Abstract:
A garment comprises a fabric and an elastomeric coating on at least a portion of at least one side of the fabric to provide designed, localized stretch and support in a garment, wherein the elastomeric coating is located where reduced stretch of the garment is desired. Garments having structures to facilitate cooling and heating are also described.

Description:
[0001]    This application claims the benefit of U.S. Provisional Application No. 61/251,354, filed Oct. 14, 2009, which is hereby incorporated by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates to garments, and more particularly, to garments having controlled stretch and designed thermal properties. 
         [0004]    2. Discussion of the Related Art 
         [0005]    Garments are often made of a material with a uniform modulus of elasticity. However, some areas of the body require more support than others. Further, some areas of the body require more control and restriction of muscle movement than others. Accordingly, there is a need for a garment with controlled stretch properties. Further, it may be desirable for a garment to aid in cooling or insulating the wearer depending on ambient conditions and the activities of the wearer. Certain garments with various means of thermal management are known in the prior art. However, these garments are often cumbersome for athletic or even normal movement, are uncomfortable, and are difficult to manufacture. Accordingly there is also a need for a garment with desirable thermal management characteristics that is relatively easy to manufacture and is comfortable for the wearer. 
       SUMMARY OF THE INVENTION 
       [0006]    Accordingly, the present invention is directed to a garment with elastomeric coatings that substantially obviates one or more of the problems due to limitations and disadvantages of the related art. 
         [0007]    In one aspect of the invention, a garment with controlled stretch and support characteristics is provided. In certain embodiments, a garment is described that includes a fabric having a plurality of elastomeric coatings on at least a portion of at least one side of the fabric, wherein the coating is designed to be located in a portion of the garment where reduced stretch is desired. In other embodiments, a coating is placed on a fabric to enhance the support in a particularized area of the garment. 
         [0008]    In certain aspects, the elastomeric coating may be formed in various configurations such as dots, stripes, circles, triangles, octagons, and hexagons and combinations and patterns of various configurations. The thickness of the elastomeric coating may be varied according to design specifications in particular embodiments. The coating or coatings may be applied to the inside, outside or inside and outside of a garment. The interior of the garment may be embedded with flock fibers and silicone may be employed as an elastomeric coating. 
         [0009]    The present invention also provides a garment that aids in cooling the wearer. In one aspect, the garment includes a fabric and one or more elastomeric coatings on at least a portion of the inside of the fabric of the garment with the elastomeric coating forming at least one channel in the fabric of the garment. In one aspect, a channel is formed that is substantially bounded by the fabric on one side and the elastomeric coating on two sides such that at least a portion of the fabric is held away from the skin of a wearer when the garment is worn. In another aspect the elastomeric coating forms a channel that engages the wearer. 
         [0010]    The geometry of the channels may be varied including curved, straight, zigzag, and diagonal shapes and the coating forming the channels may be in the form of dots or lines. One or more openings may be provided throughout various locations of the garment that permit communication of a channel or channels with ambient air. In certain embodiments, the elastomeric coating is embedded with flock fibers and is made of a silicone. In certain aspects, a garment may include an elastomeric coating forming one or more channels and additionally may include one or more elastomeric coatings on the inside, outside, or both sides of the garment that are designed to be located in a portion of the garment where reduced stretch is desired. 
         [0011]    In another aspect of the invention, a garment is provided that insulates the wearer from ambient conditions. In one embodiment, the garment includes a fabric and an elastomeric coating on at least a portion of the inside of the fabric of the garment, and at least one air pocket being formed by the elastomeric coating. An air pocket may be formed by a combination of fabric and elastomeric coating or coating alone. In one aspect, an air pocket is substantially bounded by the fabric on one side and the elastomeric coating on at least three sides. In certain embodiments, an elastomeric coating is designed to hold at least a portion of the fabric away from the skin of a wearer when the garment is worn. 
         [0012]    Air pockets may also be created by an arrangement of fabric, elastomeric coating, and the skin of a wearer. In various configurations, the formed air pocket is designed to temporarily trap air therein and may be in the shape of a square, rectangle, circle, triangle, octagon, hexagon, or an irregular shape. The elastomeric coating may be embedded with flock fibers and may be made of silicone. In certain embodiments, a garment may include elastomeric coatings forming one or more air pockets and may also include one or more elastomeric coatings on the inside, outside, or both sides of the garment that are designed to be located in a portion of the garment where reduced stretch is desired. 
         [0013]    Additional features and advantages of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings. 
         [0014]    It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0015]    The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention. In the drawings: 
           [0016]      FIG. 1  depicts a silkscreen configuration for applying an elastomeric coating; 
           [0017]      FIG. 2  depicts a garment with power zones; 
           [0018]      FIG. 3  depicts fabric panels with various designs of elastomeric coating; 
           [0019]      FIG. 4  depicts a garment with power zones having different forms and levels of controlled stretch; 
           [0020]      FIG. 5  depicts a fabric panel with an elastomeric coating of varying thickness along the length of the coating; 
           [0021]      FIG. 6  depicts a fabric panel with an elastomeric coating that is embedded with flock fibers; 
           [0022]      FIG. 7  depicts a fabric panel with an elastomeric coating that forms channels between the fabric and a wearer&#39;s skin; 
           [0023]      FIG. 8  depicts a garment with an elastomeric coating that forms channels; 
           [0024]      FIG. 9  depicts fabric panels with elastomeric coatings that form channels of various shapes; 
           [0025]      FIG. 10  depicts a garment with openings; 
           [0026]      FIG. 11  depicts a garment with slits; 
           [0027]      FIG. 12  depicts a fabric panel with an elastomeric coating that forms channels between the fabric and a wearer&#39;s skin where the elastomeric coating is embedded with flock fibers; 
           [0028]      FIG. 13  depicts a garment with an elastomeric coating that forms channels on the inside of the garment as well as power zones on the outside of the garment; 
           [0029]      FIG. 14  depicts a garment with openings and power zones on the outside of the garment; 
           [0030]      FIG. 15  depicts a garment with slits and power zones on the outside of the garment; 
           [0031]      FIG. 16  depicts a fabric panel with an elastomeric coating that forms air pockets; 
           [0032]      FIG. 17  depicts fabric panels with elastomeric coatings forming air pockets of various geometries; 
           [0033]      FIG. 18  depicts a garment with an elastomeric coating forming air pockets; 
           [0034]      FIG. 19  depicts a fabric panel with an elastomeric coating forming air pockets where the elastomeric coating is embedded with flock fibers; and 
           [0035]      FIG. 20  depicts a garment with an elastomeric coating forming air pockets on the inside of the garment as well as power zones on the outside of the garment. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0036]    Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. 
         [0037]      FIG. 1  depicts a silkscreen configuration for applying an elastomeric coating to a garment. As shown in  FIG. 1 , a garment  100  may be placed beneath a silkscreen  101  on an area where an elastomeric coating is desired. An elastomeric coating substance  102  may be passed through screen apertures  104  of silkscreen  101  using squeegees  103 , which move in the direction of arrow  105 . In one embodiment, the elastomeric coating substance  102  is transferred to the garment  100  by capillary action in controlled and prescribed quantities to form an elastomeric coating  106  on the garment  100 . The apertures  104  may be provided in a wide variety of patterns and squeegees  103  may be operated in a number of orientations and directions. The elastomeric coating  106  forms a three dimension (3D) structure on the garment  100 . The thickness of the 3D structure may be determined by parameters including, but not limited to, the distance between the garment  100  and the silkscreen  101 , the dimension of the apertures  104  of the silkscreen  101 , and the viscosity of the elastomeric coating substance  102 . Hereinafter, “thickness” refers to the dimension of the elastomeric coating from the elastomeric coating/fabric interface to the top of the elastomeric coating. 
         [0038]    Alternatively, an elastomeric coating substance may be sprayed onto a garment with or without a silkscreen. The thickness of the coating may vary, and depends on the type and configuration of the garment (e.g., the type of fabric used and the size of the garment), as well as customer requirements. A stencil other than that of a silkscreen configuration may also be used to further enhance the process whereby a stencil with a particular pattern is placed on the garment and the elastomeric coating sprayed through the stencil onto the garment in order to achieve required patterns on the garment. 
         [0039]    Alternatively, an elastomeric coating may also be applied to a garment by a process of extrusion, whereby an elastomeric coating substance is extruded onto the fabric of the garment in controlled and prescribed quantities, and may be applied in the form of pre-designed patterns with or without the use of stencils. 
         [0040]      FIG. 2  depicts a garment according to an embodiment of the present invention. As illustrated, an elastomeric coating  202  is applied to a garment  201  in predetermined areas. The elastomeric coating increases the modulus of the fabric in areas where it is applied, thereby providing the fabric with controlled stretch or controlled support over a specific area. Thus, a single panel of fabric may be designed to possess varied stretch and support features at multiple locations as desired. The areas where the elastomeric coating is applied are hereinafter referred to generally as “power zones.” In  FIG. 2 , power zones  203  are located where the elastomeric coating  202  has been applied to the garment  201 . 
         [0041]    As shown in  FIG. 3 , different forms and levels of controlled stretch at power zones may be obtained through an elastomeric coating  302  applied to a fabric panel  301  in a variety of designs, patterns, and builds of various orientations. For example, circular, triangular, octagonal, hexagonal (honeycomb), and irregular shapes as well as various types, dimensions and combinations of dots, lines, or stripes may be used. Elastomeric coating  302  may form a single shape, dot, line, or stripe. Further, elastomeric coating  302  may form between 2 and 4 shapes, dots, lines, or stripes. Still further, elastomeric coating  302  may form a power zone may include between 5 and 10 shapes, dots, lines, or stripes. Yet still further, elastomeric coating  302  may form a pattern of shapes, dots, lines, or stripes. 
         [0042]      FIG. 4  illustrates a garment  401  with elastomeric coating  402  of exemplary patterns to form power zones  403  where the sleeves include triangular patterns and the sides of the torso depict circular shapes. 
         [0043]    As shown in  FIG. 5 , an elastomeric coating  502  of varying thickness may be applied to a fabric panel  501 . Thus, different levels of controlled stretch may be achieved along the extent of an individual power zone. The thickness of an elastomeric coating may be varied by techniques including, but not limited to, varied diameter of apertures of a single silkscreen and varied squeegee pressures. The thickness may vary linearly along the entire extent of an individual power zone. The thickness may vary in a repeating pattern such that the thickness varies linearly over a portion of the power zone and the thickness profile over that portion is repeated successively along the extent of the power zone. Gaps where no elastomeric coating is applied may be located between successive portions. Further, the thickness may vary in a non-linear manner. 
         [0044]    Power zones may be applied to the interior, exterior or both sides of a garment. An elastomeric coating including various designs, patterns, and builds in various orientations as mentioned above, such as to form honeycomb structures for example, may also contribute to the visual aesthetics of the garment, especially if the elastomeric coating is applied to the exterior of the garment. Enhancements such as, but not limited to, coloring of the elastomeric coating as well as the addition of pigments sold under the trademark HELICONE to the elastomeric coating may also be used to further improve the visual aesthetics of a garment. 
         [0045]    As shown in  FIG. 6 , power zones of elastomeric coating  602  located on the interior of a fabric panel  601  may be embedded with flock fibers  603  to increase the aesthetics and the comfort to the wearer. A flocking process such as that according to U.S. patent application Ser. No. 12/149,504, which is incorporated by reference in its entirety, may be used. 
         [0046]    Power zones may be used to control and restrict muscle movement in performance sports wear providing the user with enhanced protection and efficiency. Power zones could also support and control regions of bust, under bust and shoulder areas in intimate wear such as bras to improve comfort and performance. Power zones may also be used in many other applications, such as socks, stockings, swimwear, undergarments, and the like. For example, the present invention may be applied to any type of apparel wear which includes, but is not limited to, sportswear, performance wear, intimate wear, casual wear, and medical wear. 
         [0047]      FIG. 7  depicts another embodiment of the present invention. In  FIG. 7 , elastomeric coating  702  is applied to an inner side of a fabric panel  701 . The elastomeric coating  702  may be of sufficient build and density to create a 3D structure. In some instances, the 3D structure is well defined. The structure may be in the form of lines, walls, borders, dots, or various other designs that would elevate and hold the fabric panel  701  slightly above a wearer&#39;s skin  703 . In certain aspects, the elastomeric coating  702  is applied to create a gap between the fabric panel  701  and the wearer&#39;s skin  703 . Through the designed and controlled application of the elastomeric coating  702 , air channels  704  may be formed.  FIG. 8  depicts the interior of a garment  801  where elastomeric coating  802  is applied to a garment  801  to form air channels  803 . 
         [0048]    As shown in  FIG. 9 , elastomeric coatings  902  applied to fabric panels  901  may form air channels  903  of various geometries. Exemplary geometries include, but are not limited to, curved, straight, zigzag, diagonal, sinusoidal, parabolic, intersecting, and irregular patterns. 
         [0049]    The air channels allow air to be moved along the garment and float parallel to the wearer&#39;s skin while also forming physical pathways that may allow excess perspiration from the wearer&#39;s skin to be removed by flowing out, thereby providing a cooling effect as well as improved moisture management properties. The flow of air in the air channels may also assist in the increase of the rate of evaporation of perspiration from the wearer&#39;s skin surface. Thus, due to absorption of heat from the wearer&#39;s body by the latent heat of evaporation of water in perspiration, an enhanced cooling effect to the wearer is achieved. 
         [0050]    The cooling characteristics of a garment may be further enhanced by using a breathable fabric. Further, as shown in  FIG. 10 , a garment  1001  may include air capture and routing mechanisms illustrated by openings  1002 ,  1003  similar to air vents which may be incorporated at shoulder seams, chest areas, lower torso areas, stomach areas, back areas, or any other suitable location of the garment  1001  to further aid the flow of air through the air channels for the increased cooling effect. The openings  1002 ,  1003  may be arranged such that air channels are able to communicate with ambient air by way of the opening  1002  at one end of the channel and by way of the opening  1003  at the other end of the channel. Furthermore, as shown in  FIG. 11 , a garment  1101  may include slits  1102  in the fabric of the garment  1101 . The slits  1102  may be incised using a cutting blade or any other recognized means of cutting such as ultrasonic cutting, laser cutting, plasma cutting, dye cutting or roller cutting, to further aid the flow of air through the air channels. 
         [0051]    As shown in  FIG. 12 , an elastomeric coating  1202  located on an inner side of a fabric panel  1201  may be embedded with flock fibers  1203  to increase the aesthetics and the comfort to the wearer. A flocking process as described above may be utilized. 
         [0052]    According to the principles of the invention, these embodiments may be applied to any type of apparel wear which include but are not limited to sportswear, performance wear, intimate wear, casual wear, and medical wear. 
         [0053]    In certain aspects, a garment may include an elastomeric coating applied to an inner side of a fabric panel to form one or more channels and other additional elastomeric coatings forming power zones. For example,  FIG. 13  shows a garment  1301  with an elastomeric coating  1302  applied to the inside of the garment  1301  and an elastomeric coating  1304  applied to the outside of the garment  1301 . Elastomeric coating  1302  may be applied in such a way as to form one or more channels  1303 . Elastomeric coating  1304  may be applied to form power zones  1305 . Thus, a single garment with controlled stretch and support that also aids in the cooling of the wearer may be provided. The power zones can be applied to the inside, outside, or inside and outside of the garment with any geometry and structure as described herein according to the principles of the invention. If the power zone is located on the inside of the garment, the elastomeric coating forming the power zone may be embedded with flock fibers. Further examples are shown in  FIG. 14  and  FIG. 15 . As illustrated in  FIG. 14 , a garment  1401  with channels on the inside of the garment  1401  and openings  1402  and  1403  is further provided with power zones  1404  on the outside of the garment  1401 . As depicted in  FIG. 15 , a garment  1501  with channels (not shown) on the inside of the garment  1501  connected to slits  1502  is further provided with power zones  1503  on the outside of the garment  1501 . 
         [0054]      FIG. 16  depicts another embodiment of the present invention.  FIG. 16  illustrates an elastomeric coating  1602  that has been applied to a fabric panel  1601 . The elastomeric coating  1602  may be of sufficient build and density to create multiple 3D structures thereby creating air pockets  1603 . In certain embodiments, the 3D structures are well defined. The air pockets  1603  shown in  FIG. 16  are hexagons; however, various geometries including, but not limited to, squares, rectangles, circles, triangles, octagons, hexagons (honeycombs), and irregular shapes, or combinations thereof may be used. Any shape that is useful to create a structure that confines air therein, such as a structure substantially bounded on at least three sides, may be used. As used herein, a side of a structure refers to a straight segment of the structure. A structure with a curved segment includes infinite sides.  FIG. 17  depicts exemplary geometries of air pockets  1702  on fabric panels  1701 .  FIG. 18  depicts the interior of a garment of this embodiment where elastomeric coating  1802  is applied to a garment  1801  to form air pockets  1803 . 
         [0055]    When a garment according to this embodiment of the invention is worn, an air pocket may be designed and constructed to temporarily trap air between the garment and the wearer&#39;s skin. Similarly, when a wearer wears a tight fitting article of clothing under the garment according to this embodiment, an air pocket may be designed and constructed to temporarily trap air between the garment and the tight fitting article of clothing. Because air has high insulating properties, in certain aspects the invention provides an insulating layer of air between the wearer&#39;s skin or tight fitting article of clothing and the garment which may significantly reduce heat loss by conduction and convection, thus allowing the wearer of the garment to retain heat. 
         [0056]    Further, according to the invention the movement of air inside the garment may be minimized which may reduce passive convection which draws cool air into the garment and displaces the warm light air already existent in the garment. Thus, heat loss is further reduced as heat is further retained. The heat retention feature may be further enhanced by a garment including non-breathable fabric which may further minimize the movement of air in the garment. 
         [0057]    As shown in  FIG. 19 , an elastomeric coating  1902  located on an inner side of a fabric panel  1901  may be embedded with flock fibers  1904  to increase the aesthetics and the comfort to the wearer. The elastomeric coating forming a boundary of the air pockets or, in some cases, inside the air pockets may be embedded with flock fibers. A flocking process as described above, in accordance with the methods of U.S. patent application Ser. No. 12/149,504, which is incorporated by reference in its entirety, may be employed. 
         [0058]    According to the principles of the invention, these embodiments may be applied to any type of apparel wear which include but are not limited to sportswear, performance wear, intimate wear, casual wear, and medical wear. 
         [0059]    In certain aspects, the garment may include an elastomeric coating applied to an inner side of a fabric panel to form one or more air pockets and an elastomeric coating forming power zones. For example,  FIG. 20  shows a garment  2001  with elastomeric coating  2002  forming air pockets  2003  on the inside of the garment  2001  and elastomeric coating  2004  forming power zones  2005  on the outside of the garment  2001 . Thus, a single garment with controlled stretch and support that aids in the insulation of the wearer may be provided. The power zones may be provided on the inside, outside, or inside and outside of the garment with any geometry and build according to the invention. If power zones are provided on the inside of the garment, the elastomeric coating forming the power zones may be imbedded with flock fibers. 
         [0060]    The elastomeric coating described above in the various embodiments of the present invention may be a silicone. 
         [0061]    It will be apparent to those skilled in the art that various modifications and variations can be made in the garment with elastomeric coating of the present invention without departing from the spirit or scope of the invention. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.