Leak-proof lower body clothing

Abstract

A lower body garment is provided having an internal leak prevention feature, which may be achieved by an integral gusset or internal assembly disposed within an outer layer forming the lower body garment, the internal assembly including a front torso section, a rear torso section, and a crotch section, the crotch section including a spacer fabric layer configured to be disposed adjacent a body surface of a wearer, and a moisture barrier layer secured to the spacer fabric layer and configured to face outward.

Description

[Technical field]

[0001] SUMMARY OF THE DISCLOSURE Aspects of the present invention relate to leak-resistant lower body garments. [Background technology]

[0002] Women who exercise during their period may use disposable menstrual pads to prevent leakage. Similarly, women who have incontinence problems may feel the need to use disposable pads to prevent leakage. In some cases, garments may have built-in leak protection. Summary of the Invention

[0003] The following sections represent exemplary aspects of the concepts contemplated herein. Any of the following sections may be combined in a multiple dependent manner and depend on one or more other sections. Furthermore, any combination of dependent claims (sections that are explicitly dependent on a previous section) may be combined while remaining within the scope of the aspects contemplated herein. The following sections are exemplary only and not limiting.

[0004] Item 1. A lower body garment comprising: an outer layer forming a torso section, the torso section having a waist opening, a first leg opening, and a second leg opening; and an inner assembly disposed inside the outer layer, the inner assembly including a front torso section, a rear torso section, and a crotch panel between the first leg opening and the second leg opening, at least one of the front torso section or the rear torso section being bonded to the outer layer, the crotch panel including a spacer fabric layer and a moisture barrier layer secured to the spacer fabric layer.

[0005] Item 2. The lower body garment according to item 1, wherein the front torso portion of the inner assembly includes a front upper edge fixed to the outer layer, and the rear torso portion of the inner assembly includes a rear upper edge fixed to the outer layer.

[0006] Item 3. The lower-body garment according to item 1 or 2, wherein the front torso portion is located on a first side portion of the lower-body garment and has a first side edge including a lower end disposed a first distance below the waist opening, and the rear torso portion is located on the first side portion of the lower-body garment and has a first side edge including a lower end disposed a second distance below the waist opening, the second distance being greater than the first distance.

[0007] Item 4. The lower body garment according to any one of items 1 to 3, wherein the inner assembly further includes a crotch region that extends continuously between the front torso portion and the rear torso portion and includes an inward surface that faces the crotch panel.

[0008] Item 5. The lower-body garment according to any one of claims 1 to 4, wherein the front torso section has a first side edge located on a first side portion of the lower-body garment, the rear torso section has a first side edge located on the first side portion of the lower-body garment, and the first side edge of the front torso panel is spaced apart from the first side edge of the rear torso panel.

[0009] Item 6. The lower body garment according to item 5, wherein the crotch panel joins the front torso section and the rear torso section.

[0010] Item 7. Lower body clothing according to any one of items 1 to 6, in which the front and rear torso sections are treated with a durable water repellent (DWR) coating.

[0011] Item 8. The lower body garment according to any one of items 1 to 8, wherein the inner assembly further includes a crotch region that extends continuously between the front torso portion and the rear torso portion and wraps around the side edges of the crotch panel.

[0012] Item 9. The lower body garment of any one of items 1 to 8, wherein the spacer fabric layer comprises an innermost surface of the lower body garment and also comprises a first layer, a second layer, and a plurality of tie yarns interconnecting the first layer and the second layer, the plurality of tie yarns comprising an elastic yarn.

[0013] Item 10. The lower body garment according to any one of items 1 to 9, wherein the moisture barrier layer includes a thermoplastic polymer material.

[0014] Item 11. A lower-body garment according to any one of items 1 to 10, wherein the front torso portion has a first side edge located on a first side portion of the lower-body garment, and the rear torso portion has a first side edge located on the first side portion of the lower-body garment, and the first side edge of the front torso portion is assembled to the first side edge of the rear torso portion.

[0015] Item 12. A garment comprising a torso portion including a first leg opening and a second leg opening, and a crotch portion between the first leg opening and the second leg opening, the crotch portion comprising a composite textile including a spacer fabric and a moisture barrier layer, the moisture barrier layer comprising a thermoplastic polymer film.

[0016] Item 13. The garment according to item 12, wherein the crotch area further comprises a textile layer treated with a durable water repellent (DWR) solution, and at least a portion of the moisture barrier layer is layered between the spacer knit textile and the textile layer.

[0017] Item 14. The garment of item 13, wherein the spacer knit textile includes a side edge near the first leg opening, and the textile layer is wrapped around the side edge to form a hem.

[0018] Item 15. The garment of item 13, wherein the spacer knit textile includes a front edge bonded to the front of the torso, and the garment further includes a DWR-treated bonding strip at least partially overlapping the front edge and the front of the torso.

[0019] Item 16. The garment according to item 15, wherein the DWR-treated bonding strip comprises a textile layer and an adhesive layer, and the textile layer comprises a DWR solution.

[0020] Item 17. The garment according to any one of items 12 to 16, wherein the spacer fabric comprises a spacer knit textile including a first knit layer, a second knit layer, and a tie yarn connecting the first knit layer and the second knit layer.

[0021] Item 18. The garment of item 17, wherein the tie yarn includes a first yarn having a first denier and a second yarn having a second denier of a different size than the first denier.

[0022] Item 19. The garment according to any one of items 12 to 18, comprising an inner assembly and an outer layer, the torso and the crotch forming at least a part of the inner assembly, the torso including a front upper edge and a rear upper edge, and at least one of the front upper edge and the rear upper edge being assembled to the outer layer.

[0023] Item 20. The garment according to any one of items 12 to 19, wherein the garment includes an undergarment configured to be selectively worn under various outer lower body garments.

[0024] Item 21. A method for manufacturing a lower body garment, the method including the steps of: forming a torso section from an outer layer of material, the torso section having a waist opening, a first leg opening, and a second leg opening; disposing an inner assembly inside the outer layer of material, the inner assembly including a front torso panel, a rear torso panel, and a crotch panel between the first leg opening and the second leg opening; joining the front torso panel to the rear torso panel, the crotch panel including a spacer fabric layer partially forming an innermost surface of the lower body garment and a moisture barrier layer laminated to the spacer fabric layer; and fastening the inner assembly to the outer layer of material at a plurality of fastening regions.

[0025] Item 22. A method comprising assembling a crotch gusset to a front torso section and a rear torso section as part of an interior assembly of a lower body garment, the crotch gusset including a spacer fabric textile and a moisture barrier layer; securing the front torso section to an outer layer of the lower body garment, the outer layer including a torso section having a waist opening, a first leg opening, and a second leg opening; and assembling the rear torso section to the outer layer of the lower body garment.

[0026] Item 23. The method of item 22, wherein the front torso section is continuous with the rear torso section based on a crotch region extending between the front torso section and the rear torso section, and the step of assembling the crotch gusset to the front torso section and the rear torso section includes wrapping an edge of the crotch region into a side edge of a spacer fabric textile and assembling the edge of the crotch region to the spacer fabric textile.

[0027] Item 24. The method of item 22, wherein the forward fuselage section includes a side edge, and the step of fastening the forward fuselage section to the outer layer includes a step of fastening the side edge of the forward fuselage section to a side of the fuselage section, and the rear fuselage section includes a side edge, and the step of fastening the rear fuselage section to the outer layer includes a step of fastening the side edge of the rear fuselage section to the side of the fuselage section and spaced apart from the side edge of the forward fuselage section.

[0028] Item 25. The method of any one of items 22 to 24, further comprising laminating the spacer fabric textile and a moisture barrier layer.

[0029] Item 26. A lower body garment comprising a composite laminate associated with a crotch region of the lower body garment, the composite laminate comprising a spacer fabric layer and a moisture barrier layer secured to the spacer fabric layer.

[0030] Item 27. The lower body garment according to item 26, further comprising a textile layer, the moisture barrier layer being layered between the textile layer and the spacer fabric layer.

[0031] Item 28. The lower body garment according to item 27, wherein the textile layer is treated with a durable water repellent (DWR).

[0032] Item 29. The lower body garment of item 27 or 28, wherein the spacer fabric layer, the moisture barrier layer, and the textile layer include an integral crotch gusset associated with the lower body garment.

[0033] Item 30. The lower body garment according to any one of items 26 to 29, the lower body garment including a first leg portion and a second leg portion.

[0034] Item 31. The lower body garment according to any one of items 27 to 30, wherein the spacer fabric layer, the moisture barrier layer, and the textile layer comprise a crotch region of an integrated undergarment assembled inside the lower body garment.

[0035] Item 32. The lower body garment of any one of items 27 to 31, wherein the spacer fabric layer includes a first edge, the moisture barrier layer includes a second edge, and the textile layer includes a third edge that envelops the first edge and the second edge.

[0036] Item 33. The lower body garment according to any one of items 27 to 32, wherein the textile layer is laminated with a spacer fabric layer and a moisture barrier layer.

[0037] Item 34. The lower body garment of any one of items 26 to 33, wherein the composite laminate includes a second spacer fabric layer layered between the spacer fabric layer and the moisture barrier layer.

[0038] Item 35. The lower body garment according to any one of items 26 to 34, wherein the composite laminate includes a natural fiber layer layered between the spacer fabric layer and the moisture barrier layer.

[0039] Item 36. The lower body garment according to any one of items 26 to 35, wherein the spacer fabric layer includes a first knit layer, a second knit layer, and a tie yarn connecting the first knit layer and the second knit layer, and the tie yarn includes a first yarn having a first denier and a second yarn having a second denier different from the first denier. [Brief description of the drawings]

[0040] Hereinafter, examples of each aspect of the present application will be described in detail with reference to the drawings. [Figure 1] 1 shows a front view of the exterior of a first example lower body garment according to an embodiment of the present specification. [Diagram 2] 1 illustrates a rear view of the exterior of a first example lower body garment according to embodiments of the present disclosure. [Diagram 3] 2 shows a side view of the exterior of the lower body garment of the first example of FIG. 1 according to an embodiment of the present specification, and a similar view of the opposite side. [Figure 4] 1 shows a front view of the inside of a first example lower body garment according to an embodiment of the present specification. [Diagram 5] 1 shows a rear view of the inside of a first example lower body garment according to an embodiment of the present specification. [Figure 6] 2 shows a side view of the inside of a lower-body garment of the first example of FIG. 1 according to an embodiment of the present specification, and a similar view of the opposite side. [Figure 7] 2 is a bottom view of the inside of the crotch panel of the lower body garment of the first example of FIG. 1 according to an embodiment of the present specification. [Figure 8A] 1 illustrates a perspective view of a first surface of a leak-resistant composite structure for use in an exemplary lower body garment as described herein in accordance with an embodiment of the present disclosure. [Figure 8B] FIG. 8B illustrates a perspective view of the opposing second surface of the leak-resistant composite structure of FIG. 8A according to an embodiment of the present disclosure. [Figure 9] 1 illustrates a cross-section of a portion of an exemplary lower body garment described herein taken at one or more of the front and rear torso panels of an inner assembly of a lower body garment according to an embodiment of the present disclosure. [Figure 10] 1 illustrates a first exemplary cross-section taken at a crotch panel of an exemplary inner assembly of a lower body garment as described herein in accordance with aspects of the present disclosure. [Figure 11] 13 illustrates a second exemplary cross-section taken at a crotch panel of an exemplary inner assembly of a lower body garment according to embodiments described herein. [Figure 12] 1 shows a front view of the exterior of a second example lower body garment according to an embodiment of the present disclosure. [Figure 13] 1 illustrates a rear view of the exterior of a second example lower body garment according to embodiments of the present disclosure. [Figure 14] 13 shows a side view of the exterior of the second example lower body garment of FIG. 12 according to embodiments herein, with a similar view of the opposite side. [Figure 15] 1 shows a front view of the inside of a lower body garment according to a second example embodiment of the present specification. [Figure 16] 1 illustrates a rear view of the interior of a second example lower body garment according to an embodiment of the present specification. [Figure 17]13 shows a side view of the interior of the lower body garment of the second example of FIG. 12 according to embodiments herein, with a similar view of the opposite side. [Figure 18] 4 illustrates an exemplary process for incorporating a crotch panel into an inner assembly in accordance with an aspect of the present invention. [Figure 19] 10A-10C illustrate various examples of band seams used in lower body garments described herein in accordance with aspects of the present disclosure. [Figure 20] 10A-10C illustrate various examples of band seams used in lower body garments described herein in accordance with aspects of the present disclosure. [Figure 21] 1 illustrates a flow chart of an example method for manufacturing a leak-resistant lower body garment according to aspects of the present disclosure. [Figure 22A] 1 illustrates a composite textile including two or more layers of spacer fabric according to an example. [Figure 22B] 1 illustrates a composite textile including at least one additional textile layer between a spacer fabric and a moisture barrier membrane according to one example. [Figure 22C] 1 illustrates a composite textile including one or more additional textile layers assembled to a moisture barrier membrane according to an example embodiment. [Figure 23A] 1 illustrates another lower body garment having a leak-resistant composite structure according to an example of the present disclosure. [Figure 23B] 1 illustrates another lower body garment having a leak-resistant composite structure according to an example of the present disclosure. [Figure 23C] 1 illustrates another lower body garment having a leak-resistant composite structure according to an example of the present disclosure. [Figure 23D] 1 illustrates another lower body garment having a leak-resistant composite structure according to an example of the present disclosure. [Figure 23E] 1 illustrates another lower body garment having a leak-resistant composite structure according to an example of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0041] The subject matter of the present invention is described in detail herein to meet legal requirements. However, the description itself is not intended to limit the scope of the disclosure. Rather, the inventors contemplate that the claimed or disclosed subject matter may be embodied in other ways in combination with other current or future technologies to include different steps or combinations of steps similar to those described herein. Additionally, the terms "step" and / or "block" may be used herein to suggest different elements of the method used, but should not be construed as suggesting any particular order between the steps disclosed herein, unless the order of the individual steps is explicitly stated.

[0042] Women who exercise during their period may wear disposable sanitary napkins to prevent leakage. Similarly, women with incontinence issues may also feel the need to wear disposable pads to prevent leakage. These pads are often secured to clothing using a removable adhesive and discarded after use. The additional pads not only create unsightly panty lines, but they may also shift during activity, negating the protection the pads provide. Some garments with built-in leak protection are typically in the form of underwear worn as a separate item under athletic wear; these garments can be bulky, uncomfortable, and create unsightly (e.g., exaggerated) panty lines. Additionally, additional layers of clothing may be required, which can create additional costs and affect overall breathability, moisture management, thermal management (e.g., associated with heating and cooling), etc.

[0043] At least some examples of the present disclosure relate to leak-proof composite structures, textiles, or laminates that can be incorporated into various types of garments. In some examples, the composite textile can include multiple layers of textiles that cooperate with each other to absorb moisture inside the garment and reduce the likelihood of the moisture being visible (e.g., see-through) on the outside of the garment. For example, the leak-proof composite textile can include a spacer fabric combined with a moisture barrier layer, where the spacer fabric is configured to face the wearer (e.g., the inner surface of the garment). In some examples, the leak-proof composite textile can function to absorb moisture even though it is relatively thin. The leak-proof composite textile can be incorporated into various garments and in various locations within the garment. For example, the leak-proof composite can be incorporated into the crotch area of ​​a lower body garment (e.g., to help absorb and hide menstrual blood, urine, sweat, etc.).

[0044] At least some embodiments herein relate to a lower body garment (e.g., form-fitting athletic shorts, athletic capris, or pants) having built-in leak protection, the lower body garment being configured for repeated use and washable without affecting the leak protection of the garment. The built-in leak protection is achieved through the use of an inner assembly disposed within an outer layer forming the lower body garment. The inner assembly includes a front torso panel, a rear torso panel, and a crotch panel extending between the front and rear torso panels and disposed between the leg openings of the lower body garment (i.e., in the crotch region of the lower body garment). In some embodiments, the crotch panel includes a spacer fabric (e.g., a spacer knit textile, a spacer mesh textile, or other type of spacer fabric) configured to be disposed adjacent to a body surface of the wearer, and a moisture barrier layer secured to the spacer fabric and configured to face outward (i.e., away from the body surface of the wearer). Bodily fluids produced by the wearer, such as menstrual blood and / or urine, may be stored in a space between the first and second layers of the spacer fabric. The moisture barrier layer prevents bodily fluids leaking through the spacer fabric from leaking onto the outer layer. The different parts of the inner assembly are patterned and secured to the outer layer in a way that minimizes panty lines, which is important considering how the lower body garment is form-fitting. The result is an athletic garment with a clean aesthetic and aerodynamic profile that women can wear repeatedly throughout their menstrual period or as needed.

[0045] As used herein, the term "lower body garment" refers to a garment that is configured to be worn on the lower body of a wearer. Lower body garments may take the form of legless underwear-type garments (e.g., brief-style underwear), boxer briefs, boy-short style underwear, shorts, capri pants, leggings, and the like. When a lower body garment is described as "form-fitting," it means that the lower body garment conforms closely to the basic body shape of the wearer. This is typically achieved through the use of elastic yarns that have stretch and recovery properties.

[0046] The positional terms used in describing the lower body garment relate to the lower body garment being worn as intended with the wearer standing upright. In the embodiments herein, the lower body garment is intended to be worn with the spacer mesh layer of the crotch panel in contact with the wearer's body surface, since wearing the garment inside-out would not achieve the intended purpose of the garment (e.g., leak prevention). As used herein, the term "front torso" refers to the portion of the lower body garment configured to be positioned adjacent to the wearer's front lower torso region, and as used herein, the term "rear torso" refers to the portion of the lower body garment configured to be positioned adjacent to the wearer's rear lower torso region. As used herein, the term "side" refers to the portion of the lower body garment configured to be positioned adjacent to the wearer's side torso region and / or side leg region. As used herein, the term "crotch" refers to the portion of the lower body garment configured to be positioned adjacent to the wearer's crotch region, as that term is generally recognized.

[0047] As used in this specification, the terms "upper" and "lower" are relative terms, e.g., the "upper edge" is located closer to the waist opening of the lower body garment than the "lower edge", and the "lower edge" is located closer to the leg openings of the lower body garment than the "upper edge".

[0048] The terms "outer" and "inner" as used herein are relative terms, with an outer layer being positioned outside one or more inner layers, and an inner layer being positioned inside one or more outer layers. In an exemplary embodiment, the outer layer is exposed to the external environment, and the inner layer is not exposed to the external environment. The term "innermost surface" as used in reference to a lower body garment refers to the layer that is closest to the wearer's body surface compared to other layers of the lower body garment. The term "outermost surface" as used in reference to a lower body garment refers to the layer that is closest to the external environment compared to other layers of the lower body garment.

[0049] The term "spacer fabric" as used herein is meant to encompass both warp knitted and weft knitted spacer knit textiles. Spacer fabrics are generally formed by interweaving a first layer and a second layer of a textile using at least one tie yarn. More specifically, each of the first and second layers are knitted separately, and the tie yarn(s) are used to connect the first and second layers. For example, the tie yarn may have a "loop" portion that extends through each of the first and second layers, and the loop portion is interweaved with the yarns of the first and second layers to connect the two layers. In an exemplary embodiment, the tie yarn is oriented generally perpendicular to the surface plane of the first and second layers and serves to space the first and second layers apart. As a result, a space is formed between the first and second layers that may be used to hold or store liquids, such as menstrual fluid and / or urine. Because the first and second layers are knitted separately, each of the first layer, second layer, and tie yarn may be knitted with different yarns and / or different yarn types. For example, the tie yarns can include different construction materials and / or different sizes (eg, different lengths between knit layers, different diameters, different denier, etc.).

[0050] As used herein, the term "moisture barrier layer" generally refers to a layer that is impermeable or substantially impermeable to the penetration of moisture, particularly moisture in liquid form. The layer may be in the form of a waterproof film, such as, for example, a thermoplastic polymer (e.g., a thermoplastic elastomer film), although other types of films are contemplated herein.

[0051] In exemplary embodiments, the moisture barrier layer may be secured to the spacer fabric layer by a lamination process (e.g., a dot adhesive lamination process) such that the spacer fabric layer and the moisture barrier layer form a composite, unitary structure. In at least some examples, the dot adhesive lamination process can improve flexibility of the laminate structure as compared to alternative lamination processes in which the adhesive or pressure sensitive adhesive is more widely distributed.

[0052] In at least some instances, the moisture barrier layer allows at least some vapor to pass through and is substantially impermeable to moisture penetration (e.g., liquid moisture penetration) and significantly impedes moisture from completely penetrating the moisture barrier layer (e.g., significantly impedes complete penetration from one side of the film to the other side).

[0053] As used herein, the term "about" means within ±10% of a given value.

[0054] 1-3 respectively show a front view, a back view, and a side view of the exterior of a first example lower-body garment 100, which exterior is visible to an observer observing the lower-body garment 100 worn by a wearer. The lower-body garment 100 is shown in the form of short pants, but embodiments of the present specification contemplate that the lower-body garment 100 may be in the form of "underwear-type" garments (which may be called boy shorts), capri pants, leggings, unitards, and the like.

[0055] In an exemplary embodiment, the exterior of the lower body garment 100 is formed from an outer layer 110, which forms a torso region 111 including a front torso region 112 (see FIG. 1) and a rear torso region 210 (see FIG. 2) that together at least partially define a waist opening 116. In an exemplary embodiment, the lower body garment 100 may optionally include a waistband 114 that further defines the waist opening 116. The outer layer 110 also optionally forms a first leg portion 118 having a first leg opening 120 and a second leg portion 122 having a second leg opening 124. In an exemplary embodiment in which the lower body garment 100 does not include first and second leg portions 118 and 122, the first and second leg openings 120 and 124 may be located in the torso region 111 (similar to an undergarment type garment). In the side view of the lower body garment 100 shown in FIG. 3, the outer layer 110 further includes a side panel 310 extending generally vertically from a lower edge of the waistband 114 to the first leg opening 120. The side panel 310 may be formed from the same material as the outer layer 110. The opposite side view of the lower body garment 100 also includes a side panel extending from a lower edge of the waistband 114 to the second leg opening 124. Thus, the description of the side panel 310 is also applicable to the opposite side located side panel. The side panel 310 may be a separate panel secured or joined at a first seam 312 and a second seam 314 to the portions of the outer layer 110 forming the front torso section 112, the first leg section 118, and the rear torso section 210. The first seam 312 and the second seam 314 may be formed using fastening techniques such as stitching, bonding, adhesives, welding, and the like.

[0056] In an exemplary embodiment, the outer layer 110 includes, for example, a knit or woven textile with elastic yarns. As used herein, the term "elastic yarn" refers to a yarn that has stretch and recovery properties, where the elastic yarn may stretch to about 100% to 200% of its resting length and substantially return to its resting length when the stretching force is removed. In examples including elastic yarns, the outer layer 110 may closely conform to the basic morphology of the wearer (i.e., the outer layer 110 fits snugly to the body), as shown in Figures 1-3. In at least some examples, the outer layer 110 may have a looser fit (e.g., a looser fit than a tight style lower body garment). In some examples, the outer layer may include yarns that are less elastic (e.g., stretch less than 100% of their resting length and return to their resting length) or yarns that are considered inelastic (e.g., as that term is understood in the industry). The lower body garment 100 includes an exemplary panel structure (e.g., exemplary panel sizes, shapes, etc.) that form the main body of the lower body garment 100, and in other examples, the lower body garment may include different panel structures (e.g., panels having different sizes, shapes, positions, etc.).

[0057] 4-6 respectively show front, back, and side views of the lower body garment 100 as viewed from the inside of the lower body garment 100 based on the respective reference positions identified in FIG. 1 and FIG. 3 (e.g., the inside is not necessarily visible to an observer viewing the lower body garment 100 worn by a wearer). In an exemplary embodiment, the lower body garment 100 includes an inner assembly generally referenced by the numeral 405. With reference to FIG. 4, the inner assembly 405 includes a front torso portion 410 (shown hatched) configured to cover the front lower body of a wearer. In an exemplary embodiment, as shown, the front torso portion 410 does not include a leg portion.

[0058] In some examples, the front torso portion 410 can include a front portion of a larger brief-type article that is coupled to the inside of the lower body garment 100. In some examples, the front torso portion 410 can continue through the crotch region of the brief-type article and transition to the rear torso portion (e.g., rear torso portion 510 of FIG. 5), an example similar to which is also shown with respect to FIG. 18. In some examples, the front torso portion 410 can include a panel that is attached to the crotch panel 412 (e.g., the front torso portion 410 terminates at the crotch panel 412 and does not penetrate the crotch region).

[0059] The front torso portion 410 includes a front upper edge 414 and a front lower edge 416. In an exemplary embodiment, the front upper edge 414 is permanently secured to the outer layer 110, for example, by stitching, gluing, or the like. Further, in an exemplary embodiment, the front upper edge 414 is permanently secured adjacent the waist opening 116 (e.g., by about 0.1 mm to about 8 cm). If the lower body garment 100 includes a waistband, such as the waistband 114, the front upper edge 414 is permanently secured to a lower edge of the waistband 114. In an exemplary embodiment, the front lower edge 416 is a free end edge that is not secured or attached to the outer layer 110. In a further exemplary embodiment, the front lower edge 416 may include an uncut edge of the material used to form the front torso portion 410. In other words, the front bottom edge 416 is not hemmed and does not include trim pieces, which may provide a clean aesthetic and minimize the appearance of panty lines on the lower body garment 100. Figure 4 further illustrates a portion of the crotch panel 412, which is described in more detail below.

[0060] 5, the inner assembly 405 further includes a rear torso section 510 (shown with hatching) configured to cover the rear lower body of the wearer. In some examples, the rear torso section 510 may include a rear portion of a larger brief-type article coupled to the inside of the lower body garment 100. In some examples, the rear torso section 510 may continue through the crotch region of the brief-type article and transition into the front torso section 410, an example similar to this is also shown with respect to FIG. 18. In some examples, the rear torso section 510 may include a panel that is attached to the crotch panel 412 (e.g., the rear torso section 510 may terminate at the crotch panel 412 and not pass through the crotch region).

[0061] In an exemplary embodiment, the rear torso section 510 does not include legs, as shown. The rear torso section 510 includes a rear upper edge 512 and a rear lower edge 514. In an exemplary embodiment, the rear upper edge 512 is permanently secured to the outer layer 110, for example, by stitching, banding, or the like. Further, in an exemplary embodiment, the rear upper edge 512 is permanently secured adjacent the waist opening 116 (e.g., by about 0.1 mm to about 8 cm). If the lower body garment 100 includes a waistband, such as the waistband 114, the rear upper edge 512 is permanently secured to a lower edge of the waistband 114. In an exemplary embodiment, the rear lower edge 514 is a free end edge that is not secured or attached to the outer layer 110. In a further exemplary embodiment, the rear lower edge 514 may include an uncut edge of the material used to form the rear torso section 510. In other words, the rear lower edge 514 is not hemmed and does not include a trim piece, which may provide a clean aesthetic and may minimize the appearance of panty lines on the lower body garment 100. FIG.

[0062] In an exemplary embodiment, both the front torso section 410 and the rear torso section 510 may be formed of a lightweight knit material having elastic yarns. For example, the material forming the front torso section 410 and the rear torso section 510 may have a weight of about 100 grams per square meter (gsm) to about 150 gsm, about 120 gsm to about 140 gsm, or about 125 gsm. The lightweight properties of the material may be achieved by using a single knit construction, such as a single knit plain tricot. In an exemplary embodiment, the material may include both polyester yarns and elastic yarns to provide a soft feel and good moisture management properties while achieving a desired degree of stretch and recovery. For example, the material may include about 60% polyester, including recycled polyester, and about 40% elastane.

[0063] In at least some examples, the forward and rear torso sections 410, 510 can include moisture barrier properties. For example, the textiles forming the forward and rear torso sections 410, 510 can include a durable water repellent (DWR) treatment. In some examples, the DWR is applied to one or both sides of the textile (e.g., the inward and / or outward facing surfaces).

[0064] In some examples, the textiles forming the front and rear torso sections 410 and 510 are treated with a DWR during padding and then heat set. In some cases, the fabric is soaked in a DWR solution that is incorporated throughout the textile. In some examples, the DWR is integrated into the yarn(s) that make up the front and rear torso sections 410 and 510.

[0065] 6 illustrates a side view of a lower body garment 100 including a side panel 310 formed from the outer layer 110. As shown, the front torso portion 410 includes a first side edge 610 having an upper end 612 and a lower end 614. In the exemplary embodiment, the first side edge 610 is secured to the side panel 310 of the outer layer 110 at a first seam 312 along its length 626. In the exemplary embodiment, the lower end 614 of the first side edge 610 is disposed a first distance 622 below the waist opening 116.

[0066] The rear torso section 510 also includes a first side edge 616 having an upper end 618 and a lower end 620. In the exemplary embodiment, the first side edge 616 is secured to the side panel 310 at a second seam 314 along a length 628 thereof. Additionally, the lower end 620 of the first side edge 616 is disposed a second distance 624 below the waist opening 116, the second distance 624 being greater than the first distance 622. In other words, the length 626 of the first side edge 610 of the front torso section 410 is less than the length 628 of the first side edge 616 of the rear torso section 510. As shown in FIG. 6, the first side edge 610 of the front torso section 410 is spaced apart from the first side edge 616 of the rear torso section 510 by the side panel 310, and the first side edge 610 is not assembled to or directly secured to the first side edge 616. The same configuration is present on a second, opposite side of the lower body garment 100 .

[0067] For example, the configuration shown in FIG. 6 provides several different advantages. For example, in a conventional undergarment having a front torso panel and a rear torso panel, the respective side edges are equal in length, allowing them to be joined or assembled at the sides of the undergarment without excess material. This limits how the front and rear panels can be patterned. By separating the front torso section 410 from the rear torso section 510 at their respective first side edges 610 and 616, the panels 410 and 510 may be patterned in a manner that provides a functional advantage to the wearer when wearing the lower body garment 100. For example, the front lower edge 416 may be positioned significantly higher than the rear lower edge 514 to provide a generally unrestricted range of motion when the wearer lifts the leg forward. In other words, the front lower edge 416 is positioned generally above the hip flexion area. This is accomplished, at least in part, by positioning the lower end 614 of the first side edge 610 of the front torso section 410 closer to the waist opening 116 than the lower end 620 of the first side edge 616 of the rear torso section 510. This configuration also minimizes panty lines. The rear lower edge 514 may be positioned significantly lower than the front lower edge 416 to fully cover the wearer's buttocks. In other words, the rear lower edge 514 may be positioned below the crease of the buttocks. This is accomplished, at least in part, by positioning the lower end 620 of the first side edge 616 of the rear torso section 510 farther from the waist opening 116 compared to the lower end 614 of the first side edge 610 of the front torso section 410. This configuration also minimizes panty lines. Figures 4-6 show an example in which the respective side edges of the front and rear sections are spaced apart and not directly connected to each other (e.g., along a side seam). In at least some examples, the side edges of each of the forward and aft fuselage sections may be joined along the side edges.

[0068] As mentioned above, the inner assembly 405 further includes a crotch panel 412, shown in Figures 4 and 5, and further shown in Figure 7. The crotch panel 412 is located between the first leg opening 120 and the second leg opening 124. In some examples, the crotch panel 412 extends between the front torso section 410 and the rear torso section 510, thereby joining the front torso section 410 to the rear torso section 510. In some examples, the front torso section 410 and the rear torso section 510 are connected by a crotch region portion (e.g., a continuous panel of material), and the crotch panel 412 is joined to the crotch region.

[0069] The crotch panel 412 is sized and positioned to cover the groin area of ​​a wearer, particularly a female wearer. With reference to FIG. 7 , the crotch panel 412 includes a front edge 710 joined near the front torso section 410 and a rear edge 712 joined near the rear torso section 510. In examples, the front edge 710 and the rear edge 712 are not assembled to the outer layer 110 to allow relative movement of the crotch panel 412 with respect to the outer layer 110. The crotch panel 412 further includes a first side edge 714 and an opposing second side edge 716. In an exemplary embodiment, the first side edge 714 and the second side edge 716 are not secured to or assembled to the outer layer 110, which also facilitates relative movement of the crotch panel 412 with respect to the outer layer 110. The size and shape of the crotch panel 412 may be configured to minimize the surface area of ​​the crotch panel 412 while still providing sufficient coverage surface area to capture, for example, menstrual blood, urine, etc. In some examples, the crotch panel 412 may include a size different than that shown in FIG. 7. For example, the rear edge 712 may extend further up the rear torso portion 510. In some examples, the rear edge 712 extends to a yoke seam and is attached near the yoke seam. In some examples, the rear edge 712 extends to a waistband and is attached near the waistband.

[0070] In at least some examples, the crotch panel 412 includes a spacer fabric layer 718 that forms at least a portion of an inwardly facing surface 720 of the lower body garment 100 such that the spacer fabric layer 718 contacts the wearer's crotch area when the lower body garment 100 is worn. In an exemplary embodiment, as shown in Figures 8A and 8B, a moisture barrier layer (not shown in Figure 7) is secured to an outwardly facing surface of the spacer fabric layer 718 to form a leak-proof composite structure.

[0071] 8A shows a perspective view of a first surface 810 of a leak-proof composite structure 800 that may at least partially form the crotch panel 412. The first surface 810 may correspond to the inwardly facing surface 720 of the crotch panel 412. FIG 8B shows a perspective view of an opposing second surface 826 of the leak-proof composite structure 800. The second surface 826 may correspond to the outwardly facing surface of the crotch panel 412 in some embodiments.

[0072] The leak-proof composite structure 800 includes the spacer fabric layer 718 of the crotch panel 412. A first surface 810 of the leak-proof composite structure 800 corresponds to a first surface of the spacer fabric layer 718. A moisture barrier layer 814 is secured to an opposing second surface 816 of the spacer fabric layer 718 to form a second surface 826 of the leak-proof composite structure 800.

[0073] As shown in the enlarged view, the spacer fabric layer 718 includes a first layer 818 forming a first surface 810, an opposing second layer 820 forming a second surface 816 of the spacer fabric layer 718, and a plurality of tie yarns 822 interconnecting the first layer 818 and the second layer 820. The plurality of tie yarns 822 are oriented generally perpendicular to the surface planes of the first layer 818 and the second layer 820, respectively. In an exemplary embodiment, the spacer fabric layer 718 may have a weight of about 200 gsm to about 300 gsm, about 220 gsm to about 280 gsm, or about 240 gsm. In an exemplary embodiment, the first layer 818 and the second layer 820 may be formed from the same yarn type. For example, both the first layer 818 and the second layer 820 may comprise about 60% polyester and about 40% elastane, about 65% polyester and about 35% elastane, or about 66% polyester and about 34% elastane, including recycled polyester. In some examples, the polyester is recycled polyester, virgin polyester, or a combination thereof. The polyester yarn, in an exemplary embodiment, can wick menstrual blood and / or urine into the space between the first layer 818 and the second layer 820 by capillary action between the filaments forming the individual yarns and between the yarns themselves.

[0074] In some examples, the first layer 818 and the second layer 820 can include 30D / 36F polyester (eg, virgin or recycled) and 20D elastane.

[0075] The plurality of tie yarns 822 may include an elastic yarn (e.g., elastane). For example, the tie yarns 822 may include an elastic yarn of about 40 denier.

[0076] In some examples, the first layer 818 and the second layer 820 can be formed of different yarn types. For example, the first layer 818 can include a more hydrophilic yarn. In some examples, the tie yarns 822 can include various properties such as construction materials, denier, etc. For example, tie yarns within the same spacer fabric panel can include different construction materials and / or different sizes (e.g., different lengths between knit layers, different diameters, different denier, etc.).

[0077] In an exemplary embodiment, the moisture barrier layer 814 is secured to the spacer fabric layer 718 by a lamination process to form a coherent, unitary structure. In an exemplary embodiment, the lamination process may include a dot lamination process. As previously described, the moisture barrier layer 814 may be formed of a material that is substantially or completely impermeable to water or liquids, including menstrual blood and / or urine. In one example, the moisture barrier layer 814 may include a thermoplastic material (e.g., a film), such as a thermoplastic elastomer (TPE) film, although other impermeable materials are contemplated within the embodiments herein. In some examples, the moisture barrier layer 814 is relatively thin. For example, the thickness of the moisture barrier layer 814 may range from about 10 micrometers to about 15 micrometers. In some examples, the thickness of the moisture barrier layer 814 is about 12 micrometers. The relatively thin structure of the moisture barrier layer 814 contributes to a thin overall structure, at least in some cases, which can provide a less bulky (yet still absorbent) textile for imparting leak-proofing to various garments.

[0078] 9-11 show example cross-sections of different portions of the lower body garment 100. For example, FIG. 9 shows example cross-sections taken at the front torso section 410 and / or the rear torso section 510. As shown, the front torso section 410 and / or the rear torso section 510 are disposed adjacent to the wearer's skin surface 910 and further disposed inside the outer layer 110. The front torso section 410 and / or the rear torso section 510 are not assembled or attached to the outer layer 110 as shown, except for the top edges 414 and 512 and the respective side edges 610 and 616 of the front torso section 410 and the rear torso section 510, respectively.

[0079] FIG. 10 illustrates a first exemplary cross-section taken in an area of ​​the lower body garment 100 corresponding to the crotch panel 412. As shown, the spacer fabric layer 718 is disposed adjacent to the wearer's skin surface 1010, and the moisture barrier layer 814 is secured to the spacer fabric layer 718. In at least some examples, the additional layer 1012 is disposed outside the moisture barrier layer 814, and the additional layer 1012 may include continuous extensions of the front torso section 410 and the rear torso section 510. The additional layer 1012 may be wrapped around the first and second side edges 714 and 716 of the crotch panel 412 to prevent the edges of the moisture barrier layer 814 from contacting, for example, the wearer's legs, improving comfort for the wearer. The outer layer 110 of the lower body garment 100 is disposed outside the additional layer 1012. As shown, the outer layer 110 may not be secured directly to the additional layer 1012.

[0080] 11 illustrates a second exemplary cross-section taken in an area of ​​the lower body garment 100 corresponding to the crotch panel 412. As illustrated, the spacer fabric layer 718 is positioned adjacent to the wearer's skin surface 1110, and the moisture barrier layer 814 is secured to the spacer fabric layer 718. The cross-section illustrated in FIG. 11 does not include the additional layer 1012. As such, the outer layer 110 of the lower body garment 100 is positioned outside the moisture barrier layer 814. As illustrated, the outer layer 110 may not be secured directly to the moisture barrier layer 814, and there may be a potential space between the outer layer 110 and the moisture barrier layer 814.

[0081] 12-17 show a second example lower body garment 1200 having a built-in leak prevention portion in accordance with embodiments herein. FIGS. 12-14 show front, back, and side views, respectively, of the exterior of lower body garment 1200. Lower body garment 1200 is shown in the form of short pants, although embodiments herein contemplate that lower body garment 1200 may be in the form of "underwear-type" garments (also known as boy shorts), capri pants, leggings, unitards, and the like.

[0082] In an exemplary embodiment, the exterior of the lower body garment 1200 is formed from an outer layer 1210 that forms a torso portion 1211 including a front torso portion 1212 (see FIG. 12) and a rear torso portion 1310 (see FIG. 13), which together at least partially define a waist opening 1216. In an exemplary embodiment, the lower body garment 1200 may optionally include a waistband 1214 that further defines the waist opening 1216. The outer layer 1210 also optionally forms a first leg portion 1218 having a first leg opening 1220 and a second leg portion 1222 having a second leg opening 1224. In the exemplary embodiment, the lower body garment 1200 does not include first and second leg sections 1218 and 1222, but rather first and second leg openings 1220 and 1224 are located in the torso section 1211 (similar to an undergarment type garment).

[0083] In the side view of the lower body garment 1200 shown in FIG. 14, the outer layer 1210 further includes a side panel 1410 that extends generally vertically from a lower edge of the waistband 1214 to the first leg opening 1220. The opposite side view of the lower body garment 1200 also includes a side panel that extends from a lower edge of the waistband 1214 to the second leg opening 1224. Thus, the description of the side panel 1410 is also applicable to the opposite side located side panel. The side panel 1410 may be a separate panel that is secured or joined at a first seam 1412 and a second seam 1414 to the portions of the outer layer 1210 that form the front torso section 1212, the first leg section 1218, and the rear torso section 1310. The first seam 1412 and the second seam 1414 may be formed using fastening techniques such as stitching, bonding, adhesives, welding, and the like.

[0084] Similar to outer layer 110, outer layer 1210 may be constructed, for example, from a knit or woven textile having elastic yarns. Because outer layer 1210 is formed at least in part using elastic yarns, outer layer 1210 closely conforms to the morphology of the wearer's underlying layers (i.e., outer layer 1210 is form-fitting), as shown in Figures 12-14. 15-17 show front, back, and side views, respectively, of the lower body garment 1200, from the inside of the lower body garment 1200, which is not visible to an observer viewing the lower body garment 1200 worn by a wearer. In an exemplary embodiment, the lower body garment 1200 includes an inner assembly, generally designated 1505. With reference to FIG. 15, the inner assembly 1505 includes a front torso panel 1510 (shown in cross-hatched form) configured to cover the front lower body of a wearer. In an exemplary embodiment, as shown, the front torso panel 1510 does not include legs.

[0085] The front torso panel 1510 includes a front upper edge 1514 and a front lower edge 1516. In an exemplary embodiment, the front upper edge 1514 is permanently secured to the outer layer 1210, for example, by stitching, banding, or the like. Further, in an exemplary embodiment, the front upper edge 1514 is permanently secured adjacent the waist opening 1216 (e.g., by about 0.1 mm to about 4 cm). If the lower body garment 1200 includes a waistband, such as the waistband 1214, the front upper edge 1514 is permanently secured to a lower edge of the waistband 1214. In an exemplary embodiment, the front lower edge 1516 is a free end edge that is not secured or attached to the outer layer 1210. In a further exemplary embodiment, the front lower edge 1516 may include a raw cut edge of the material used to form the front torso panel 1510. In other words, the front bottom edge 1516 is not hemmed and does not include a trim piece, which may provide a clean aesthetic and minimize the appearance of panty lines in the lower body garment 1200. FIG.

[0086] 16, the inner assembly 1505 further includes a rear torso panel 1610 (shown hatched) configured to cover the rear lower torso of the wearer. In the illustrated embodiment, the rear torso panel 1610 does not include legs, as shown. The rear torso panel 1610 includes a rear upper edge 1612 and a rear lower edge 1614. In the illustrated embodiment, the rear upper edge 1612 is permanently secured to the outer layer 1210, e.g., by stitching, banding, or the like. Further, in the illustrated embodiment, the rear upper edge 1612 is disposed below the front upper edge 1514 of the front torso panel 1510 relative to the waist opening 1216. If the lower body garment 1200 includes a waistband, such as the waistband 1214, the rear upper edge 1612 is permanently secured below a lower edge of the waistband 1214, e.g., about 2 cm to about 15 cm below the lower edge of the waistband 1214. In an exemplary embodiment, the rear lower edge 1614 is a free ending edge that is not secured or attached to the outer layer 1210. In a further exemplary embodiment, the rear lower edge 1614 may comprise a raw cut edge of the material used to form the rear torso panel 1610. In other words, the rear lower edge 1614 may not be hemmed or include a trim piece, providing a clean aesthetic and minimizing the appearance of panty lines in the lower body garment 1200. FIG. 16 further illustrates a portion of the crotch panel 412. In an exemplary embodiment, both the front torso panel 1510 and the rear torso panel 1610 may be formed of a lightweight knit material having elastic and polyester yarns, the same as described with respect to the front torso portion 410 and the rear torso portion 510 of the lower body garment 100.

[0087] 17 illustrates a side view of the interior of a lower body garment 1200 including a side panel 1410 formed from an outer layer 1210. As shown, the front torso panel 1510 includes a first side edge 1710 having an upper end 1712 and a lower end 1714. In the exemplary embodiment, the first side edge 1710 is secured to the side panel 1410 of the outer layer 1210 at a first seam 1412 along its length 1726. In the exemplary embodiment, the upper end 1712 of the first side edge 1710 is disposed a distance 1722 below the waist opening 1216. The rear torso panel 1610 further includes a first side edge 1716 having an upper end 1718 and a lower end 1720. In the exemplary embodiment, the first side edge 1716 is secured to the side panel 1410 at a second seam 1414 along its length 1728. Additionally, an upper end 1718 of the first side edge 1716 is disposed below the waist opening 1216 by a distance 1724, which is greater than the distance 1722. As shown in FIG. 17 , the first side edge 1710 of the front torso panel 1510 is spaced from the first side edge 1716 of the rear torso panel 1610 by the side panel 1410 such that the first side edge 1710 is not assembled to or directly secured to the first side edge 1716. A similar configuration is present on a second, opposite side of the lower body garment 1200.

[0088] As with the lower body garment 100, the configuration shown in FIG. 17, for example, provides various advantages. By separating the front torso panel 1510 from the rear torso panel 1610 at their respective first side edges 1710 and 1716, the front lower edge 1516 may be positioned significantly higher than the rear lower edge 1614, providing a generally unrestricted range of motion when the wearer lifts the leg in a forward direction (e.g., the front lower edge 1516 is positioned above the hip flexion area). This is accomplished, at least in part, by positioning the lower end 1714 of the first side edge 1710 of the front torso panel 1510 closer to the waist opening 1216 than the lower end 1720 of the first side edge 1716 of the rear torso panel 1610. This configuration also minimizes panty lines. The rear lower edge 1614 may be positioned significantly lower than the front lower edge 1516 (e.g., the rear lower edge 1614 may be positioned below the buttocks crease) to fully cover the wearer's buttocks. This is accomplished, at least in part, by positioning the lower end 1720 of the first side edge 1716 of the rear torso panel 1610 farther from the waist opening 1216 as compared to the lower end 1714 of the first side edge 1710 of the front torso panel 1510. This configuration also minimizes panty lines.

[0089] Additionally, positioning the rear upper edge 1612 of the rear torso panel 1610 lower or below the front upper edge 1514 of the front torso panel 1510 may result in only fuller, rounder portions of the wearer's buttocks being covered by the rear torso panel 1610, thereby minimizing material waste. In other words, positioning the top end 1718 of the first side edge 1716 of the rear torso panel 1610 a greater distance (e.g., distance 1724) below the waist opening 1216 compared to the top end 1712 of the first side edge 1710 of the front torso panel 1510 (e.g., distance 1722) will result in only fuller, rounder portions of the wearer's buttocks being covered by the rear torso panel 1610, thereby minimizing material waste. FIGS. 12-16 show an example in which the back upper edge 1612 is lower. In other examples, the rear top edge 1612 may extend all the way to the waist opening and / or waistband 1214 (eg, the rear top edge 1612 may be attached above the yoke seam near the waistband 1214).

[0090] 18 illustrates examples of how the crotch panel 412 may be incorporated into various types of lower body garments or inner assemblies, such as lower body garment 100, lower body garment 1200, lower body garment 2310, or other lower body garments described in this disclosure, or their equivalents. Reference numeral 1810a illustrates a portion of an inner assembly including a front torso section 1812 (which may be front torso section 410 or 1510), a rear torso section 1814 (which may be rear torso section 510 or 1610), and a crotch region 1816 that extends continuously between the front torso section 1812 and the rear torso section 1814. In an exemplary embodiment, the front torso section 1812, the rear torso section 1814, and the crotch region 1816 may include continuous panels of material without seams.

[0091] At reference numeral 1810b, a leak-proof composite structure 1818, which may be the leak-proof composite structure 800, is disposed on an inwardly facing surface of the crotch region 1816 (e.g., configured to face toward the wearer) and secured thereto as described with respect to FIGS. 19 and 20. In examples, the material forming the crotch region 1816 can protect a moisture barrier layer (e.g., 814) associated with the leak-proof composite structure 1818. For example, the material forming the crotch region 1816 (and the front torso portion 1812 and the rear torso portion 1814) can include a DWR-treated textile, such as a DWR-treated knit textile (e.g., similar to the knit textile forming portions 410 and 510). The leak-proof composite structure 1818 includes a front edge 1820, a rear edge 1822, a first side edge 1824, and an opposing second side edge 1826.

[0092] FIG. 19 illustrates an example of one method of securing the leading edge 1820 and / or trailing edge 1822 of the leak-proof composite structure 1818 to the front torso section 1812 and / or rear torso section 1814, respectively. In one exemplary embodiment, a banding strip 1910, such as a hot melt tape or other type of adhesive tape, may be positioned to cover the leading edge 1820 and / or trailing edge 1822 of the leak-proof composite structure 1818 and also partially cover the front torso section 1812 and / or rear torso section 1814. Upon application of heat and / or pressure to the banding strip 1910, the leading edge 1820 and / or trailing edge 1822 are banded to the respective front torso section 1812 and / or rear torso section 1814. For example, the use of banding strips rather than stitching creates a low profile banded area, minimizes panty lines, and reduces the possibility of chafing due to threads used in stitching.

[0093] In at least some examples, the banding strip 1910 can include a multi-layer banding strip including an outer textile layer (e.g., knit, nonwoven, or woven) on the exterior surface 1912 and an inner adhesive layer on the interior surface 1914 and between the outer textile layer and the water-leakage-resistant composite structure 1818. In some examples, the outer textile layer includes a knit textile (e.g., similar to the knit textile forming portions 410, 510, 1812, and 1814). In some examples, the outer textile layer may include a DWR-treated textile layer. The multi-layer banding strip can function in some cases to help seal the edges (e.g., 1820) of the water-leakage-resistant composite structure 1818 to reduce the possibility of moisture leaking through. Additionally, the outer textile layer can provide a softer finish (e.g., compared to exposed seam tape, stitching, or other seaming structures) to reduce the possibility of discomfort to the wearer.

[0094] FIG. 20 illustrates one method of finishing the first and second side edges 1824 and 1826 of the leak-resistant composite structure 1818. As shown, material from the crotch region 1816 may be wrapped around each of the first and second side edges 1824 and 1826 and secured thereto using an adhesive tape 2020, such as a hot melt adhesive tape. In some examples, the edges of the material from the crotch region wrapped around the first and second side edges 1824 and 1826 may form a hem. Wrapping the first and second side edges 1824 and 1826 of the leak-resistant composite structure 1818 may prevent the moisture barrier layer from contacting the wearer's skin surface and may improve comfort for the wearer. Other exemplary methods of attaching the leak-resistant composite structure 1818 to the front and rear torso panels 1812 and 1814, including stitching, are considered within the scope of the embodiments herein.

[0095] In some examples, edge finishes associated with the first and second side edges 1824 and 1826 can reduce the likelihood of moisture leaking out of the leak-resistant composite structure 1818. For example, as shown in FIG. 20 , the wrapped side edges (e.g., hem) of the crotch region 1816 form an envelope that joins the edges 1826 of the leak-resistant composite structure 1818. In at least some examples, the textile forming the crotch region 1816 and wrapped side edges includes a DWR treatment (e.g., a DWR treatment incorporated throughout the textile as described elsewhere in this disclosure), which significantly reduces the likelihood of leakage (e.g., as compared to a textile that is not DWR treated).

[0096] FIG. 21 shows a flow chart of a method 2100 of manufacturing a lower body garment, such as lower body garment 100 or 1200 described herein. In step 2110, a torso section of the lower body garment is formed from an outer layer material, such as outer layer 110 or 1210, the torso section having at least a waist opening, a first leg opening, and a second leg opening. In step 2112, an inner assembly, such as inner assembly 405 or 1505, is placed inside the outer layer material. The inner assembly includes a front torso panel, such as front torso section 410 or 1510, a rear torso panel, such as rear torso section 510 or 1610, and a crotch panel, such as crotch panel 412. The crotch panel is positioned between the first leg opening and the second leg opening and joins the front torso panel to the rear torso panel. The crotch panel includes a spacer fabric layer (such as spacer fabric layer 718) and a moisture barrier layer (such as moisture barrier layer 814), where the spacer fabric layer forms, in part, the innermost surface of the lower body garment. In step 2114, the inner assembly is secured to the outer layer of material at a number of fastening areas (e.g., at the waistband of the lower body garment, at the side panels of the lower body garment (e.g., seams 312 and 314 of lower body garment 100 and seams 1412 and 1414 of lower body garment 1200), etc.).

[0097] In examples of the present disclosure, the leak-resistant composite structures (e.g., textiles, multi-layer textiles, laminates, etc.) can include a variety of features and characteristics and can be incorporated into a variety of different articles (e.g., apparel). For example, FIG. 8 is associated with an exemplary leak-resistant composite structure 800 that includes a spacer fabric 718 and a moisture barrier layer 814. In at least some examples, the leak-resistant composite structure can include one or more additional layers, as shown in FIGS. 22A-22C.

[0098] 22A, the leak-proof composite structure 2200A can include multiple layers of spacer textiles that can be bonded to the moisture barrier layer 2202 (e.g., having any of the properties of the moisture barrier textiles described in this disclosure). For example, the leak-proof composite structure 2200A can include a first layer of spacer textile 2204 and a second layer of spacer textile 2206, where each layer 2204 and 2206 can include a spacer textile having any of the properties associated with the spacer textiles described in this disclosure (e.g., a first textile layer and a second textile layer connected by a tie yarn). In at least some examples, the moisture barrier layer 2202 and the spacer textiles 2204 and 2206 are banded (e.g., laser banded, adhesive banded, or otherwise combined) as a laminate. In particular, the multiple layers of spacer textiles 2204 and 2206 can enhance moisture absorption and capture capabilities associated with the leak-proof composite structure 2200A (e.g., as compared to the composite material 800). In examples, the leak-proof composite structure 2200A can be incorporated into any of the garments or articles of clothing described in this disclosure.

[0099] In at least some examples, the leak-proof composite structure 2200B (FIG. 22B) can include one or more additional layers of textile disposed between the moisture barrier layer 2208 (e.g., having the properties of any of the moisture barrier textiles described in this disclosure) and the spacer textile 2210 (e.g., having the properties of any of the spacer textiles described in this disclosure). For example, the leak-proof composite structure 2200B can include one or more additional absorbent layers 2212 bonded between the moisture barrier layer 2208 and the spacer textile 2210. Examples of the additional absorbent layer 2212 include textiles having yarns (e.g., fibers) with absorbent properties. In at least some examples, the additional absorbent layer 2212 can include textiles (e.g., knits, wovens, nonwovens, etc.) that include natural fibers (e.g., cotton). In at least some examples, the moisture barrier layer 2208, the spacer textile 2210, and the additional absorbent layer 2212 are banded (e.g., laser banded, adhesive banded, or otherwise combined) as a laminate. Notably, the combination of the spacer textile 2210 and the additional absorbent layer 2212 can enhance the moisture absorption and capture capabilities associated with the leak-proof composite structure 2200B (e.g., compared to the composite material 800). In examples, the leak-proof composite structure 2200B can be incorporated into any of the garments or articles of clothing described in this disclosure.

[0100] In at least some examples, the leak-proof composite structure 2200C (FIG. 22C) can include a moisture barrier layer 2214 banded on one side with a spacer textile 2216 (e.g., similar to leak-proof composite structure 800) and banded on the opposite side with one or more additional layers of textile 2218. In at least some examples, the one or more additional layers of textile 2218 can include any of a variety of different textiles (e.g., knit, woven, nonwoven, etc.), including textiles that can form an exterior surface of an article of clothing.

[0101] In at least some examples, the one or more additional layer textiles 2218 may include a lightweight knit material including elastic yarns, such as the material forming the front torso section 410 and the rear torso section 510. For example, the weight of the one or more additional layer textiles 2218 may be from about 100 grams per square meter (gsm) to about 150 gsm, from about 120 gsm to about 140 gsm, or about 125 gsm. The lightweight properties of the material may be achieved by using a single knit construction, such as a single knit plain tricot. In an exemplary embodiment, the material may include both polyester yarns and elastic yarns to provide a soft feel and good moisture management capabilities while achieving a desired degree of stretch and recovery. For example, the material may include about 60% polyester, including recycled polyester, and about 40% elastane. In at least some examples, the one or more additional layer textiles 2218 may include moisture barrier properties, such as a durable water repellent (DWR) treatment. In at least some examples, the moisture barrier layer 2208, the spacer textile 2210, and the additional layer(s) textile 2218 are banded (e.g., laser banded, adhesively banded, or otherwise combined) as a laminate.

[0102] Among other things, the combination of the moisture barrier layer 2214, the spacer textile 2216, and the additional layer(s) 2218 can provide a textile that can be used to construct both the interior assembly (e.g., a built-in brief or built-in gusset) and the outer panel of the garment (e.g., by forming an outer layer crotch gusset in a lower body garment). The laminate can potentially improve manufacturability based on having only a single composite textile rather than multiple individual textile layers. Additionally, the laminate can potentially provide less insulating properties (e.g., compared to a construction of multiple individual layers that may trap heat between layers). In examples, the leak-proof composite structure 2200C can be incorporated into any of the garments or garments described in this disclosure.

[0103] In examples, the leak-proof composite structure (e.g., leak-proof composite structure 800, 1818, 2202A, 2202B, 2202C, or any of the other leak-proof composite structures described in this disclosure) can be incorporated into a variety of different garments, such as garments that may include areas where it is desirable to mask moisture (e.g., blood, urine, sweat, milk, etc.). For example, the leak-proof composite structure can be incorporated into a variety of lower body garments, such as various areas of the lower torso, including the crotch area. In some examples, the leak-proof composite structure can be incorporated into a variety of upper body garments, such as the breast support portion of a bra (e.g., a nursing bra, a breast pumping bra, a sports bra, a tank-type support garment) or other breast support garment.

[0104] 23A-23E, an example of a lower body garment 2310 can include a leak-proof composite structure 2312 (e.g., any of the leak-proof composite structures 800, 1818, 2202A, 2202B, 2202C, or other leak-proof composite structures described in this disclosure). In some examples, the leak-proof composite structure 2312 is directly incorporated into a gusset of the lower body garment 2310. In some examples, the lower body garment 2310 includes an undergarment configured to be worn under another lower body garment (e.g., shorts, tights, pants, skirt, etc.). That is, the lower body garment 2310 can include an undergarment configured to be selectively worn under various outer lower body garments. In general, the lower body garment 2310 includes a torso section (e.g., a front torso section, a rear torso section, a right torso section or right hip, and a left torso section or left hip) with leg openings (e.g., a right leg opening and a left leg opening).

[0105] The styles shown in FIGS. 23A-23E are examples, and in other examples, undergarment styles include boy shorts, thongs, and the like. In some examples, the lower body garment 2310 includes a portion of a swimsuit. In some examples, the lower body garment 2310 is configured to be worn during athletic or fitness activities (e.g., track and field, long distance running, triathlons, duathlons, volleyball, and the like). In some examples, the leak-proof composite structure 2312 can include at least a majority of the undergarment garment (e.g., areas such as the crotch area as well as the front and / or back torso). In some examples, the lower body garment 2310 can be coupled (e.g., as an inner assembly) to the interior of a lower body garment (e.g., shorts, tights, pants, skirts, and the like) to provide a built-in undergarment.

[0106] In some examples, the leak-proof composite structure 2312 is positioned in a selected area (e.g., the crotch area) similar to the structures associated with 1810a and 1810b. Additionally, similar to the structures associated with 1810a and 1810b, the lower body garment 2310 may include an outer layer, similar to layer 1816, coupled to the leak-proof composite structure 2312 similar to the structures shown in FIG. 19 and / or FIG. 20. For example, the outer layer of the lower body garment 2310 may include side edges (e.g., similar to the structure shown in FIG. 20) that wrap around the sides of the leak-proof composite structure and be secured to the leak-proof composite structure (e.g., by banding). In some examples, the leading edge and / or trailing edge of the leak-proof composite structure 2312 may be coupled to the outer layer via seam tape (e.g., similar to tape 1910).

[0107] In various examples, panels including a leak-resistant composite structure for a lower body garment can include various shapes and sizes. The figures above include various examples, but are not limited to these. For example, in some examples, the rear top edge of the leak-resistant composite structure can extend at least to the yoke seam, and in some examples to the waistband. In some examples, a rear top edge that extends further up the lower body garment can provide greater coverage compared to a structure where the rear top edge terminates at the bottom of the garment.

[0108] Aspects of the present disclosure are described for purposes of illustration, not limitation. Alternative aspects will be apparent to those skilled in the art that do not depart from its scope. Those skilled in the art may develop alternative means of implementing the improvements described above without departing from the scope of the present disclosure.

[0109] It will be understood that certain features and subcombinations are of utility and may be utilized without reference to other features and subcombinations and are contemplated within the scope of the claims. Not all of the steps described in the various figures need be performed in the particular order described.

Claims

1. 1. A lower body garment comprising: an outer layer forming a torso section, the torso section having a waist opening, a first leg opening, and a second leg opening; and an inner assembly disposed within the outer layer, the inner assembly including a front torso section, a rear torso section, and a crotch panel between the first leg opening and the second leg opening, at least one of the front torso section or the rear torso section being bonded to the outer layer, the crotch panel including a spacer fabric layer and a moisture barrier layer secured to the spacer fabric layer.

2. 2. The lower body garment of claim 1, wherein the front torso portion of the inner assembly includes a front upper edge secured to the outer layer, and the rear torso portion of the inner assembly includes a rear upper edge secured to the outer layer.

3. 2. The lower-body garment according to claim 1, wherein the front torso portion has a first side edge including a lower end located on a first side portion of the lower-body garment and a first distance below the waist opening, and the rear torso portion has a first side edge located on the first side portion of the lower-body garment and a lower end located a second distance below the waist opening, the second distance being greater than the first distance.

4. The lower body garment of claim 1 , wherein the inner assembly further includes a crotch region extending continuously between the front torso portion and the rear torso portion and including an inwardly facing surface facing the crotch panel.

5. 2. The lower body garment of claim 1, wherein the front torso section has a first side edge located on a first side of the lower body garment, the rear torso section has a first side edge located on the first side of the lower body garment, and the first side edge of the front torso panel is spaced apart from the first side edge of the rear torso panel.

6. The lower body garment according to claim 5 , wherein the crotch panel joins the front torso portion and the rear torso portion.

7. 2. The lower body garment of claim 1, wherein the front and rear torso sections are treated with a durable water repellent (DWR) treatment.

8. 2. The lower body garment of claim 1, wherein the inner assembly further includes a crotch region extending continuously between the front torso portion and the rear torso portion and enveloping side edges of the crotch panel.

9. 2. The lower body garment of claim 1, wherein the spacer fabric layer comprises an innermost surface of the lower body garment and comprises a first layer, a second layer, and a plurality of tie yarns interconnecting the first layer and the second layer, the plurality of tie yarns comprising elastic yarns.

10. The lower body garment of claim 1 , wherein the moisture barrier layer comprises a thermoplastic polymer material.

11. 2. The lower body garment according to claim 1, wherein the front torso portion has a first side edge located on a first side portion of the lower body garment, the rear torso portion has a first side edge located on the first side portion of the lower body garment, and the first side edge of the front torso portion is assembled to the first side edge of the rear torso portion.

12. 1. A garment comprising: a torso portion including a first leg opening and a second leg opening; and a crotch portion between the first leg opening and the second leg opening, the crotch portion comprising a composite textile including a spacer fabric and a moisture barrier layer, the moisture barrier layer comprising a thermoplastic polymer film.

13. 13. The garment of claim 12, wherein the crotch area further comprises a textile layer treated with a durable water repellent (DWR) solution, and at least a portion of the moisture barrier layer is layered between a spacer knit textile and the textile layer.

14. The garment of claim 13 , wherein the spacer knit textile includes a side edge proximate the first leg opening, and the textile layer is wrapped around the side edge to form a hem.

15. 14. The garment of claim 13, wherein the spacer knit textile includes a leading edge bonded to the front of the torso, the garment further including a DWR treated bonding strip at least partially overlapping the leading edge and the front of the torso.

16. 16. The garment of claim 15, wherein the DWR treated bonding strip comprises a textile layer and an adhesive layer, the textile layer comprising a DWR solution.

17. The garment of claim 12 , wherein the spacer fabric comprises a spacer knit textile including a first knit layer, a second knit layer, and a tie yarn connecting the first knit layer and the second knit layer.

18. 20. The garment of claim 17, wherein the tie yarn comprises a first yarn having a first denier and a second yarn having a second denier of a different size than the first denier.

19. 13. The garment of claim 12, wherein the garment comprises an inner assembly and an outer layer, the torso portion and the crotch portion forming at least a portion of the inner assembly, the torso portion including a front upper edge and a rear upper edge, and at least one of the front upper edge and the rear upper edge being assembled to the outer layer.

20. The garment of claim 12 , wherein the garment comprises an undergarment configured to be selectively worn under a variety of outer lower body garments.

21. 1. A method of manufacturing a lower body garment, the method comprising: forming a torso section from an outer layer of material, the torso section having a waist opening, a first leg opening, and a second leg opening; disposing an inner assembly within the outer layer of material, the inner assembly including a front torso panel, a rear torso panel, and a crotch panel between the first leg opening and the second leg opening; joining the front torso panel to the rear torso panel, the crotch panel including a spacer fabric layer partially forming an inwardly facing surface of the lower body garment and a moisture barrier layer laminated to the spacer fabric layer; and fastening the inner assembly to the outer layer of material at a plurality of fastening regions.

22. 1. A method comprising the steps of assembling a crotch gusset to a front torso section and a rear torso section as part of an interior assembly of a lower body garment, the crotch gusset including a spacer fabric textile and a moisture barrier layer; securing the front torso section to an outer layer of the lower body garment, the outer layer including a torso section having a waist opening, a first leg opening, and a second leg opening; and assembling the rear torso section to the outer layer of the lower body garment.

23. 23. The method of claim 22, wherein the front torso section is continuous with the rear torso section based on a crotch region extending between the front torso section and the rear torso section, and the step of assembling the crotch gusset to the front torso section and the rear torso section includes wrapping edges of the crotch region into side edges of the spacer fabric textile and assembling edges of the crotch region to the spacer fabric textile.

24. 23. The method of claim 22, wherein the forward fuselage section includes a side edge, and wherein securing the forward fuselage section to the outer layer includes securing a side edge of the forward fuselage section to a side of the fuselage section, and the aft fuselage section includes a side edge, and wherein securing the aft fuselage section to the outer layer includes securing a side edge of the aft fuselage section to a side of the fuselage section and spaced apart from the side edge of the forward fuselage section.

25. 23. The method of claim 22, further comprising laminating the spacer fabric textile and the moisture barrier layer.

26. A lower body garment comprising a composite laminate associated with a crotch region of the lower body garment, the composite laminate including a spacer fabric layer and a moisture barrier layer secured to the spacer fabric layer.

27. 27. The lower body garment of claim 26, further comprising a textile layer, the moisture barrier layer being layered between the textile layer and a spacer fabric layer.

28. 28. The lower body garment of claim 27, wherein the textile layer is treated with a durable water repellent (DWR) treatment.

29. 28. The lower body garment of claim 27, wherein the spacer fabric layer, the moisture barrier layer, and the textile layer include an integral crotch gusset associated with the lower body garment.

30. 30. The lower body garment of claim 29, wherein the lower body garment includes a first leg portion and a second leg portion.

31. 28. The lower body garment of claim 27, wherein the spacer fabric layer, the moisture barrier layer, and the textile layer comprise a crotch region of an integrated undergarment assembled within the lower body garment.

32. 30. The lower body garment of claim 27, wherein the spacer fabric layer includes a first edge, the moisture barrier layer includes a second edge, and the textile layer includes a third edge that encases the first edge and the second edge.

33. 28. The lower body garment of claim 27, wherein the textile layer is laminated with the spacer fabric layer and the moisture barrier layer.

34. 27. The lower body garment of claim 26, wherein the composite laminate includes a second spacer fabric layer layered between the spacer fabric layer and the moisture barrier layer.

35. 27. The lower body garment of claim 26, wherein the composite laminate includes a natural fiber layer layered between the spacer fabric layer and the moisture barrier layer.

36. 27. The lower body garment of claim 26, wherein the spacer fabric layer includes a first knit layer, a second knit layer, and a tie yarn connecting the first knit layer and the second knit layer, the tie yarn including a first yarn having a first denier and a second yarn having a second denier different from the first denier.

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