Costumes with semi-rigid fabric components and method of manufacture of same

Abstract

A process for manufacturing a costume having semi-rigid costume components, and the costume itself. The semi-rigid costume components are capable of being sewn to fabric to form an integrated costume. An embodiment is shown in which the costume includes a semi-rigid muscular torso suitable for a superhero chestpiece. The sewn rigid component is formed from fusing a layer of fabric to a layer of foam and the resulting laminate is vacuum molded into a three-dimensional shape.

What is claimed is:  
     
       1. A method for manufacturing a component for a costume, comprising the steps of: 
       (a) providing a sheet of fabric and a separate foam sheet;  
       (b) fusing said sheet of fabric to said foam sheet to form a fused, laminated sheet; and,  
       (c) vacuum molding said laminated sheet to form the  a three-dimensional shape of a human, upper torso.  
     
     
       2. A method for manufacturing as claimed in  claim 1 , further comprising the step of applying stretchable ink to said laminated sheet. 
     
     
       3. A method for manufacturing as claimed in  claim 2 , wherein said stretchable ink is applied to said laminated sheet before said step of vacuum molding. 
     
     
       4. A method for manufacturing as claimed in  claim 1 , further comprising the step of gross die cutting a first section of said laminated material, and before said step of vacuum molding. 
     
     
       5. A method for manufacturing as claimed in  claim 4 , further comprising the step of performing a fine die cut on said vacuum molded, laminated sheet. 
     
     
       6. A method for manufacturing as claimed in  claim 5 , further comprising the step of sewing said component for a costume to fabric pieces to form a complete costume. 
     
     
       7. A method as claimed in  claim 2  wherein said step of applying stretchable ink accommodates the differences in surface configuration of said laminated sheet before and after said step of vacuum molding, to present an integrated visual effect after said step of vacuum molding. 
     
     
       8. A method for manufacturing as claimed in  claim 1  further comprising the step of sewing said component to fabric pieces to form a unitard-style costume. 
     
     
       9. A three-dimensional costume component representing the pectoral and/or abdominal muscles of a well-toned human comprising: 
       a) a fabric layer; and  
       b) a foam layer; said fabric and foam layers being fused to form a laminated sheet which is vacuum molded.  
     
     
       10. A three-dimensional costume component as claimed in  claim 9  further comprising a stretchable ink design printed on said fabric layer. 
     
     
       11. A three-dimensional costume component as claimed in  claim 9  wherein said costume component is in the shape of an upper torso. 
     
     
       12. A three-dimensional costume component as claimed in  claim 9  wherein said costume component is integrated into a unitard. 
     
     
       13. A three-dimensional costume component as claimed in  claim 9  wherein said costume component is sewn to additional fabric to form an integrated costume. 
     
     
       14. A costume comprising: 
       a costume component, said costume component comprising a first layer of fabric and a second layer of foam fused to said fabric to form a laminated sheet, said laminated sheet being vacuum molded into a three-dimensional desired shape in the shape of an upper torso.  
     
     
       15. A costume as claimed in  claim 14 , wherein said first layer of fabric comprises polyester. 
     
     
       16. A costume as claimed in  claim 14 , in which said costume component further has stretchable ink applied to said fabric of said laminated sheet. 
     
     
       17. A costume as claimed in  claim 14 , in which said costume component is sewn to fabric pieces to form a unitard. 
     
     
       18. A costume as claimed in  claim 14 , in which said costume component comprises a chestpiece sewn to fabric, said chestpiece having stretchable ink on its surface. 
     
     
       19. A costume, said costume comprising a semi-rigid and three-dimensional upper-torso component, said upper torso component comprising a layer of fabric, heat laminated and fused to a layer of foam, said upper-torso component being vacuum formed into a three-dimensional shape of a well-toned human and sewn to other fabric components. 
     
     
       20. A costume as claimed in  claim 19 , in which said other fabric components together with said upper torso component form a unitard. 
     
     
       21. A costume as claimed in  claim 19 , in which said semi-rigid component has stretchable ink applied on its surface. 
     
     
       22. A method for manufacturing a component for a costume as claimed in  claim 19  wherein said layer of foam comprises H-cell foam material. 
     
     
       23. A method for manufacturing a component for a costume, comprising the steps of: 
       ( a )  providing a sheet of fabric and a separate foam sheet;    
       ( b )  fusing said sheet of fabric to said foam sheet to form a fused, laminated sheet; and,    
       ( c )  molding said laminated sheet to form a three-dimensional shape of a human upper torso.   
     
     
       24. A method for manufacturing as claimed in  claim 23 , further comprising the step of applying stretchable ink to said laminated sheet. 
     
     
       25. A method for manufacturing as claimed in  claim 24 , wherein said stretchable ink is applied to said laminated sheet before said step of molding. 
     
     
       26. A method as claimed in  claim 24  wherein said step of applying stretchable ink accommodates the differences in surface configuration of said laminated sheet before and after said step of molding, to present an integrated visual effect after said step of molding. 
     
     
       27. A method for manufacturing as claimed in  claim 23 , further comprising the step of gross die cutting a first section of said laminated material, and before said step of molding. 
     
     
       28. A method for manufacturing as claimed in  claim 27 , further comprising the step of performing a fine die cut on said molded, laminated sheet. 
     
     
       29. A method for manufacturing as claimed in  claim 28 , further comprising the step of sewing said component for a costume to fabric pieces to form a complete costume. 
     
     
       30. A method as claimed in  claim 29  wherein said sewing step comprises the use of conventional sewing techniques. 
     
     
       31. A method for manufacturing as claimed in  claim 23  further comprising the step of sewing said component to fabric pieces to form a unitard-style costume. 
     
     
       32. A method for manufacturing a component for a costume claimed in  claim 23 , in which said sheet of fabric forms the top layer of said laminated sheet. 
     
     
       33. A three-dimensional costume component as claimed in  claim 23  wherein said foam layer comprises H-cell foam material. 
     
     
       34. A method for manufacturing a component for a costume as claimed in  claim 23  wherein said three-dimensional shape of said human upper torso is fabric-covered. 
     
     
       35. A costume component as claimed in  claim 23  wherein said fusing step is performed by heat and pressure. 
     
     
       36. A three-dimensional costume component representing the pectoral and/or abdominal muscles of a well-toned human comprising: 
         a )  fabric layer; and    
         b )  a foam layer; said fabric d foam layers being fused to form a laminated sheet which is molded.   
     
     
       37. A three-dimensional costume component as claimed in  claim 36  further comprising a stretchable ink design printed on said fabric layer. 
     
     
       38. A three-dimensional costume component as claimed in  claim 36  wherein said costume component is in the shape of an upper torso. 
     
     
       39. A three-dimensional costume component as claimed in  claim 36  wherein said costume component is integrated into a unitard. 
     
     
       40. A three dimensional costume as claimed in  claim 39  wherein said costume component is integrated into a unitard by conventional sewing. 
     
     
       41. A three-dimensional costume component as claimed in  claim 36  wherein said costume component is sewn to additional fabric to form an integrated costume. 
     
     
       42. A three-dimensional costume component representing the pectoral and/or abdominal muscles of a well-toned human as claimed in  claim 36  in which said fabric layer forms the top layer of said laminated sheet. 
     
     
       43. A three-dimensional costume component as claimed in  claim 36  wherein said foam layer comprises H-cell foam material. 
     
     
       44. A three-dimensional costume component as claimed in  claim 36  wherein said laminated sheet which is molded is fabric-covered. 
     
     
       45. A three dimensional costume component as claimed in  claim 36  wherein said fusing is performed by heat and pressure. 
     
     
       46. A costume comprising: 
       
         a costume component, said costume component comprising a first layer of fabric and a second layer of foam fused to said fabric to form a laminated sheet, said laminated sheet being molded into a three-dimensional desired shape in the shape of an upper torso. 
       
     
     
       47. A costume as claimed in  claim 46 , wherein said first layer of fabric comprises polyester. 
     
     
       48. A costume as claimed in  claim 46 , in which said costume component further has stretchable ink applied to said fabric of said laminated sheet. 
     
     
       49. A costume as claimed in  claim 46 , in which said costume comment is sewn to fabric pieces to form a unitard. 
     
     
       50. A costume as claimed in  claim 46 , in which said costume component comprises a chestpiece sewn to fabric, said chestpiece having stretchable ink on its surface. 
     
     
       51. A costume as claimed in  claim 46  in which said first layer of fabric is the top layer of said laminated sheet. 
     
     
       52. A costume as claimed in  claim 46  wherein said layer of foam comprises H-cell foam material. 
     
     
       53. A costume as claimed in  claim 46  wherein said costume component is attachable by conventional sewing technique to at least one additional fabric-only piece. 
     
     
       54. A costume as claimed in  claim 46  wherein said three-dimensional desired shape in the shape of an upper torso is fabric-covered. 
     
     
       55. A costume as claimed in  claim 46  wherein said fusing is performed by heat and pressure. 
     
     
       56. A costume, said costume comprising a semi-rigid and three-dimensional upper-torso component, said upper torso component comprising a layer of fabric, heat laminated and fused to a layer of foam, said upper-torso component being formed into a three-dimensional shape of a well-toned human and sewn to other fabric components. 
     
     
       57. A costume as claimed in  claim 56 , in which said other fabric components together with said upper torso component form a unitard. 
     
     
       58. A costume as claimed in  claim 56 , in which said semi-rigid component has stretchable ink applied on its surface. 
     
     
       59. A costume as claimed in  claim 56  wherein said layer of fabric is the top layer of said three-dimensional upper torso component. 
     
     
       60. A costume as claimed in  claim 56  wherein said layer of foam comprises H-cell foam material. 
     
     
       61. A costume as claimed in  claim 56  wherein said upper torso component is integrated to said other fabric components by conventional sewing techniques. 
     
     
       62. A costume as claimed in  claim 56  wherein said upper-torso component is fabric-covered. 
     
     
       63. A costume as claimed in  claim 56  wherein fusing is performed by heat and pressure.