技术领域：
[0002]The present invention, in some embodiments thereof, relates to an article-of-clothing and fashion, and more particularly, but not exclusively, to garments based on a seamless wearable structure.
[0003]Current garment and fashion technologies produce articles of clothing in the traditional lengthy process that starts in obtaining fibrous material, either from natural sources (e.g., growing cotton or sheep), or from synthetic/artificial sources, continues through cloth/fabric production and ends with cutting and stitching. A typical traditional garment making process involves cultivating, ginning, harvesting, cleaning, blending, carding, combing, drawing, spinning, twisting and winding (yarn manufacture), looming, weaving, bleaching, coloring and dyeing, cutting and stitching, just to name some of the steps on the way of making an article of clothing.
[0004]Although modern production methods and automation are used extensively in the garment industry, these lengthy process is no longer adequate to provide and satisfy current demands in terms of flexibility and personalization. For example, this-year's fashion is typically decided-upon at least a year before to allow the manufacturers to order fabrics and have them dyed and printed, cut and sewed well ahead in order to be marketed as this-year's fashion mode.
[0005]The demand of today's dynamic garment market for up-to-date, fine and personalized yet fashionable and affordable apparel, cannot be met by today's garment industry, which is still routed in the traditional garment production methodologies and processes.
[0006]In an attempt to lower the cost, steps and lead-time of fabric production, many technologies have been developed to produce fine synthetic fibers and nonwoven fabrics. For example, methods for producing shape-retaining and/or directional stretchable nonwoven fabrics for custom made garments, are disclosed in U.S. Patent Application Publication Nos. 20140271966, 20140200527, 20130262260, 20120322333, 20120156427, 20050124957 and 20050119631, to Tamicare LTD.
[0007]Modern weaving, knitting and needling techniques have also been developed to lower the cost, steps and lead-time of fabric production. For example, U.S. Pat. Nos. 9,352,516, 8,132,431, 7,331,200, 7,299,660, 7,107,658, 6,993,939 to 6,691,535, to Karl Mayer Textilmaschinenfabrik GmbH, provide Raschel and warp-knitting methods and apparati, as well as warp-knitted textiles and needling technologies for nonwoven fabrics.
[0008]International Patent Application Publication Nos. WO 2016/055904, WO 2015/140687, WO 2014/191868, WO 2013/037654, WO 2012/093316, WO 2011/004310, WO 2010/142478, WO 2009/013773, WO 2006/072969, WO 2005/100659, WO 2004/097092, WO 2003/100147, WO 2001/048288 to Santoni S.P.A., teach various aspects and uses of circular knitting machines.
[0009]Circular knitting has been provided in numerous documents, including, for example, U.S. Pat. Nos. 9,347,156, 9,010,156, 8,726,699, 8,561,434, 8,484,998, 8,418,507, 7,900,483, 7,765,836, 6,948,342, 6,915,666, 6,848,280, 6,568,221, 6,247,335, 5,165,259, 5,070,711, 3,854,304, 3,754,416 and 3,530,686. Circular knitting lead to spin-knit machines that spin yarn from rovings that are mounted close to the machine then subsequently knit the spun yarn. This technology is aimed at shortening the fabric production process, making separate ring spinning, cleaning and rewinding steps no longer required, which lowers production costs and lower investment in machinery.
[0010]U.S. Pat. No. 6,941,775, Patent Application Publication No. 20030224685 and International Patent Application Publication No. WO 2003/087451 to Vikram Sharma, teach a tubular knit fabrics and used thereof.
[0011]U.S. Pat. Nos. 8,124,549 and 8,088,315, U.S. Patent Application Publication Nos. 20100286583, 20090036014 and 20050222320, and International Patent Application Publication Nos. WO 2007/000598, WO 2007/000599 and WO 2003/104540, and EP 1511577 to Manel Torres, teach a sprayable composition for forming a nonwoven fabric on a solid substrate, comprising fibers, binders and carriers.
[0012]3D-printing has been developing rapidly, and has been proposed for producing garments, in, for example, U.S. Patent Application Publication Nos. 20150324490 and 20160046803, U.S. Pat. No. 6,402,403 and International Patent Application Publication No. WO 2015/153400. However, this approach suffers from highly limited compatibility of the materials for truly wearable articles of clothing (stretchability, breathability, strength, drape, wash- and rub-fastness, to name a few), and from the effort, cost and time of production, regardless of the used materials, making this very promising model-making technology inappropriate for industrial production of garments.
[0013]Thus, all the abovementioned and other technologies do not provide a comprehensive solution to the production of personalized, high-end, fine, fashionable and affordable garments.
发明内容：
[0014]A garment based of a seamless wearable structure is provided herein, wherein the structure is made by molding, spinning, dipping or spraying, and characterized by at least one attribute such as breathability, drape, stretch and recovery, dimensional stability, wash-fastness, tensile strength, tearing strength, abrasion flex and resistance, water absorbency and wrinkle recovery, which is within acceptable values according to the standards used in the garment industry.
[0015]According to an aspect of some embodiments of the present invention, there is provided a garment which includes a seamless wearable structure.
[0016]In some embodiment, the structure is characterized by at least one tubular portion.
[0017]In some embodiment, the structure is characterized by at least one body-part opening. In some embodiment, the structure is characterized by at least two body-part openings. In some embodiment, the structure is characterized by at least three body-part openings.
[0018]In some embodiment, the garment comprises a single seamless wearable structure. In some embodiment, the garment is a single seamless wearable structure.
[0019]In some embodiment, the structure includes at least one structural feature selected from the group consisting of appendix mounting, pattern, hole, eyelet, slit, mesh, net, thickening, bulge, protrusion, pleats, ribs, fold, crease, ridge, latch, loop, strap and any combination thereof.
[0020]In some embodiment, the appendix is selected from the group consisting of a pocket panel, a button, a zipper, a collar, a cufflink, a belt, a buckle, a hood, a glove, a sleeve and another garment.
[0021]In some embodiment, the appendix is integrally formed with the structure. In some embodiment, the appendix is attached to the structure. In some embodiment, the appendix is attached to the structure post manufacturing of the structure.
[0022]In some embodiment, the garment presented herein is selected from the group consisting of baby grow, blazer, blouse, body shaper, boot, boxers, bra, briefs, burka, camisole, cargos, catsuit, chemise, coat, corset, dungarees, glove, gown, hat, headdress, headpiece, hijab, hood, hooded pullover, jacket, jellabiya, jersey, jumper, kimono, knickers, overalls, poncho, pullover, robe, romper, shapewear, shellsuit, swimwear, tankini, thong, tights, top, trousers, trunks, T-shirt, undergarment, underpants, undershirt, vest, waistcoat and wetsuit. In some embodiment, the garment is not a headwear, a handwear or a footwear.
[0023]In some embodiment, the structure includes at least one structural region. In some embodiment, the structure includes a plurality of structural regions, each of the structural regions is individually characterized by a thickness that ranges from 0.1 to 10 mm. In some embodiment, the structure includes a plurality of structural regions, each of the structural regions is individually characterized by a mass per unit area that ranges from 50 to 400 grams per square meter.
[0024]In some embodiment, the structure is made of one type of material. In some embodiment, the structure is made of at least two types of materials. In some embodiment, the structure is made of a plurality of materials being distributed in a predetermined arrangement of portions of the structure, the portions merge into one-another in a seamless interface.
[0025]In some embodiment, the structure or any portion thereof, or each of the materials is individually characterized by at least one of:
[0026]a breathability level that ranges from 0 Ret to 20 Ret according to standard ISO 11092 (the Ret or Hohenstein test), or another industry acceptable standard for desired breathability;
[0027]a drape coefficient that ranges from 10% to 80% according to Cusick drape test, or another industry acceptable standard for desired drape;
[0028]a stretch and recovery level at 2 kg that ranges from 4% to 400% according to standard ASTM D 3107, or another industry acceptable standard for desired stretch and recovery;
[0029]a dimensional stability to laundering after 3 washes lower than 5% according to standard AATCC 135, or another industry acceptable standard for desired stretch and recovery and wash fastness;
[0030]a tensile strength of at least 10 kg according to standard ASTM D 5034, or another industry acceptable standard for desired tensile strength, such as, for example ASTM D638 or ASTM D412;
[0031]a tearing strength of at least 1 kg according to standard ASTM D 1424, or another industry acceptable standard for desired tearing strength;
[0032]an abrasion flex of no rupture or damage for at least 1000 cycles according to standard ASTM D 3885, or another industry acceptable standard for desired abrasion flex;
[0033]an abrasion resistance of no rupture to at least 10,000 cycles according to standard ASTM D 4966, or another industry acceptable standard for desired abrasion resistance;
[0034]a water absorbency under 5 seconds according to AATCC/ASTM TS-018, or another industry acceptable standard for desired water absorbency; and
[0035]a wrinkle recovery/resistance better than 2 on a scale of 1-5 according to AATCC 128/143, or another industry acceptable standard for desired wrinkle recovery/resistance.
[0036]In some embodiment, the material is selected from the group consisting of a polymer, a co-polymer, a fiber-polymer mixture, a polymeric foam, the polymer is a synthetic polymer, a naturally occurring polymer, and a mixture thereof.
[0037]In some embodiment, the structure is a single layered structure or a multi-layered structure.
[0038]In some embodiment, the structure is formed by mold casting, mold injection, spinning, dipping, spraying, painting and brushing.
[0039]In some embodiment, the structure is not a woven fabric. In some embodiment, the structure is a nonwoven fabric.
[0040]According to an aspect of some embodiments of the present invention, there is provided a method of manufacturing the garment presented herein, the method includes forming the seamless wearable structure by a process selected from the group consisting of mold casting, mold injection, spinning, dipping, spraying, painting and brushing.
[0041]In some embodiment, the method further includes, after forming the seamless wearable structure, attaching at least one appendix to the structure.
[0042]According to an aspect of some embodiments of the present invention, there is provided a mold for manufacturing the garment presented herein, the mold includes at least one mold cavity in the shape of a seamless wearable structure, and at least one sprue for letting a material precursor into the mold's cavity.
[0043]In some embodiment, the mold is characterized by at least one molding feature in its cavity, for forming at least one structural feature in the structure.
[0044]In some embodiment, the molding feature is for forming a structural feature selected from the group consisting of appendix mounting, pleat, pattern, hole, eyelet, slit, mesh, net, thickening, bulge, protrusion, pleats, ribs, fold, crease, ridge, latch, loop, strap and any combination thereof.
[0045]In some embodiment, the mold is characterized by a plurality of sprues distributed in the mold for feeding a predetermined arrangement of portions of the cavity.
[0046]In some embodiment, each of the plurality of sprues is configured individually for delivering a different and/or an identical liquid or powdered precursor of a material to form a predetermined arrangement of portions of the structure.
[0047]Unless otherwise defined, all technical and/or scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention pertains. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of embodiments of the invention, exemplary methods and/or materials are described below. In case of conflict, the patent specification, including definitions, will control. In addition, the materials, methods, and examples are illustrative only and are not intended to be necessarily limiting.
具体实施方式：
[0058]The present invention, in some embodiments thereof, relates to an article-of-clothing and fashion, and more particularly, but not exclusively, to garments based on a seamless wearable structure.
[0059]Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not necessarily limited in its application to the details of construction and the arrangement of the components and/or methods set forth in the following description and/or illustrated in the drawings and/or the Examples. The invention is capable of other embodiments or of being practiced or carried out in various ways.
[0060]The present invention is directed at a class of garments which is characterized by comprising a seamless wearable structure, rather than being formed from joining several flat panels into a single structure. The present invention is also directed at a class of garments which is characterized by being formed in a process wherein the entire garment, or at least the major part of the garment, is produced at once, as opposed to the hierarchical production of garments that typically includes twisting, spinning, weaving, looming, cutting, sewing, stitching and accessorizing. The present invention is also directed at a class of garments being one-piece, seamless articles-of-clothing, which can be fitted with various appendices and accessories that can be mounted on or attached to structural features in the garment. The present invention is also directed at a class of garments being one-piece, seamless articles-of-clothing having at least one, at least two, at least three or at least four body-part opening.
Seamless Wearable Structure
[0061]According an aspect of some embodiments of the present invention, there is provided a garment which includes a seamless wearable structure.
[0062]The term “garment”, as used herein, is meant to encompass article of clothing for humans as well as for animals and pets. In the context of embodiments of the present invention, a garment comprises as a major part thereof a seamless wearable article-of-manufacturing, referred to herein as a structure, which is capable of being worn or is suitable to wear. The term “wearable”, as used herein, means that a person can use the garment as clothing, being at least sufficiently flexible, or sufficiently breathable, or sufficiently stretchable, or sufficiently light weight, or sufficiently protective, or sufficiently concealing, or sufficiently fashionable, comfortable and/or desirable, or any combination thereof.
[0063]As known in the art, garments are typically formed by attaching a number of panels, which are flat pieces of fabric cut into predesigned polygons, typically by sewing the sides of the panels, and/or forming tubular structures by rolling a panel and stitching together two opposite sides thereof.
[0064]The present invention is therefore drawn to garments that are not made of panels, but rather substantially made of a seamless wearable structure. The term “structure”, as used in the context of the present invention, refers to a monolithic, unified, continuous and cohesive object, which may include at least one sheet-like, tubular and cap-like structural elements, which is used to form a garment. In some embodiments, the structure is a single seamless wearable object. In the context of embodiments of the present invention, a structure includes or one or more tubular structure element.
[0065]The term “garment”, as used herein, refers to an article of clothing that is used as an outer covering or outward appearance on a body of a subject. Exemplary garments for humans include, without limitation, undergarment, shirt, pants, dress, baby grow, blazer, blouse, body shaper, boot, boxers, bra, briefs, burka, camisole, cargos, catsuit, chemise, coat, corset, dungarees, glove, gown, hat, headdress, headpiece, hijab, hood, hooded pullover, jacket, jellabiya, jersey, jumper, kimono, knickers, overalls, poncho, pullover, robe, romper, shapewear, shellsuit, shoe, shorts, skirt, skivvy, sock, stockings, strapless, suit, sweatshirt, swimwear, tankini, thong, tights, top, trousers, trunks, T-shirt, underpants, undershirt, vest, waistcoat and wetsuit.
[0066]In some embodiments of the present invention, the term “garment” excludes articles-of-clothing intended for use of bodily appendices, such as head, hands and feet, thus the garment is not a headwear (hats, caps and the like), a handwear (gloves, mittens and the like) or a footwear (sock, boot, shoe and the like).
[0067]In the context of embodiments of the present invention, a structure may comprise more than one stratum, layer or lamina, wherein the strata share essentially the same planar shape, but not necessarily the same area; hence, a multi-stratum structure, according to some embodiments of the present invention, may have different strata at different regions thereof.
[0068]In the context of embodiments of the present invention, a seamless wearable structure may comprise several cohesive regions, cohesive portions or cohesive areas being characterized by seamless transitions from one portion to another, wherein each portion or region may be characterized by a material, a pattern, a thickness, a stratum, a layer, a color, a texture and any combination thereof.
[0069]Having at least some sheet-shaped regions/portions, a seamless wearable structure can also be characterized by two sides, which in the context of a garment can be, for example, an inwards side facing and/or touching the body and typically concealed from view, and an outwards facing side, typically visible to a viewer. In some embodiments, the garment is designed such that in some parts the same side flowingly changes from being an outwards facing side to an inwards facing side and vice versa. Such transition is oftentimes achieved by twisting or inverting parts of the structure in the garment.
[0070]The terms “one-piece” and “seamless”, are used herein to define the garment as not being formed from several structures attached to one-another, and being devoid of seams and stiches that connect several structures. In some embodiments, the term “seamless” refers to a structure being devoid of seams and stiches that connect two sides or regions of the structure. Thus, the term “one-piece” refers to a unified cohesive structure, and the term “seamless” refers to a structure devoid of seams. The term “seam”, as used herein, refers to any mean of connecting, joining or attaching two objects or two sides of an object together. A seam can be formed, for example, by sewing, gluing, welding, fusing, riveting, stitching or otherwise adjoining two sides of an object or sides of several objects.
[0071]In the context of embodiments of the present invention, a garment may be characterized by having one or more body-part openings. The phrase “body-part opening”, as used herein, refers to an opening in a seamless wearable structure for allowing a body part to extend through. For example, a neck opening is an opening for allowing the head and neck to extend through a garment.
[0072]Garments can be divided into groups according to the number of body-part openings: half finger or fingerless gloves have six body-part opening, five for the fingers and one for the wrist; baby grows typically have five body-part openings, one for the neck, two for the arms/hands and two for the legs/feet; shirts, tops, bras, jumpers, dresses, pullovers, jackets, jerseys and the likes typically have four body-part openings, for the torso, two for the arms/hands and one for the neck; pants, shorts, tankini, thong, tights, trousers, underpants and the likes typically have three body-part openings, one for the torso and two for the legs/feet; strapless shirts, corsets skirts and the likes typically have two body-part openings; and hats, shoes, gloves, socks, stockings and the likes typically have one body-part opening.
[0073]According to some embodiments of the present invention, the garment has one body-part opening. According to some embodiments of the present invention, the garment has two body-part openings.
[0074]According to some embodiments of the present invention, the garment has three or more body-part openings. According to some embodiments of the present invention, the garment has at least four body-part openings.
[0075]In some embodiments of the invention, the garment has at least one tubular portion/part, which is designed to enclose a tubular body part, such as a torso, a neck, an arm, a leg, a finger and the likes. A tubular portion of a seamless wearable structure has at least two body-part openings wherein at least one of which may be continued to form another part of the structure. For example, a sleeve is a two body-part tubular portion of a garment which is open on one side and typically continues to form a tubular portion/part inclosing a torso.
[0076]Referring now to the drawings, FIG. 1 presents a schematic wireframe illustration of an exemplary garment, according to some embodiments of the present invention, showing garment 10 comprising seamless wearable structure 11, having four body-part openings, neck opening 12, arm opening 13a, arm opening 13b, and torso opening 14, wherein tubular arm portion 15 is open on one side and continues flowingly into tubular torso portion 16.
Structural Features and Regions
[0077]According to some embodiments, the garment is having at least one structural feature which forms a part of the seamless wearable structure. In the context of a single seamless wearable structure, the term “structural feature”, as used herein, refers to a part of the structure that is structurally or geometrically or conspicuously different that other parts of the structure in one or more characteristics, such as thickness or continuity (hole; void; cut). It is noted that the structural feature is not appended to the structure but is an integral part of the structure. Exemplary structural features include an appendix mounting, a panel, a pattern, a hole, an eyelet, a slit, a mesh, a net, a thickening, a bulge, a protrusion, a prong, one or more pleats, one or more ribs, a fold, a crease, a ridge, a latch, a loop and a strap. Structural features are also afforded by combining more than one type of feature, and afford stamping, engraving, prominence, lacelike (lacy, tatting) patterns.
[0078]In some embodiments, the garment exhibits one or more structural features which are placed on the outwards facing side, the inwards facing side, both (e.g., a bulge) or through the structure (e.g., a hole). Structural features can be arranged in particular locations in the garment in singletons, small groups or large groups, orderly arranged in a pattern or randomly distributed.
[0079]A structural feature which is a break in the continuity of the structure can be in the form of a hole or a slit. An eyelet or a hole can be used to hitch an appendix to the garment, or be used as a buttonhole. A bulge or a protrusion in the structure can also be used to hitch an appendix to the garment. A pattern of slits and holes can form a mesh or a net region in the structure. Structural regions being a net or mesh may be useful in areas which require more ventilation or heat exchange, or for decorative/fashion consideration (e.g., lacework-like).
[0080]A plurality of bulges, protrusions, ribs, folds, creases or ridges can form a structural feature characterized by a regional texture with or without a conceivable repeated pattern or a decorative design motif. A regional structural feature that involves a change in the thickness of the structure may be used to harden, soften or render certain areas of the garment more or less flexible, and/or to give a different texture (feel) and/or a different visible appearance (look).
[0081]A structural feature in the form of thickness variations made in a pattern of folds, creases or ridges, may form a set of pleats. Pleats are useful in forming stretchable/elastic or contractible/shrinkable regions in the garment. Following are some exemplary pleat types, as these are known in the art, useful in the context of the present invention. “Accordion pleats” or “knife pleats” are a form of tight pleating which allows the garment to expand its shape when moving, and is useful for garment sleeves, such as pleating the end of the elbow, with the fullness of the pleat gathered closely at the cuff. “Box pleats”, “stacked-” and “double box pleats” are back-to-back knife pleats, create fullness or aired thickness having longitudinal channels which can be useful in many garments to channel heat, moisture and air. “Cartridge pleats” are useful in gathering a tubular portion of the garment into a smaller width. “Fluted pleats” or “flutings” are typically small, rounded or pressed pleats used as trimmings around body opening. Other types of pleats include “fortuny pleats”, “honeycomb pleats”, “kick pleats”, “organ pleats”, “plissé pleats”, “rolled pleats”, “Watteau pleats” and “Kinguissie pleats”.
[0082]FIGS. 2A-B present schematic illustrations of an exemplary garment, according to some embodiments of the present invention, showing in FIG. 2A garment 20 comprising pleated neck opening structural region 21, pleated shoulder structural region 22, pleated underarm structural region 23, and pleated torso flank panel region 24, wherein each of the pleated structural regions confers stretchability/contractibility to that particular region of the garment, and showing in FIG. 2B garment 20 comprising sleeve folding strap 25, configured to latch on to prong 26 positioned on the shoulder, wherein sleeve 27 is shown folded and held in place by sleeve folding strap 25.
[0083]Single structural features and regional structural features (structural regions) may combine geometric features and material variations, as these are discussed hereinbelow. As mentioned hereinabove, the structure can be made from more than one structural regions. Each structural region can be individually characterized by a thickness, a texture, a color, a pattern, and a material.
[0084]For example, in some embodiments, the structure comprises a plurality of structural regions, each of which is individually characterized by a thickness that ranges from 0.1 to 10 mm.
[0085]For another example, in some embodiments, the structure comprises a plurality of structural regions, each of which is individually characterized by a mass per unit area that ranges from 50 to 400 grams per square meter.
[0086]In the context of placing various structural features in the shape and texture of the structure, according to some embodiments of the present invention, a transition from one structural region can be perceived by sight and touch, in some embodiments, the transition can be perceived either sight or touch, and in some embodiments the transition may be sensed by neither sight nor touch.
[0087]In some embodiments, the structure is a single layered structure or a multi-layered structure, wherein each layer of the structure can have similar or different structural features (pattern/texture) and/or can be made from a similar or different material, as these are discussed hereinbelow.
Appendix Mounting and Appendices
[0088]One of the optional structural features is designed to allow hitching an appendix to the garment, thus, the term “appendix mounting”, as used herein, refers to a structural feature that is designed to allow appending one or more appendices to or on the garment. Typically, appendix mounting is in the form of a hole, an eyelet, a slit, a thickening and/or a bulge, and a combination thereof.
[0089]It is noted that appendices are not regarded as an integral part of the seamless wearable structure. Exemplary appendices include, without limitation, a pocket panel, a button, a zipper, a collar, a cufflink, a belt, a buckle, a hood, a glove, a sleeve, a lace, a thong, a hook, a loop, a fastener, an interlocking hooks strip and an interlocking loops strip (Velcro), and another garment.
[0090]FIGS. 3A-B present an exemplary garment, according to some embodiments of the present invention, showing garment 30 having a set of holes 31 arranged so as to allow hitching pocket panel 32 (FIG. 3A), and showing garment 30 having a pocket made from pocket panel 32 (FIG. 3B).
Material, Structure and Garment Properties
[0091]In some embodiments, the structure is made from one type of material.
[0092]Alternatively, as mentioned hereinabove, the structure can comprise more than one regions distinguished from one another by the material comprising the same. In order to distinguish structurally different regions from chemically (material) different regions, the latter are referred to herein as “portions of the garment” or “portions”.
[0093]In some embodiments of the present invention the structural comprises a plurality of materials being distributed in a predetermined arrangement of portions of the garment, whereas the portions merge into one-another in a seamless interface.
[0094]In the context of use of various materials to form the structural, according to some embodiments of the present invention, a transition from one region to another can be perceived by sight and touch, in some embodiments, the transition can be perceived either by sight or by touch, and in some embodiments the transition may be sensed by neither sight nor touch.
[0095]According to some embodiments of the present invention, the seamless wearable structure is not made of a woven fabric, which is typically formed by weaving on a loom, and is made of a plurality of ordered threads. According to some embodiments of the present invention, the seamless wearable structure is not made of a knitted fabric, which is typically formed by knitting a plurality of threads into a consecutive rows of interlocking loops.
[0096]According to some embodiments of the present invention, the seamless wearable structure is made of a nonwoven fabric. In the context of embodiments of the present invention, the term “nonwoven” refers to any “cloth-like” sheet-shaped object which is not formed by weaving, knitting, crocheting or knotting of fibers and yarns, and encompasses monolithic sheet-shaped objects as well as fibrous sheet-shaped objects.
[0097]The material comprising the structural or portions thereof, determines some of its properties, along with the structural features (pattern, texture, thickness, holes, slits etc.). For a given fixed thickness and area, each material will form a structural that is characterized by at least one, at least two, at least three, at least four, at least five or more of the following material-based properties, as these are known in the art, and for each of which there exists a widely-accepted standard for quantified analysis:
[0098]a breathability level that ranges from 0 Ret to 20 Ret according to standard ISO 11092 (the Ret or Hohenstein test);
[0099]a drape coefficient that ranges from 10% to 80% according to Cusick drape test;
[0100]a stretch and recovery level at 2 kg that ranges from 4% to 400% according to standard ASTM D 3107;
[0101]a dimensional stability to laundering after 3 washes (wash-fastness) lower than 5% according to standard AATCC 135;
[0102]a tensile strength of at least 10 kg according to standard ASTM D 5034;
[0103]a tensile strength testing standard ASTM D638 or ASTM D412;
[0104]a tearing strength of at least 1 kg according to standard ASTM D 1424;
[0105]an abrasion flex of no rupture or damage for at least 1000 cycles according to standard ASTM D 3885;
[0106]an abrasion resistance of no rupture to at least 10,000 cycles according to standard ASTM D 4966;
[0107]a water absorbency under 5 seconds according to AATCC/ASTM TS-018; and
[0108]a wrinkle recovery/resistance better than 2 on a scale of 1-5 according to AATCC 128/143.
[0109]According to some embodiments of the present invention, at least some materials useful in making the garment, are known in the art and are readily available.
[0110]Such materials may be synthetic or naturally occurring polymers, co-polymers of synthetic or naturally occurring polymers, fiber-polymer mixtures comprising synthetic or naturally occurring fibers and polymers, polymeric foams, and any mixture thereof.
[0111]Naturally occurring polymers include proteins (as in, e.g., wool, mohair and silk), cellulosic (cellulose-base) polymers (as in, e.g., cotton, flax, jute and hemp), and mineral fibers (as in, e.g., asbestos). Natural fibers are made from naturally occurring polymers.
[0112]Families of synthetic polymers, processed/artificial polymers and other materials, the members for which are useful in the making of garments according to some embodiments of the present invention include, without limitation, acrylics, acrylonitriles, aramids (nomex; kevlar; twaron), carbon fibers, ceramic fibers, derclon, dyneema/spectra, lyocell, M-5 (PIPD), modacrylic, modal, nylons, polyolefins, orlon, polybenzimidazole (PBI), polyesters, polylactic acid (polylactide; PLA), polyoxazoles, polyvinyl chloride, rayon (artificial silk), saran, spandex, sulfar, tencel, vectran (TLCP; vectra LCP polymer), vinalon, vinyon, zylon (PBO), and any combination thereof, as well as metal and glass.
[0113]Preferable synthetic polymers include, without limitation, thermoplastic elastomers based on styrene, ethylene, butylene, isoprene and their block copolymers, polyesters, polyamides, acrylics, polyurethanes, water soluble polymers, polymers soluble in organic solvents, emulsions or suspensions in solvents or their mixtures. Preferably, contemplated polymers include styrene-ethylene-butylene-styrene copolymer (SEBS) and/or styrene-isoprene-styrene (SIS) copolymer.
[0114]Any of the above-mentioned polymers can be diluted in a solvent, such as, without limitation, water, ethanol, methanol, other alcohols, acetone, MEK, other ketones, hydrocarbons, halogenated hydrocarbons, DMF, THF, ethyl acetate, diethyl ether, petroleum ether, other ethers, and mixtures thereof.
[0115]In some embodiments, the garment is designed for temporary use as a disposable garment. In such embodiments, it is preferable that the material from which the garment is made would be degradable into environmentally friendly materials. Garments made from polymers can be designed to be degradable by formulating the polymer to exhibit at least some degradable bonds therein, and preferably designed to decompose upon extended exposure to ambient conditions, such as moisture, oxygen, light and microorganisms. Exemplary degradable polymers which are useful in the production of textile for garments include, without limitation, poly(desaminotyrosyl-tyrosine dodecyl dodeca-nedioate) (p(DTD DD)) and poly(L-lactic acid) (PLLA).
[0116]The material can have a microstructure that endows some of the properties mentioned hereinabove. The term “microstructure”, as opposed to macrostructure properties such as thickness and shape, refers to the arrangement of structural elements in the formed and cured material at the microscopic level (about 0.5-500 microns). For example, a polymeric material can be cured to form a foam, which is highly porous and light in density compared to an object of equal size made from the same polymer in solid bulk form.
[0117]FIGS. 4A-F present exemplary microstructures useful in making at least some portions of the garment, according to some embodiments of the present invention, wherein FIGS. 4A-B show schematic illustrations of the microstructure of some reticulated foams, FIG. 4C shows an electron micrograph of a reticulated foam, and FIGS. 4D-F show a class of foams known as open-cell polymerized high internal phase emulsions (polyHIPEs).
[0118]A review of recent developments in polyHIPE technology which is useful in the context of some embodiments of the present invention, can be found in an article by Silverstein, M.S. [“PolyHIPEs: Recent advances in emulsion-templated porous polymers”, Progress in Polymer Science, 2014, 39, p. 199-234] and references cited therein, which are incorporated herein by reference.
[0119]A review of recent developments in reticulated and auxetic foams technology which is useful in the context of some embodiments of the present invention, can be found in an article by Critchley, R. et al., [“A review of the manufacture, mechanical properties and potential applications of auxetic foams”, Phys. Status Solidi B, 2013, 250(10), pp. 1963-1982], and references cited therein, which are incorporated herein by reference.
Methods and Processes of Forming the Garment
[0120]In some embodiments of the present invention, the seamless wearable structure forming the garment presented herein, is produced in a unified process step.
[0121]In other words, the entire structure is produced in its final three-dimensional shape, including structural features and portions if present, in one unified process. In some embodiments, the process by which the structure is formed, defines the structure resulting therefrom, namely, the chemical, mechanical/physical and structural characteristics of the structure are determined by the process used to form the structure. For example, in some embodiments, the structure is manufactured processes that include, for example, molding processes, spinning processes, dipping processes, painting/brushing processes and spraying processes.
[0122]It is noted that 3D printing, referring to a range of versatile additive manufacturing processes, as this term is used in the art, is limited in its capacity to produce garments effectively, as contemplated in the present invention, due to the following inherent practical reasons. 3D printing is a process that is used to produce one object at a time, following a digital representation of the object using materials that are selected based on their adequacy to the 3D printing process. This process is inherently slow and expensive, typically resulting in object of limited usability as a garment due to poor or insufficient mechanical properties, such as ductility and flexibility, strength and stretchability, breathability and drape. Thus, due to the cost and the general frailty and incompatibility of the materials used in 3D printing in the context of garments, this type of process is excluded from the scope of the present invention. Thus, the seamless wearable structure presented herein is not manufactured by a 3D printing process.
[0123]Since painting, bushing and spraying may be seen as forms of additive manufacturing processes, albeit typically not following a digital representation of the object and typically not executed by a computerized and fully automated process, in some embodiments, the seamless wearable structure presented herein is not manufactured by a painting, a bushing or a spraying process.
[0124]According to an aspect of some embodiments of the present invention, there is provided a method of manufacturing the garment presented herein, which includes manufacturing a seamless wearable structure, as provided herein, by a process selected from the group consisting of mold injection, mold casting, spinning, dipping, painting/brushing and spraying.
[0125]In some embodiments, the garment consists of the seamless wearable structure provided herein, namely the garment is complete once the structure is produced. In the context of such embodiments, the process of producing the structure includes removing from the finished structure excess material left in the sprue (it is noted that this excess material is sometimes also called a sprue), removing materials from holes and openings in the structure that are left in their place after molding, and generally cleaning the structure from excess material.
[0126]In some embodiments, the method further includes attaching an appendix to the seamless wearable structure, after it has been produced by any one of the aforementioned processes. In some embodiments, an appendix can be attached or integrally formed in or on the seamless wearable structure during the production of the structure in any one of the aforementioned processes.
[0127]In some embodiments, the method includes adding sacrificeable materials to the mold or model in or on which the structure is formed, or adding sacrificeable materials to the material precursor from which the structure is formed. A sacrificeable material is a material that is essentially removed from the structure and leaves an imprint or a hole in the structure after its removal. For example, particles a sacrificeable water-soluble substance, which are added to the material precursor that is injected into a mold to form a structure, will be dissolved when the structure is placed in water, leaving voids in their place, thereby rendering the material of the structure porous, or mesh-like. In another embodiment, an object made of a sacrificeable low melting substance, placed within the cavity of a mold before casting or injecting the material precursor, will melt during the molding process or thereafter, leaving a void in its place, thereby forming a structural feature in the finished structure.
[0128]Molding
[0129]In molding processes, a mold having a cavity in the shape of the seamless wearable structure is filled with a cast, a liquid or powder precursor of the material(s) comprising the structure, referred to herein as a material precursor, and once cured, the mold or opened to release the structure. Molding processes include casting and injection processes (mold casting; mold injection). The mold can be as simple as having two parts that form a cavity therebetween when put together and can be separated to release the cured structure from therein. In other embodiments, the mold is a multi-part mold, which when assembled, is having a cavity therein in the shape of the structure. Any two- or multi-part mold can be taken apart to release the cured structure formed therein. In the case of a structurally complex structure, the mold and cavity may be designed so as to allow the release of the structure. In some embodiments, the releasing step of the structure from the mold is based on the elasticity of the structure at least in some regions and/or parts thereof. In some embodiments the cavity is designed in a shape that allows release of the structure, which once released, takes a different form than the cavity based on stretchable and/or contractible regions/portions in the structure.
[0130]According to an aspect of embodiments of the present invention, there is provided a mold for manufacturing the structure presented herein, comprising at least one mold cavity in the shape of the structure and at least one sprue.
[0131]In some embodiments, the mold has at least one sprue for inletting the cast (material precursor) into the cavity. The sprue can be used for pouring or injecting the cast into the cavity. In some embodiments of the invention, injection may be a preferred mode of casting for reasons known to the skilled artisan of the art. A single sprue may be sufficient for manufacturing some structures; alternatively, the mold comprises a plurality of sprues for a more efficient and effective introduction of the material precursor into the entire cavity. In some embodiments, sprues are distributed in the mold for feeding material precursor into the cavity in a predetermined arrangement of locations in the cavity, such that the seamless wearable structure is formed with a predetermined arrangement of portions. In some embodiments, different materials can be injected into certain sprues according to a predetermined arrangement of sprues and portions. In such embodiments, each of a plurality of sprues is configured individually for delivering a different and/or an identical liquid or powdered precursor of the material (cast) to form a predetermined arrangement of portions in the structure.
[0132]In order to form structural features and regions in the structure the mold is having one or more molding features attached thereto on the surface of the cavity.
[0133]The molding features correspond in shape to the desired structural features, as these are discussed hereinabove. In some embodiments, the molding features are made from sacrificeable substances.
[0134]Dipping and Spraying
[0135]Dipping and spraying processes useful in the context of some embodiments of the present invention, are based on a physical model of the structure, the surface of which is used to apply directly thereon, by dipping or spraying, a liquid or powdered precursor of the material(s), which cures to form the structure. Once the material is cured, the formed st