Patent Description:
There are various types of male garments, specifically undergarments such as boxers and jockstraps. Boxers are commonly produced using traditional cut and sew constructions which result in unsightly stitches and seams at the groin region that can be uncomfortable for the male user wearing the boxer. A jockstrap has an elastic waistband with a support pouch for the groin region and elastic straps joining the support pouch to the waistband. These components of the jockstrap are separately formed and joined together, resulting in unsightly and uncomfortable joints at the groin region like the boxers.

Therefore, in order to address or alleviate at least one of the aforementioned problems and/or disadvantages, there is a need to provide an improved male garment.

<CIT> discusses an undergarment including a body having a substantially tubular shape and configured to at least partially surround a torso of a user. The body includes a pouch region about a front surface of the body, and a stitch region including held stitches, the held stitches at least partially bordering the pouch region, and the stitch region having less lateral stretch than a remainder of the body.

<CIT> discusses an undergarment comprising a front panel composed of a first stitch pattern, a rear panel composed of a second stitch pattern, a waistband formed at the top of the front and rear panels, a leg band formed at the bottom of the front and rear panels and an interface. The interface is formed between the front and rear panels and generally extending at least partially between the waistband and the leg band on a side of the undergarment. The interface interleaves at least a portion of the front panel with at least a portion of the rear panel.

<CIT> discusses an underwear system which includes underwear having a front panel, a back panel, a pouch, a waist band, and a lining. The underwear provide support, comfort, breathability, wicking capability and ease of motion with the use. <CIT> discusses a men's underwear garment made of a stretchable cloth and worn without giving feeling of pressure to an area from the waist line to the knee joint of a human body. The garment has partly a stretch part with strong tension, is made up of a single body or the connection of a plurality of belt-like cloths. An area having the stretch part with strong tension tightens a plurality of muscles of part of adductors and part of hamstring from an area including part of the middle gluteal muscle and the greatest gluteal muscle and at least sartorius muscle inside the thighbone, and is stitched overlapping a garment main body made of a stretch cloth.

According to a first aspect of the present disclosure, there is a seamlessly knitted structure for a male garment, knitted structure comprising: a main fabric layer comprising nylon yarn, polyester yarn, polypropylene yarn, cotton yarn or wool yarn; a support fabric layer knitted to the main fabric layer, the support fabric layer formed of a stiffer material than the main fabric layer and comprising yarns made of high modulus material, the high modulus material including spandex, elastane natural rubber, synthetic rubber or thermoplastic polyurethane; and a pouch fabric layer knitted to and extending outwardly from the main fabric layer and supported by the support fabric layer, the pouch fabric layer forming a pouch space for accommodating a groin region of a male user wearing the male garment comprising the knitted structure.

According to a second aspect of the present disclosure, there is a male garment comprising a fabric body and the knitted structure joined to the fabric body.

According to a third aspect of the present disclosure, there is a method of producing the knitted structure, the method comprising seamlessly knitting the knitted structure using a knitting machine.

A knitted structure for a male garment according to the present disclosure is thus disclosed herein. Various features, aspects, and advantages of the present disclosure will become more apparent from the following detailed description of the embodiments of the present disclosure, by way of non-limiting examples only, along with the accompanying drawings.

For purposes of brevity and clarity, descriptions of embodiments of the present disclosure are directed to a seamlessly knitted structure for a male garment, in accordance with the drawings. While aspects of the present disclosure will be described in conjunction with the embodiments provided herein, it will be understood that they are not intended to limit the present disclosure to these embodiments. On the contrary, the present disclosure is intended to cover alternatives and modifications to the embodiments described herein, which are included within the scope of the present disclosure as defined by the appended claims. Furthermore, in the following detailed description, specific details are set forth in order to provide a thorough understanding of the present disclosure. However, it will be recognized by an individual having ordinary skill in the art, i.e. a skilled person, that the present disclosure may be practiced without specific details, and/or with multiple details arising from combinations of aspects of particular embodiments. In a number of instances, well-known systems, methods, procedures, and components have not been described in detail so as to not unnecessarily obscure aspects of the embodiments of the present disclosure.

In embodiments of the present disclosure, depiction of a given element or consideration or use of a particular element number in a particular figure or a reference thereto in corresponding descriptive material can encompass the same, an equivalent, or an analogous element or element number identified in another figure or descriptive material associated therewith.

References to "an embodiment / example", "another embodiment / example", "some embodiments / examples", "some other embodiments / examples", and so on, indicate that the embodiment(s) / example(s) so described may include a particular feature, structure, characteristic, property, element, or limitation, but that not every embodiment / example necessarily includes that particular feature, structure, characteristic, property, element or limitation. Furthermore, repeated use of the phrase "in an embodiment / example" or "in another embodiment / example" does not necessarily refer to the same embodiment / example. The terms "comprising", "including", "having", and the like do not exclude the presence of other features / elements / steps than those listed in an embodiment. Recitation of certain features / elements / steps in mutually different embodiments does not indicate that a combination of these features / elements / steps cannot be used in an embodiment. As used herein, the terms "a" and "an" are defined as one or more than one. The use of "/" in a figure or associated text is understood to mean "and/or" unless otherwise indicated. The terms "first", "second", etc. are used merely as labels or identifiers and are not intended to impose numerical requirements on their associated terms.

In representative or exemplary embodiments of the present disclosure, as shown in <FIG>, there is a seamlessly knitted structure <NUM> for a male garment <NUM>, such as undergarments like boxers. Further as shown in <FIG> and <FIG>, the male garment <NUM> comprises a fabric body <NUM> and the knitted structure <NUM> joined to the fabric body <NUM>. The knitted structure <NUM> comprises a main fabric layer <NUM> and a support fabric layer <NUM>. The support fabric layer <NUM> is knitted to the main fabric layer <NUM>. The support fabric layer <NUM> is formed of a stiffer material than the main fabric layer <NUM>, the support fabric layer <NUM> is formed of a high modulus material. The knitted structure <NUM> further comprises a pouch fabric layer <NUM> knitted to and extending outwardly from the main fabric layer <NUM> and the pouch fabric layer <NUM> is supported by the support fabric layer <NUM>. More specifically, the pouch fabric layer <NUM> is knitted to the main fabric layer <NUM> via the support fabric layer <NUM> that interfaces between the pouch fabric layer <NUM> and main fabric layer <NUM>. The pouch fabric layer <NUM> forms a pouch space for accommodating the groin region of a male user wearing the male garment <NUM> comprising the knitted structure <NUM>.

The main fabric layer <NUM>, support fabric layer <NUM>, and pouch fabric layer <NUM> are knitted continuously and seamlessly such that there are no seams around the knitted structure <NUM>. The knitting may be performed using a knitting machine such as a flatbed knitting machine, particularly a V-bed flat knitting machine. Embodiments of the present disclosure also describe a method of producing the knitted structure <NUM> for the male garment <NUM>, the method comprising seamlessly knitting the knitted structure <NUM> using the knitting machine.

In some embodiments, the knitted structure <NUM> is separately formed and later joined to a front panel <NUM> of the fabric body <NUM> of the male garment <NUM> as shown in <FIG>, such as by sewing, stitching, adhesive, or bonding. The front panel <NUM> and back panel <NUM> (as shown in <FIG>) of the fabric body <NUM> are then joined together, such as by sewing, stitching, adhesive, or bonding, to form the male garment <NUM>.

Alternatively, the front panel <NUM> and back panel <NUM> may be knitted continuously as a single fabric panel and then joined at both edges with one seam. The fabric body <NUM> comprising the front panel <NUM> and back panel <NUM> may be in the form of a plated structure having main yarns and plating yarns. In some embodiments, the knitted structure <NUM> is seamlessly knitted together with the front panel <NUM>, and the front panel <NUM> comprising the seamless knitted structure <NUM> is then joined with the back panel <NUM> to form the male garment <NUM>. In some embodiments, the knitted structure <NUM> is seamlessly knitted together with the front panel <NUM> and back panel <NUM> to form a seamless male garment <NUM>.

When the male garment <NUM> comprising the seamlessly knitted structure <NUM> is worn by the male user, the seamless construction of the knitted structure <NUM> results in significantly reduced chafing at the groin region, thus improving comfort during all day wear and especially during movement. The seamless construction also results in a more durable product, especially with frequent washing and wearing, as the seams are often the weakest part of a garment produced using the traditional cut and sew constructions.

The main fabric layer <NUM> can be formed of any knit design, such as a single jersey knit structure or a pique knit structure. In some embodiments, the main fabric layer <NUM> comprises a mesh or porous structure that provides ventilation and improves breathability. The main fabric layer <NUM> comprises nylon yarn, polyester yarn, polypropylene yarn, cotton yarn or wool yarn.

In some embodiments, the main fabric layer <NUM> comprises frictional yarns or high friction yarns. Knitting of the main fabric layer <NUM> using frictional yarns can mitigate the tendency of the male garment <NUM> riding up the user's thighs when the user is moving. This riding up can occur because during movement, the male garment <NUM> is subject to external forces which can lead to a shift in position of the male garment <NUM> upwards along the thighs.

The frictional yarns may be knitted along peripheral edges <NUM> of the main fabric layer <NUM>. These peripheral edges <NUM> may coincide with the hem area <NUM> of the male garment <NUM> where the knitted structure <NUM> is joined to the fabric body <NUM>. The hem area <NUM> may include a microfiber structure to similarly mitigate the riding up issue. The frictional yarns may be alternatingly knitted with the yarns of the fabric body <NUM> at the hem area <NUM> to seamlessly knit and integrate the knitted structure <NUM> with the fabric body <NUM>. The hem area <NUM> may comprise a tube knit. The frictional yarns may comprise one or more of nano yarns / fibres, micro yarns / fibres, and silicone yarns / fibres.

The support fabric layer <NUM> is arranged to support the pouch fabric layer <NUM> that forms the pouch space or 3D pouch for accommodating the groin region of the user wearing the male garment <NUM>. The support fabric layer <NUM> is formed of a stiffer material than the main fabric layer <NUM>, a high modulus material, so that the support fabric layer <NUM> is able to provide sufficient support for the pouch fabric layer <NUM> and consequently for the groin region. The support fabric layer <NUM> may be knitted in the form of a double jersey knit structure, spacer structure, or plated structure. The pouch fabric layer <NUM> may be knitted in the form of a single jersey knit structure. Further, the pouch fabric layer <NUM> may be knitted using the holding down knitting technique to create the required volume of the pouch space. The support fabric layer <NUM> and pouch fabric layer <NUM> can be knitted or formed according to desired / customized requirements, enabling the male garment <NUM> to be personalized to customer needs. The support fabric layer <NUM> comprises yarns made of a high modulus material, the high modulus material including spandex, elastane, rubber (natural or synthetic), or thermoplastic polyurethane (TPU) which would limit stretching of the yarns. The yarns may include but are not limited to single covered yarns, doubled covered yarns, mechanical stretch yarns. Notably, the material of the support fabric layer <NUM> is stiffer and has a higher modulus than the material of the main fabric layer <NUM>, meaning that a larger force is required to stretch one unit length of the support fabric layer <NUM> compared to the main fabric layer <NUM>.

In some embodiments, the knitted structure <NUM> comprises a functional layer <NUM> knitted to the pouch fabric layer <NUM> and disposed within the pouch space. Similarly, the functional layer <NUM> is seamlessly knitted to the pouch fabric layer <NUM> such that the knitted structure <NUM> is seamless. The functional layer <NUM> is configured for various functionalities such as for absorbing and/or wicking moisture. For example, the functional layer <NUM> comprises an absorbent / wicking material to absorb and wick moisture away from user. For example, the absorbent / wicking material may be cotton, rayon, polycotton, or poly rayon. The functional layer <NUM> may comprise a double jersey knit structure, spacer structure, or plated structure to provide additional support for the pouch fabric layer <NUM>. Having the absorbent / wicking functional layer <NUM> can address certain conditions that the user may suffer from, such as urinary incontinence.

It will be appreciated that knitting of the knitted structure <NUM> can be done in the vertical direction or horizontal direction. For example, a draw thread <NUM> is knitted in the knitted structure <NUM> for dividing the knitted structure <NUM> if the knitted structure <NUM> is knitted in the left-right or right-left direction. The knitted structure <NUM> can be joined or stitched to the fabric body <NUM> of the male garment <NUM> after removing the draw thread <NUM>. It will also be appreciated that different knit designs may be formed in any area of the knitted structure <NUM> and fabric body <NUM> of the male garment <NUM>.

<FIG> illustrates an alternative embodiment of the male garment <NUM> comprising the knitted structure <NUM> in the front panel <NUM> of the fabric body <NUM>. The main fabric layer <NUM> may include first fabric areas <NUM> adjacent to both sides of the support fabric layer <NUM>. The first fabric areas <NUM> are arranged such that when the male garment <NUM> comprising the knitted structure <NUM> is worn, the first fabric areas <NUM> are aligned to the groin region and inner thigh regions of the user. The first fabric areas <NUM> may be made of a smooth or low friction material to reduce chafing at the inner thigh regions, especially when the thighs come into contact together during movement.

The main fabric layer <NUM> may include second fabric areas <NUM> adjacent to the first fabric areas <NUM>. The second fabric areas <NUM> start from the top and sides of the main fabric layer <NUM> and extend downwards and inwards and at angle to the bottom. The second fabric areas <NUM> are arranged such that when the male garment <NUM> comprising the knitted structure <NUM> is worn, the second fabric areas <NUM> are aligned to the sartorius muscles in the thighs of the user. The second fabric areas <NUM> separate the first fabric areas <NUM> and the fabric body <NUM> of the male garment from each other, allowing them to move independently. The second fabric areas <NUM> may have a mesh or porous structure which increases the frictional forces with the skin, reducing the tendency for the male garment <NUM> to shift in position during movement. The second fabric areas <NUM> may be made of a high modulus or substantially inelastic material, i.e. a material that is non-elastic or has low elasticity. Alternatively or additionally, the second fabric areas <NUM> include frictional yarns or a high frictional material to increase the frictional forces.

The main fabric layer <NUM> may include third fabric areas <NUM> between the first fabric areas <NUM> and the support fabric layer <NUM>. The third fabric areas <NUM> may have a mesh or porous structure to provide additional ventilation and improved breathability.

The back panel <NUM> of the fabric body <NUM> may include additional features to improve support of the garment <NUM> for the user. In one embodiment as shown in <FIG>, the back panel <NUM> is knitted with pockets <NUM>. Padded layers can be inserted into the pockets <NUM> to shape the back panel <NUM> and provide support and comfort to the butt area of the user. In one embodiment, the back panel <NUM> is knitted with a thicker material or structure, such as double jersey knit structure, spacer structure, or plated structure, to shape the back panel <NUM> and achieve the padded butt lift effect. In one embodiment as shown in <FIG>, the back panel <NUM> is knitted with a stiffer or high modulus material to shape various areas <NUM> of the back panel <NUM> not limited to the butt area. In one embodiment, the back panel <NUM> includes a mesh or porous structure to provide ventilation at the butt area of the user.

It will be appreciated that various features of the embodiments as described in <FIG>, <FIG>, <FIG>, <FIG> can apply similarly or analogously to one another.

Accordingly, embodiments herein describe the seamlessly knitted structure <NUM> and male garment <NUM> comprising the knitted structure <NUM>. Various parts of the knitted structure <NUM> are seamlessly knitted together to produce a seamless product that can provide support for the groin region and superior comfort to the user. Additional functionalities can be provided, such as moisture absorbency and wicking, with a suitable absorbent and wicking layer seamlessly knitted with the knitted structure <NUM>.

Moreover, the riding up issue has been addressed by the knitted structure <NUM> and male garment <NUM> with suitable fabric arrangements and materials. The male garment <NUM> can be produced as standard everyday men's boxers or as performance boxers for sportsmen. For example, the male garment <NUM> for making performance boxers may include covered yarns with spandex cores as the main yarns in the fabric body <NUM>.

Claim 1:
A seamlessly knitted structure (<NUM>) for a male garment (<NUM>), the knitted structure (<NUM>) comprising:
a main fabric layer (<NUM>) comprising nylon yarn, polyester yarn, polypropylene yarn, cotton yarn or wool yarn;
a support fabric layer (<NUM>) knitted to the main fabric layer (<NUM>), the support fabric layer (<NUM>) formed of a stiffer material than the main fabric layer (<NUM>) and comprising yarns made of a high modulus material, the high modulus material including spandex, elastane, natural rubber synthetic rubber or thermoplastic polyurethane; and
a pouch fabric layer (<NUM>) knitted to and extending outwardly from the main fabric layer (<NUM>) and supported by the support fabric layer (<NUM>), the pouch fabric layer (<NUM>) forming a pouch space for accommodating a groin region of a male user wearing the male garment (<NUM>) comprising the knitted structure (<NUM>).