Briefs for male wearers and method for manufacturing same

Abstract

A method for manufacturing a brief includes use of a first stretchable fabric and a second stretchable fabric adherable to the first stretchable fabric. The second stretchable fabric defines a gluteal portion. The second stretchable fabric is placed between a core, having a buttocks profile, and a cavity of a die assembly. The core pushes a section of the gluteal portion into the cavity. Heat and pressure are applied at the section to cause a volume of a synthetic compound of the section to melt while retaining the section in the stretched state. The section is cooled such that a melted volume of the synthetic compound is infused into a remainder of the section and solidified therewithin to cause the section to acquire a shape as that acquired in the stretched state and form a molded sac configured to accommodate and conform to buttocks of a wearer.

We claim: 
     
         1 . A method for manufacturing a brief for a wearer, the method comprising:
 using a first stretchable fabric defining a first leg portion, a second leg portion, and a first crotch portion extending between the first leg portion and the second leg portion;   using a second stretchable fabric adherable to the first stretchable fabric, the second stretchable fabric defining a third leg portion, a fourth leg portion, and a second crotch portion integrally and contiguously extending between the third leg portion and the fourth leg portion, the second stretchable fabric defining a gluteal portion extending at least in part across each of the third leg portion, the fourth leg portion, and the second crotch portion;   placing the second stretchable fabric into a die assembly such that the gluteal portion sits between a core and a cavity of the die assembly, the core including a profile of buttocks of the wearer;   mating the core with the cavity to cause the core to push a section of the gluteal portion into the cavity such that the section is stretched from a non-stretched state to a stretched state with respect to a remaining section of the gluteal portion, the section including a synthetic compound;   applying heat and pressure at the section to cause a volume of the synthetic compound to melt while retaining the section in the stretched state; and   cooling the section such that a melted volume of the synthetic compound is infused or incorporated into a remainder of the section and solidified therewithin to cause the section to acquire a shape as that acquired in the stretched state and be retained in the shape to form a molded sac seamlessly integrated with the remaining section of the gluteal portion, the molded sac configured to accommodate and conform to buttocks of the wearer when the brief is worn by the wearer.   
     
     
         2 . The method of  claim 1 , wherein
 the section is stretched from the non-stretched state to the stretched state to increase sizes of holes defined in the section from relatively smaller hole sizes to relatively larger hole sizes,   when the melted volume of the synthetic compound is infused or incorporated into the section and solidified therewithin, the sizes of holes in the section are retained with the relatively larger hole sizes,   the section of the gluteal portion sustains a stretching pressure when the section is stretched from the non-stretched state to the stretched state, and   a percentage increase in the sizes of holes when the section is stretched from the non-stretched state to the stretched state is at least twice of a percentage rise in the stretching pressure.   
     
     
         3 . The method of  claim 1 , wherein
 the first leg portion defines a first side edge, the second leg portion defines a second side edge, the third leg portion defines a third side edge, and the fourth leg portion defines a fourth side edge, the method further including:
 overlapping the first side edge with the third side edge and using a first adhesive volume therebetween to fuse and join the first side edge with the third side edge, thereby forming a first suture-less and seamless joint of the brief; and 
 overlapping the second side edge with the fourth side edge and using a second adhesive volume therebetween to fuse and join the second side edge with the fourth side edge, thereby forming a second suture-less and seamless joint of the brief. 
   
     
     
         4 . The method of  claim 3 , wherein the first crotch portion defines a first crotch periphery, the second crotch portion defines a second crotch periphery, the method further including:
 overlapping the first crotch periphery with the second crotch periphery and using a third adhesive volume therebetween to fuse and join the first crotch periphery with the second crotch periphery, thereby forming a third suture-less and seamless joint of the brief.   
     
     
         5 . The method of  claim 1  further including heat pressing the second stretchable fabric on steel rollers to reduce a coefficient of friction of the second stretchable fabric prior to placing the second stretchable fabric into the die assembly. 
     
     
         6 . The method of  claim 1 , wherein the second stretchable fabric includes a satin weave synthetic composite fabric including elongated nano fibers having a length anywhere between ten (10) to hundred (100) microns. 
     
     
         7 . The method of  claim 1 , wherein the second stretchable fabric is made using a polyamide weave that is transformed to a satin weave and thinned out. 
     
     
         8 . The method of  claim 1 , wherein the second stretchable fabric includes polyester and the synthetic compound includes polyethylene terephthalate (PET). 
     
     
         9 . The method of  claim 1 , wherein the second stretchable fabric includes a thickness anywhere between 0.0045-0.0048 millimeters (mm). 
     
     
         10 . The method of  claim 1 , wherein
 the section of the second stretchable fabric defines a first fabric weight in a range of 70 and 100 grams per square meter, and   the molded sac, formed from the section of the second stretchable fabric, defines a second fabric weight in a range of 65 percent to 75 percent of the first fabric weight.   
     
     
         11 . The method of  claim 1 , wherein the cavity is formed in a first support part of the die assembly, the method including using a second support part of the die assembly to impinge against the first support part when or prior to mating the core with the cavity to clinch and restrain the remaining section of the gluteal portion in between the first support part and the second support part. 
     
     
         12 . The method of  claim 1 , wherein a temperature value during an application of the heat is anywhere between 330.2 degrees Fahrenheit to 402 degrees Fahrenheit. 
     
     
         13 . The method of  claim 1 , wherein a pressure value during an application of the pressure is anywhere between 3.899 to 7.024 pounds per square inch (psi). 
     
     
         14 . The method of  claim 1 , wherein the heat is applied for a period of at least 10.05 seconds and up to a maximum of 13.03 seconds. 
     
     
         15 . The method of  claim 1 , wherein the pressure is applied for a period of at least 10.05 seconds and up to a maximum of 13.03 seconds. 
     
     
         16 . The method of  claim 1 , wherein
 cooling is applied to the section for a period of at least thirty (30) seconds, and   when cooling is applied, the section is subjected to a temperature ranging between 71 degrees Fahrenheit to 76 degrees Fahrenheit.   
     
     
         17 . The method of  claim 1 , wherein the heat and the pressure are applied simultaneously. 
     
     
         18 . A brief for a wearer, the brief comprising:
 a first stretchable fabric defining a first leg portion, a second leg portion, and a first crotch portion extending between the first leg portion and the second leg portion; and   a second stretchable fabric adhered to the first stretchable fabric and including a satin weave synthetic composite fabric including elongated nano fibers, the second stretchable fabric defining a third leg portion, a fourth leg portion, a second crotch portion integrally and contiguously extending between the third leg portion and the fourth leg portion, and a gluteal portion extending at least in part across each of the third leg portion, the fourth leg portion, and the second crotch portion, the gluteal portion defining a molded sac configured to accommodate and conform to buttocks of the wearer when the brief is worn by the wearer, wherein
 the molded sac is formed by a section of the gluteal portion that is stretched outwardly to a stretched state to define a bulge with respect to a remaining section of the gluteal portion, the molded sac being seamlessly integral with the remaining section of the gluteal portion, 
 a first fabric region of the second stretchable fabric other than the molded sac defines first holes and a second fabric region of the second stretchable fabric within the molded sac defines second holes, 
 the first holes define a diameter in a range of 0.01 millimeters (mm) to 0.024 mm in between warp and filament yarn, and 
 the second holes define a diameter in a range of 0.025 mm to 0.05 mm in between warp and filament yarn. 
   
     
     
         19 . The brief of  claim 18 , wherein
 the satin weave synthetic composite fabric is formed from a polyamide weave transformed into a satin weave and thinned out,   the satin weave synthetic composite fabric includes polyester and the molded sac includes a melted, infused, and solidified volume of a synthetic compound associated with the polyester, enabling the molded sac to be retained in the stretched state, and   the synthetic compound includes polyethylene terephthalate (PET).   
     
     
         20 . The brief of  claim 18 , wherein
 the first leg portion defines a first side edge, the second leg portion defines a second side edge, the third leg portion defines a third side edge, and the fourth leg portion defines a fourth side edge,   the first side edge is overlapped with the third side edge and adhered thereto by a first adhesive volume applied therebetween to fuse and join the first side edge with the second side edge, thereby defining a first suture-less and seamless joint of the brief, and   the second side edge is overlapped with the fourth side edge and adhered thereto by a second adhesive volume applied therebetween to fuse and join the second side edge with the fourth side edge, thereby defining a second suture-less and seamless joint of the brief.   
     
     
         21 . The brief of  claim 20 , wherein
 the first crotch portion defines a first crotch periphery and the second crotch portion defines a second crotch periphery, and   the first crotch periphery is overlapped with the second crotch periphery and adhered thereto by a third adhesive volume applied therebetween to fuse and join the first crotch periphery with the second crotch periphery, thereby defining a third suture-less and seamless joint of the brief.