Patent Publication Number: US-9833024-B2

Title: Wire casing and method of making the same

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S) 
     This Non-Provisional U.S. Patent Application relies for priority on U.S. Provisional Patent Application Ser. No. 61/529,550, which was filed on Aug. 31, 2011, the contents of which are incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to a tubular fabric, a method of making the tubular fabric, an encased wire, and to articles manufactured therefrom, particularly underwired garments such as brassieres. 
     DESCRIPTION OF RELATED ART 
     It is known to produce fabric tubing for receiving a curved underwire. The term “underwire” is intended to include any substantially rigid structural member, and it need not be made from a metal. Other materials include plastics, metal composites, non-metal composites, and materials combining any of the foregoing, among other materials. 
     A considerable problem with known fabric tubing for underwires is that the ends of the underwires can penetrate the tubing, either during the course of garment manufacture or in use by a wearer. 
     At present, a significant proportion of brassiere (“bra”) manufacturer&#39;s products are returned because of the underwire has a tendency to protrude through the fabric tubing after a period of time. As should be understood, product failure as a result of underwire protrusion can have a deleterious effect on customer satisfaction. Specifically, after the underwire protrudes from the fabric tubing, the customer no longer wishes to wear the garment. 
     A feature of conventional tubular fabric includes a fusible yarn that is arranged within the fabric tube so that the fusible yarn is capable of forming a penetration barrier. Specifically, the fusible yarn may be heated (among other types of treatments) to facilitate fusing. Once fused, the final material confers the advantage that the tubular fabric product will not deteriorate on washing in a washing machine, for example. 
     While fusible yarn materials offer advantages, they also present disadvantages. Specifically, after the fusible yarn is melted to provide a penetration barrier, the tubular fabric displays the following undesirable characteristics: (1) the fused fabric material no longer is as soft as the original material, (2) the fused material has a more stiff feel, which is less comfortable to wearers, and (3) the sides of the internal tube will more easily adhere to one another, which hinders insertion of the wire into the tube, thereby increasing manufacturing costs. 
     Consequently, the fusible fabric material of the prior art is more stiff, less comfortable, increases production costs, and reduces production efficiency. 
     SUMMARY OF THE INVENTION 
     The present invention seeks to avoid the difficulties and problems associated with the prior art, among other advantages and improvements as should become apparent from the discussion herein. 
     Specifically, with increased customer sophistication, there has developed an increased preference for products that minimize or eliminate the disadvantages associated with prior art underwire construction(s). To this end, there is an increasing trend to move away from conventional wire casing materials and constructions. Specifically, there is an increasing trend to move away from fusible fabric materials. 
     The present invention breaks away from the traditional approach to underwire materials and construction. Among other advances, the present invention relies upon modified sewing machines and devices to sew tubular fabric to form an improved wire casing that minimizes or eliminates the disadvantages noted with respect to the prior art. 
     In one embodiment, the present invention avoids reliance on fusible yarns, which are used in conventional wire casings. This eliminates (or at least minimizes) the creation of underwires for brassieres with a stiff feel and construction. 
     As such, it is one aspect of the present invention to provide an encased wire for a garment that includes a wire with first and second ends, and a casing surrounding the wire. The casing includes a first fabric ribbon woven from a polyamide that resists penetration by at least one of the ends of the wire. The casing also has a first edge, a second edge, and a first, stitched seam disposed adjacent to the first edge to close the casing, thereby containing the wire. 
     In one contemplated embodiment of the present invention, the fabric ribbon is folded along a fold line and the fold line defines the second edge of the casing. 
     In another embodiment, a second seam is disposed adjacent to the second edge. 
     In still another contemplated embodiment, the casing includes a second fabric ribbon woven from a polyamide that resists penetration by at least one of the ends of the wire and a second, stitched seam disposed adjacent to the second edge. In this embodiment, the first and second fabric ribbons are connected to one another via the first and second stitched seams adjacent to the first and second edges. 
     The present invention also contemplated that the defines first and second woven regions, the second woven regions being adjacent to the first and second edges, the first woven region being between the second woven regions, the first woven region being resistant to penetration by at least one of the ends of the wire, the second woven regions providing increased comfort to a wearer of a garment incorporating the encased wire. If so, the woven density of the first woven region is greater than the woven density of the second woven region. 
     It is also contemplated that the encased wire may include a third fabric ribbon disposed atop and attached to the first fabric ribbon, the third fabric ribbon being provided for contact with skin of a wearer of a garment incorporating the encased wire, the third fabric ribbon providing increased comfort to the wearer. 
     Still further, the encased wire may have a fourth fabric ribbon disposed atop and attached to the second fabric ribbon, the fourth fabric ribbon being provided thr contact with skin of a wearer of a garment incorporating the encased wire, the fourth fabric ribbon providing increased comfort to the wearer. 
     It is contemplated that the polyamide to be employed for the present invention is nylon. 
     It is also contemplated that the casing is made from polyamide and a polyurethane-polyurea copolymer. If so, the polyamide may be nylon and the polyurethane-polyurea copolymer may be spandex. 
     Further, the casing may be made from 95.6% nylon and 4.4% spandex. Alternatively, the casing may be made from 96.8% nylon and 3.2% spandex. 
     In another contemplated embodiment, the casing may be made from a material that wicks moisture. 
     The encased wire of present invention is considered to be suitable for an underwire for a brassiere. 
     The present invention also encompasses a sewing machine that includes a needle, and a casing guide disposed upstream of the needle. The casing guide is essentially U-shaped to fold a fabric ribbon onto itself along a fold line defined thereby. 
     The sewing machine also may include at least one feeding reel disposed upstream of the casing guide to deliver the fabric ribbon to the casing guide. 
     Still further, the sewing machine may include at least one alignment device disposed between the feeding reel and the casing guide to orient the fabric ribbon prior to being fed into the casing guide. 
     The present invention also encompasses a method for forming a casing for a wire. The method includes the steps of attaching a first fabric ribbon to a second fabric ribbon to form an intermediate ribbon, wherein the first fabric ribbon is configured to resist penetration by the wire and the second fabric ribbon is finished suitably for contact with a wearer&#39;s, attaching two intermediate ribbons to one another such that the first fabric ribbons face one another, thereby forming a pre-sewn casing, folding the pre-sewn casing into a predetermined orientation whereby the second fabric ribbon forms an exterior surface thereof, and sewing the pre-sewn casing to form the casing. 
     It is contemplated that the method also may include inserting the wire into the casing to form an encased wire. 
     Other aspects of the present invention will be made apparent from the discussion that follows. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present invention will now be described in connection with the drawings appended hereto, in which: 
         FIG. 1  is a top view of a first embodiment of a casing for an underwire according to the present invention; 
         FIG. 2  is a top view of the casing illustrated in  FIG. 1 , shown in a condition before being sewn into the orientation illustrated in  FIG. 1 ; 
         FIG. 3  is cross-sectional end view of the casing illustrated in  FIG. 1 ; 
         FIG. 4  is cross-sectional end view of a second embodiment of a casing according to the present invention; 
         FIG. 5  is cross-sectional end view of a third embodiment of a casing according to the present invention; 
         FIG. 6  is cross-sectional end view of a fourth embodiment of a casing according to the present invention; 
         FIG. 7  is cross-sectional end view of a fifth embodiment of a casing according to the present invention; 
         FIG. 8  is cross-sectional end view of a sixth embodiment of a casing according to the present invention; 
         FIG. 9  is cross-sectional end view of a seventh embodiment of a casing according to the present invention; 
         FIG. 10  is a perspective view of a sewing machine according to the present invention; 
         FIG. 11  is an enlarged perspective view of the sewing machine illustrated in  FIG. 10 , showing a casing guide; 
         FIG. 12  is a further, enlarged view of the sewing machine shown in  FIG. 11 ; 
         FIG. 13  is a side view of the feeder elements that form a part of the sewing machine of the present invention; 
         FIG. 14  is an enlarged view of some of the feeder elements shown in  FIG. 13 ; 
         FIG. 15  is an enlarged view of the remainder of feeder elements shown in  FIG. 13 ; and 
         FIG. 16  is a graphical depiction of one method for forming a casing according to the present invention. 
     
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION 
     The present invention may be implemented using a variety of construction techniques and materials. Any discussion of particular materials, etc., is intended to be exemplary of the wide scope of the present invention. In other words, the present invention should not be understood to be limited to any of the specific materials that are discussed in the examples and embodiments that are provided herein. 
       FIG. 1  is an illustration of one contemplated embodiment of an encased wire  10  according to the present invention (also referred to as an “encased underwire” herein). The encased wire  10  includes a casing  12  that surrounds an underwire  14 . 
     In the illustrated embodiment, the casing  12  is made from a woven fabric material, as indicated by the woven pattern  16  designated on the casing  12  shown in  FIG. 1 . While a woven fabric  16  may comprise the casing  12 , it is contemplated that the casing  12  alternatively may be made from a non-woven material without departing from the scope of the present invention. 
     With respect to the embodiment illustrated in  FIG. 1 , the basic yarn that forms the casing  12  encapsulating the underwire  14  is a combination of nylon and spandex. More specifically, the yarn that forms the casing  12  is made from 95.6% nylon and 4.4% spandex. 
     An alternative material contemplated for the casing  12  is made of 96.8 nylon and 3.2% spandex. In this alternative embodiment, the material for the casing  12  may include a warn yarn (source, dtex, and filament count) designated as 78/24F/2 Twist Polyamide and/or 78/24F/1 Polyamide, with an elastomer (source, dtex) with a designation 311 Spandex covered by 44/1 Polyamide, and a weft yarn (dtex and filament count) having a designation 78/18F/1 Twist S.D Polyamide. The total width of the casing  12  is contemplated to be about 10 mm. The elongation of the material is contemplated to be about 20%. 
     As a point of reference, nylon is known as a thermoplastic material. In particular, the term “nylon” designates a family of synthetic fibers, generally known as polyamides. Spandex also is a synthetic fiber with well-known elastic properties. Spandex is generally known as a polyurethane-polyurea copolymer. The use of the terms “nylon” and “spandex” is not intended to be limiting of the present invention. To the contrary, use of these terms is intended to refer to the broad class of materials identified. 
     Nylon is considered to be an acceptable material for the primary component of the fabric  16 , because nylon is understood to lie flat against the underwire  14 . If materials other than nylon are selected as the primary constituent of the casing  12 , it is contemplated that the ability of the material to lie flat against the wire  14  will be at least one parameter that is considered when selecting the alternative material. Still other parameters may be considered consistent with the discussion that follows and within the skill of those in the art. 
     As should be apparent to those skilled in the art, the casing  12  is not limited to a combination of nylon and spandex. Other materials and combinations of materials may be employed without departing from the scope of the present invention. These other materials include, inter alia, polymers and co-polymers, including polyamides, such as Kevlar (trademark) and Twaron (trademark), to name a few specific examples. 
       FIG. 1  also illustrates a sewn seam  18  that extends along a first edge  20  of the casing  12 . For reference, the second edge  22  of the casing also is designated. It is noted that the terms “first” and “second,” when referring to the edges  20 ,  22  are merely provided to differentiate one edge  20  from the other  22 . In the discussion that follows, the first edge  20  also may be referred to as the “top” edge  20 , and the second edge  22  may be referred to as the “bottom” edge  22 . As should be apparent, the terms “top” and “bottom” refer to the orientation of the casing  12  that is designated in  FIG. 1 . 
     The seam  18 , which is a sewn stitch, closes the casing  12  along the first edge  20  to encapsulate the underwire  14  therein. The seam  18  may be a continuous or discontinuous stitch, as should be apparent to those skilled in the art. 
     It is contemplated that the casing  12  will be formed by folding over the fabric  16  onto itself and sewing the mated edges  20  of the fabric  16  to one another, creating the single seam  18 . It should be noted, however, that additional seams  18  may be incorporated into the casing  12  without departing from the scope of the present invention. For example, the seam  18  may be reinforced by an additional, parallel seam (not shown) sewn adjacent thereto. 
     While the present invention contemplates that the casing  12  will be made from a single ribbon of fabric  16  folded onto itself, the casing  12  may be made from plural ribbons (or pieces) of fabric  16  without departing from the scope of the present invention. If so, it is contemplated that the casing  12  may include one or more seams  18  along both of the first and second edges  20 ,  22 . In this context, it is contemplated that the casing  12  may be made from two separate ribbons of fabric  16  that are sewn together, with seams  18  adjacent to the to the first and second edges  20 ,  22 . 
     Regardless of the exact construction employed for the casing  12 , the fabric  16  is contemplated to form a penetration barrier that retains the underwire  14  within the casing  12 , while maintaining a desirable degree of flexibility. 
     In addition, the fabric is contemplated to be woven in a manner to increase the comfort fit associated with the encased wire  10 . Specifically, it is contemplated that the fabric  16  of the casing  12  will define first and second regions with differing woven densities. A first woven region  24  is identified in  FIG. 1 . Two second woven regions  26  are designated in the same illustration. As is apparent from the illustration, the first woven region  24  is flanked on either side by the second woven regions  24 . 
     With continued reference to  FIG. 1 , it is noted that a first delineation line  28  defines the transition between the first woven region  24  and the second woven region  26  adjacent to the first edge  20 . Similarly, the second delineation line  30  identifies the transition between the first woven region  24  and the second woven region  26  adjacent to the second edge  22  of the casing  12 . The first and second delineation lines  28 ,  30  are provided for reference and are not structural parts of the invention, as should be apparent. 
     It is contemplated that the two second woven regions  26  will incorporate a woven structure that provides a softer feel for the casing  12  adjacent to the first and second edges  20 ,  22 . In this manner, it is contemplated that the wearer of a garment incorporating the encased wire  10  of the present invention will appreciate a softer feel to the edges  20 ,  22  of the encased wire  10 . 
     With regard to the first woven region  24 , it is contemplated that the fabric  16  will be more compactly (or densely) woven in this region. In the second woven regions  26 , it is contemplated that the fabric  16  will be less densely woven. The more compact weave is contemplated to resist penetration by the underwire  14 . The less dense weave is contemplated to provide a softer feel to the edges  20 ,  22  of the encased wire  10  of the present invention. 
     While a casing  12  with first and second woven regions  24 ,  26  is contemplated as one embodiment of the present invention, the present invention is not so limited. To the contrary, it is contemplated that the casing  12  may not include regions with different woven characteristics. To the contrary, a fabric  16  with a uniform weave may be employed without departing from the scope of the present invention. 
       FIG. 2  is a top view of the casing  12  as it would appear when laid flat, prior to the sewing of the seam  18 . This illustration provides a top view of a segment of the fabric ribbon  16  that is sewn closed to form the casing  12 . 
     As is apparent, the fabric ribbon  16  defines five separate woven regions  32 ,  34 ,  36 ,  38 ,  40 . The regions are separated from one another by delineation lines  42 ,  44 ,  46 ,  48 . As a reference point, a fold line  50  also is shown. As discussed above, the delineation lines  42 ,  44 ,  46 ,  48  and the fold line  50  are not actual elements of the fabric ribbon  16 . Instead, they are provided to facilitate discussion of the present invention. 
     While there are five woven regions  32 ,  34 ,  36 ,  38 ,  40  designated in  FIG. 2 , the woven regions  32 ,  34 ,  36 ,  38 ,  40  also may be categorized as being first woven regions  24  or second woven regions  26 , as described above. Specifically, the regions  32 ,  36 , and  40  are second woven regions  26 . The regions  34  and  38  are first woven regions  24 . 
     As noted above, during manufacture, the fabric ribbon  16  is folded onto itself to create the casing  12 .  FIG. 2  illustrates the location of the fold line  50  which defines the approximate location where the fabric ribbon  16  is folded onto itself. As should be apparent from  FIG. 2 , when the fabric ribbon  16  is folded onto itself, the first and second regions  24 ,  26  are placed into register with one another. 
     As also noted above, it is contemplated that the fabric ribbon  16  may be pre-assembled from two separate ribbons. If so, the two ribbons are anticipated to be connected to one another at a seam line located approximately at the location of the fold line  50 . 
       FIG. 3  is a cross-sectional, end view of the encased wire  10  according to the first embodiment of the present invention. With the fabric ribbon  16  folded along the fold line  50  and sewn along the seam  18 , the fabric ribbon  16  forms the casing  12  that encapsulates the underwire  14 . The first and second woven regions  24 ,  26  are designated for clarity, as are the first and second edges  20 ,  22 , among others of the features discussed above. 
     In  FIG. 3 , the underwire  14  is shown with a circular cross-section. It is noted that this shape is merely exemplary of one contemplated cross-sectional shape for the underwire  14 . Other shapes may be employed without departing from the scope of the present invention. For example, the underwire  14  may have an oval, elliptical, asymmetric, angular, square, rectangular, triangular, polygonal, or other shape. While any shape may be employed for the underwire  14 , it is contemplated that rounded shapes will be employed to increase the comfort associated with the encased wire  10 . 
     In one embodiment, the underwire  14  is contemplated to be a single filament of material. The exact construction of the underwire  14 , however, is not critical to the present invention. The underwire  14  may be made from a plurality of filaments that are stranded together without departing from the scope of the present invention. 
     The underwire  14  may be made from any suitable material, as should be understood by those skilled in the art. The underwire  14  may be made from metal, plastic, or composite materials, to name a few representative examples. Where metals are employed, it is contemplated that the metals may be pure metals or alloys. Suitable plastics include any of an enormous variety of polymer materials. Composite materials include combinations of materials such as carbon fibers embedded in resin. The recitation of specific materials is not intended to be limiting of the invention. Specific materials are identified to demonstrate the enormous breadth and scope of the present invention. 
     In connection with the encased wire  10 , it has been determined that yarns textured for improved comfort and low shrinkage properties are better suited for the casing  12  of the present invention. One popular yarn is a 2 fold 78 dtex 24 filament Nylon 6 or Nylon 66. This yarn is intended to be exemplary of one specific embodiment of the present invention. This yarn is not required for the present invention, and its identification is not intended to be limiting of the present invention. 
     With respect to the casing  12 , it is contemplated that the fabric  16  will have a dry tensile strength within a range of about 35.2 to 39.4 kg. Moreover, it is contemplated that the fabric  16  will have an average dry tensile strength of about 36.5 kg. Finally, it is contemplated that the fabric  16  will have a minimum, dry tensile strength of about 25.0 kg. While these values are exemplary of the properties contemplated for the fabric  16 , other materials may be selected without departing from the scope of the present invention. 
     A popular way of forming yarns into a tubular fabric (such as the casing  12 ) is by a weaving process. In general, weaving produces a denser fabric than an equivalent knitting process. Also, a knitted fabric is typically less comfortable than a woven fabric due to its more open (i.e., loose) structure. As a result, woven fabrics are anticipated to for the fabric  16  from which the casing  12  is manufactured. 
     Weaving may be performed using a conventional narrow fabric loom. A preferred loom is produced by Jakob Muller AG, of Frick CHK-5070, Frick, Switzerland. 
       FIG. 4  is a cross-sectional view of a second embodiment of an encased wire  52  of the present invention. In this illustration, the casing  54  is similar to the first embodiment illustrated in  FIG. 3 . In this embodiment, however, the casing  54  includes a second seam  56  that extends along the second edge  22  of the casing  52 . Since features of this casing are similar to the casing  12  illustrated in the prior embodiment, reference numbers are repeated in this illustration for simplicity. 
       FIG. 5  is a cross-sectional view of a third embodiment of an encased wire  58  according to the present invention. In this figure, the casing  60  is not folded around a fold line  50 . Instead, as discussed above, the casing  60  is formed from two separate fabric ribbons  62 ,  64  that are joined at the seams  66 ,  68 . As before, for simplicity, reference numbers are repeated for elements common to the other embodiments. 
     With continued reference to  FIGS. 1-5 , it is noted that the seams  18 ,  56 ,  66 ,  68  are each disposed within the first woven regions  24  of the casings  12 ,  54 ,  60 . The positioning of the seams  18 ,  56 ,  66 ,  68  in the first woven regions  24  is not required to practice the present invention. The seams  18 ,  56 ,  66 ,  68  may be disposed within the second woven regions  26  without departing from the scope of the present invention. 
     As noted above, it is contemplated that the wire casing  12 ,  54 ,  60  comprises textured nylon and weft threads woven into one or more (i.e., two) fabric ribbons  16 ,  62 ,  64  which have strong resistance to penetration by the underwire  14 . The fabric  16  is contemplated to have a grooved texture such that the one or two fabric ribbons  16 ,  62 ,  64  may be joined together. After joining, the top and bottom sides (first and second edges  20 ,  22 ) of the casings  12 ,  54 ,  60  are anticipated to be fixed and sewed together at the seams  18 ,  66 ,  68  by sewing machines with a predetermined operation. The end products are the casings  12 ,  54 ,  60 . 
     The tensile strength of the casing  12 ,  54 ,  60  incorporated into the present invention resists penetration by the underwire  14 . As indicated above, the tensile strength of the casing  12 ,  54 ,  60  of the present invention is contemplated to fall within a range of between about 35 and 39 kg, with a minimum tensile strength of about 25 kg. 
     While preparing the present invention, it was discovered that the tensile strength of the casing  12 ,  54 ,  60  of the present invention resists penetration by the underwire  14  to a much better degree than similar structures within the prior art. Laboratory tests suggest that conventional wire casings exhibit a tensile strength of between 15-20 kg. As noted, the casing  12 ,  54 ,  60  of the present invention exhibits a tensile strength of between about 35-39 kg, which is almost double the tensile strength of casing known in the prior art. As a result, the casing  12 ,  54 ,  60  of the present invention is understood to be about twice as effective for resisting penetration by the underwire  14  than comparative prior art casings. 
     It is contemplated that the casing  12 ,  54 ,  60  will have a total width, as measured between the first and second edges  20 ,  22  of about 10 mm±1 mm, with the effective width (excluding any frill) of about 10 mm. The warp yarn may be one or both of 78/24F/2 Twist Polyamide and/or 78/24F/1 Polyamide with an elastomer such as 311 Spandex covered by 44/1 Polyamide and a weight of 10.89 g/m±10%. The weft yarn may be 78/18F/1 Twist S.D Polyamide. The material is contemplated to have finished ends (picks)/course (wales) per cm of 27±3. The material also is contemplated to have the following joins per 100 m (maximum): 4 joins (for white and pastel colors) and 5 joins (for dark colors). The material is contemplated to satisfy the Marks &amp; Spencer Standard C4A-C6-C7-C8. As a result, the material is contemplated to conform to the Marks &amp; Spencer Children-wear Metal Detection Policy. As such, the material will comply with the Marks &amp; Spencer Environmental Code of Practice for dyeing, printing and finishing, including German consumer legislation. As should be apparent, the material also is contemplated to comply with other local, national and international standards that are similar to or parallel to these stated standards. 
       FIG. 6  provides a cross-sectional view of a fourth embodiment of an encased underwire  70  of the present invention. Here, the casing  72  is formed with two layers of fabric positioned adjacent to one another. The first fabric  74  is the inner fabric layer and the second fabric  76  is the outer fabric layer. The outer fabric layer  76  defines the outer surface of the casing  72 . In this embodiment, which is similar to the third embodiment illustrated in  FIG. 5 , there are two seams  78 ,  80  that are disposed adjacent to the first and second edges  20 ,  22  of the casing  72 . The underwire  11  is shown in this view, as in the prior views. 
     The first fabric layer  74  is constructed such that there is an absence of excessive fibers woven into it. As such, the first (or inner) fabric layer  74  layer provides a strong structure that may be combined into lingerie (specifically the chest cup) without any gaps (or with very small gaps) in the weave forming the structure. In this manner, the first fabric layer  74  provides a woven fabric that resists penetration by the encased wire  14 . The first fabric layer  74 , therefore, share characteristics with the first woven region  24  as discussed above. 
     The second fabric layer  76  is the external layer and, as such, has the potential for directly contacting the wearer&#39;s skin. As a result, the second fabric layer  76  (or outer fabric layer) is constructed to provide comfort to the wearer. To provide comfort, the second fabric layer  76  is woven to provide a soft surface. One way in which this is accomplished is for second fabric layer  76  to be provided with a lower density of fibers. In other words, a lower number of fibers are incorporated into the second fabric layer  76  to provide a softer surface than are provided for the first fabric layer  74 , which is designed to resist penetration by the encased wire  14 . As should be apparent, the second fabric layer  76  shares characteristics of the second fabric region  26  described above. 
     In addition, because the second fabric layer  76  is designed for contact with the wearer&#39;s skin, the second fabric layer  76  may be constructed from (or may incorporate) materials that are moisture absorbent. So that moisture does not accumulate in the second fabric layer  76 , the second fabric layer  76  also may be constructed from a fabric that permits a rapid dissipation of moisture (i.e., perspiration) from the casing  72 . Moreover, the second fabric layer  76  may be made from a material that is gas-permeable. 
     In connection with the property of water absorption and dissipation, materials that are contemplated for the second fabric layer  76  are referred to as materials that facilitate wicking of moisture. As is known in the art, such materials provide the benefit of removing moisture from a person&#39;s skin and allowing the moisture to evaporate more rapidly than non-wicking materials. 
     It is noted that, while the second fabric layer  76  is described as being made from a wicking material, the first fabric layer  74  also may be constructed, either partially or wholly, from a similar material. As a result, the casing  72 , which combines the two layers  71 ,  76 , discourages the accumulation of water therein. 
     With respect to the fourth embodiment of the casing  72  of the present invention, it is noted that aspects from the first through third embodiments also may be incorporated therein without departing from the scope of the present invention. For example, the combination of first fabric layer  74  and the second fabric layer  76  may be preformed into a ribbon. Two such ribbons may be sewn together and then folded around the underwire  14 , as discussed above. 
       FIG. 7  is a cross-sectional illustration of a fifth embodiment of an encased wire  82 . The casing is designated  84 . This embodiment of the encased wire  82  incorporates first and second fabric layers  74 ,  76 , as in the embodiment illustrated in  FIG. 6 . In this embodiment, however, the second end  22  includes a folded end, similar to the embodiment illustrated in  FIG. 4 . 
       FIG. 8  is a cross-sectional illustration of a sixth embodiment of an encased wire  86  according to the present invention. A casing  88  is shown. The casing  88  includes the double-layer construction as discussed in connection with  FIG. 6 . In this embodiment, the second end  22  excludes a seam, which is similar to the embodiment illustrated in  FIG. 3 . 
       FIG. 9  is a cross-sectional illustration of a seventh embodiment of an encased wire  90  according to the present invention. In this embodiment, the casing  92  is asymmetrical. Specifically, the second fabric layer  76  is omitted from one side of the casing  92 . For this embodiment, it is anticipated that the side of the casing  92  that excludes the second fabric layer  76  will not be positioned to rest against the user&#39;s skin. The side of the casing  92  that includes the second fabric layer  76  will be positioned such that it is in contact with the user&#39;s skin. 
     As should be apparent from the foregoing, there are numerous variations associated with the present invention. Features of one embodiment may be combined with features of other embodiments without departing from the scope of the present invention, as should be apparent to those skilled in the art. 
     Aspects of the production and/or manufacture of the casing of the present invention will now be discussed in connection with the casing  70 , which is illustrated in  FIG. 6 . While the following discussion focuses on the manufacture of the casing  70 , the same manufacturing techniques and steps may be applied to any of the remaining embodiments without departing from the scope of the present invention. 
     To produce the casing  70 , the present invention combines both an improved sewing machine and also a method of manufacture of the casing  70 , the details of which are summarized in the paragraphs that follow. 
     Specifically, a sewing machine  100  has been developed that differs from sewing machines that are generally known in the prior art.  FIGS. 10-15  provide various views of one embodiment of a sewing machine  100  according to the present invention. 
     With respect to the sewing machine  100 , a casing fixture  102  is provided on the sewing machine  100  to hold the first and second fabric layers  74 ,  76  in register with one another and to facilitate sewing of the layers  74 ,  76  to one another along the seams  78 ,  80 . The casing fixture  102  also facilitates automatic sewing of the casing  72  into a tubular structure by folding the first and second fabric layers  74 ,  76  onto one another prior to and during the travel of the two layers  74 ,  76  through the sewing machine  100 . Specifically, the casing fixture  102  folds the layers  74 ,  76  and feeds the folded layers into the sewing machine  100  so that the needle  104  is able to sew the layers  100  together to form the tubular casing  72 .In this manner, it is possible to create a continuous (or nearly continuous) casing  72  that may be used to construct the brassiere, lingerie, or other garment requiring an encased wire  70 . 
     As should be appreciated, by providing the casing fixture  102  on the sewing machine  100 , it is possible to manufacture the casing  72  in an automated or semi-automated fashion, thereby increasing the speed of manufacture and reducing the cost of production, among other advantages. 
     As should be apparent, the present invention contemplates different constructions for the casing fixture  102  that is attached to a sewing machine  100 . The different embodiments accommodate different fabric types and sizes, the details of which depend on the parameters associated with the garment to be constructed therefrom. 
     In one embodiment, the wire casing is 10 mm in width in its final dimension. As such, the casing fixture  102  incorporates a guide that is 20 mm in width to accommodate the first and second fabric layers  74 ,  76  before they are folded over and sewn to one another. As noted, the casing fixture  102  folds the layers  74 ,  76  onto one another prior to the sewing operation. 
     As should be immediately apparent, the dimensions of the first and second fabric layers  74 ,  76  and the casing fixture  102  may differ without departing from the present invention. Specifically, the dimensions may be greater than or smaller than 10 mm without departing from the scope of the present invention. 
     Next, the stitch contemplated to secure the first and second fabric layers  74 ,  76  to one another, along the seams  78 ,  80 , may be what is referred to as an “Organ 10” stitch. Still other stitch types maybe employed without departing from the present invention. 
     Further details concerning the sewing machine  100  of the present invention and its operation are provided in connection with  FIGS. 10-15 . 
       FIG. 10  is an end view of the sewing machine  100  according to the present invention. The sewing machine  100  includes a casing guide  106 , which is part of the casing fixture  102  attached to the sewing machine  100 . The casing guide  106  folds the pre-sewn casing  110  before introducing the pre-sewn casing  110  to the needle  104 . In  FIG. 10 , the pre-sewn casing  110  is shown being spooled from a feeding reel  108 . The sewn casing  72  is also visible leaving the needle  104 . 
     As a point of reference, the pre-sewn casing  110  incorporates two parallel ribbons, each including the first and second fabric layers  74 ,  76  in the proper orientation. The two parallel ribbons may be attached to one another along a seam, which may be a stitched seam. 
       FIG. 11  is an enlarged view of a portion of the sewing machine  100  of the present invention shown in  FIG. 10 . The casing fixture  102  is shown with increased detail in this view. As is apparent from this view, the casing fixture  102  incorporates the casing guide  106  therein. In this embodiment, the casing guide  106  is a metal, U-shaped structure into which the pre-sewn casing  110  is inputted. The casing guide  106  is configured to fold the pre-sewn casing  110  into a configuration to form the sewn casing  72 . 
       FIG. 11  also illustrates a feeder  112  that is connected to the casing guide  106 . The feeder  112  is a sinusoidally-shaped wire element through which the pre-sewn casing  110  is threaded. The feeder  112  assures that the pre-sewn casing  110  is in the proper orientation so that it may be folded properly by the casing guide  106 . The feeder  112  also assures that the second fabric layer  76  layer will form the exterior surface of the sewn casing  72 . Specifically, with the second fabric layer  76  facing away from the casing guide  106 , the second fabric layer  76  will become the exterior surface of the casing  72  after being folded by the casing guide  106 . 
       FIG. 12  is a further, enlarged view of the casing guide  106  attached to the sewing machine  100  of the present invention. The U-shape of the casing guide  106  may be better appreciated from this illustration. 
       FIG. 13  is a side view of feeder elements  114  that are connected to the sewing machine  100  of the present invention and form a part thereof. In this side view, a feeder reel  116  is shown. The pre-sewn casing  110  travels over the feeder reel  116  and passes through a first alignment device  118  and a second alignment device  120 . The two alignment devices  118 ,  124  assure that the pre-sewn casing  110  is in a proper orientation prior to being sewn to form the sewn casing  72 . The alignment devices  118 ,  120  assure, for example, that the second fabric layer  76  is oriented such that, after folding, the second fabric layer  76  layer is on the exterior side of the sewn casing  72 . 
       FIG. 13  also illustrates two vertical alignment devices  122 ,  124 , which hold the pre-sewn casing  110  in a vertical orientation for proper threading into the casing guide  106 . Consistent with the orientation of the pre-sewn casing  110 , the first fabric layer  74  is visible in this view. 
       FIG. 14  is an enlarged, detailed view of some of the feeder elements  114  of the sewing machine  100  of the present invention. Specifically, this view shows the vertical alignment devices  122 ,  124  in greater detail. 
       FIG. 15  is an enlarged, detailed view of some of the feeder elements  114  of the sewing machine  100  of the present invention. In this view, the feeder reel  116  and the two alignment devices  118 ,  120  are shown in greater detail. 
       FIG. 16  is a graphic illustration of a method contemplated as a part of the present invention. Specifically, the graphical illustration identifies selected steps in the manufacture of the casing  72 , which steps are detailed below. While the method will be described in connection with the manufacture of the casing  72 , the method is intended to apply to any of the embodiments described herein. 
     The method is designated as  130  in  FIG. 16 . The method begins at step  132 . The method then proceeds to step  134  where a ribbon of the first fabric material  74  is attached to a ribbon of the second fabric material  76 . The ribbon of the first fabric material  74  may be attached to the ribbon of the second fabric material  76  by sewing or any other attachment means known to those skilled in the art. Attachment of the first and second fabric materials  74 ,  76  to one another creates a first intermediate fabric ribbon. 
     After step  134 , the method proceeds to step  136  where two intermediate fabric ribbons are joined to one another to form the pre-sewn casing  110 . After this step, the first fabric material  74  will essentially form one side of the pre-sewn casing and the second fabric material  76  will form the other side of the pre-sewn casing  110 . 
     At step  138 , the pre-sewn casing is fed into the casing guide  106 , which folds the pre-sewn casing  110  so that the first fabric material  74  is positioned on the inside of the folded casing structure. The folded casing structure is then fed to sewing machine  100 . 
     At step  140 , the folded casing structure is sewn along at least one of the edges  20 ,  22  to form the casing  72 . The method  130  ends at step  142 . 
     As should be apparent, for embodiments of the casing that do not have a bilayer construction, the method begins at steps  136  or  138 , depending upon the construction of the casing. 
     As also should be apparent, after the casing  72  is formed, the underwire  14  may be inserted therein to complete the encased wire structure  70 . 
     As should be apparent from the foregoing, different materials and dimensions for the various elements of the present invention may be employed without departing from the present invention. Moreover, the details for specific embodiments are intended to be exemplary of the scope of the present invention and are not intended to be limiting thereof.