edge 114 of the base layer 110. In such embodiments, the peripheral edge 114 may define a surface area that completely includes the surface area defined by the line boundary.

[0085] In some embodiments, the rows of threads of the thread layer (or thread pattern) can exert a compressive force on the surface 112 of the base layer 110, the compressive force being exerted along an axis extending from a first end of the row of threads to a second end. In such embodiments, the compressive force exerted via each row of threads can be configured to impart a desired shape to the article of clothing, as described herein with reference to, for example, Figures 14A-14B as described.

[0086] In some embodiments, the base layer 110 may include a single material panel. In some embodiments, the base layer 110 may include multiple material panels (e.g., panel 116). In such embodiments, the base layer 110 may include a first material panel and a second material panel adjacent to the first material panel. The material panels disposed adjacent to each other may be disposed in a side-by-side relationship, wherein the peripheral edge of the first panel is adjacent to the peripheral edge of the second panel. In some embodiments, the first material panel and the second material panel may be joined at a seam 150, as described herein. In some embodiments, the first material panel and the second material panel may not be joined at a seam, such that a gap 160 exists between adjacent material panels. In either case, one or more rows of lines of the line layers 120, 130, 140 (or line patterns) may extend across and be connected to both the first material panel and the second material panel. In some embodiments, one or more rows of lines of the line layers 120, 130, 140 (or line patterns) may extend across and be directly connected to both the first material panel and the second material panel. Figure 6-9 A layer of threads is shown extending across and connected to multiple panels of material in accordance with some embodiments.

[0087] As used herein, a "seam" is any attachment area between two parts of a single material panel or two different material panels. Exemplary attachment areas include, but are not limited to, stitched attachment areas, adhesive attachment areas, heat-bonded attachment areas, and interlocking attachments. Exemplary seam structures include, but are not limited to, self-attached seams, hems, butt stich, Merrow stitch (tight overlock stitch), gathered edge, surge stitch, overlock stitch, and interlocking seam constructions. In some embodiments, a "seam" may include an area where two parts of a single material panel or two different material panels overlap. For example, a seam may be an area where a first material panel overlaps and joins a second material panel.

[0088] In some embodiments, the base layer 110 may include three or more adjacent material panels. For example, the base layer 110 may include three, four, five, six, seven, eight, nine, or ten material panels.

[0089] In some embodiments, the base layer 110 or the material pieces defining the base layer 110 may include a fabric material. In some embodiments, the fabric material may be a nonwoven, woven, or knitted fabric material. In some embodiments, the base layer 110 or the material pieces defining the base layer may include a foam material. Exemplary fabric materials for the base layer 110 include, but are not limited to, thermoplastic polyurethane (TPU), polyester, polyamide, polyethylene (PE), PE foam, polyurethane (PU foam), nylon, ultra high molecular weight polyethylene (e.g. (a type of ultra-high molecular weight polyethylene), carbon fiber, (a type of para-aramid), synthetic spider silk, cotton, wool, natural or artificial silk, polyethersulfone (PES), (polyether-polyurea copolymer) or a blend of two or more of these materials. In some embodiments, the base layer 110 or the material pieces defining the base layer 110 may include a polymer sheet or film, such as a TPU sheet or film. In some embodiments, the base layer 110 or the material pieces defining the base layer 110 may include a mesh material.

[0090] In some embodiments, the base layer 110 or the material piece defining the base layer 110 may include a first base layer 110a disposed below the line layer or line pattern and a second base layer 110b disposed above the line layer. In such an embodiment, the line layer or line pattern may be sandwiched between the first base layer 110a and the second base layer 110b, such as Fig.19 As shown, also in such embodiments, the line array of the line layer or line pattern can be (i) attached to the surface 112 of the first substrate layer along at least a portion of the length of the line array, (ii) attached to the surface 112 of the second substrate layer along at least a portion of the length of the line array, or (iii) both. In some embodiments, the line array can be directly attached to the surface 112 of the first substrate layer 110a, directly attached to the surface 112 of the second substrate layer 110b, or both.

[0091] In some embodiments, thread layers 120 , 130 , 140 (or thread patterns) may define a portion of a layered structure that forms a chamber on article of apparel 100 , for example, layered structure 1200 .

[0092] The wire layers as described herein (e.g., wire layers 200, 220, and 240) may each include a wire boundary 250 defined by the space in which the wire rows of the wire layer are located. The wire boundary 250 of the wire layer is: the space in which the wire rows of the wire layer are located after the wire layer is removed (e.g., cut) from the anchor point used to wind the wire layer. Multiple wire rows within the wire pattern may include a first end located on a first side of the wire boundary 250 and a second end located on a second side of the wire boundary 250. For example, the wire row 204 of the wire layer 200 may include a first end 210 located on a first side of the wire boundary 250 and a second end 212 located on a second side of the wire boundary 250.

[0093] Figure 2A-2C Line boundaries 250a-c are shown for line layers 200, 220, and 240. For a line pattern including multiple line layers, the line pattern may include a line pattern boundary 250 defined by the space occupied by the combination of the individual line layers. For example, a line pattern including line layers 200, 220, and 240 includes a line pattern boundary defined by the space occupied by the combination of boundary 250a and boundary 250c. Boundary 250b is completely contained within boundary 250a.

[0094] As used herein, the side of a peripheral edge or border refers to the top side, bottom side, right side and left side of the shape defined by the edge or border. The top side, bottom side, right side and left side of the shape are located at the top, bottom, right part and left part of the geometric center of the shape. Therefore, the peripheral edge or border will have a top side defined by the part of the edge located above the geometric center, a bottom side defined by the part of the edge located below the geometric center, a right side defined by the part of the edge located on the right side of the geometric center, and a left side defined by the part of the edge located on the left side of the geometric center. The top side and the bottom side do not overlap. Similarly, the left side and the right side do not overlap. The top side and the left side overlap at the part of the edge or border located at the upper left of the geometric center. The top and the right side overlap at the part of the edge or border located at the upper right of the geometric center. The bottom and the left side overlap at the part of the edge or border located at the lower left of the geometric center. The bottom and the right side overlap at the part of the edge or border located at the lower right of the geometric center. In order to determine the shape defined by the peripheral edge or border, the material with the edge or border is laid into a flat layout, and any part of the material does not overlap with itself.

[0095] As used herein, a first side of a peripheral edge or border can be the top side, bottom side, right side, or left side of the edge or border, and a second side of the peripheral edge can be the top side, bottom side, right side, or left side of the edge or border, provided that the first side and the second side are not the same side. Similarly, a third side of a peripheral edge or border can be the top side, bottom side, right side, or left side of the edge or border, and a fourth side of the edge or border can be the top side, bottom side, right side, or left side of the edge or border, provided that the third side and the fourth side are not the same and are not the same as the first side or the second side.

[0096] In some embodiments, one or more wire layers (e.g., wire layers 120, 130, 140) may include wires that define: (i) a plurality of wire rows that each extend from a first side of a wire boundary of a material to a second side of the wire boundary and cross each other at overlapping points between two or more wire rows, and (ii) a plurality of wire rows that each extend from a third side of the wire boundary to a fourth side of the wire boundary and cross each other at overlapping points between two or more wire rows. The wire rows extending from the first side to the second side may extend continuously from the first side to the second side, and the wire rows extending from the third side to the fourth side may extend continuously from the third side to the fourth side.

[0097] Wire layer 200 includes continuous wire 202 wrapped around anchor points 290. Wire layer 220 includes continuous wire 222 wrapped around anchor points 290. Wire layer 240 includes continuous wire 242 wrapped around anchor points 290. In some embodiments, anchor points 290 may be different sets of anchor points around which different wire layers are wrapped. In some embodiments, multiple wire layers may be wrapped around the same set of anchor points 290. In such embodiments, the separate wire layers may be wrapped over each other, with one wire layer arranged over one or more other wire layers.

[0098] As used herein, "anchor point" means such a position: a group of lines or lines is fixedly attached to it. Lines or lines can be wound around, wrapped, linked or otherwise attached at the anchor point. In some embodiments, the anchor point can be a position on a clothing article. For example, the anchor point can be a hole or opening left by a structure (e.g., a pin, a protrusion or a bump) for winding a continuous line of a line layer or a line pattern. In some embodiments, the line layer or line pattern for a clothing article may not include any anchor point position, because all anchor point positions present during the winding of the line layer or line pattern have been removed (e.g., cut off). The anchor point can also be a structure (e.g., a pin, a protrusion or a bump) for winding a continuous line of a line layer or a line pattern. And the anchor point structure may or may not form a part of the line layer or line pattern for a clothing article.

[0099] The continuous line wrapped around or wound around the anchor point does not need to be wrapped around or wound around the anchor point completely (that is, 360 degrees). The continuous line wrapped around or wound around the anchor point can only be wrapped around or wound around a portion of the anchor point. For example, the continuous line wrapped around or wound around the anchor point can be wrapped around 25% (90 degrees) of the circumference, 50% (180 degrees) of the circumference of the anchor point, 75% (270 degrees) of the circumference of the pin, or 100% (360 degrees) of the circumference of the anchor point. In some embodiments, the continuous line can be wrapped around or wound around the circumference of the anchor point more than once before passing to the next anchor point. For example, the continuous line can be wrapped around or wound around the circumference of the anchor point once and a half (540 degrees) or twice (720 degrees) before passing to the next anchor point.

[0100] The continuous wire 202 may be wound around a plurality of anchor points 290 and include a plurality of wire rows 204. Each row 204 extends between two respective anchor points 290.

[0101] The continuous line 202 can be wound around a plurality of anchor points 290 under tension, so that the individual line row 204 is under tension when it is wound around the anchor point 290. In some embodiments, the tension of the line row 204 winding can be in the range of 0 centi-newton (cN) to 25cN, including sub-ranges. For example, in some embodiments, the tension of the line row 204 winding can be in the range of 0.01cN to 25cN, 0.1cN to 25cN, 1cN to 25cN, 5cN to 25cN, 10cN to 25cN or 15cN to 25cN. In some embodiments, the tension of the line row 204 winding can be in the range of 2cN to 10cN. In some embodiments, the tension of the line row 204 winding can be in the range of 2cN to 6cN. In such embodiments, as described herein, tension can produce a compressive force applied along the line row. In some embodiments, the compressive force can be in the range of 0cN to 25cN, including sub-ranges. For example, in some embodiments, the compressive force can be in the range of 0.01 cN to 25 cN, 0.1 cN to 25 cN, 1 cN to 25 cN, 5 cN to 25 cN, 10 cN to 25 cN, or 15 cN to 25 cN. In some embodiments, the compressive force can be in the range of 2 cN to 10 cN. In some embodiments, the compressive force can be in the range of 2 cN to 6 cN.

[0102] The wire array 204 directly attached to the surface 112 of the base layer 110 may exert a compressive force on the surface 112 along an axis extending from the first end 210 to the second end 212 of the wire array 204. The compressive force may be the result of the wire array 204 being wrapped around the anchor point under tension and being directly attached to the surface while still under tension.

[0103] In some embodiments, different rows of wires 204 may be wound around the anchor point 290 at different tensions to impart desired properties to the wire layer 200. In some embodiments, a first group of rows of wires 204 may be wound at a first tension in any of the above-mentioned centi-newton ranges, and a second group of rows of wires 204 may be wound at a second tension in any of the above-mentioned centi-newton ranges, wherein the first tension is greater than or less than the second tension. In some embodiments, the first tension may be at least 0.5 cN greater or less than the second tension. In some embodiments, the first tension may be at least 1 cN greater or less than the second tension.

[0104] By winding the continuous line 202 under tension, the line layer 200 can be connected, while the line row 204 is under tension, so that the line row 204 is under tension in the connected line layer or line pattern. The line row 204 is connected when the line row 204 is under tension, and the line row 204 is fixed in the layer or pattern under tension. Fixing the line row 204 under tension will cause the line row 204 to want to shrink-when removing (e.g., cutting) the line layer 200 from the anchor point 290 used to wind the line layer 200. In the case where a part of the line row 204 is not connected in a completely fixed position, the line row 204 can shrink when removed from the anchor point. In such an embodiment, the part of the line row 204 that is fixed during the connection process will be under tension, while the other parts will shrink freely. In such an embodiment, the part of the line row 204 that is fixed during the connection process can be under tension in the line layer or line pattern on the clothing article, while the other parts will not be under tension in the layer or pattern.

[0105] In embodiments where different rows of threads 204 are wound at different tensions, different rows of threads 204 of thread layer 200 will be at different tension values ​​in thread layer 200. The tension of thread rows 204 can be used to control the characteristics of thread layer 200, and thus the characteristics of the article of clothing including thread layer 200.

[0106] The number of thread rows 204 for the thread layer 200 fixed to the anchor point 290 is defined by the "thread line communication number" of the anchor point 290. As used herein, the "thread line communication number" means the number of thread rows extending from one anchor point to different anchor points. For the purpose of calculating the thread row communication number of an anchor point, two thread rows extending between the same two anchor points (i.e., covered thread rows) are counted as "1" only. For example, a thread row communication number of 5 means that an anchor point has 5 thread rows extending from the anchor point, and each of the 5 thread rows leads to another different anchor point. As another example, a thread row communication number of 6 means that an anchor point has 6 thread rows extending from the anchor point, and each of the 6 thread rows leads to another different anchor point.

[0107] Similarly, the number of lines fixed to an anchor point 290 of a line pattern comprising multiple line layers is defined by the "line line communication number" of the anchor point 290 of the line pattern. For a line pattern, the "line line communication number" of an anchor point 290 is the total number of line lines of multiple layers extending from one anchor point to a different anchor point.

[0108] For a line layer or line pattern, the line row communication number of an anchor point 290 can be "X" or more. In some embodiments, the line row communication number of two or more separate anchor points 290 can be "X" or more. In some embodiments, the line row communication number of all anchor points 290 of a line layer or line pattern can be "X" or more. "X" can be, for example, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, or 50, in a range with any two of these values ​​as endpoints. For example, in some embodiments, "X" can be in the range of 2 to 50, 3 to 50, 4 to 50, 5 to 50, 6 to 50, 7 to 50, 8 to 50, 9 to 50, 10 to 50, 15 to 50, 20 to 50, 25 to 50, 30 to 50, 35 to 50, 40 to 50, or 45 to 50. In some embodiments, "X" can be greater than 50. In some embodiments, "X" may be in the range of 2-100, 10-100, or 20-100.

[0109] A line layer, such as line layer 200, may include any suitable number of lines. In some embodiments, the line layer may include 10 or more lines. In some embodiments, the line layer may include 20 or more lines. In some embodiments, the line layer may include 50 or more lines. In some embodiments, the line layer may include 100 or more lines. In some embodiments, the line layer may include 200 or more lines. In some embodiments, the line layer may include 300 or more lines. In some embodiments, the line layer may include 500 or more lines. In some embodiments, the line layer may include a number of lines in the range of 10 to 300. For example, the line layer may include 10 to 300, 50 to 300, 100 to 300, or 150 to 300 lines. In some embodiments, the line layer may include 10 to 500 lines. In some embodiments, the line layer may include 100 to 500 lines. In some embodiments, the line layer may include 100 to 1000 lines.

[0110] In some embodiments, the rows of wires 204 may be joined at the anchor points 290. In such embodiments, the rows of wires 204 may be joined at the anchor points 290 via adhesives, tie layers, thermal (conductive or convective) heating (e.g., in a heat press or oven), IR (infrared) heating, laser heating, microwave heating, steam, mechanical fasteners (e.g., clips), hook and loop fasteners, needle punching, hydroentanglement, ultrasonic / vibration entanglement, felting, knotting, chemical bonding using a catalyst of a biomaterial, adhesive spraying (e.g., CNC adhesive spray deposition), or by pushing one row of wires through the other rows of wires.

[0111] In some embodiments, the rows of wires 204 may be directly joined together at the anchor points 290. In some embodiments, the rows of wires 204 may be directly joined together at the anchor points 290 via the polymer material of the continuous wire 202. For example, heat and / or pressure may be applied to directly join the rows of wires 204 at the anchor points 290. In embodiments that utilize heat and / or pressure to directly join the polymer material of the rows of wires 204, the rows of wires 204 may be heat-fused together at one or more anchor points 290. In embodiments that include directly joining the rows of wires 204 at the anchor points 290, the rows of wires 304 may be directly joined at the anchor points 290 without the use of an adhesive or a joining layer.

[0112] In some embodiments, the row of lines 204 can be linked together via a tie layer. In some embodiments, the row of lines 204 can be linked together at anchor points 290 via a tie layer. In this embodiment, the tie layer can be, for example, a laminate layer, an adhesive layer, a stitching layer, a solidified layer, a screen printing layer, or a blown fiber layer. In some embodiments, the blown fiber layer can include polymer fibers that can link the row of lines 204.

[0113] In some embodiments, the line array 204 can be bonded together without using a bonding layer. For example, in some embodiments, the line array 204 can be directly bonded together via, for example but not limited to, direct local bonding of the material of the line array 204, needle punching, hydraulic entanglement, and ultrasonic / vibration entanglement.

[0114] In some embodiments, the rows of wires 204 may be joined at points where two or more rows of wires 204 overlap in the layer of wires 200 (i.e., intersections 206). The rows of wires 204 may be joined at intersections 206 via adhesive, a tie layer, thermal (conductive or convective) heating (e.g., in a heat press or oven), IR (infrared) heating, laser heating, microwave heating, steam, mechanical fasteners (e.g., clips), hook and loop fasteners, needle punching, hydroentanglement, ultrasonic / vibration entanglement, felting, knotting, chemical bonding using a catalyst of a biomaterial, adhesive spraying (e.g., CNC adhesive spray deposition), or by pushing one row of wires through other rows of wires. The intersections 206 of the rows of wires may be referred to as "overlap points" or "overlapping points."

[0115] In some embodiments, the rows of wires 204 may be directly joined together at the intersections 206. In some embodiments, the rows of wires 204 may be directly joined together at the intersections 206 via the polymeric material of the continuous wires 202. In embodiments that include directly joining the rows of wires 204 at the intersections 206, the rows of wires 204 may be joined at the intersections 206 without the use of an adhesive or a joining layer. For example, heat and / or pressure may be applied to the wire layer 200 to directly join the rows of wires 204 at the intersections 306. In embodiments that utilize heat and / or pressure to directly bond the polymeric material of the rows of wires 204, the rows of wires 204 may be heat-fused together at one or more intersections 206.

[0116] In some embodiments, the tie layer may tie the rows of threads 204 together at a plurality of intersections 306 within the thread layer 200. In such embodiments, the tie layer may be, for example, a laminate layer, an adhesive layer, a stitching layer, a curing layer, a screen-printed layer, or a blown fiber layer containing polymer fibers that may tie the rows of threads 204.

[0117] In some embodiments, the continuous line 202 may include an overlaying thread line 204. As used herein, an "overlaying thread line" means two or more thread lines that follow the same path between two separate anchor points. Overlaying thread lines do not need to directly overlay each other. As long as they extend between the same two anchor points, two or more thread lines are considered to be overlaying.

[0118] The line rows 204 of the line layer 200 may not be woven or knitted together. In such an embodiment, the line rows 204 may be referred to as "non-woven" and "non-knitted" line rows. The line rows 204 of the line layer 200 may not be embroidery lines sewn to the base layer. In such an embodiment, the line rows 204 may be referred to as "non-embroidery" line rows.

[0119] In some embodiments, the continuous line 202 can be a polymer line. As used herein, "polymer line" refers to a line at least partially composed of a polymer material. In some embodiments, the polymer line can be completely composed of one or more polymer materials. In some embodiments, the polymer line can include a polymer material coated around a core (which can be composed of a polymer material or not). In such embodiments, the core can be encapsulated by a coating material. In some embodiments, the polymer line can include a non-polymer core coated, covered or encapsulated with a polymer material. In some embodiments, the polymer line can include a polymer core coated, covered or encapsulated with a non-polymer material. In some embodiments, the polymer line can be a braided line with one or more braids composed of a polymer material. In some embodiments, the (one or more) polymer materials of the polymer line can be (one or more) thermoplastic materials. In some embodiments, the continuous line 202 can be a line coated with an activatable agent, such as a heat-activated adhesive or a UV-activated adhesive. In some embodiments, a CNC machine tool for winding a continuous line 202 with an activatable agent coating can include a robotic arm for activating the coating when the continuous line 202 is wound around the anchor point 290.

[0120] Suitable polymer materials for the polymer threads discussed herein include, but are not limited to, thermoplastic polyurethane (TPU), rubber, and silicone. In some embodiments, the TPU may be recycled TPU. In some embodiments, the polymer material may be a photoreactive (infrared or ultraviolet light reactive) polymer material, such as a photoreactive TPU. In some embodiments, the polymer material may be soluble (e.g., water soluble). In embodiments comprising a polymer thread having a coated core, suitable materials for the core include, but are not limited to, polyester, nylon, ultra high molecular weight polyethylene (e.g., (a type of ultra-high molecular weight polyethylene), carbon fiber, (a type of para-aramid), bioengineered woven, knitted or layered materials (e.g., synthetic spider silk), woven, knitted or layered plant-based materials, cotton, wool and natural or artificial silk. In some embodiments, the polymer thread can be a polyester thread coated with thermoplastic polyurethane. In some embodiments, the continuous thread 202 can be a non-polymer thread composed of a non-polymer material, such as carbon fiber, cotton, wool or silk. In some embodiments, the continuous thread 202 can be a thread composed of a biomaterial, such as mango yarn or biosilk. In some embodiments, the polymer thread can be a thermoplastic melt yarn, a polymer thread with a non-melting core, and other similar types of threads.

[0121] In some embodiments, the polymer material for the polymer thread may include a melting temperature in a range from greater than or equal to 110° C. to less than or equal to 150° C. In such embodiments, the polymer material may be referred to as a “low melting temperature polymer material.”

[0122] In some embodiments, the continuous thread 202 may include an elastomeric thread. Suitable elastomeric materials for the elastomeric continuous thread 202 include, but are not limited to, (a polyether-polyurea copolymer). In some embodiments, the elastomeric thread may include an elongation percentage in the range of 100% to 300%, including subranges. For example, in some embodiments, the elastomeric thread may include an elongation percentage in the range of 100% to 300%, 150% to 300%, 200% to 300%, 100% to 250%, or 100% to 200%. Unless otherwise indicated, the elongation percentage of the elastomeric thread is measured according to ISO 2062 (Textiles - Yarn from packaging - Determination of single-end breaking force and elongation at break).

[0123] In some embodiments, continuous wire 202 may be a plied thread. In some embodiments, the plied thread may be plied while winding wire 202. For example, a winding assembly for winding wire 202 may use wires from multiple spools to ply the wires (e.g., see winding assembly 440). In some embodiments, the plied thread may be a pre-plied thread wound around a spool.

[0124] In some embodiments, the twisted yarn may include one or more elastomeric yarns and one or more polymer yarns. In such embodiments, the twisted yarn may include one or more elastomeric yarns and one or more polymer yarns comprising a low melting temperature polymer material.

[0125] In some embodiments, the strands may include multiple different types of strands. For example, the strands may include one or more polymer strands and one or more non-polymer strands. As another example, the strands may include one or more polymer strands comprising a first polymer material and one or more strands comprising a different second polymer material.

[0126] In some embodiments, the continuous wire 202 may be a composite co-extruded wire. In such embodiments, different portions of the composite co-extruded wire are formed from different materials. In such embodiments, the different materials of the composite co-extruded wire may provide varying mechanical properties for the wire layers or wire patterns.

[0127] In some embodiments, the continuous thread 202 may be a foamable thread. In such embodiments, the foaming agent in the foamable thread may be activated after the thread is wound in a thread layer to expand the thread. The foaming agent in the foamable thread layer may be activated by, for example, heat. In such embodiments, the continuous thread 202 may be wound in a thread layer to provide an area of ​​added padding on an article of clothing.

[0128] In some embodiments, the continuous wire 202 may be a soluble wire. The soluble wire may be dissolved by a solvent after being wound in a wire layer. In such embodiments, all or a portion of the wire layer may be removed by dissolving the soluble wire. In some embodiments, the soluble wire may be an acid soluble wire, and the solvent may be an acid solution that etches the wire.

[0129] In some embodiments, continuous thread 202 may be an electrically conductive thread. In such embodiments, the electrically conductive thread may be coupled to a power source configured to heat the electrically conductive thread, and thus heat the article of clothing including continuous thread 202.

[0130] In some embodiments, the continuous thread 202 may be a reflective thread. In some embodiments, the continuous thread 202 may be a sticky thread.

[0131] In some embodiments, the continuous thread 202 can be an "active thread". As used herein, an "active thread" is a thread that changes length when activated by an activating agent. When activated by an activating agent, the length of the active thread can expand or contract. Exemplary activators include, but are not limited to, heat, water, and electric current. In embodiments including active threads, after winding the thread layer, the dimensional properties of the thread layer and, therefore, the dimensional properties of the thread pattern can be changed. For example, in some embodiments, the dimensional properties of the thread layer can be changed when the thread pattern is heated in a heat press as described herein or on a mannequin. In such embodiments, changing the dimensional properties can impart a desired shape to the article of apparel.

[0132] In some embodiments, the continuous thread 202 may be composed of a viscoelastic shear thickening (dilatant) material. The elastic modulus of a dilatant material depends on the strain rate applied to the material. By incorporating threads composed of dilatant materials into a thread layer, the stiffness of the thread layer can be varied during use depending on the degree of strain applied to the thread layer. For example, during low-stress activities such as walking, the thread layer can remain relatively compliant, but when high stress levels are applied during high-stress activities such as running, the stiffness increases.

[0133] In some embodiments, the denier of the continuous threads 202 of the thread layer 200 can be in the range of 1 denier to 3000 denier, including subranges. For example, the denier of the continuous threads 202 can be: 1, 10, 50, 100, 200, 300, 400, 500, 600, 700, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2500, or 3000 denier, or in any range having any two of these values ​​as endpoints. For example, in some embodiments, the denier of the continuous line 202 can be in the following range: from 10 denier to 2500 denier, from 50 denier to 2000 denier, from 100 denier to 1900 denier, from 200 denier to 1800 denier, from 300 denier to 1700 denier, from 400 denier to 1600 denier, from 500 denier to 1500 denier, from 600 denier to 1400 denier, from 700 denier to 1300 denier, from 800 denier to 1200 denier, from 900 denier to 1100 denier, or from 900 denier to 1000 denier.

[0134] The line pattern as described herein may include any number of line layers. For example, the line pattern may include two or more, three or more, four or more, five or more, six or more, seven or more, eight or more, nine or more, ten or more, fifteen or more, or twenty or more line layers. For example, the line pattern may include line layer 200, line layer 220, and line layer 240.

[0135] The continuous wires of any wire layer (e.g., wire layers 220 and 240) can be wrapped around and extend between anchor points 290 in the same manner as described above for continuous wire 202. In addition, the rows of continuous wires of any wire layer (e.g., wire layers 220 and 240) can be linked in the same manner as described above for wire layer 200.

[0136] Similar to continuous thread 202, continuous threads for other thread layers (e.g., threads 222 and 242) may include multiple rows of threads (e.g., rows of threads 224 and 244) wound around two corresponding anchor points and extending between the two corresponding anchor points. In some embodiments, the continuous threads of different thread layers may be the same thread material. In some embodiments, the continuous threads of different thread layers may be composed of different thread materials. In such embodiments, the materials of different continuous threads in the thread pattern may be selected to provide target properties to areas of the thread pattern (and therefore to the garment article). In some embodiments, the denier of the continuous threads of different thread layers in the thread pattern may be selected to provide different degrees of properties (e.g., strength or stretchability) to different areas of the thread pattern.

[0137] In embodiments including a line pattern having a plurality of line layers, the plurality of line layers may be stacked on top of one another. For example, line layer 200 may define a line pattern for a first layer, and second line layer 220 may define a line pattern for a second layer. Different line layers of a line pattern may be disposed on top of one another in an overlapping region between two line layers. For example, in an overlapping region between two line layers, first line layer 200 may be disposed on second line layer 220, or vice versa.

[0138] In embodiments comprising a line pattern having a plurality of line layers, the plurality of line layers may be joined to one another in the line pattern. In some embodiments, one or more layers may be directly joined to one another via a continuous line of polymer material, wherein the continuous line defines a line row for at least one of the layers. In some embodiments, one or more layers may be joined via a tie layer. In such embodiments, the tie layer may be, for example, a laminate layer, an adhesive layer, a stitching layer, a cured layer, a screen printed layer, or a blown fiber layer.

[0139] In some embodiments, one or more wire layers of a wire pattern may be used to connect other wire layers of the wire pattern together. In such embodiments, these one or more wire layers may be wrapped with polymer wires that, when heated, connect the other layers of the wire pattern together at anchor points and / or intersections between continuous wires. For example, in a wire pattern comprising three wire layers, one of the three wire layers (e.g., an intermediate wire layer) may be wrapped with a polymer wire that is used to connect all three wire layers together. In some embodiments, one or more wire layers of a wire pattern may be defined by a wound continuous wire coated or impregnated with an adhesive. In some embodiments, the adhesive may be activated by applying heat. In some embodiments, the adhesive may be a soluble adhesive that completely or partially dissolves when in contact with a solvent (such as water) to connect the wire layers together.

[0140] Figure 2CA line layer 240 is shown including a continuous line 242 having a line 244 extending tangentially to a perimeter boundary according to some embodiments. Line layer 240 includes an edge 260. Edge 260 may be a portion of line boundary 250c.

[0141] The row 244 of continuous lines 242 may include a plurality of rows 244 extending between two corresponding anchor points 290 and extending tangentially to the edge 260. The row 244 extending tangentially to the edge 260 may be referred to as a "boundary tangent row." Figure 2C A plurality of boundary tangent line rows 246 are shown.

[0142] The row 244 of continuous lines 242 may also include a plurality of rows 244 that extend between two corresponding anchor points 290 and are not tangential to the edge 260. The rows 244 that do not extend tangentially to the edge 260 may be referred to as "non-boundary tangential rows." Figure 2C A plurality of non-boundary tangent line rows 248 are shown.

[0143] In some embodiments, the line rows 246 extending tangentially to the edge 260 are not wrapped around an anchor point located at the edge 260. In some embodiments, the line layer 240 may not have an anchor point located at the edge 260.

[0144] The boundary tangent line rows 246 may include line rows 246 that overlap each other at an overlap point 247 of the line layer 240. Any two line rows 246 of the line layer 240 may overlap each other at the overlap point 247. For example, Figure 2C As shown, the first boundary tangent line row 246 may overlap with the second boundary tangent line row 246 at an overlap point 247 .

[0145] The boundary tangent line rows 246 that overlap each other at the overlap point 247 may be arranged at an angle relative to each other. The relative angle of the two line rows 246 may be defined by the intersection angle (θ) at the overlap point 247. Unless otherwise specified, the intersection angle (θ) is the angle formed by the intersection of the two line rows 246 and is measured on the side of the line row 246 facing the edge 260 (e.g., Figure 2C shown).

[0146] In some embodiments, the intersection angle (θ) at the overlap point 247 can be in the range of 90° to 179°, including sub-ranges. For example, θ can be 90°, 100°, 110°, 120°, 130°, 140°, 150°, 160°, 170°, or 179°, or in a range with any two of these values ​​as endpoints, including endpoints. In some embodiments, θ can be in the range of 90° to 179°, 100° to 179°, 110° to 179°, 120° to 179°, 130° to 179°, 140° to 179°, 150° to 179°, 160° to 179°, or 170° to 179°. In some embodiments, θ can be greater than 90°, greater than 120°, or greater than 150°.

[0147] The line layer 240 may include any suitable number of boundary tangent line rows 246. In some embodiments, the line layer 240 may include four or more boundary tangent line rows 246. In some embodiments, the line layer 240 may include 10 or more boundary tangent line rows 246. In some embodiments, the line layer 240 may include 20 or more boundary tangent line rows 246. In some embodiments, the line layer 240 may include 30 or more boundary tangent line rows 246. In some embodiments, the line layer 240 may include 50 or more boundary tangent line rows 246. In some embodiments, the line layer 240 may include a plurality of boundary tangent line rows 246 in the range of 2 to 50. For example, the line layer 240 may include 2 to 50, 4 to 50, 10 to 50, 20 to 50, or 30 to 50 boundary tangent line rows 246.

[0148] In some embodiments, a plurality of adjacent anchor points 290 used to form a line layer 240 may each include a boundary tangent line row 246 extending therefrom. As used herein, a first anchor point that is described as being "adjacent" to a second anchor point means that the second anchor point is the first or second closest anchor point neighbor of the first anchor point. An anchor point typically includes two "adjacent" anchor point neighbors, which are typically located on opposite sides of the anchor point. In embodiments that include equally spaced anchor points, the first nearest anchor point neighbor and the second nearest anchor point neighbor of an anchor point may be located at the same distance from the anchor point. As an example, in Figure 2C , anchor points 290a and 290c are adjacent to anchor point 290b.

[0149] In some embodiments, the boundary tangent line rows 246 that overlap at the overlap point 247 may be directly connected to each other at the overlap point 247. In some embodiments, the boundary tangent line rows 246 that overlap at the overlap point 247 may be directly connected to each other via the polymer material of the boundary tangent line rows 246.

[0150] In some embodiments, the anchor point 290 may include a boundary tangent line row 246 extending therefrom and a plurality of non-boundary tangent line rows 248 extending therefrom. In some embodiments, the anchor point 290 may have a line row communication number, and at least one line counted in the line row communication number may be a boundary tangent line row 246, and the remaining line rows may be non-boundary tangent line rows 248.

[0151] Figure 3 A method 300 of manufacturing an article of clothing (e.g., garment 100) according to some embodiments is shown. In step 310, a plurality of anchor points (e.g., anchor points 290) on a support structure may be defined. In some embodiments, the support structure may be a support plate (e.g., support plate 430, support plate 1502, or support plate 1702). In some embodiments, the support structure may be a mannequin. In some embodiments, the anchor points may include protrusions on the support plate. In some embodiments, the anchor points may include protrusions extending laterally from the peripheral edge of the support plate. In some embodiments, the anchor points may include pins on the support plate.

[0152] Unless otherwise specified, the steps of method 300 do not need to be performed in the order set forth herein. In addition, unless otherwise specified, the steps of method 300 do not need to be performed sequentially. These steps may be performed in different orders or simultaneously. As an example, step 330 of method 300 does not need to be performed between steps 320 and 340. On the contrary, step 330 may be performed after step 340. As another example, step 360 does not need to be performed between steps 350 and 370. On the contrary, step 360 may be performed between steps 340 and 350. As another example, steps 340 and 350 may be performed simultaneously. In addition, method 300 may not include all the steps shown in the figure. For example, method 300 may not include step 330.

[0153] In step 320, one or more continuous wires (e.g., continuous wire 202) may be wound (wrapped) around anchor points 290 so that individual rows of the continuous wire (e.g., row 204) extend between two corresponding anchor points. In step 320, the continuous wire is wound to form one or more desired wire layers (e.g., wire layer 200) and / or a wire pattern comprising multiple wire layers (e.g., a wire pattern comprising wire layers 200, 220, and 240). During the winding step 320, the anchor points may be defined by fixed or movable members, such as pins, protrusions, bumps, or shafts coupled to a support structure, or any other similar fixed anchor points discussed herein. These members are used to support the continuous wire during the winding step 320. For example, the wire may be wound around an anchor point on a plate, a three-dimensional object (e.g., a mannequin), or a frame. For example, the anchor point may be a pin coupled to a mannequin. As another example, the anchor point may be a protrusion extending from a support plate (e.g., support plate 430).

[0154] In some embodiments, the plate, object or frame can remain stationary and the winding device can wind the wire around a stationary anchor point. In some embodiments, the plate, object or frame can move relative to the fixed wire source during winding. In some embodiments, the plate, object or frame can move relative to the winding device, which winds the wire around a moving anchor point.

[0155] In some embodiments, one or more continuous lines (e.g., continuous line 202) may be wrapped (wrapped) around anchor points 290 on a base layer (e.g., base layer 110). In such embodiments, base layer 110 may be disposed on a surface of a support structure including anchor points 290. For example, base layer 110 may be disposed on surface 432 of support plate 430.

[0156] In step 330, one or more parts may be molded onto the wire layer or wire pattern. For example, in some embodiments, one or more parts may be molded onto the wire layer or wire pattern, as described herein with reference to Figure 15-18 In some embodiments, one or more parts can be molded by injecting a polymer material (eg, polymer foam) around at least a portion of the wire layer or wire pattern.

[0157] In some embodiments, step 320 may be repeated after step 330 to form a line layer (or line pattern) on one or more molded parts formed in step 330. In such embodiments, method 300 may form a line pattern including a first line layer having one or more molded parts and a second line layer disposed on the first line layer. In some embodiments, the second line layer may be disposed on one or more molded parts. In some embodiments, the second line layer may be located between one or more molded parts. In some embodiments, method 300 may not include step 330.

[0158] In step 340, the continuous threads may be joined within a thread layer or thread pattern. In some embodiments, the continuous threads may be joined at the intersections between the rows of threads by, for example, adhesives, tie layers, thermal (conductive or convective) heating (e.g., in a heat press or oven), IR (infrared) heating, laser heating, microwave heating, steam, mechanical fasteners (e.g., clips), hook and loop fasteners, needle punching, hydroentanglement, ultrasonic / vibration entanglement, felting, knotting, chemical bonding using a catalyst of a biomaterial, adhesive spraying (e.g., CNC adhesive spray deposition), or by pushing one row of threads through other rows of threads. In some embodiments, the continuous threads may be joined directly at the intersections between the rows of threads.

[0159] In some embodiments, the continuous threads may be joined at the anchor points by, for example, adhesives, tie layers, thermal (conductive or convective) heating (e.g., in a heat press or oven), IR (infrared) heating, laser heating, microwave heating, steam, mechanical fasteners (e.g., clips), hook and loop fasteners, needle punching, hydroentanglement, ultrasonic / vibration entanglement, felting, knotting, chemical bonding using a catalyst of a biomaterial, adhesive spraying (e.g., CNC adhesive spray deposition), or by pushing one row of threads through other rows of threads. In some embodiments, the continuous threads may be joined directly at the anchor points.

[0160] In some embodiments, the method 300 may include multiple winding steps 320 and multiple joining steps 340. For example, a portion of the wire pattern may be wound in a first winding step 320, and then the portion may be joined in a first joining step 340. Then, a second portion of the wire pattern may be wound in a second winding step 320, and the portion may be joined in a second joining step 340. In some embodiments, the joining step 340 may include a preliminary joining step to maintain the pattern of the wire layer or wire pattern until a final joining step is performed. For example, the preliminary joining step may allow the wire layer or wire pattern to be removed from an anchor point and finally joined after removal.

[0161] In some embodiments, steps 320 and 340 may be performed in the absence of a substrate layer (eg, substrate layer 110 ) disposed between the wire layer or wire pattern and the support structure including the anchor points.

[0162] In some embodiments, steps 320 and 340 may be performed in the presence of a base layer (e.g., base layer 110) disposed between the wire layer or wire pattern and the support structure including the anchor points. In such embodiments, the wire layer or wire pattern may be bonded to the base layer in step 340. In such embodiments, steps 340 and 350 may be performed simultaneously.

[0163] In some embodiments, step 340 may include selectively heating all or a portion of the wire layer or wire pattern to form a solid part on the wire layer or wire pattern. For example, all or a portion of the wire layer or wire pattern may be heated to consolidate the wire array into a solid part. Exemplary solid parts include, for example, protective panels, such as elbow guards or shin guards. As a non-limiting example, Fig.11 Thread layer 1120 shown in FIG. 1 may be consolidated to form a shin guard on article of clothing 1100 .

[0164] In step 350, the thread layer or thread pattern formed in step 320 may be attached to a base layer (e.g., base layer 110). In some embodiments, the thread layer or thread pattern may be attached to the base layer via a laminate layer, an adhesive layer, a stitching layer, a curing layer, a screen printing layer, a blown fiber layer, or a combination thereof. In some embodiments, the thread layer or thread pattern may be directly attached to the base layer by, for example, but not limited to, direct attachment of the thread array and / or the material of the base layer, needle punching, hydraulic entanglement, and ultrasonic / vibration entanglement.

[0165] In some embodiments, the thread layer or thread pattern formed in step 320 can be attached to a base layer (e.g., base layer 110) while the base layer is under tension. For example, the base layer can be held in a stretched position when the thread layer or thread pattern is attached to the base layer. In such embodiments, attaching the thread layer or thread pattern to the base layer can lock some portions of the base layer under tension while leaving other portions free to contract when the applied tension is removed from the base layer. In such embodiments, selectively locking portions of the base layer under tension can impart a desired shape to the article of apparel. For example, selectively locking portions under tension can impart a desired shape as described in reference to FIG. Figures 14A-14B As another example, selectively locking portions of the substrate layer under tension can impart a corrugated or curled structure, as described in reference Figures 20A-23BIn such an embodiment, after the line layer or line pattern is attached to the stretched position of the base layer, the tension applied to the base layer can be removed so that the base layer is allowed to relax to a relaxed, unstretched state. In some embodiments, the base layer held in the stretched position can have a flat shape.

[0166] In some embodiments, the substrate layer can be maintained in a stretched position with a length and / or width of 5% to 50% of the unstretched length and / or width of the substrate layer. In some embodiments, the tension applied to the substrate layer in the length and / or width direction can be in the range of 0.03N to 500N.

[0167] In step 360, the wire layer or wire pattern may be cut. In some embodiments, the cutting in step 360 may define all or a portion of the wire boundary 250 for the wire layer of the wire pattern and all or a portion of the wire pattern boundary 250. In some embodiments, the base layer 110 may be cut simultaneously with the wire layer or wire pattern. For example, in embodiments where step 350 is performed before step 360, the base layer and the wire layer or wire pattern may be cut simultaneously.

[0168] The material including the base layer and the thread layer or thread pattern can be formed into an article of apparel in step 370. In some embodiments, forming the material can include joining the material to itself at a seam.

[0169] In some embodiments, shaping the material in step 370 may include attaching the material to one or more additional material panels to form the article of clothing. In some embodiments, attaching the material to the one or more additional material panels may include sewing the material to the one or more additional material panels at one or more seams. In some embodiments, one or more of the additional material panels may be manufactured using method 300. In some embodiments, one or more of the additional material panels may be material panels that do not have a thread layer or thread pattern as described herein.

[0170] Figure 4 A computer numerical control (CNC) machine 400 is shown for winding wire in step 320 according to some embodiments. The machine 400 includes a robot 405 for winding a wire layer (e.g., wire layer 200) and / or multiple wire layers of a wire pattern around an anchor point 290 on a support plate 430, the wire pattern including a wire row (e.g., wire row 204).

[0171] The robot 405 may include one or more spools 410 for threading and winding a wire array of one or more wire layers around the anchor point 290. In some embodiments, the CNC machine 400 may include a winding assembly 440 including a plurality of spools 410 for threading and winding a plurality of different wires.

[0172] In some embodiments, the CNC machine 400 may include one or more wire tensioners 412 configured to apply a desired tension to the wire wrapped around the anchor point 290. The CNC machine 400 may include a controller 415 configured to use the wire model and input data to wrap one or more wire layers around the anchor point 290. In some embodiments, the controller 415 may control the tensioners 412 to wrap the wire at a desired tension.

[0173] In some embodiments, CNC machine 400 can wind multiple wires from multiple spools 410 simultaneously when winding wire layers. In some embodiments, machine 400 can be used to wind overlapping rows of wires from multiple spools 410 simultaneously.

[0174] In some embodiments, CNC machine 400 may include two or more manipulators 405 for winding multiple wires simultaneously. In such embodiments, two or more manipulators 405 may simultaneously wind different wires in different regions of the wire pattern.

[0175] In some embodiments, the manipulator 405 may ply two or more threads from different spools 410. In such embodiments, the thread layer or thread pattern may include one or more ply threads. As used herein, "plying" two or more threads refers to coupling two or more threads together by twisting at least one of the two or more threads. In some embodiments, plying may include twisting one or more threads around one or more untwisted threads. In some embodiments, plying may include twisting two or more threads together.

[0176] In some embodiments, tensioner 412 may be a mechanical tensioning device with digitally controlled impedance that is used to dynamically control how tight the wire fed through machine tool 400 is. In some embodiments, by adjusting the voltage in tensioner 412, the tension value of the wire may be dynamically changed. In some embodiments, tensioner 412 may be a manually adjustable tensioner. In some embodiments, tensioner 412 may include a spring configured to adjust the amount of tension applied to the wire. The spring may be manually controlled or digitally controlled.

[0177] In some embodiments, the tension of the continuous wire winding of the wire layer can be in the range of 0 centinewtons (cN) to 25 cN, including sub-ranges. For example, in some embodiments, the tension can be in the range of 0.01 cN to 25 cN, 0.1 cN to 25 cN, 1 cN to 25 cN, 5 cN to 25 cN, 10 cN to 25 cN, or 15 cN to 25 cN. In some embodiments, the tension of the continuous wire winding of the wire layer can be in the range of 2 cN to 10 cN. In some embodiments, the winding tension of the continuous wire of the wire layer can be in the range of 2 cN to 6 cN.

[0178] In some embodiments, a first wire layer (e.g., wire layer 200) may include continuous wire 202 wound at a first tension, and a second wire layer (e.g., wire layer 220) disposed above the first wire layer may include continuous wire 222 wound at a second tension greater than the first tension. In some embodiments, the second tension may be at least 0.5 cN greater than the first tension. In some embodiments, the second tension may be at least 1 cN greater than the first tension.

[0179] Figure 5 A heat press 500 is shown for use in step 340, step 350, or both, according to some embodiments. In step 340, the heat press 500 may apply pressure and heat to the wire layer or wire pattern to join the continuous wires at the locations of the anchor points and / or the intersections between the wire rows. In step 350, the heat press 500 may apply pressure and heat to the wire layer or wire pattern to join the continuous wires to the base layer. In some embodiments, for example, Figure 5 As shown, the heat press 500 may apply pressure and heat to the line layer or line pattern on the support plate 430 .

[0180] In some embodiments, the heat press 500 may provide heat at a predetermined temperature that is equal to or greater than the melting point of the polymer material of the polymer wires of the wire layer or wire pattern. In some embodiments, the heat press 500 may provide heat at a predetermined temperature that is lower than the melting point of the polymer material of the polymer wires of the wire layer or wire pattern, but high enough to bond (fuse) the polymer material together or to other materials of the wire layer or wire pattern.

[0181] Heat may be applied to the wire layer or wire pattern in the heat press 500 in one or more ways, such as but not limited to radio frequency heat sealing (welding), high frequency heat sealing (welding), infrared welding, and steaming. Heat transfer between the wire layer or wire pattern and the heat press 500 may be performed by conduction and / or convection. In some embodiments, in the heat press 500, heat may be applied to a single outer surface of the wire layer or wire pattern. In some embodiments, in the heat press 500, heat may be applied to both outer surfaces of the wire layer or wire pattern.

[0182] In some embodiments, in the heat press 500, heat can be applied to the line layer or line pattern uniformly. In such an embodiment, the temperature of the connection line layer or line pattern in the heat press 500 can be substantially the same on all parts of the line layer or line pattern. In some embodiments, in the heat press 500, heat can be applied to the line layer or line pattern unevenly. In such an embodiment, for different parts and / or regions of the line layer or line pattern, the temperature of the connection line layer or line pattern in the heat press 500 is different. By changing the connection temperature of different parts and / or regions of the line layer or line pattern in the heat press 500, the characteristics of the line layer or line pattern in different parts and / or regions of the clothing article can be changed. In some embodiments, in the heat press 500, heat can be applied to the line layer or line pattern unevenly to define a chamber or pocket as described herein.

[0183] In some embodiments, the heat applied to the wire layer or wire pattern can be controlled by controlling the heat applied to the heat press 500. In some embodiments, the heat applied to the wire pattern or wire layer can be additionally or alternatively controlled by one or more inserts 540 disposed between the inner surface of the heat press 500 and the wire layer or wire pattern. In such embodiments, the insert 540 can control the heat applied by controlling the heat transfer between the heat press 500 and the wire layer or wire pattern. In some embodiments, the insert 540 can be used to evenly distribute heat over all or a portion of the wire layer or wire pattern within the heat press 500. In some embodiments, the insert 540 can be used to change the temperature of different portions and / or regions of the wire layer or wire pattern in the heat press 500.

[0184] Figure 6 and Figure 7 Exemplary garments 600 and 660 are illustrated that include a thread layer attached to surface 112 of base layer 110 according to some embodiments. For purposes of discussion, Figure 6 and Figure 7 Thread layers 620, 630, 640, 650, 670, and 680 are illustrated as being attached to garments 600 and 660. That is, a thread pattern including multiple thread layers may also be attached to garments 600 and 660 in the same manner as thread layers 620, 630, 640, 650, 670, and 680 as described herein.

[0185] like Figure 6 As shown in , the article of clothing 600 may include a base layer 110 that includes a plurality of material panels 116a-d. The material panels 116a-d may each define a portion of the article of clothing 600. Figure 6In the non-limiting example shown in , panel 116a may define all or part of the front portion of article of garment 600, panel 116b may define all or part of the first sleeve of article of garment 600, panel 116c may define all or part of the second sleeve of article of garment 600, and panel 116d may define all or part of the back portion of article of garment 600.

[0186] like Figure 7 As shown, the article of clothing 660 may include a base layer 110 that includes a plurality of material panels 116a-116f. The material panels 116a-116f may each define a portion of the article of clothing 660. Figure 7 By way of non-limiting example, shown in FIG. 6A , the combination of panel 116 a , second panel 116 b , and third panel 116 c may define first and second legs of article of clothing 660 .

[0187] Each panel 116 includes a shape defined by a peripheral edge 114 .

[0188] In some embodiments, a line layer (e.g., line layer 620) may include a line boundary 250, and a panel of base layer 110 (e.g., panel 116a) may include a peripheral edge (e.g., peripheral edge 114a) surrounding line boundary 250. In such embodiments, the area occupied by line layer 620 on surface 112 may be less than the total surface area of ​​surface 112 defined by peripheral edge 114a of base panel 116a.

[0189] In some embodiments, a thread layer (e.g., thread layer 630) may include a thread boundary 250 that extends across a plurality of adjacent panels (e.g., panels 116a and 116b) of base layer 110. In such embodiments, the area on surface 112 occupied by thread layer 630 may occupy: a portion of the surface area of ​​surface 112 defined by peripheral edge 114a of base layer panel 116a, and a portion of the surface area of ​​surface 112 defined by peripheral edge 114b of base layer panel 116b.

[0190] In embodiments including a thread layer (e.g., thread layer 630) that includes a thread boundary 250 that extends across a plurality of adjacent panels of a base layer 110, one or more rows of threads of the thread layer may extend from a first base layer panel to a second base layer panel. In such embodiments, the one or more rows of threads of the thread layer may be attached to a surface 112 of the base layer 110 defined by a first panel (e.g., panel 116a) and a surface 112 of the base layer 110 defined by a second panel (e.g., panel 116b). In some embodiments, the one or more rows of threads of the thread layer may be attached directly to a surface 112 of the base layer 110 defined by a first panel and a surface 112 of the base layer 110 defined by a second panel.

[0191] In some embodiments, a first wire layer (e.g., wire layer 620) may include a wire boundary 250 that overlaps a wire boundary of a second wire layer (e.g., wire layer 630) in an overlap region 602. In such embodiments, the first wire layer may be coupled to the second wire layer in the overlap region 602. In some embodiments, the first wire layer may be directly coupled to the second wire layer in the overlap region 602.

[0192] In some embodiments, for example, Figure 6 and 7 16a and 16b, or panels 116a and 116c, can be separated by gaps 160. In such embodiments, gaps 160 can be defined by the space between the peripheral edges of adjacent panels of substrate layer 110. Also, in such embodiments, one or more rows of threads of a thread layer (e.g., thread layer 620) can extend through gaps 160—from a first material panel to a second material panel. In some embodiments, all or a portion of gaps 160 can be free of seams 150. In embodiments that include gaps 160 between adjacent panels of substrate layer 110, the rows of threads of the thread layer can be used to attach adjacent panels of substrate layer 110 together.

[0193] In some embodiments, the gap 160 may include a minimum distance 162 between adjacent panels 116. In some embodiments, the minimum distance 162 may be greater than or equal to 1 mm. In some embodiments, the minimum distance 162 may be greater than or equal to 2 mm. In some embodiments, the minimum distance 162 may be greater than or equal to 1 cm. In some embodiments, the minimum distance 162 may be greater than or equal to 2 cm.

[0194] In some embodiments, for example, Figure 7 As shown, a wire layer (e.g., wire layer 670) may extend across at least three panels of the base layer 110. The wire layer 670 extends across the first panel 116a, the second panel 116b, and the third panel 116c. In such an embodiment, the wire layer 670 may extend across a plurality of gaps 160 between panels of the base layer 110.

[0195] In some embodiments, for example, Figure 7As shown, the line layer (e.g., line layer 670 and 680) can extend across the base layer 110 so that the line boundary 250 of the line layer occupies the area extending around the perimeter of the clothing article. In such an embodiment, the line layer can completely surround a part of the clothing article. For example, the line layer can completely surround the trouser legs, sleeves, waist, torso, abdomen or chest of the clothing article. In certain embodiments, the line layer completely surrounding a part of the clothing article can be coupled to a tightening mechanism, which is configured to adjust the tension in the line row of the line layer. Exemplary tightening mechanisms include, but are not limited to, a boa tightening mechanism and a ratchet tightening mechanism.

[0196] In some embodiments, for example, Figure 8 and 9 As shown, adjacent panels of base layer 110 (e.g., panels 116a and 116b, or panels 116a and 116c) can be joined at seam 150. In such embodiments, seam 150 can join the peripheral edges of adjacent panels of base layer 110 to form an article of clothing. Also, in such embodiments, one or more rows of threads of a thread layer (e.g., thread layer 820) can extend through seam 150—from a first material panel to a second material panel.

[0197] like Figure 8 As shown in , the article of clothing 800 may include a base layer 110 that includes a plurality of material panels 116a-d. The material panels 116a-d may each define a portion of the article of clothing 800. Figure 8 In the non-limiting example shown in , panel 116a may define all or part of the front portion of article of garment 800, panel 116b may define all or part of the first sleeve of article of garment 800, panel 116c may define all or part of the second sleeve of article of garment 800, and panel 116d may define all or part of the back portion of article of garment 800.

[0198] Garment 800 may include a first thread layer 820 attached to a first area on garment 800 , a second thread layer 830 attached to a second area on garment 800 , a third thread layer 840 attached to a third area on garment 800 , and a fourth thread layer 850 attached to a fourth area on garment 800 .

[0199] like Fig. 9 As shown, the article of clothing 860 may include a base layer 110 that includes a plurality of material panels 116a-116e. The material panels 116a-116f may each define a portion of the article of clothing 860. Fig. 9By way of non-limiting example, the combination of second panel 116b, third panel 116c, fourth panel 116d, and fifth panel 116e may define first and second legs of garment 860.

[0200] Apparel 860 may include a first thread layer 870 attached to a first area on the article of apparel 860 , a second thread layer 880 attached to a second area on the article of apparel 860 , and a third thread layer 890 attached to a third area on the article of apparel 860 .

[0201] In some embodiments, seam 150 may join a first side of a peripheral edge of a base panel to a second side of a peripheral edge of the base panel. Figure 8 As shown, seam 150 may join a first side of peripheral edge 114b to a second side of peripheral edge 114b to form a portion of a sleeve of an article of apparel.

[0202] In some embodiments, for example, Fig. 9 As shown, the thread layer (e.g., thread layer 870, 880, or 890) can extend across base layer 110 so that thread boundary 250 of the thread layer occupies an area that extends across one or more seams 150 and completely surrounds the perimeter of the article of apparel. In such an embodiment, the thread layer can completely surround a portion of the article of apparel. For example, the thread layer can completely surround a trouser leg, a sleeve, a waist, a torso portion, an abdominal portion, or a chest portion of the article of apparel.

[0203] Seam 150 may include one or more mechanical attachments, including but not limited to direct bond attachment, adhesive attachment, interlocking mechanical attachment, and / or stitch attachment. Exemplary seams for seam construction of seam 150 include but are not limited to Milo stitch (tight hem seam), gathered hem, overlock seam, or hem seam.

[0204] In some embodiments, the thread layer (or thread pattern) can completely surround all or a portion of the article of clothing and provide a stiffness configured to maintain the shape of the article of clothing during use. For example, the thread layer (or thread pattern) can completely surround all or a portion of the article of clothing to provide support for the wearer's joints during use.

[0205] Fig.10 An article of clothing 1000 is shown that includes an ankle cuff and a thread layer 1020 that completely surrounds the garment 1000 to maintain the shape of the ankle cuff. In some embodiments, thread layer 1020 can be directly attached to surface 112 of base layer 110 that defines the shape of article of clothing 1000.

[0206] In some embodiments, the thread layer 1020 directly bonded to the surface 112 may provide 20% to 90% stiffness as measured according to the Cusick drape test using a test template diameter of 30 centimeters.

[0207] Although Fig.10 An article of clothing 1000 is illustrated that includes an ankle cuff, but other articles of clothing configured to fit around a wearer's joint during use may include a thread layer 1020. Additional exemplary articles configured to fit around a wearer's joint during use include, but are not limited to, pant legs, arm cuffs, knee cuffs, belts, elbow cuffs, wrist cuffs, or shoulder wraps.

[0208] In some embodiments, the tension of the winding of the rows of wire layer 1020 may exert a compressive force on surface 112 that contributes to the stiffness provided by wire layer 1020. In some embodiments, the rows of wire layer 1020 may be wound at tension values ​​as described herein.

[0209] In some embodiments, the line array of the line layer (or line pattern) may be joined to the surface 112 of the base layer 110 only at the peripheral region of the line layer (or line pattern) to define pockets between the line layer (or line pattern) and the base layer 110 . Fig.11 An article of apparel 1100 is illustrated that includes a pocket 1130 formed from a thread layer 1120 , according to some embodiments.

[0210] According to some embodiments, garment 1100 includes thread layer 1120, which is joined to surface 112 of base layer 110 at a peripheral region 1122 of thread layer 1120 to define pocket 1130. Peripheral region 1122 may be a peripheral region of linear layer 1120 that includes thread boundary 250 of linear layer 1120. In some embodiments, thread layer 1120 may be directly joined to surface 112 of base layer 110 at peripheral region 1122 of thread layer 1120 to define pocket 1130.

[0211] In some embodiments, thread layer 1120 may be attached to surface 112 around the entire perimeter region 1122. In some embodiments, thread layer 1120 may be attached to surface 112 around a portion of perimeter region 1122. For example, in some embodiments, all or a portion of side 1123 of perimeter region 1122 may not be attached to surface 112 to define an open perimeter portion 1124. In such embodiments, open perimeter portion 1124 may provide an opening through which insert 1140 may be inserted and removed from pocket 1130.

[0212] In some embodiments, pocket 1130 can be configured to receive insert 1140. In some embodiments, pocket 1130 can include insert 1140 disposed within pocket 1130. In some embodiments, insert 1140 can include a plate, such as a shin guard or liner plate. In some embodiments, insert 1140 can include an insulating material.

[0213] As a non-limiting example, Fig.11 An article of clothing 1100 is shown including a sleeve having a pocket 1130 defined by a thread layer 1120 and including an insert 1140 in the form of a shin guard.

[0214] In some embodiments, an article of clothing as described herein (e.g., article of clothing 100) may include a layer or pattern of threads coupled together in a layered structure to form a chamber on the article of clothing. In such embodiments, the chamber may be filled with a material, such as an insulating material.

[0215] Fig.12 and 13 A hierarchical structure 1200 is shown according to some embodiments. For discussion purposes, Fig.12 and 13 There are shown line layers 1210 and 1250. That is, a line pattern including a plurality of line layers may form a layered structure in the same manner as the line layers 1210 and 1250.

[0216] The layered structure 1200 may include a wire layer 1210 including a wire boundary 1212 and wires 1220 defining a plurality of first wire rows 1222, each of which extends from a first side 1214 of the wire boundary 1212 to a second side 1216 of the wire boundary 1212 and crosses each other at overlapping points between two or more of the wire rows 1222. The layered structure 1200 may further include a second wire layer 1250 disposed on the first wire layer 1210 and including a wire boundary 1252 and second wires 1260 defining a plurality of wire rows 1262, each of which extends from a first side 1254 of the wire boundary 1252 to a second side 1256 of the wire boundary 1252 and crosses each other at overlapping points between two or more of the wire rows 1262.

[0217] Wire layer 1210 and layer 1250 may be coupled together to form chamber 1280 occupying volume 1282 between wire layer 1210 and wire layer 1250 .

[0218] In some embodiments, thread layer 1210 and thread layer 1250 may be coupled at seam 1290, which is located at edge 1284 of chamber 1280. Seam 1290 may include any suitable attachment area for joining thread layer 1210 and thread layer 1250 along edge 1284. Exemplary attachment areas include, but are not limited to, stitch attachment areas, adhesive attachment areas, heat bond attachment areas, and interlock attachments. Exemplary seam structures include, but are not limited to, self-attachment seams, hems, butt stich, Merrow stitch (tight overlock stitch), gathered edge, surge stitch, overlock stitch, and interlock seam constructions.

[0219] In some embodiments, the layered structure 1200 may include a base layer 1230 disposed between the first wire layer 1210 and the second wire layer 1250 such that a portion of the base layer 1230 defines a portion of the chamber 1280. In such embodiments, the base layer 1230, the first wire layer 1210, and the second wire layer 1250 may be coupled together to form the chamber 1280. Also in such embodiments, the base layer 1230, the first wire layer 1210, and the second wire layer 1250 may be attached at a seam 1290, which is located at an edge 1284 of the chamber 1280. In some embodiments including the base layer 1230, the wire array 1222 of the first wire layer 1210 may be attached to the surface 1232 of the base layer 1230. For example, the wire array 1222 of the first wire layer 1210 may be directly attached to the surface 1232 of the base layer 1230 - in the same manner as described above for the wire layer and base layer 110.

[0220] In some embodiments, the layered structure can include a base layer 1270 disposed between the first thread layer 1210 and the second thread layer 1250, such that a portion of the base layer 1270 defines a portion of the chamber 1280. In such embodiments, the base layer 1270, the first thread layer 1210, and the second thread layer 1250 can be coupled together to form the chamber 1280. Also in such embodiments, the base layer 1270, the first thread layer 1210, and the second thread layer 1250 can be attached at a seam 1290, which is located at an edge 1284 of the chamber 1280. In some embodiments including the base layer 1270, the line array 1262 of the second thread layer 1250 can be attached to the surface 1272 of the base layer 1270. For example, the line array 1262 of the second thread layer 1250 can be directly attached to the surface 1272 of the base layer 1270 - in the same manner as described above for the thread layer and the base layer 110.

[0221] In some embodiments, layered structure 1200 can include both base layer 1230 and base layer 1270. In such embodiments, base layer 1230, base layer 1270, first thread layer 1210, and second thread layer 1250 can be attached at seam 1290.

[0222] In some embodiments, chamber 1280 can be filled with a material or insert 1286. In some embodiments, the material of chamber 1280 can be insulating.

[0223] Base layers 1230 and 1270 can be the same as base layer 110. In some embodiments, base layers 1230 and 1270 can include, as described herein with respect to base layer 110, a plurality of material panels 116.

[0224] In some embodiments, chamber 1280 may be a tubular chamber. In such embodiments, layered structure 1200 may form all or a portion of an article of clothing that is configured to surround a portion of a wearer's body during use. For example, layered structure 1200 may form all of a pant leg, an arm sleeve, a knee sleeve, a waistband, an elbow sleeve, an ankle sleeve, a wrist sleeve, a collar, a double panel shirt, or a portion of a fully-fashioned tubular fabric.

[0225] In some embodiments, an article of clothing, or a portion thereof, may include a thread layer (or thread pattern) configured to impart a desired shape on the article of clothing. Fig.14A and 14B Illustrated is a forming material 1400 for an article of apparel, according to some embodiments. Figures 20A-23A Shown are forming materials 2000 and 2200 for use in articles of apparel, according to some embodiments.

[0226] Material 1400 includes base layer 110 and wire layer 1420, wire layer 1420 includes wire array 1424 wound tangentially to edge 260, which defines the edge of shaped area 1410 on base layer 110. As referred to herein Figure 2C As described above with respect to the wire layer 240 in FIG. 1 , the wire array 1424 can be wrapped tangentially to the edge 260. As described herein, the tension of the wire array 1424 wrapped and attached to the base layer, the tension maintained by the base layer 110 while attached to the wire array layer 1420, or a combination thereof can produce the shaped region 1410. The wire array 1424 of the wire layer 1420 can exert a compressive force on the surface 112 of the base layer 110 along an axis extending from the first end 1426 to the second end 1428 of the wire array 1424.

[0227] The shaped region can include a curved shape relative to the shape of the base layer 110 around the edge 260. In some embodiments, the curved shape can have a maximum height 1412 and a maximum length 1414. In some embodiments, the ratio of the maximum height 1412 to the maximum length 1414 can be in the range of 5:1 to 1:20, including sub-ranges. For example, the ratio can be 5:1 to 1:20, 5:1 to 1:15, 5:1 to 1:10, 5:1 to 1:5, 5:1 to 1:4, 5:1 to 1:3, 5:1 to 1:2, 5:1 to 1:1, 5:1 to 2:1, 5:1 to 3:1, 5:1 to 4:1, 4:1 to 1:20, 3:1 to 1:20, 2:1 to 1:20, 1:1 to 1:20, 1:2 to 1:20, 1:3 to 1:20, 1:4 to 1:20, 1:5 to 1:20, 1:10 to 1:20 or 1:15 to 1:20. Unless otherwise indicated, maximum height 1412 is measured relative to a flat surface 1450 on which material 1400 is placed, wherein a portion of base layer 110 surrounding edge 260 is placed flat on surface 1450, such as Fig. 14B As shown. Fig. 14B Other than the forces shown applied to position material 1400 on surface 1450, no external loads are applied to material 1400 for purposes of measuring height 1412. Unless otherwise indicated, maximum length 1414 is defined by the maximum lateral dimension measured in a straight line along surface 1450 between opposite sides of edge 260. Fig. 14B Other than the force shown applied to position material 1400 on surface 1450 , no external load is applied to material 1400 for purposes of measuring length 1414 .

[0228] In some embodiments, material 1400 can include a plurality of shaped regions 1410 on base layer 110. In some embodiments, the plurality of shaped regions can provide a desired texture to an article of apparel including material 1400.

[0229] In some embodiments, a line layer (or line pattern) as described herein may include one or more molded parts. In some embodiments, a line layer (or line pattern) may include multiple molded parts. In some embodiments, a molded part may include a curved shape.

[0230] refer to Figures 20A-21B , material 2000 includes base layer 110 and wire layer 2020, wire layer 2020 includes wire rows 2024, wire rows 2024 are arranged in a pattern where adjacent wire rows extend linearly relative to each other, so that adjacent wire rows 2024 do not overlap. In some embodiments, adjacent wire rows 2024 may extend parallel to each other. Fig. 20A and 21AThe material 2000 is shown with the base layer 110 in a stretched position under tension. Fig. 20B and 21B The material 2000 is shown with the base layer 110 in a relaxed position with no tension applied.

[0231] In some embodiments, the rows of wires 2024 of the wire layer 2020 may exert a compressive force on the surface 112 of the base layer 110 along an axis extending from a first end 2026 to a second end 2028 of the wire row 2024. In some embodiments, the rows of wires 2024 of the wire layer 2020 may not exert a compressive force on the surface 112 of the base layer 110 along an axis extending from a first end 2026 to a second end 2028 of the wire 2024. In some embodiments, the rows of wires 2024 of the wire layer 2020 may include overlapping rows of wires.

[0232] like Fig. 20A and 21A As shown, when the base layer 110 is in the stretched position, adjacent rows of lines 2024 can be spaced apart by a spacing length 2025 on the surface 112 of the base layer 110. In some embodiments, the spacing length 2025 between adjacent rows of lines 2024 can be constant across the line layer 2020. In some embodiments, the spacing length 2025 between adjacent rows of lines 2024 can vary across the line layer 2020. In such embodiments, the spacing length 2025 can vary in the same manner as described below for the spacing lengths 2225a, 2225b.

[0233] like Fig. 20B and 21B As shown, when the base layer 110 is in a relaxed position without applied tension, the spacing between adjacent lines 2024 changes. Because the lines 2024 are attached to portions of the base layer 110, other portions of the base layer 110 between the lines 2024 are free to contract when the tension is removed, the spacing can change.

[0234] The tension-removed material 2000 may include a corrugated or curled structure including a plurality of ridges 2010 and a plurality of grooves 2018. The ridges 2010 and the grooves 2018 may be arranged in an alternating manner, wherein a groove 2018 is arranged between two ridges 2010 and a ridge 2010 is arranged between two grooves 2018. The grooves 2018 may include a concave shape formed by the surface 112 of the substrate layer 110. The ridges 2010 may include a convex shape formed by the surface 112 of the substrate layer 110. The line rows 2024 may be located within the grooves 2018 on the surface 112 of the substrate layer 110.

[0235] like Figures 20A-21BAs shown, the spacing between adjacent rows 2024 decreases from a spacing length 2025, thereby forming a ridge 2010 including a base length 2014. Unless otherwise specified, the base length 2014 is defined by the maximum transverse dimension of the ridge 2010, which is measured in a straight line in cross-section between the opposing inner surfaces of the ridge 2010 and between adjacent rows 2024. Fig. 21B As shown, the baseline length 2014 is measured parallel to the flat surface 2050. Fig. 21B Other than the force shown being applied to position the material 2000 on the surface 2050 , no external load is applied to the material 2000 in order to measure the baseline length 2014 .

[0236] In some embodiments, the baseline length 2014 can be "zero", which means that the opposing inner surfaces of the ridges 2010 are in contact on the material 2000. In some embodiments, the baseline length 2014 of the ridges 2010 can range from 0.5 centimeters (cm) to 10 cm, including sub-ranges. For example, the baseline length 2014 can range from 0.5 cm to 10 cm, from 0.5 cm to 5 cm, from 0.5 cm to 4 cm, from 0.5 cm to 3 cm, or from 0.5 cm to 2 cm. The baseline length 2014 of the plurality of ridges 2010 can be defined by the average baseline length 2014 of the ridges 2010.

[0237] In some embodiments, the ridge 2010 can include a maximum length 2016 that is greater than the baseline length 2014. In some embodiments, the ratio of the baseline length 2014 to the maximum length 2016 can be in the range of 1:1.2 to 1:10, including sub-ranges. For example, the ratio can be in the range of 1:1.2 to 1:10, 1:1.2 to 1:8, 1:1.2 to 1:6, 1:1.2 to 1:5, 1:1.2 to 1:4, 1:1.2 to 1:2, 1:1.2 to 1:1, or 1:1.2 to 1:1.5. Unless otherwise specified, the maximum length 2016 is defined by the largest lateral dimension of the ridge 2010 measured in a straight line in cross-section between the opposing inner surfaces of the ridge 2010. Similar to the baseline length 2014, the maximum length 2016 can be in the range of 1:1.2 to 1:10, including sub-ranges. For example, the ratio can be in the range of 1:1.2 to 1:10, 1:1.2 to 1:8, 1:1.2 to 1:6, 1:1.2 to 1:5, 1:1.2 to 1:4, 1:1.2 to 1:2, 1:1.2 to 1:1, or 1:1.2 to 1:1.5. Fig. 21B As shown, it is measured parallel to the planar surface 2050. The maximum length 2016 of the plurality of ridges 2010 can be defined by an average maximum length 2016 of the ridges 2010.

[0238] In some embodiments, the ridges 2010 may include a maximum height 2012 ranging from 0.5 cm to 10 cm, including sub-ranges. For example, the maximum height 2012 may be in the range of 0.5 cm to 10 cm, 0.5 cm to 5 cm, 0.5 cm to 4 cm, 0.5 cm to 3 cm, or 0.5 cm to 2 cm. The maximum height 2012 of the plurality of ridges 2010 may be defined by the average maximum height 2012 of the ridges 2010. Unless otherwise specified, the maximum height 2012 is measured relative to the flat surface 2050, such as Fig. 21B As shown. Fig. 21B Other than the forces shown applied to locate material 2000 on surface 2050 , no external loads are applied to material 2000 for purposes of measuring height 2012 .

[0239] In some embodiments, the ratio of the maximum height 2012 to the baseline length 2014 can be in the range of 20:1 to 1:5, including sub-ranges. For example, the ratio can be 20:1 to 1:5, 20:1 to 1:2, 20:1 to 1:1, 20:1 to 2:1, 20:1 to 5:1, 20:1 to 10:1, 20:1 to 15:1, 15:1 to 1:5, 10:1 to 1:5, 5:1 to 1:5, 2:1 to 1:5, 1:1 to 1:5, or 1:2 to 1:5.

[0240] refer to Figures 22A-22B , material 2200 includes a base layer 110 and a thread layer 2220, the thread layer 2220 including rows of threads 2224 arranged in a pattern, wherein the rows of threads 2224 overlap each other at intersections 2227. The rows of threads 2224 of interest may define a plurality of quadrilateral regions 2230 that are shaped when the tension applied to the base layer 110 is removed and the base layer 110 is in a relaxed state. Fig.22A and 22B A diamond-shaped quadrilateral region 2230 is shown, but the line array of interest 2224 may define any quadrilateral shape, including squares, rhombuses, rectangles, parallelograms, trapezoids, and kites. Fig.22A and 23A Material 2200 is shown with base layer 110 in a stretched position under tension. Fig. 22B and 23B The base layer 110 is shown with no tension applied to the material but in a relaxed position.

[0241] In some embodiments, the line rows 2224 of the line layer 2220 may exert a compressive force on the surface 112 of the base layer 110 along an axis extending from the first end 2226 to the second end 2228 of the line row 2224. In some embodiments, the lines 2224 of the line layer 2220 may not exert a compressive force on the surface 112 of the base layer 110 along an axis extending from the first end 2226 to the second end 2228 of the line 2224. In some embodiments, the line rows 2224 of the line layer 2220 may include overlapping line rows.

[0242] like Fig.22A and 23A As shown, when the base layer 110 is in a stretched position, adjacent rows 2224 may be spaced apart by a spacing length 2225 on the surface 112 of the base layer 110. In some embodiments, the spacing length 2225 between adjacent rows 2024 may be constant across the line layer 2220. In some embodiments, the spacing length 2225 between adjacent rows 2224 may vary on the line layer 2220. In such embodiments, the spacing length 2225 of the first plurality of rows 2224 may include a first spacing length 2225a, and the spacing length of the second plurality of rows 2224 may include a second spacing length 2225b. In some embodiments, the first spacing length 2225a may be at least 10% larger or smaller than the second spacing length 2225b. By changing the spacing length 2225 between adjacent rows 2224, the size of the ridges 2210 and the grooves 2218 may be changed according to the material 2200.

[0243] like Fig. 22B and 23B As shown, when the base layer 110 is in a relaxed position without tension applied, the spacing between adjacent lines 2224 changes. The spacing can change because the line rows 2224 are attached to portions of the base layer 110, while other portions of the base layer 110 between the line rows 2224, particularly portions of the base layer 110 in the quadrilateral regions 2230, are free to contract when the tension is removed.

[0244] The tension-removing material 2200 may include a corrugated or curled structure including a plurality of ridges 2210 and a plurality of grooves 2218. The ridges 2210 and the grooves 2218 may be arranged in an alternating manner, wherein a groove 2218 is arranged between two ridges 2210 and a ridge 2210 is arranged between two grooves 2218. The grooves 2218 may include a concave shape formed by the surface 112 of the substrate layer 110. The ridges 2210 may include a convex shape formed by the surface 112 of the substrate layer 110. The line rows 2224 may be located within the grooves 2218 on the surface 112 of the substrate layer 110.

[0245] like Figures 22A-23BAs shown, the spacing between adjacent rows 2224 is reduced from a spacing length 2225 to produce a ridge 2210 that includes a baseline length 2214. Unless otherwise indicated, the baseline length 2214 is defined by the maximum transverse dimension of the ridge 2210 measured in a straight line in cross-section between opposing inner surfaces of the ridge 2210 and between adjacent rows 2224. The baseline length 2214 is measured relative to the surface 2250 - in the same manner as described above for the baseline length 2014.

[0246] In some embodiments, the baseline length 2214 can be "zero," meaning that the opposing inner surfaces of the ridge 2210 are in contact on the material 2200. In some embodiments, the baseline length 2214 of the ridge 2210 can be any value or within any range, as described above for the baseline length 2014 of the ridge 2010. The baseline length 2214 of the plurality of ridges 2210 can be defined by an average baseline length 2214 of the ridges 2210.

[0247] In embodiments including varying interval lengths 2225, the ridges 2210 may include varying baseline lengths 2214. In such embodiments, the baseline lengths of the plurality of first ridges 2210 may include a first baseline length 2214a, and the baseline lengths of the plurality of second ridges 2210 may include a second baseline length 2214b. In some embodiments, the first baseline length 2214a may be at least 10% greater or less than the second baseline length 2214b. In some embodiments, the ridges 2210 may include a maximum length 2216 that is greater than the baseline length 2214. In some embodiments, the ratio of the baseline length 2214 to the maximum length 2216 may be within any range described above for the ratio of the baseline length 2014 to the maximum length 2016. The maximum length 2216 is measured in the same manner as described above for the maximum length 2016.

[0248] The ridge 2210 may include a maximum height 2212. The maximum height 2212 may be any value or within any range, as described above for the maximum height 2012 of the ridge 2010. The maximum height 2212 is measured in the same manner as described above for the maximum height 2012. In some embodiments, the ratio of the maximum height 2212 to the baseline length 2214a and / or the baseline length 2214b may be within any of the ranges described above for the ratio of the maximum height 2012 to the baseline length 2014.

[0249] Fig.15A molding assembly 1500 for molding a part on a wire layer 1520 is shown according to some embodiments. The molding assembly 1500 may include a support plate 1502 for supporting the wire layer 1520. In some embodiments, the support plate 1502 may include an anchor point 1590 around which the wire layer 1520 may be wrapped. The anchor point 1590 may be, for example, a pin or protrusion extending from a surface 1506 of the support plate 1502.

[0250] like Fig.15 As shown, the wire layer 1520 may be disposed on the support plate 1502 such that at least a portion of the wire layer 1520 is located within the opening 1504 defined by the support plate 1502 .

[0251] The molding assembly 1500 may also include one or more molds 1510 configured to mold a part (eg, part 1530 ) on the wire layer 1520 within the opening 1504 . In some embodiments, the molding assembly 1500 may include a plurality of molds 1510 .

[0252] Mold 1510 may include first mold plate 1512 and second mold plate 1514 defining mold cavity 1516. During use, material may flow into mold cavity 1516 through a port, such as port 1518, to mold part 1530 over or around a portion of wire layer 1520. In some embodiments, material may be injected into mold cavity 1516 through port 1518.

[0253] like Fig.15 As shown, a portion of wire layer 1520 may be disposed between first mold plate 1512 and second mold plate 1514 such that the portion of wire layer 1520 is located within mold cavity 1516. The portion of wire layer 1520 located within mold cavity 1516 may be fully or partially embedded in the material molded with mold 1510.

[0254] Fig.16 Wire layer 1520 is shown including molded parts 1530 according to some embodiments. In some embodiments, a portion of wire layer 1520 may be fully or partially embedded within each molded part 1530. In some embodiments, each molded part 1530 may be a separate part molded on a different portion of wire layer 1520.

[0255] In some embodiments, the wire layer 1520 may define a first wire layer including a wire pattern of the wire layer 1520 and a second wire layer 1522 disposed on the first wire layer 1520. In some embodiments, the second wire layer 1522 may be disposed on the molded part 1530. In some embodiments, the second wire layer 1522 may be coupled to the wire layer 1520. In some embodiments, the second wire layer 1522 may be directly coupled to the wire layer 1520. In some embodiments, the second wire layer 1522 may be coupled to the molded part 1530. In some embodiments, the second wire layer 1522 may be directly coupled to the molded part 1530.

[0256] Fig.17 A molding assembly 1700 for molding a curved part on a wire layer 1720 is shown according to some embodiments. The molding assembly 1700 may include a support plate 1702 for supporting the wire layer 1720. In some embodiments, the support plate 1702 may include an anchor point 1790 around which the wire layer 1720 may be wrapped. The anchor point 1790 may be, for example, a pin or protrusion extending from a surface 1706 of the support plate 1702.

[0257] like Fig.17 As shown, the wire layer 1720 may be disposed on the support plate 1702 such that at least a portion of the wire layer 1720 is located within an opening 1704 defined by the support plate 1702 .

[0258] Mold assembly 1700 may also include one or more molds 1710 configured to mold a part (eg, part 1730 ) on wire layer 1720 within opening 1704 . In some embodiments, molding assembly 1700 may include a plurality of molds 1710 .

[0259] Mold 1710 may include first mold plate 1712 and second mold plate 1714 defining mold cavity 1716. During use, material may flow into mold cavity 1716 through a port, such as port 1718, to mold part 1730 over a portion of wire layer 1720. In some embodiments, material may be injected into mold cavity 1716 through port 1718.

[0260] In some embodiments, first mold plate 1712 may include curved surface 1713. In some embodiments, curved surface 1713 may include a convex curvature. In some embodiments, curved surface 1713 may include a concave curvature. In use, the curved surface may be pressed against wire layer 1720 within opening 1704 so that a portion of wire layer 1720 takes on the shape of the curved surface. In such embodiments, mold 1710 may mold part 1730 having a desired concave or convex shape on wire layer 1720. In such embodiments, molded part 1730 may impart a desired shape to the portion of wire layer 1720 that is pressed against surface 1713 during molding.

[0261] In some embodiments, the second mold plate 1714 can include a curved surface 1715. In some embodiments, the curved surface 1715 can include a convex curvature. In some embodiments, the curved surface 1715 can include a concave curvature.

[0262] like Fig.17 As shown, a portion of wire layer 1720 can be disposed between first mold plate 1712 and second mold plate 1714 such that a portion of wire layer 1720 is located within mold cavity 1716 and is pressed against surface 1713. The portion of wire layer 1720 located within mold cavity 1716 can be fully or partially embedded in the material molded with mold 1710.

[0263] Fig.18 A wire layer 1720 including a curved molded part 1730 is shown according to some embodiments. In some embodiments, a portion of the wire layer 1720 can be fully or partially embedded within the molded part 1730. The molded part 1730 includes a first surface 1732 and a second surface 1734 opposite the first surface 1732. In some embodiments, the first surface 1732 can be a curved surface including a convex curvature or a concave curvature. In some embodiments, the second surface 1734 can be a curved surface including a convex curvature or a concave curvature.

[0264] In some embodiments, a portion of the wire layer 1720 may be fully or partially embedded in the second surface 1734. In such embodiments, the wire layer 1720 includes a first portion fully or partially embedded in the second surface 1734 and a second portion not embedded in the second surface 1734.

[0265] In some embodiments, wire layer 1720 may define a first wire layer of a wire pattern including wire layer 1720 and a second wire layer 1722 disposed on first wire layer 1720. In some embodiments, second wire layer 1722 may be disposed on molded part 1730. In some embodiments, second wire layer 1722 may be connected to wire layer 1720. In some embodiments, second wire layer 1722 may be directly bonded to wire layer 1720. In some embodiments, second wire layer 1722 may be bonded to surface 1732 of molded part 1730. In some embodiments, second wire layer 1522 may be directly bonded to surface 1732 of molded part 1730.

[0266] Suitable materials for molding with molds 1510, 1710 include, but are not limited to, polymer materials such as polymer foams. Suitable polymer foams include, but are not limited to, ethylene vinyl acetate (EVA) foams, polyurethane (PU) foams, or expanded thermoplastic polyurethane (eTPU).

[0267] In some embodiments, molded parts 1530, 1730 can be pads, such as cups or padding plates. In some embodiments, molded parts 1530, 1730 can be rigid components, such as shin guards or protective plates. In some embodiments, molded parts 1530, 1730 can be insulating, such as insulating plates.

[0268] Although the articles of clothing discussed herein (e.g., article of clothing 100) may be described or illustrated in the context of a particular article (e.g., a shirt), other types of clothing may include features of the described embodiments. Exemplary articles of clothing include, but are not limited to, insoles, pants, shorts, leggings, socks, jackets, coats, hats, sleeves, shoes, sweaters, shirts, jerseys, booties, gloves, sleeves, headbands, wristbands, or straps.

[0269] It should be understood that the Detailed Description section, rather than the Summary and Abstract sections, is intended to be used to interpret the claims. The Summary and Abstract sections may set forth one or more but not all exemplary embodiments of the present invention as contemplated by the inventors, and therefore, are not intended to limit the present invention and the appended claims in any way.

[0270] The present invention has been described above with the aid of functional building blocks that illustrate the implementation of specified functions and their relationships. For ease of description, the boundaries of these functional building blocks are arbitrarily defined herein. Alternative boundaries may be defined as long as the specified functions and their relationships are properly performed.

[0271] The above description of specific embodiments will fully reveal the general nature of the present invention, and others can easily modify and / or adapt various applications of these specific embodiments by applying the knowledge known to those skilled in the art, without excessive experimentation, without departing from the general concept of the present invention. Therefore, based on the teachings and guidance presented herein, such adaptations and modifications are intended to be within the meaning and scope of the equivalents of the disclosed embodiments. It should be understood that the wording or terminology herein is for descriptive purposes rather than for limiting purposes, and thus the terms or wording of this specification will be interpreted by those skilled in the art based on the teachings and guidance.

[0272] The breadth and scope of the present invention 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.

Claims

1. A clothing product, comprising: Basal layer; as well as a line layer defined by lines, the line layer comprising a plurality of lines rows, the lines rows crossing each other at overlapping points between two or more lines rows, wherein each of the lines extends continuously across the line layer, wherein the row of threads is not woven or knitted thread, wherein the row of threads is not embroidery thread sewn to the base layer, and Each of the rows of wires is directly bonded to a surface of the base layer along at least a portion of the length of the row of wires.

2. The article of clothing according to claim 1, wherein the thread layer occupies a surface area defined by thread boundaries on the surface of the base layer, in, Each of the line rows includes a first end disposed at the line boundary and a second end disposed at the line boundary.

3. The article of apparel of claim 2, wherein the first end and the second end of each of the rows of wires are directly attached to the surface of the base layer.

4. The article of apparel according to claim 1, wherein the thread layer occupies a surface area defined by a thread boundary on the surface of the base layer, wherein the base layer includes a peripheral edge surrounding the thread boundary.

5. The article of apparel of claim 1 , wherein the base layer comprises a first panel of material and a second panel of material adjacent to the first panel of material, and in, One or more of the rows of lines extend across and are directly connected to the first and second material panels.

6. The article of apparel of claim 5, further comprising a gap between the first panel of material and the second panel of material, wherein one or more of the rows of threads extend across the gap.

7. The article of apparel of claim 1, wherein the base layer comprises a first panel of material and a second panel of material joined together at a seam, and in, One or more of the rows of threads extend across the seam and are directly joined to the first and second material panels.

8. The article of apparel of claim 1, wherein each of the rows applies a compressive force on the surface of the base layer, the compressive force being applied along an axis extending from a first end to a second end of the row.

9. The article of clothing according to claim 1, further comprising a second thread layer defined by second threads, the second thread layer comprising a plurality of second thread rows, the second thread rows crossing each other at overlapping points between two or more of the second thread rows, wherein each of the second line rows extends continuously across the second line layer, The second row of threads is not woven or knitted, wherein the second row of threads is not embroidery thread sewn to the base layer, and Each of the second lines is directly bonded to the surface of the base layer along at least a portion of the length of the second line.

10. The article of apparel of claim 1, wherein each of the rows of threads is directly joined to the surface of the base layer at a perimeter of the thread layer to define a pocket between the thread layer and the base layer.

11. The article of clothing of claim 10, further comprising an insert disposed within the pocket.

12. The article of apparel of claim 11, wherein the insert comprises a shin guard.

13. The article of apparel according to claim 1, wherein the base layer comprises a foam material.

14. The article of clothing according to claim 1, wherein: The base layer is the first base layer disposed below the line layer. The article of clothing also includes a second base layer disposed above the thread layer, and Each of the rows of wires is directly bonded to a surface of the second substrate layer along at least a portion of the length of the row of wires.

15. The article of clothing according to claim 14, wherein: The substrate layer comprises a foam material, and the second substrate layer comprises a foam material.

16. A clothing article comprising: a first line layer, the first line layer comprising a first line boundary and first lines, the first lines defining a plurality of first line rows, each of the first line rows extending from a first side of the first line boundary to a second side of the first line boundary and crossing each other at overlapping points between two or more of the first line rows; a second wire layer disposed above the first wire layer and comprising a second wire boundary and second wires, the second wires defining a plurality of second wire rows, each second wire row extending from a first side of the second wire boundary to a second side of the second wire boundary and crossing each other at overlapping points between two or more of the second wire rows; as well as a base layer, the base layer being disposed between the first line layer and the second line layer; The first wire layer, the second layer, and the base layer are coupled together to form a chamber occupying a volume between the first wire layer and the second wire layer.

17. The article of apparel of claim 16, wherein a portion of the base layer defines a portion of the chamber.

18. The article of apparel of claim 16, wherein the base layer, the first thread layer, and the second thread layer are attached at a seam, the seam being located at an edge of the chamber.

19. The article of clothing according to claim 16, wherein: The plurality of first lines are directly bonded to the surface of the base layer.

20. The article of apparel of claim 16, wherein the base layer is a first base layer and the article of apparel further comprises a second base layer disposed between the first base layer and the second thread layer, and a portion of the second base layer defines a portion of the chamber.

21. The article of apparel of claim 20, wherein the first base layer, the second base layer, the first thread layer, and the second thread layer are attached at a seam, the seam being located at an edge of the chamber.

22. The article of apparel according to claim 20, wherein the plurality of second rows are directly attached to a surface of the second substrate layer.

23. The article of apparel of claim 16, wherein the chamber is filled with an insulating material.

24. The article of apparel of claim 16, wherein the chamber is filled with an insert.

25. The article of apparel according to claim 16, wherein the chamber is a tubular chamber.

26. The article of apparel of claim 25, wherein the article comprises a pant leg, an arm cuff, a knee cuff, a waistband, an elbow cuff, an ankle cuff, a wrist cuff, a collar, a two-piece shirt, or a fully fashioned tubular fabric.

27. A method of manufacturing an article of clothing, the method comprising: winding a continuous wire around a plurality of anchor points on the support plate to form a wire layer, the continuous wire comprising a plurality of wire rows, wherein each wire row extends between two corresponding anchor points; as well as Foam is injected around at least a portion of the thread layer.

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