Patent Description:
<CIT> discloses a further doll accessory for play or use with a doll or other toy figure.

<CIT> discloses a display system which comprises, in combination, a display panel and a modular multi-layer three dimensional figure which can be readily disassembled and re-assembled in different forms. The display panel has a structural member with a first and second outer covering member, at least one of which is a hook or loop material, and which outer coverings are joined at their lateral edges in a narrow, unobtrusive seam. The figure is comprised of a plurality of first flexible elements, flat in relaxed state, and having hook or loop fabric on at least one facial surface, and a plurality of second flexible elements, also flat in relaxed state, with hook or loop material on both facial surfaces which are releasably secured to the first flexible elements. A method of making the panel and a finger or hand puppet constructed from the flexible elements are further disclosed.

<CIT> discloses a method for manufacturing vinyl doll clothes.

<CIT> discloses an emblem capable of expressing multiple colors and having a metal (deposition effect) and a hologram effect, and a manufacturing method thereof.

This disclosure relates to a method of manufacturing clothing for a toy figure such as a doll. The manufacturing method produces a three-dimensional garment that has a full, three-dimensional effect, can stand on its own, and is easy for the user to dress on the toy figure and also to remove from the toy figure.

The present invention is defined by the independent claims <NUM>, <NUM>, and <NUM>. The dependent claims describe optional features and preferred embodiments.

In some general aspects, a method of manufacturing a garment includes forming a multilayer composition having one or more design elements. The multilayer composition is formed by applying a material that includes the one or more design elements to an elastomeric polymer base layer. The method further includes heating the multilayer composition, and after the multilayer composition has been heated, then aligning each design element with a respective three-dimensional design feature of a three-dimensional mold, and pressing the heated multilayer composition into the three-dimensional mold. The method further includes cooling the pressed heated multilayer composition to form a three-dimensional molded multilayer composition that includes one or more three-dimensional design elements; and forming a three-dimensional garment from the three-dimensional molded multilayer composition.

Implementations can include one or more of the following features. For example, the material can be applied by attaching a fabric material that includes the one or more design elements to the elastomeric polymer base layer. The fabric material can be attached to the elastomeric polymer base layer by adhering the fabric material to the elastomeric polymer base layer. The fabric material can be adhered to the elastomeric polymer base layer by applying adhesive to the elastomeric polymer base layer, heating the elastomeric polymer base layer with applied adhesive, and pressing the fabric to the heated elastomeric polymer base layer with applied adhesive so that the one or more design elements of the fabric material remain visible after pressing.

The method can also include storing the multilayer composition.

The multilayer composition can be heated by heating the laminated composition to a temperature in a range of <NUM> to <NUM>.

Each design element can be aligned with a respective three-dimensional design feature of a three-dimensional mold by fixing at least one reference location on the multilayer composition to a respective mold reference location on the three-dimensional mold. The at least one reference location on the multilayer composition can be fixed to a respective mold reference location on the three-dimensional mold by engaging a first aligner of the multilayer composition with a second complementary aligner formed in a three-dimensional mold plate of the three-dimensional mold. The first aligner can include an opening in the multilayer composition and the second aligner can include a post formed in the three-dimensional mold plate, in which the post is configured in size to be inserted through the opening.

The at least one reference location on the multilayer composition can be fixed to the respective mold reference location on the three-dimensional mold by aligning two or more reference locations on the multilayer composition to respective mold reference locations on the three-dimensional mold.

The heated multilayer composition can be pressed into the three-dimensional mold by placing the heated multilayer composition between complementary three-dimensional mold plates and pressing the complementary three-dimensional mold plates together with the heated multilayer composition positioned between the complementary three-dimensional mold plates. The pressed heated multilayer composition can be cooled by cooling the pressed heated multilayer composition while the multilayer composition is being pressed between the complementary three-dimensional mold plates. The complementary three-dimensional mold plates can be pressed together with the heated multilayer composition positioned between the complementary three-dimensional mold plates by pressing with about <NUM>-<NUM> tons of force for about <NUM>-<NUM> seconds without application of heat.

The three-dimensional garment can be formed from the three-dimensional molded multilayer composition by die cutting the three-dimensional molded multilayer composition. The three-dimensional garment can be formed from the three-dimensional molded multilayer composition by attaching two regions of the three-dimensional garment together to form a cavity configured to receive a toy figure. The two regions of the three-dimensional garment can be attached together to form the cavity by attaching with hook and loop fasteners.

The elastomeric polymer layer can include a copolymer of ethylene and vinyl acetate. The weight percent of vinyl acetate can be between <NUM>-<NUM>% of the total.

The elastomeric polymer base layer can have a thickness of between <NUM> and <NUM> millimeters (mm) or a thickness of between <NUM> and <NUM>.

The elastomeric polymer base layer can have a hardness of about <NUM>-<NUM> shore.

The material that includes the one or more design elements can be applied to the elastomeric polymer base layer by screen printing the material to the elastomeric polymer base layer so that the one or more design elements are printed along with a base design onto the elastomeric polymer base layer. The material can be screen printed to the elastomeric polymer base layer by pressing ink through a stretched porous fabric mesh onto which a stencil has been applied, and the one or more design elements and the base design are printed based on the stencil.

In other general aspects, a three-dimensional garment for a toy figure includes: a multilayer composition that is shaped into the three-dimensional garment and is able to stand on its own. The multilayer composition includes: an elastomeric polymer base layer; and a print material applied to the elastomeric polymer base layer. The print material includes one or more printed design elements, each printed design element being aligned with a respective three-dimensional design feature of the elastomeric polymer base layer.

Implementations can include one or more of the following features. For example, the multilayer composition can include at least two connection regions at distinct locations for connecting the distinct locations to thereby form the three-dimensional garment that is able to stand on its own.

The elastomeric polymer layer can include a copolymer of ethylene and vinyl acetate. The weight percent of vinyl acetate can be between <NUM>-<NUM>% of the total. The elastomeric polymer base layer can have a thickness of between <NUM> and <NUM> millimeters (mm) or between <NUM> and <NUM>. The elastomeric polymer base layer can have a hardness of about <NUM>-<NUM> shore.

The multilayer composition can be a laminated composition and the print material can be a fabric material including the one or more printed design elements and being attached to the elastomeric polymer base layer. A thickness of the fabric material can be between <NUM>-<NUM>.

The print material can be ink applied to the elastomeric polymer base layer in accordance with a stencil design. A thickness of the applied ink can be between <NUM>-<NUM>. The ink can include a plurality of different colors of ink applied to the elastomeric polymer base layer, each ink color applied in accordance with its own stencil design.

In other general aspects, a toy includes: a toy figure; and three-dimensional garment configured to dress the toy figure. The three-dimensional garment includes a multilayer composition that is shaped into the three-dimensional garment and is able to stand on its own. The multilayer composition includes: an elastomeric polymer base layer; and a print material applied to the elastomeric polymer base layer. The print material includes one or more printed design elements, each printed design element being aligned with a respective three-dimensional design feature of the elastomeric polymer base layer.

Implementations can include one or more of the following features. For example, the three-dimensional garment can be made of a single piece and can be configured to wrap around the toy figure.

The toy figure can include a body and one or more appendages extending from the body; and the three-dimensional garment can be made of a single piece and can be configured to wrap around the body of the toy figure.

The toy figure can be able to stand under only the support from the three-dimensional garment when the three-dimensional garment is dressed on the toy figure.

The print material can include a first region that includes a fabric material and can be attached to the elastomeric polymer base layer and a second region that includes ink applied to the elastomeric polymer base layer in accordance with a stencil design. The one or more printed design elements can be in the first region, in the second region, or in both the first region and the second region.

Referring to <FIG>, an implementation of a garment <NUM> is shown. The garment <NUM> includes a multilayer composition <NUM> that is shaped into a three-dimensional form to dress (for example, to fit over, around, or partially around) at least part of a toy figure <NUM>. The multilayer composition <NUM> is able to stand on its own, that is, without any assistance from the toy figure <NUM>, the user, or any other device. The multilayer composition <NUM> includes an elastomeric polymer base layer <NUM> (<FIG>) and a print material <NUM> applied to the elastomeric polymer base layer <NUM>. The garment <NUM> is wrapped around the part of the toy figure <NUM> so that the elastomeric polymer base layer <NUM> faces the toy figure <NUM> and the print material <NUM> is visible to a user and faces away from the toy figure <NUM>.

The multilayer composition <NUM> includes a first connection region <NUM> and a second connection region <NUM>. The first and second connection regions <NUM>, <NUM> are in physical communication with each other in <FIG> and <FIG> and the garment <NUM> is in a closed state around the toy figure <NUM>. The print material <NUM> is visible in <FIG>. On the other hand, the first and second connection regions <NUM>, <NUM> are physically separated from each other in <FIG> and <FIG>, and the garment <NUM> is in an open state in <FIG> and <FIG>. The base layer <NUM> is visible in <FIG>. The first and second connection regions <NUM>, <NUM> can be fitted with mating connection devices such as hook and loop fasteners.

The print material <NUM> comprises one or more printed design elements <NUM>-i, where i is a positive integer. Each printed design element <NUM>-i is aligned with or in registration with a respective three-dimensional design feature <NUM>-i formed in the elastomeric polymer base layer <NUM>. In the implementation of the garment <NUM> that is shown in <FIG>, printed design elements <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM> are visible in <FIG>; and three-dimensional design features <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM> are visible in <FIG>. Printed design elements <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM> and corresponding three-dimensional design features <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM> are visible in the cross-sectional view C-C shown in <FIG> and also in the cross-sectional and extended view shown in <FIG>.

Each printed design element <NUM>-i is formed as a color or a contrast in color when compared to the print material <NUM> that is adjacent to that printed design element <NUM>-i. For example, each of the printed design elements <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> has a darker color or distinct color or a darker tone from the print material <NUM> adjacent to that printed design element <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>. Moreover, the color or contrast of a particular printed design element <NUM>-i is related to or shaped to conform with the geometry of the underlying three-dimensional design feature <NUM>-i. As an example, each of the printed design elements <NUM>-<NUM>-<NUM> is in registration with its respective three-dimensional design feature <NUM>-<NUM>-<NUM>. Each three-dimensional design feature <NUM>-i is a shape formed into the base layer <NUM> that deviates from a plane or smooth shape. Thus, a design feature <NUM>-i can be a protrusion that extends above the smooth shape of the base layer <NUM> or a design feature <NUM>-i can be an indentation that presses into the smooth shape of the base layer <NUM>. With reference to <FIG>, for example, the design features <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM> are protrusions that extend above a smooth shape of the base layer <NUM> along the Y direction, while the design feature <NUM>-<NUM> is an indentation that presses into the smooth shape of the base layer <NUM> along the Y direction, where the general shape or extend of the base layer <NUM> in the regions outside the design features <NUM>-i is in an XZ plane.

The shape of the printed design element <NUM>-i matches with the shape of the underlying or in-registration design feature <NUM>-i. For example, the printed design element <NUM>-<NUM> is shaped like a bird and the underlying design feature <NUM>-<NUM> also has a shape of a bird. As another example, the printed design element <NUM>-<NUM> is shaped like a ribbon and the underlying design feature <NUM>-<NUM> has a shape of a ribbon. As a further example, the printed design element <NUM>-<NUM> is shaped like an abstract flower and the underlying design feature <NUM>-<NUM> has a geometry that also resembles the abstract flower in shape and scale. The printed design elements <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM> are shadows that evoke folds or creases of a dress and the underlying respective design features <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> are either indentations or extensions to mimic the fold or crease of a dress.

The elastomeric polymer base layer <NUM> can include a copolymer, and the copolymer can be made up of ethylene and vinyl acetate. The weight percent of the vinyl acetate in the copolymer can be between <NUM>-<NUM>% of the total. A thickness T(<NUM>) of the base layer <NUM> when taken along the shortest extent can be between about <NUM> to about <NUM> millimeters (mm). In some implementations the thickness T(<NUM>) of the base layer <NUM> is about <NUM> to about <NUM>. In order to provide for some amount of rigidness to the garment <NUM>, for example, to enable the garment to stand up without external support, the base layer <NUM> can have a hardness of about <NUM>-<NUM> shore. The print material <NUM> also has a thickness T(<NUM>) taken along its shortest extent, and this thickness T(<NUM>) can depend on the type or composition of the print material <NUM>. For example, the thickness T(<NUM>) of the print material <NUM> is less than the thickness T(<NUM>) of the base layer <NUM> to enable some flexibility in the garment. Thus, in some implementations, the thickness T(<NUM>) of the print material <NUM> can be less than <NUM>% of the thickness T(<NUM>) of the base layer <NUM>. In some implementations, the thickness T(<NUM>) of the print material <NUM> can be less than <NUM>% of the thickness T(<NUM>) of the base layer <NUM>.

In some implementations, the multilayer composition <NUM> is a laminated composition, which means that it includes superposed layers of one or more materials that are united by an adhesive or other suitable method. For example, the multilayer composition <NUM> includes the elastomeric polymer base layer <NUM> and the print material <NUM> is a fabric material on which the one or more printed design elements are presented. In this example, the fabric material is applied (for example, by adhesion) to the elastomeric polymer base layer <NUM>.

<FIG> and <FIG> show front (2A) and back (2B) views of an implementation of a garment <NUM> that includes a laminated multilayer composition <NUM>. The multilayer composition <NUM> includes a print material <NUM> that is a fabric material applied to an elastomeric polymer base layer <NUM>. The fabric material <NUM> includes a set of printed design elements <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> (2A) in registration with underlying design features <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> (2B). The fabric material <NUM> can have a thickness T(<NUM>) that is about <NUM>% of the thickness T(<NUM>) of the base layer <NUM>. For example, the thickness T(<NUM>) of the fabric material <NUM> can be between about <NUM> micrometers (µm) and about <NUM>.

The fabric material <NUM> can be a stretchy fabric such as, for example, Spandex, knit, or pique knit fabric.

In other implementations, the print material <NUM> is an ink applied to the elastomeric polymer base layer <NUM>. For example, the ink can be applied using a silkscreen printing technique, as discussed below. The ink can include a plurality of different colors, and the colors can be overlaid onto the base layer <NUM>, laid adjacently to each other, or laid separated from each other onto the base layer <NUM>, depending on the design. In this case, the ink is applied in accordance with one or more stencil designs, each stencil design corresponding to a particular color. In some implementations, the ink is a water-based ink. In other implementations, the ink is an oil-based silkscreen ink. For example, an oil-based silkscreen ink applied onto EVA foam as the base layer <NUM> can avoid or reduce cracking in the print material <NUM>.

<FIG> and <FIG> show front (3A) and back (3B) views of an implementation of a garment <NUM> having a multilayer composition <NUM> in which a print material <NUM> is ink and the ink is applied to an elastomeric polymer base layer <NUM>. The applied ink <NUM> includes a set of printed design elements <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> (3A) in registration with underlying design features <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> (3B). The applied ink <NUM> can have a thickness T(<NUM>) that is on the order of about <NUM>% of the thickness T(<NUM>) of the base layer <NUM>. For example, the thickness T(<NUM>) of the applied ink <NUM> can be between about <NUM> and about <NUM>.

Referring to <FIG>, a toy <NUM> can include both the toy figure <NUM> and the garment <NUM>. The garment <NUM> is a single piece and is configured to wrap around the toy figure <NUM>. The toy figure <NUM> includes a body 110B and one or more appendages 110A. Thus, the garment <NUM> is configured to wrap around the body 110B of the toy figure <NUM>. The garment <NUM> can include one or more openings that enable one or more of the appendages 110A to pass unimpeded, and without limiting movement of the appendages 110A. For example, openings <NUM>-<NUM>, <NUM>-<NUM> are formed near a side and top region of the garment <NUM> for enabling arm appendages of the toy figure <NUM> to pass through the garment <NUM>. As another example, the bottom of the garment <NUM> can form a large opening <NUM>-<NUM> that permits leg appendages of the toy figure <NUM> to move and the top of the garment <NUM> can form a small opening <NUM>-<NUM> that receives a head or a neck appendage of the toy figure <NUM>.

Referring to <FIG>, in some implementations, the garment <NUM> is a hybrid print garment <NUM>. The hybrid print garment <NUM> includes a print material <NUM> that is made up of a plurality of regions. In this implementation, the print material <NUM> includes a first region 520A that includes a fabric material attached to an elastomeric polymer base layer <NUM> and a second region 520B that includes an ink applied to the elastomeric polymer base layer <NUM>. The first region 520A can include one or more printed design elements 525A-i (such as printed design elements 525A-<NUM> and 525A-<NUM>) and one or more of the printed design elements 525A-i can be on a back side of the garment <NUM> (as shown in <FIG>). The second region 520B can include one or more printed design elements 525B-k (such as printed design elements 525B-<NUM>, 525B-<NUM>, 525B-<NUM>) and at least one of the printed design elements 525B-k can be on the back side of the garment <NUM> (as shown in <FIG>), where k is a positive integer greater than i. Each of the printed design elements 525A-i, 525B-k is in registration with a three-dimensional design feature <NUM>-j formed in the base layer <NUM> (where j is the integer i or k). Thus, in this implementations, the three-dimensional design features <NUM>-<NUM>, <NUM>-<NUM> are in registration with the printed design elements 525A-<NUM>, 525A-<NUM>, respectively, of the first region 520A of the print material <NUM> and the three-dimensional design features <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> are in registration with the printed design elements 525B-<NUM>, 525B-<NUM>, 525B-<NUM>, respectively, of the second region 520B of the print material <NUM>.

Referring to <FIG>, a procedure <NUM> is performed for manufacturing a garment such as the garment <NUM>, <NUM>, <NUM>, <NUM>. Reference is made to <FIG> when describing the procedure <NUM>. The procedure <NUM> includes forming a multilayer composition <NUM> having one or more design elements <NUM>-i (<NUM>). The multilayer composition <NUM> is formed by applying a print material <NUM>, which includes the one or more design elements <NUM>-i to an elastomeric polymer base layer <NUM> (<NUM>). For example, the design elements <NUM>-i include design element <NUM>-<NUM> (in the shape of a star), design element <NUM>-<NUM> (in the shape of a hexagon), design element <NUM>-<NUM> (in the shape of a cross, and design element <NUM>-<NUM> (in the shape of a donut).

At this stage in the procedure <NUM>, the base layer <NUM> extends beyond the print material <NUM>; to put it another way, the print material <NUM> is applied to a portion of the base layer <NUM>. The reason for this is to enable further processing of the multilayer composition <NUM> before final formation into the garment. For example, the base layer <NUM>, at the regions that lack the print material <NUM>, includes one or more reference locations716. These reference locations <NUM> can be used during the procedure <NUM> to align the print material <NUM> with a three-dimensional mold. Additionally, at this stage of the procedure <NUM>, the base layer <NUM> does not yet include any three-dimensional design features <NUM>-i and thus is relatively flat (extending in the XZ plane as shown in <FIG>.

Examples or implementations of how the print material <NUM> is applied to the base layer <NUM> (<NUM>) are discussed below with reference to <FIG>, <FIG>.

Once the multilayer composition <NUM> is formed (<NUM>), then the multilayer composition <NUM> is heated (<NUM>), as shown in <FIG>. The multilayer composition <NUM> is heated (<NUM>) to soften the composition <NUM> to enable it to be deformed in three dimensions (for example, also along the Y axis of the multilayer composition <NUM> during the next step). For example, the multilayer composition <NUM> can be heated (<NUM>) to a temperature in the range of <NUM> - <NUM>° C by inserting the multilayer composition <NUM> into an oven.

Referring to <FIG>, after the multilayer composition <NUM> has been heated (<NUM>), and is therefore softened, then each design element <NUM>-i is aligned with a respective three-dimensional design feature <NUM>-i of a three-dimensional mold <NUM> (<NUM>). The three-dimensional mold <NUM> includes a pair of mold components 960A, 960B, with each mold component 960A, 960B including aligned and complementarily-shaped three-dimensional design features 926A-i, 926B-i. Each design feature 926A-i, 926B-i is a shape that extends not only in the XZ plane but also along the Y axis. Additionally, each of the design features 926A-i, 926B-i can be formed on a three-dimensional mold form 927A, 927B that also extends along the Y axis. Each three-dimensional design feature <NUM>-i is shaped to complement the design element <NUM>-i in registration with that design feature <NUM>-i (along the XZ plane).

The design elements <NUM>-i can be aligned with their respective design feature <NUM>-i (<NUM>) by fixing each reference location <NUM> of the multilayer composition <NUM> with a respective mold reference location 961A, 961B on each of the mold components 960A, 960B, respectively, of the three-dimensional mold <NUM>. Each of the reference locations <NUM> can be openings or holes formed in the base layer <NUM>;each of the reference locations 961B can be openings that align with the reference locations <NUM>; and each of the reference locations 961A can be posts that are configured to fit into respective holes <NUM> and openings 961B.

Referring to <FIG>, after the design elements <NUM>-i are properly aligned with their respective design features <NUM>-i (<NUM>), the heated multilayer composition <NUM> is pressed into the three-dimensional mold <NUM> (<NUM>) by, for example, pressing the mold components 960A, 960B together (such that the multilayer composition <NUM> is between the mold components 960A, 960B). The mold components 960A, 960B can be pressed together with about <NUM>-<NUM> tons of force F for about <NUM>-<NUM> seconds and without any additional application of heat.

The pressed pre-heated multilayer composition <NUM> is cooled (<NUM>) to form a three-dimensional molded multilayer composition that includes one or more three-dimensional design elements <NUM>-i. The cooling (<NUM>) can occur while the multilayer composition <NUM> is being pressed (<NUM>). For example, because no additional heat is applied while the multilayer composition <NUM> is pressed (<NUM>), the multilayer composition <NUM> can cool naturally (without any additional cooling mechanism).

After the multilayer composition <NUM> has cooled enough (<NUM>), then the multilayer composition <NUM> (which includes the three-dimensional design elements <NUM>-i) is formed into a three-dimensional garment (<NUM>).

For example, with reference to <FIG> and <FIG>, a cooled multilayer composition <NUM> in which the print material <NUM> is formed as an ink applied to an elastomeric polymer base layer <NUM> and has been processed using the procedure <NUM> is cut (for example, die cut) into the shape of the garment, and in this step the die cutting can also separate a portion <NUM> of the elastomeric polymer base layer <NUM> that lacks any print material <NUM>. After die-cutting, the multilayer composition <NUM> takes the shape of the garment including print material <NUM> over the base layer <NUM>.

As another example, with reference to <FIG> and <FIG>, a cooled multilayer composition <NUM> in which the print material <NUM> is formed as a fabric applied to an elastomeric polymer base layer <NUM> and has been processed using the procedure <NUM> is cut (for example, die cut) into the shape of the garment. In this step the die cutting can also separate a portion <NUM> of the elastomeric polymer base layer <NUM> that lacks any print material <NUM>. After die-cutting, the multilayer composition <NUM> takes the shape of the garment including print material <NUM> over the base layer <NUM>.

The multilayer composition <NUM> can be further formed into the three-dimensional garment (<NUM>) by attaching mating connection devices (such as hook and loop fasteners) to first and second connection regions of the multilayer composition <NUM>. For example, with reference to <FIG>, mating connection devices <NUM>, <NUM> (hook and loop fasteners) are attached (for example, by sewing) to respective first and second connection regions <NUM>, <NUM> of the composition <NUM>. As another example, with reference to <FIG>, mating connection devices <NUM>, <NUM> (hook and loop fasteners) are attached (for example, by sewing) to respective first and second connection regions <NUM>, <NUM> of the composition <NUM>. The respective garment <NUM> and <NUM> is now formed and can be placed on the toy figure by, for example, wrapping the garment <NUM>, <NUM> around the body of the toy figure and connecting the connection regions so that the garment <NUM>, <NUM> is in the closed state.

Referring again to <FIG>, as mentioned above, in step <NUM>, the multilayer composition <NUM> is formed by applying the print material <NUM> to the base layer <NUM> (<NUM>).

In one implementation in which the print material is a fabric material (such as the fabric material <NUM> of <FIG>), the print material <NUM> is applied to the base layer <NUM> according to a procedure <NUM> shown in <FIG>. In the procedure <NUM>, a multilayer composition <NUM> is formed from applying a fabric <NUM> (which includes one or more design elements) to a sheet <NUM> of material that is the elastomeric polymer that will form the base layer <NUM>. Initially, an adhesive <NUM> is applied to the sheet <NUM>, for example, by rolling the adhesive <NUM> onto the sheet <NUM> as it is conveyed across a roller of the adhesive <NUM>. The sheet <NUM> including the adhesive <NUM> is heated in an oven <NUM> to a suitable temperature to activate the adhesive <NUM> and then the fabric <NUM> is pressed onto the adhesive <NUM> side of the sheet <NUM> by way of a pressure roller <NUM> to form the multilayer composition <NUM>. The print material <NUM> therefore includes the fabric <NUM> and the adhesive <NUM> and this is applied to the base layer <NUM> (which is made from the sheet <NUM>), as shown in <FIG>. This multilayer composition <NUM> can be stored until it is needed for the next steps in the procedure <NUM>.

In another implementation in which the print material is and ink (such as the ink <NUM> of <FIG>), the print material <NUM> is applied to the base layer <NUM> according to a screen or mesh procedure <NUM> shown in <FIG>. The procedure <NUM> can be a silkscreen procedure in which one or more separate layers of ink <NUM> (where k is a positive integer) are applied to the sheet <NUM> of elastomeric polymer. Each ink <NUM> can be applied according to a geometry or pattern of a screen or mesh <NUM>, such mesh <NUM> including a stencil that is specifically designed for the particular color of the ink <NUM>. The ink <NUM> is pushed through tiny through holes in the mesh by the use of the squeegee <NUM> and the mesh <NUM> is held taut by being secured to a frame <NUM>. The ink <NUM> that is applied to the sheet <NUM> forms a printing material layer <NUM>. The final printing material <NUM> is formed from the one or more layers <NUM> of different colors that are applied in succession on top of each other.

As discussed in the implementation above, the reference locations <NUM> are provided at the base layer <NUM> at the regions that lack the print material <NUM>. These reference locations <NUM> are used during the procedure <NUM> to align the print material <NUM> with the three-dimensional mold <NUM>. In other implementations, as shown in <FIG>, one or more reference locations <NUM> can be embedded within the print material 1420B, one or more reference locations <NUM> can be embedded inside of regions <NUM> that lack the print material 1420A, or one or more reference locations <NUM> can be placed between disconnected regions 1420A, 1420B of the print material <NUM>. In this implementation, the print material <NUM> is applied to distinct and disconnected regions 1420A, 1420B on the base layer <NUM>. Thus, in some implementations, it is possible for the print material <NUM> to be applied in one or more distinct and disconnected regions onto the base layer <NUM>.

Claim 1:
A method of manufacturing a garment (<NUM>), the method comprising:
forming a multilayer composition (<NUM>; <NUM>) having one or more design elements (<NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>), wherein forming the multilayer composition comprises applying a material that includes the one or more design elements to an elastomeric polymer base layer (<NUM>), which preferably has a thickness of between <NUM> and <NUM> millimeters (mm) or a thickness of between <NUM> and <NUM> or a hardness of about <NUM>-<NUM> shore;
heating the multilayer composition (<NUM>), wherein heating the multilayer composition preferably comprises heating the laminated composition to a temperature in a range of <NUM> to <NUM>;
after the multilayer composition has been heated:
aligning each design element (<NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>) with a respective three-dimensional design feature (<NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>) of a three-dimensional mold (<NUM>); and
pressing the heated multilayer composition into the three-dimensional mold (<NUM>);
cooling the pressed heated multilayer composition (<NUM>) to form a three-dimensional molded multilayer composition that includes one or more three-dimensional design elements;
forming a three-dimensional garment (<NUM>) from the three-dimensional molded multilayer composition.