Apparel comprising a wound thread layer and methods of making the same

Abstract

Articles of apparel and methods of making articles of apparel comprising a base layer and a thread layer defined by a thread having a plurality of thread lines crossing over each other at points of overlap between two or more of the thread lines. In some embodiments, the thread layer can be directly bonded to the base layer. In some embodiments, the base layer and the thread layer can define a chamber or pocket for an article of apparel.

What is claimed is: 
     
         1 . An article of apparel, comprising:
 a base layer; and   a thread layer defined by a thread, the thread layer comprising a plurality of thread lines crossing over each other at points of overlap between two or more of the thread lines,   wherein each of the thread lines extends continuously across the thread layer,   wherein the thread lines are not woven or knitted threads,   wherein the thread lines not embroidered threads stitched to the to the base layer, and   wherein each of the thread lines is directly bonded to a surface of the base layer along at least a portion of a length of the thread line.   
     
     
         2 . The article of apparel of  claim 1 , wherein the thread layer occupies a surface area defined by a thread border on the surface of the base layer,
 wherein each of the thread lines comprises a first end disposed at the thread border and a second end disposed at the thread border.   
     
     
         3 . The article of apparel of  claim 2 , wherein the first end and the second end of each of the thread lines are directly bonded to the surface of the base layer. 
     
     
         4 . The article of apparel of  claim 1 , wherein the thread layer occupies a surface area defined by a thread border on the surface of the base layer, wherein the base layer comprises a perimeter edge surrounding the thread border. 
     
     
         5 . The article of apparel of  claim 1 , wherein the base layer comprises a first piece of material and a second piece material adjacent to the first piece of material, and
 wherein one or more of the thread lines extends across and is directly bonded to both the first piece of material and the second piece of material.   
     
     
         6 . The article of apparel of  claim 5 , further comprising a gap between the first piece of material and the second piece material, wherein the one or more of the thread lines extends across the gap. 
     
     
         7 . The article of apparel of  claim 1 , wherein the base layer comprises a first piece of material and a second piece material joined together at a seam, and
 wherein one or more of the thread lines extends across the seam and is directly bonded to both the first piece of material and the second piece of material.   
     
     
         8 . The article of apparel of  claim 1 , wherein each of the thread lines applies a compressive force on the surface of the base layer, the compressive force being applied along an axis extending from a first end to a second end of the thread line. 
     
     
         9 . The article of apparel of  claim 1 , further comprising a second thread layer defined by a second thread, the second thread layer comprising a plurality of second thread lines crossing over each other at points of overlap between two or more of the second thread lines,
 wherein each of the second thread lines extends continuously across the second thread layer,   wherein the second thread lines are not woven or knitted threads,   wherein the second thread lines not embroidered threads stitched to the base layer, and   wherein each of the second thread lines is directly bonded to a surface of the base layer along at least a portion of a length of the second thread line.   
     
     
         10 . The article of apparel of  claim 1 , wherein each of the thread lines are directly bonded to the surface of the base layer at a perimeter of the thread layer to define a pocket between the thread layer and the base layer. 
     
     
         11 . The article of apparel of  claim 10 , further comprising an insert disposed within the pocket. 
     
     
         12 . The article of apparel of  claim 11 , wherein the insert comprises a shin guard. 
     
     
         13 . The article of apparel of  claim 1 , wherein the base layer comprises a foam material. 
     
     
         14 . The article of apparel of  claim 1 , wherein:
 the base layer is a first base layer disposed below the thread layer,   the article of apparel further comprises a second base layer disposed above the thread layer, and   wherein each of the thread lines is directly bonded to a surface of the second base layer along at least a portion of a length of the thread line.   
     
     
         15 . The article of apparel of  claim 14 , wherein the base layer comprises a foam material and the second base layer comprises a foam material. 
     
     
         16 . An article of apparel, comprising:
 a first thread layer comprising a first thread border and a first thread defining a plurality of first thread lines each extending from a first side of the first thread border to a second side of the first thread border and crossing over each other at points of overlap between two or more of the first thread lines;   a second thread layer disposed over the first thread layer and comprising a second thread border and a second thread defining a plurality of second thread lines each extending from a first side of the second thread border to a second side of the second thread border and crossing over each other at points of overlap between two or more of the second thread lines; and   a base layer disposed between the first thread layer and the second thread layer;   wherein the first thread layer, the second layer, and the base layer are coupled together to form a chamber occupying a volume between the first thread layer and the second thread layer.   
     
     
         17 . The article of apparel of  claim 16 , wherein a portion of the base layer defines a portion of the chamber. 
     
     
         18 . The article of apparel of  claim 16 , wherein the base layer, the first thread layer, and the second thread layer are attached at a seam located at an edge of the chamber. 
     
     
         19 . The article of apparel of  claim 16 , wherein the plurality of first thread lines are directly bonded to a surface of the base layer. 
     
     
         20 . The article of apparel of  claim 16 , wherein the base layer is a first base layer and the article of apparel further comprises a second base layer disposed between the first base layer and the second thread layer, and a portion of the second base layer defines a portion of the chamber. 
     
     
         21 . The article of apparel of  claim 20 , wherein the first base layer, the second base layer, the first thread layer, and the second thread layer are attached at a seam located at an edge of the chamber. 
     
     
         22 . The article of apparel of  claim 20 , wherein the plurality of second thread lines are directly bonded to a surface of the second base layer. 
     
     
         23 . The article of apparel of  claim 16 , wherein the chamber is filled with insulation. 
     
     
         24 . The article of apparel of  claim 16 , wherein the chamber is filled with an insert. 
     
     
         25 . The article of apparel of  claim 16 , wherein the chamber is a tubular chamber. 
     
     
         26 . The article of apparel of  claim 25 , wherein the article comprises a pant leg, an arm sleeve, a knee sleeve, a waistband, an elbow sleeve, an ankle sleeve, a wrist sleeve, a collar, a double panel shirt, or a fully-fashioned tubular fabric. 
     
     
         27 . A method of making an article of apparel, the method comprising:
 winding a continuous thread around a plurality of anchor points on a support plate to form a thread layer, the continuous thread comprising a plurality of thread lines with each thread line extending between two respective anchor points; and   injecting foam around at least a portion of the thread layer.