Patent Description:
Resilient bands, such as waistbands, wristbands, and the like, are commonly used on articles of apparel, such as pants, jackets, and the like, to snugly secure the article of apparel to the wearer.

In general, these bands should snugly synch the article of apparel to the wearer, but remain flexible enough so as to not limit the wearer's full range of movement or feel too tight by the wearer. In addition, it is often desirable for the band to be as thin as possible so as to prevent the band from feeling bulky by the wearer. For example, waistbands on yoga pants must be particularly flexible and bulk-free, yet still secure the pants to the wearer throughout the wearer's full range of motion.

Known waistbands and the like tend to inadvertently compromise, comfort, fit, or the range of motion of the wearer. For example, a commonly used waistband design includes sewing a relatively thick elastic band to a strip of outer fabric to form one or more substantially horizontal seams. While effective as a waistband, this structure tends to feel bulky and not particularly resilient, and it tends to limit the range of motion of the wearer, particularly when used in yoga apparel. Moreover, elastic bands tend to lose some of their elasticity with repeated use over time.

Accordingly, despite the benefits of known resilient band structures used on articles of apparel, there remains a need for a cost effective, durable, light weight, bulk-free resilient band that allows a full range of movement of the wearer without compromising the ability of the band to hold onto its wearer. <CIT> discloses an elastic waistband belt for trousers or a skirt, with or without a central opening or fly flap. The waistband is produced from elastic fabrics and assembled with an extensible chain stitch with a very slack tension, in order to yield an elasticity of ><NUM>%. An elastic strip of braid or piping may be introduced between two sheets of elastic material, and the three superimposed layers may be joined by means of the extensible sewing thread, in e. chain stitch. The garment may be assembled of a thick outerwear material, yet still present a smart urban aspect and cut. <CIT> discloses an elastic curtain to replace the normal inelastic curtains of outer garments such as trousers, skirts, shorts, culottes, etc., or to be added to other outer garments where a close fitting comfortable waistline is desired. The elastic curtain comprises a heavy core of elastic strip material with finished edges which strip material is stretchable in one direction and a two-way stretch elastic fabric covering the heavy strip material, or that part of the strip material which is nearest the wearer's body. <CIT> discloses an elastic waistband comprising a rubber strip <NUM> covered on one side by an edge zone of garment material <NUM> and on the other side by a cover strip <NUM> with its edges <NUM>, <NUM> folded over the edges of the rubber strip, the cover strip and edge zone of the garment material are made of interlock rib knit fabric. The rubber strip is more stretchable than the garment material which in turn is more stretchable than the cover strip. Expansion stitching <NUM>, <NUM> secures the strips <NUM>, <NUM> to the garment, the rubber strip and garment being stretched during the stitching operation; the cover strip also may be stretched but is stretched less than the garment material.

The present invention overcomes these and other shortfalls with the known resilient band structures. A resilient band for use with articles of apparel that is formed with a first fabric operably secured to a more resilient elastic, and preferably fabric, structure is disclosed.

Disclosed preferred embodiment includes the fabric and elastic structure first being placed in a stretched position along their longitudinal lengths. They are then operably secured together with fastening structures that are preferably aligned substantially perpendicular to their longitudinal lengths. The resulting resilient band is extremely flexible and comfortable while still allowing it to effectively grasp the wearer throughout the entire range of movement of the wearer.

A resilient band <NUM> for an article of apparel, the band <NUM> formed with a sheet of first fabric <NUM> being operably secured to a more resilient sheet of second fabric <NUM>, is shown in <FIG>. A first preferred resilient band <NUM>' embodiment is shown in <FIG>, <FIG>, <FIG>, <FIG>, and a second preferred resilient band embodiment <NUM>" embodiment is shown in <FIG>, <FIG>.

Referring to <FIG> , the resilient band 10is preferably a waistband 10A and the article of apparel is preferably a pair of pants, such as yoga pants. The resilient band <NUM> is operably secured to the article of apparel, and a draw string <NUM>, may be operably received within the resilient band <NUM> as shown.

The first fabric <NUM> is preferably a soft, stretchy fabric, such as fleece or the like, that may also form an outer surface <NUM> of the article of apparel. For example, <FIG> show the first fabric <NUM> extending beyond the resilient band <NUM> to also form the pair of pants.

The second fabric <NUM> is selected from a group of fabrics that are more resilient than the first fabric <NUM>. It is preferable to encircle the first fabric <NUM> around the second fabric <NUM> as best shown in <FIG> so that the second fabric <NUM> does not contact the wearer. One known second fabric <NUM> that has particularly desirable resiliency characteristics is known in the industry as "powermesh," which is a thin, sturdy, breathable, flexible fabric that is preferably stretchable in all directions, but also readily seeks to return to a neutral, unstretched position.

Preferably, the powermesh fabric used as the second fabric <NUM> is composed of <NUM> to <NUM> percent nylon or polyester with the corresponding remaining material comprising spandex. More preferably, the powermesh fabric is warp knit mesh construction formed of <NUM> to <NUM> percent nylon or polyester with the remaining material comprising spandex. Even more preferably, the powermesh fabric is formed of less than <NUM> percent spandex such as <NUM> percent nylon or polyester and <NUM> percent spandex.

Other materials having the general elasticity, resiliency, and light fabric weight of powermesh may also be used. These fabric properties are preferably within the following ranges: Fabric weight of <NUM> grams per meter squared plus or minus <NUM> percent, and using the stretch recover properties defined by an industry standard test known as ASTM D2594, the resiliency, or "growth properties," of the fabric in the length (wales) direction is preferably equal to a maximum <NUM> percent, with the width (courses) direction equal to a maximum of <NUM> percent. The corresponding desired elasticity using a <NUM> pound stretch property test is preferably between <NUM> to <NUM> percent in the length (wales) direction, and between <NUM> to <NUM> percent in the width (courses) direction.

The first and second fabrics <NUM>, <NUM>, respectively, are operably secured together so as to not unduly limit the stretchability of the resulting resilient band <NUM> in all directions. As shown in <FIG>, <FIG>, <FIG> and <FIG>, the first and second fabric <NUM>, <NUM> are placed on top of each other and then urged to a stretched position Y along the longitudinal length <NUM> of the resulting resilient band <NUM>. The fabrics <NUM>, <NUM> are secured together while both are in their stretched positions Y and the resulting fabric structure <NUM> is released to a neutral position X after the two fabrics <NUM>, <NUM> are secured together.

The first and second fabrics <NUM>, <NUM> are secured together so as to prevent a substantial continuous seam parallel to the longitudinal length <NUM> of the resilient band <NUM>. For example, the first and second fabrics <NUM>, <NUM> may be stitched together with a plurality of spaced-apart, substantially parallely-aligned stitches <NUM> that may be aligned substantially vertically and perpendicular to the longitudinal centerline <NUM> of the resilient band <NUM> as shown in <FIG>.

The resulting stitching pattern will allow the first and second fabrics <NUM>, <NUM> to rest substantially parallel to each other in the stretched position Y shown in <FIG> , but the first fabric <NUM> will tend to form small, and aesthetically pleasing, curtain-type pleats <NUM> when the resulting fabric structure <NUM> is released to its neutral position X as shown in <FIG>.

More preferably, the stitching may follow a substantially continuous serpentine pattern <NUM> along the longitudinal length <NUM> of the resilient band <NUM> with cross-over stitching <NUM> alternating which end to cross-over to the next substantially vertical parallel line <NUM> of stitching so as to prevent a substantially continuous horizontal seam along the longitudinal length <NUM> of the resilient band. Even more preferably, the horizontal cross-over stitching <NUM> extends between two adjacent, substantially vertical and parallel stitching lines <NUM>, with the horizontal cross-over stitching <NUM> being vertically spaced apart from adjacent cross-over stitching <NUM> so as to not impede the longitudinal stretching of the resulting resilient band <NUM>, particularly in the direction of the stretched position Y shown in <FIG>.

Referring to <FIG>, <FIG>, <FIG> a first construction configuration of the resilient band <NUM>' is disclosed. The first and second fabrics <NUM>, <NUM> are operably secured together as previously described, and the resulting fabric structure <NUM> is folded over upon itself at fold-line <NUM> to define a first portion <NUM> and second portion <NUM> of the resulting fabric structure <NUM> and form an internal pocket <NUM> as best shown in <FIG>. The first and second portions <NUM>, <NUM> are then operably secured together.

If desired, the draw string <NUM> may be operably received in the internal pocket <NUM> with the ends of the draw string <NUM> extending through openings <NUM> (<FIG>) through an outer wall of the resilient band <NUM> so as to allow a user to tie the drawstring together. Preferably, a draw string retention panel <NUM> is operably secured to the fabric structure <NUM> within the internal pocket <NUM> so as to maintain proper positioning and alignment of the drawstring within the internal pocket <NUM> as shown in <FIG> and <FIG>.

Referring to <FIG>, <FIG>, an alternative resilient band <NUM>" construction configuration is disclosed. The first fabric <NUM> is operably secured to a thin strip of second fabric <NUM> to form a resulting fabric structure <NUM> as previously described. Then, the resulting fabric structure <NUM> is folded over the first fabric <NUM> as best shown in <FIG> so as to allow the first fabric <NUM> to encircle the inner second fabric <NUM> and define an internal pocket <NUM>. This construction configuration results in a single layer of inner second fabric <NUM>, and therefore a thinner resilient band <NUM>".

If desired, the draw string <NUM> may be operably received within the internal pocket <NUM> of this configuration as previously shown and described.

The resulting resilient band <NUM> is bulk free and easily flexible in all directions, including along the longitudinal length <NUM> of the band, while still offering superior holding ability through the entire range of motion of the wearer.

It is not intended to be exhaustive or to limit the invention. For example, although the disclosed first fabric <NUM> is described as also serving as the fabric for forming the article of apparel <NUM>, the resilient band <NUM> of the present invention may be a discrete structure that is separate from the article of apparel to which it is attached. Similarly, the article of apparel may not be a pair of paints, but a jacket or the like with the resilient band forming a wrist-strap, waist strap or the like thereon.

Also, the stitching methods and structures for securing the two fabrics <NUM>, <NUM> together are for exemplary purposes only. Other securing methods, such as heating, using adhesives, and the like may also be used so long as the resulting securing structures do not unduly limit the range of movement of the resulting resilient band <NUM> as described. In addition, the disclosed parallely-aligned patterns for securing the two fabrics <NUM>, <NUM> together need not form straight lines nor be aligned substantially perpendicular to the longitudinal length <NUM> of the resilient band <NUM>.

Claim 1:
A resilient band (<NUM>) for an article of apparel,
the resilient band (<NUM>) having a longitudinal length (<NUM>), the resilient band comprising:
a first resilient fabric (<NUM>), having a first resiliency, and a second resilient fabric (<NUM>) having a second resiliency greater than the first resiliency, wherein the first and second resilient fabrics (<NUM>, <NUM>) are operably secured together by placing the first and second resilient fabrics (<NUM>, <NUM>) on top of each other, urging the first and second resilient fabrics (<NUM>, <NUM>) to a stretched position along the longitudinal length (<NUM>), securing the first and second resilient fabrics (<NUM>, <NUM>) together while both are in their stretched positions, and releasing the resulting fabric structure (<NUM>) to a neutral position after the first and second resilient fabrics (<NUM>, <NUM>) are secured together, characterised in that:
the resulting fabric structure (<NUM>) is folded over upon itself at a fold-line (<NUM>) to define a first portion (<NUM>), a second portion (<NUM>), and an internal pocket (<NUM>);
the first and second portions (<NUM>, <NUM>) are operably secured together and
the second resilient fabric (<NUM>) is disposed within the pocket (<NUM>).