Abstract:
Disposable garments, such as t-shirts, shorts, pants and the like are formed from nonwoven fabric and are seamed with elastomeric material which absorbs the stresses created when a wearer undergoes physical activity such as exercise. Absorbent material is used to line the garments to collect perspiration.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     This invention is concerned generally with articles of clothing and, more specifically, to clothing made to be sturdy, absorbent and disposable for use as exercise or workout clothing.  
         [0002]     People using exercise facilities such as gyms and fitness centers typically carry with them exercise-appropriate clothing to use during workouts. After exercising soiled and sweaty exercise clothing is either carried home to be laundered or, in some instances, can be laundered by the workout facility and returned to the user&#39;s locker or other storage area. Because of such factors as laundering cost, initial purchase price, sanitation issues and the wide range of sizes and garment preferences, workout centers do not usually stock a supply of workout clothes for those who do not bring their own with them. Fitness centers in facilities such as hotels and the like deal with this problem on a more frequent basis with travelers or guests who do not bring clothing with them but want to use the facilities during their stay. Those guests that do remember to bring their own clothing are also faced with the task of either laundering it before returning home or packing damp, used clothing in with their other personal effects.  
         [0003]     The concept of disposable and, in some cases, absorbent and disposable items of clothing is well represented in the prior art.  
         [0004]     U.S. Pat. No. 6,049,909 (Anderson) teaches and describes a disposable infant garment made from breathable paper impregnated with a waterproofing agent. Anderson discloses and claims a garment made to be worn the same as conventionally-made children&#39;s playwear, yet intended to be disposable. As claimed, the invention resides in the material from which the garment is made and the manner in which the clothing blank is folded and fastened together to form the garment.  
         [0005]     U.S. Pat. No. 5,915,532 (Williams) teaches and describes a disposable headband formed from an outer, non-woven sheet surrounding an insert made from a permeable material containing an absorbent material in the form of potassium or sodium polyacrylate crystals. The crystals absorb perspiration through the permeable layer. Williams also teaches the use of a label attached to the headband.  
         [0006]     U.S. Pat. No. 5,770,529 (Dennis, et al.) teaches and describes a liquid-distribution garment to be used as a liner to be worn under impermeable protective clothing. Dennis, et al. claims not only a specific construction but specific wicking rates for the fabric sections of the garment. While disposability is not claimed as a feature of the invention, the patent does state that the garment is intended to be inexpensive enough to be disposable.  
         [0007]     U.S. Pat. No. 5,103,501 (Meisels) teaches and describes traveling and disposable underwear featuring absorbent pads placed at those points in the garment where needed. Meisels also claims the use of elastic bands and magnetic fasteners to make the garment adjustable to various sizes.  
         [0008]     U.S. Pat. No. 5,058,210 (Tivis) teaches and describes a disposable sweat liner for safety hats consisting of three layers of absorbent padding shaped to fit within a protective helmet and to cover the forehead and the crown of the user&#39;s head. Tivis specifically claims the liner to be disposable and further claims a fastening system adapted to attach the liner to the inner support web of the helmet.  
         [0009]     U.S. Pat. No. 4,947,867 (Keeton) teaches and describes surgical clothing and labeling means therefor. Keeton&#39;s invention is a disposable surgical gown to be worn by a patient into surgery and which also included labels attachable to the gown and to the patient&#39;s body to alert the surgical team to the patient&#39;s identity and the surgical procedure to be performed, as shown in  FIG. 1  of the patent.  
         [0010]     U.S. Pat. No. 4,819,275 (Lunt) teaches and describes a disposable gown for medical patients consisting of a blank formed of non-woven fabric and shaped to fit onto and be secured to a patient&#39;s torso.  
         [0011]     U.S. Pat. No. 3,911,499 (Benevento, et al.) teaches and describes a disposable medical gown made without seams to form a bacteria barrier.  
         [0012]     U.S. Pat. No. 3,720,957 (Patience) teaches and describes a conformable disposable garment, sections of which are formed with micropleats, as seen in  FIG. 5  of the patent, to allow freedom of movement and adjustable fit even though the gown fabric is inelastic.  
         [0013]     U.S. Pat. No. 3,451,062 (Bradley) teaches and describes a disposable examination gown made from a single sheet of material and attachable with peel-out ties formed as part of the garment.  
         [0014]     U.S. Pat. No. 5,601,542 (Melius, et al.) teaches and describes an absorbent composite included as part of a disposable absorbent garment. The absorbent material is held between layers of semi-permeable, non-woven material.  
         [0015]     U.S. Pat. No. 5,147,343 (Kellenberger) teaches and describes absorbent products containing hydrogels with ability to swell against pressure where the superabsorbent material is dispersed among a matrix of fibers sandwiched between a liquid-impermeable backing material and a liquid-permeable facing material.  
         [0016]     U.S. Pat. No. 5,622,581 (Ducker, et al.) teaches and describes a disposable garment with de-elasticized elastic members and method for making same for use with garments having elastic gathers and then either chemically or mechanically de-elasticizing portions of the elastic gathers in order to vary the tension with which the gathers grip the wearer.  
         [0017]     U.S. Pat. No. 5,490,846 (Ellis, et al.) teaches and describes a surge management fibrous nonwoven web for personal care absorbent articles and the like consisting of a fibrous, nonwoven web used to absorb fluids very rapidly and distribute the fluids to an absorbent material.  
         [0018]     U.S. Pat. No. 4,641,381 (Heran, et al.) teaches and describes disposable underpants, such as infant&#39;s training pants and the like using disposable material formed into a pair of training pants having an elasticized waist and elasticized leg openings having a liner consisting of an absorbent batt covered with layer of nonwoven material that has an inner layer of plastic material and an outer layer of nonwoven fibrous material.  
         [0019]     U.S. Pat. No. 4,610,681 (Strohbeen, et al.) teaches and describes disposable underpants having discrete outer seals with the garment having elasticized waist and leg openings made with seams sealed with a plurality of narrow lines preferably formed with an ultrasonic anvil.  
         [0020]     U.S. Pat. No. 5,429,629 (Latimer, et al.) teaches and describes an absorbent structure having improved fluid surge management and product incorporating same comprising a garment having a “surge management” portion for rapidly receiving and dispersing liquids and a retention portion to desorb fluids form the surge management portion and to store the fluids.  
         [0021]     U.S. Pat. No. 6,240,563 (Niedermeyer) teaches and describes apparel with panel attachments along selected margins. Niedermeyer is concerned with construction techniques for manufacturing clothing from the types of non-woven fabrics used to make disposable and reusable garments, and teaches the use of bonded seams to keep the garment together.  
         [0022]     U.S. Pat. No. 5,553,326 (Moore) teaches and describes a removable, washable sweatband for hats using a “zip-loc” type fastener to hold the band in place within the hat.  
         [0023]     U.S. Pat. No. 5,098,419 (Gold) teaches and describes an undergarment to be worn by incontinent persons, and is exemplary of clothing using fabric to form an impervious barrier together with absorbent fabric.  
         [0024]     United States patent (Dillon) teaches and describes a unisex shirt and methods for making same and describes the use of the garment as a surgical scrub.  
         [0025]     While certain of these references disclose aspects of clothing that would be desirable in disposable workout wear, no reference discloses constructions suited for the uses to which such clothing is typically put.  
         [0026]     Accordingly, it is an object of the present invention to provide workout clothing that is sufficiently sturdy in construction to stand up to the stresses created during exercise movements.  
         [0027]     It is a further object of the present invention to provide such clothing with elasticized seam areas sufficiently stressable to allow the clothing to be made from generally lightweight material yet have the strength to be used for exercise.  
         [0028]     It is a further object to provide such clothing in forms which use inexpensive materials for construction and are simple and inexpensive to manufacture.  
         [0029]     Yet another object is for such clothing to be provided in forms which are disposable and can be recycled.  
         [0030]     Still another object is for such clothing to be easily personalized with initials, logos and the like.  
       BRIEF DESCRIPTION OF THE INVENTION  
       [0031]     A construction for disposable garments intended for use as exercise clothing combines the use of non-woven fabrics, absorbent material layers and elastic, expandable seaming at major stress points. Such constructions are used to make conventional and familiar workout items such as sleeved and sleeveless T-shirts, shorts, headbands and the like. The non-woven fabrics are selected to be lightweight, attractive, sturdy and capable of being marked or imprinted with logos, graphics and the like. The placement of expandable seam constructions on the garments allows the garments to absorb the stresses created by exercising yet keep the garments inexpensive to make and comfortable to wear.  
         [0032]     While the following describes a preferred embodiment or embodiments of the present invention, it is to be understood that this description is made by way of example only and is not intended to limit the scope of the present invention. It is expected that alterations and further modifications, as well as other and further applications of the principles of the present invention will occur to others skilled in the art to which the invention relates and, while differing from the foregoing, remain within the spirit and scope of the invention as herein described. Where means-plus-function clauses are used such language is intended to cover the structures described herein as performing the recited functions and not only structural equivalents but equivalent structures as well. For the purposes of the present disclosure, two structures that perform the same function within an environment described above may be equivalent structures. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0033]     These and further objects of the present invention will become more apparent upon consideration of the accompanying drawings, wherein:  
         [0034]      FIG. 1  is a front elevational view of a T-shirt constructed in accordance with a preferred embodiment of the present invention;  
         [0035]      FIG. 2  is a front elevational view of a sleeveless T-shirt constructed in accordance with a preferred embodiment of the present invention;  
         [0036]      FIG. 3  is detail of the underarm stitching of the embodiment of  FIG. 1 ;  
         [0037]      FIG. 4  is a detail of the collar stitching of the embodiment of  FIG. 1 ;  
         [0038]      FIG. 5  is a front elevational view of a front shirt panel;  
         [0039]      FIG. 6  is a front elevational view of a rear shirt panel;  
         [0040]      FIG. 7  is a front elevational view of a pair of exercise pants embodying the teachings of the present invention; and  
         [0041]      FIG. 8  is a side sectional view of a second embodiment of the clothing material.  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0042]     For the purposes of describing the invention, the articles of clothing hereinafter described are constructed in much the same manner as their more conventional counterparts. For example, a sleeved T-shirt such as that shown in  FIG. 1  is typically assembled from a front panel, a back panel, sewn-in sleeves and a sewn-in neck band or collar.  
         [0043]     Referring now to  FIG. 1  the numeral  10  identifies generally a sleeved T-shirt constructed in accordance with a preferred embodiment of the invention.  
         [0044]     Shirt  10  has a front panel  12 , a left sleeve  14 , a right sleeve  16 , a collar  18  and a rear panel  20 , not shown but understood to be substantially similar in dimension and shape to front panel  12 .  
         [0045]     Referring to  FIG. 2 a  second version of an exercise shirt is shown as a sleeveless shirt  22  having a front panel  24  and a rear panel  26 . Front panel  24  has a left shoulder “strap”  28  and a right strap  30 , while rear panel  26  has a corresponding left strap  32  and a right strap  34 . As described hereinafter, left straps  28 ,  32  and right straps  30 ,  34  are seamed together to form, respectively, left arm hole  36  and right arm hole  38 . Front panel  24  also has a front collar segment  40  while rear panel  26  has a corresponding rear collar segment  42  which, when joined as described below, combine to form a neck opening  44 .  
         [0046]     Referring now to  FIG. 3 , a first segment of elasticized seaming  46  is shown, consisting of a number of parallel seams  48  extending longitudinally along segment  46  to form a series of parallel channels  50 . When stressed longitudinally in direction A segment  46  can stretch to a certain limit but can stretch to a significantly greater degree when stressed laterally in direction B.  
         [0047]     Referring now to  FIG. 4 a  second segment of elasticized seaming  52  is shown, adapted to be used as collar segment  18 ,  40  or  42 . Collar seams  54  are sewn across the shortest dimension of segment  52 , forming transverse channels  56 . Segment  52  thus stretches to a greater degree in direction D than in direction C.  
         [0048]     Referring now to  FIGS. 5 and 6  the present invention may be described in full detail. In  FIG. 5 a  t-shirt front panel  58  is shown, preferably formed from a non-woven fabric such as polypropylene fibers. Panel  58  has a first shoulder edge  60   a,  a first sleeve edge  62   a,  a first arm edge  64   a,  a first torso edge  66   a,  a bottom edge  68   a,  a second torso edge  70   a,  a second sleeve edge  72   a,  a second arm edge  74   a,  a second shoulder edge  76   a  and a collar edge  78   a,  said edges defining the shape of panel  58 .  
         [0049]     Similarly, in  FIG. 6 a  t-shirt rear panel  80  is shown, having a first shoulder edge  60   b,  a first sleeve edge  62   b,  a first arm edge  64   b,  a first torso edge  66   b,  a bottom edge  68   b,  a second torso edge  70   b,  a second sleeve edge  72   b,  a second arm edge  74   b,  a second shoulder edge  76   b  and a collar edge  80   b,  said edges defining the shape of rear panel  80 .  
         [0050]     A first elastic segment  82  is cut such that the length of segment  82  is equal to the combined lengths of edges  70   a,    72   a.  Segment edge  82   a  is then sewn to edges  70   a,    72   a.  In like fashion, a second elastic segment  84  is cut such that the length of segment  84  is equal to the lengths of edges  64   a,    66   a  and is then sewn to edges  64   a,    66   a.  Segments  82 ,  84  are constructed as segment  46  is described and as shown in  FIG. 3 .  
         [0051]     A first elastic collar segment  86  is positioned at and is cut to the length of collar edge  78   a.  Collar segment edge  86   a  is then sewn to edge  78   a,  with collar edges  86   c,    86   d  terminating proximate edges  76   a,    60   a  respectively.  
         [0052]     In similar fashion. a second elastic collar segment  88  is positioned at and is cut to the length of collar edge  78   b.  Collar segment edge  88   a  is then sewn to edge  78   b,  with collar edges  86   c,    86   d  terminating proximate edges  76   b,    60   b  respectively.  
         [0053]     Collar segments  86 ,  88  are constructed as described and as shown in  FIG. 4 .  
         [0054]     Form  58  is then sewn to form  80  in the following fashion: edge  60   a  sewn to edge  60   b,  edge  76   a  sewn to edge  76   b,  edge  82   b  sewn to edge  70   b,  edge  84   b  sewn to edge  66   b  and, to complete collar  18  of  FIG. 1 , edges  86   c  and  88   c  are sewn together, as are edges  86   d  and  88   d.    
         [0055]     In similar fashion, shirt  22  shown in  FIG. 2  is assembled such that front and rear panels  24 ,  26  are joined together at one side by elastic segment  90  and at the opposite side by elastic segment  92 , with segments  90 ,  92  constructed as described in connection with  FIG. 3 . Elastic collar segments  94 ,  96 , constructed as described and as shown in  FIG. 4  are sewn to form collar opening  44 .  
         [0056]     So constructed, shirt  10  provides sufficient stretch capability to enable panels  58 ,  80  to be made from relatively inelastic non-woven material and still provide the freedom of motion and comfort to allow shirt  10  to be used over the ranges of motion necessary for physical exercise.  
         [0057]     As seen in  FIG. 7 , the same construction techniques and materials can be used to make exercise shorts and pants. In  FIG. 7 , a first embodiment of a pair of exercise shorts  98  has a front panel  100  having a top edge  102 , a left side edge  104 , a bottom edge  106  and a right side edge  108 . Bottom edge  106  has a left segment  110 , a left inseam edge  112 , a right inseam edge  114  and a right segment  116 . In the embodiment shown a rear panel (not shown) is a mirror image of front panel  100 .  
         [0058]     To construct shorts  98  in accordance with the present invention, a left side seam  118  made from longitudinal elastic segments as described above is attached to left side edge  104  of the front panel  100  and the corresponding edge on the rear panel. Similarly, a right side seam  120  is formed from an elasticized segment and is attached to right side edge  108  and its corresponding rear panel edge. Left inseam edge  112  is likewise seamed to its rear panel counterpart, as is right inseam edge  114 . An elastic waistband  118  is formed from a transverse elastic segment as described above.  
         [0059]     In a second embodiment, a crotch seam  124  is formed by cutting panel  100  from the point at which left and right inseam edges  112 ,  114  meet to top edge  102  and using an elasticized segment  126  to attach the panel edges together, it beign understood that the same modifications are made to the mirror-image rear panel.  
         [0060]     When manufacturing pants instead of shorts, edges  104 ,  108 ,  112  and  114  are lengthened to the desired pants size genrally following the same construction techniques as described above.  
         [0061]     The direction in which seams  118 ,  120  and  126 , and waistband  122  stretch can advantageously be set by using elastomeric materials such as those made under the trademark FLEXCEL™ by Kimberly-Clark Corporation.  
         [0062]     As seen in  FIG. 8 , the fabric panels used to assemble the embodiments above can be made with several plies, designed to absorb and retain perspiration during workouts. As seen in cross-section in  FIG. 8 , panel  128  has a first, outer layer  130  formed from non-woven material. An inner layer  132  formed from a hydrophilic or absorbent material such as that made under the trademark ABSORB.LOC by Kimberly-Clark Corporation can be laminated to layer  130 . If desired, an inner layer  134  can be added to form a three-ply construction, with layer  134  formed from a semi-permeable material such as commercially available spunbonded or carded fibrous webs as described in U.S. Pat. No. 5,147,343, or polyester or polypropylene fibers as described in U.S. Pat. No. 5,429,629, to allow moisture to travel through layer  134  to be trapped in layer  132  without soaking through layer  110 .  
         [0063]     Clothing such as described above can be provided by exercise facilities for one-time use and then discarded and recycled, reducing laundry costs and the inconvenience of traveling with clean and (ultimately) soiled workout clothes. The surface of the non-woven material can be printed or written upon and names, designs, club logos, sizes and even advertisements readily displayed. Facilities such as schools, rehabilitation and senior centers and hotels will find use for the present invention for disposable exercise or emergency garments. Runners can find particular use for the present invention for garments that can be worn at the start of a long-distance race such as a marathon and discarded along the race route as the runner&#39;s temperature goes up. The same garments can be used to warm race participants at the end of a race held in cold weather.