SHAPEWEAR GARMENTS AND METHODS OF MAKING SAME

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority to U.S. Provisional Application No. 63/703,602, filed Oct. 4, 2024, which is incorporated herein by reference in its entirety for all purposes.

BACKGROUND

This application relates to the field of shaping apparel. Consumers are demanding shapewear which mitigates the prominence or appearance of the abdomen, back, arms, and legs. Outer shapewear garments with shaping components are fashionable and desirable for the convenience of abdomen, back, arms, and legs shaping without needing to wear a separate shaping undergarment. Such garments are often tightly form-fitting to give the wearer the desired shaping effect.

Existing shaping apparel, however, presents problems due to the tightness and construction of the garment. Shapewear has to be stiff and tight enough that it can constrict the wearer's body to provide a shaping effect. At the same time, it must still provide a sleek appearance to avoid creating a pinched shape around the shaping regions of the garment.

A need therefore exists for shapewear with improved shaping components and methods of making the same. Accordingly, a solution that addresses the above-mentioned shortcomings is desired and provided herein.

BRIEF SUMMARY

Disclosed herein are methods of making shaping garments by creating an X-shaped shaping panel bonded to the garment and garments made therefrom. The stiffness of the bonded region improves the shaping effect of the X-shaped panel while maintaining the flexibility of the remainder of the garment. Advantageously, the disclosed methods can provide a stiff, bonded shaping region without adding unnecessary extra thickness that would cause the shaping region of the garment to be visible when the shaping garment is worn underneath an outer garment.

In an aspect, provided is a method of making a shapewear garment, the method including: a) applying an adhesive to a first fabric; b) curing said adhesive on the first fabric; c) cutting an X-shaped panel from the first fabric; d) bonding said X-shaped panel to a second fabric using the adhesive, thereby forming a shaping region; and e) forming the shapewear garment from the second fabric.

In some aspects, the first fabric can include a knit fabric. In other aspects, the first fabric can include satin.

In some aspects, the adhesive can include thermoplastic elastomer (TPE), thermoplastic polyurethanes (TPU), thermoplastic polyamide elastomer (TPA), or any combination thereof. In some aspects, the adhesive can be thermally activated.

In some aspects, step a) can include applying the adhesive in a dot-matrix pattern.

In some aspects, step a) can include covering from about 30% to about 100% of the surface area of the first fabric with the adhesive.

In some aspects, step b) can include allowing the adhesive to cool for from about 30 minutes to about 24 hours.

In some aspects, step c) can be executed by a rotary knife, a laser, or a straight knife.

In some aspects, the second fabric can include a knit fabric. In other aspects, the second fabric can include mesh.

In some aspects, step d) can be executed by a roller fuse or flat press.

In some aspects, the roller fuse or flat press can operate at a temperature of from about 130° C. to about 180° C.

In some aspects, the roller fuse or flat press can exert a pressure of from about 2 bar to about 5 bar.

In some aspects, step d) can have a duration of from about 10 seconds to about 25 seconds.

In some aspects, step e) can include: i) cutting the second fabric to pattern; and ii) sewing the pattern together to form the shapewear garment.

In another aspect, provided is a garment made by any of the disclosed methods.

In some aspects, top arms of the X-shaped panel can extend to an upper edge of the garment. In some aspects, the top arms of the X-shaped panel can extend completely around the upper edge of the garment. In some aspects, the garment can include a waistband on the inside or outside of the garment, and the top arms of the X-shaped panel can extend across or underneath all of the waistband.

In some aspects, the bottom arms of the X-shaped panel can extend around a wearer's thighs. In some aspects, the bottom arms of the X-shaped panel can extend under a wearer's buttocks and to a wearer's inner thighs.

In some aspects, the shaping region can have an elongation of from about 20% to about 70%. In some aspects, the shaping region can have a modulus of from about 15 N to about 50 N. In some aspects, the shaping region can have a percent recovery of from about 80% to about 100%. In some aspects, the garment can be shorts or pants. In other aspects, the garment can be a body suit.

BRIEF DESCRIPTION OF THE DRAWINGS

The garment is explained in even greater detail in the following drawings. The drawings are merely exemplary to illustrate the structure of garments and certain features that may be used singularly or in combination with other features. The drawings are not necessarily drawn to scale.

FIG. 1 is a front perspective view of a lower body garment in accordance with the present disclosure.

FIG. 2 is a rear perspective view of the lower body garment shown in FIG. 1.

FIG. 3 is a front perspective view of another lower body garment in accordance with the present disclosure.

FIG. 4 is a rear perspective view of the lower body garment shown in FIG. 3.

FIG. 5 is a front perspective view of a full body garment in accordance with the present disclosure.

FIG. 6 is a rear perspective view of the full body garment of FIG. 5.

FIG. 7 is a front perspective view of another lower body garment in accordance with the present disclosure.

FIG. 8 is a front perspective view of another full body garment in accordance with the present disclosure.

FIGS. 9A-9C depict example methods of making any of the garments disclosed herein.

FIG. 10 is a front perspective view of another full body garment in accordance with the present disclosure.

FIG. 11 is a front perspective view of another full body garment in accordance with the present disclosure.

FIG. 12 is a rear perspective view of the lower body garment shown in FIG. 11.

DETAILED DESCRIPTION

This description below refers to certain aspects of the garment relative to other aspects of the garment or to the body of a wearer. As used herein, superior indicates a direction that is closer to the wearer's head. Inferior indicates a direction that is closer to the wearer's feet. Upward, upper, or uppermost indicates a superior direction, or toward a wearer's head. Downward, lower, or lowermost indicates an inferior direction, or toward a wearer's feet. The longitudinal direction refers to an axis extending between the superior and inferior edges of the garment, or between the wearer's head and feet. Lateral indicates a positioning that is closer to the sides of the wearer. Medial indicates a positioning that is farther from the sides of the wearer. Anterior indicates a positioning closer to the front of a wearer. Posterior indicates a positioning closer to the back of a wearer. The terms right and left are in reference to the wearer's body.

The following description of certain examples of the inventive concepts should not be used to limit the scope of the claims. Other examples, features, aspects, embodiments, and advantages will become apparent to those skilled in the art from the following description. As will be realized, the garment and/or methods are capable of other different and obvious aspects, all without departing from the spirit of the inventive concepts. Accordingly, the drawings and descriptions should be regarded as illustrative in nature and not restrictive.

For purposes of this description, certain aspects, advantages, and novel features of the aspects of this disclosure are described herein. The described methods, processes, and garment should not be construed as limiting the scope of the invention to the specific aspects and embodiments described herein in any way. Instead, the present disclosure is directed toward all novel and nonobvious features and aspects of the various disclosed embodiments, alone and in various combinations and sub-combinations with one another. The disclosed methods, processes, and garment are not limited to any specific aspect, feature, or combination thereof, nor do the disclosed methods, processes, and garment require that any one or more specific advantages be present or problems be solved.

Although the operations of exemplary aspects of the disclosed method may be described in a particular, sequential order for convenient presentation, it should be understood that disclosed aspects can encompass an order of operations other than the particular, sequential order disclosed. For example, operations described sequentially may in some cases be rearranged or performed concurrently. Further, descriptions and disclosures provided in association with one particular aspect or implementation are not limited to that aspect or implementation, and may be applied to any aspect or implementation disclosed. It will understood that various changes and additional variations may be made to the disclosed invention and equivalents may be substituted for elements thereof without departing from the scope of the invention or the inventive concept thereof. Certain aspects and features of any given aspect may be translated to other aspects described herein. In addition, many modifications may be made to adapt a particular aspect or garment to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular implementations disclosed herein, but that the invention will include all implementations falling within the scope of the appended claims.

Features, integers, characteristics, compounds, chemical moieties, or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract, and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. The invention is not restricted to the details of any foregoing aspects. The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract, and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

It should be appreciated that any patent, publication, or other disclosure material, in whole or in part, that is said to be incorporated by reference herein is incorporated herein only to the extent that the incorporated material does not conflict with existing definitions, statements, or other disclosure material set forth in this disclosure. As such, and to the extent necessary, the disclosure as explicitly set forth herein supersedes any conflicting material incorporated herein by reference. Any material, or portion thereof, that is said to be incorporated by reference herein, but which conflicts with existing definitions, statements, or other disclosure material set forth herein will only be incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material.

As used in the specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another disclosed aspect of the invention. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint. The terms “about” and “approximately” are defined as being “close to” as understood by one of ordinary skill in the art. In one non-limiting aspect the terms are defined to be within 10%. In another non-limiting aspect, the terms are defined to be within 5%. In still another non-limiting aspect, the terms are defined to be within 1%.

“Optional” or “optionally” means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.

The terms “coupled,” “connected,” and the like as used herein mean the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent) or moveable (e.g., removable or releasable). Such joining may be achieved with a) the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another, or b) with the two members or the two members and any additional intermediate members being attached to one another.

Throughout the description and claims of this specification, the word “comprise” and variations of the word, such as “comprising” and “comprises,” means “including but not limited to,” and is not intended to exclude, for example, other additives, components, integers or steps. “Exemplary” means “an example of” and is not intended to convey an indication of a preferred or ideal aspect. “Such as”is not used in a restrictive sense, but for explanatory purposes.

Disclosed herein are methods of making shaping garments by creating an X-shaped shaping panel bonded to the garment and garments made therefrom. The stiffness of the bonded region improves the shaping effect of the X-shaped panel while maintaining the desired flexibility of the remainder of the garment. Advantageously, the disclosed methods, particularly the construction of the X-shaped panel, can provide a stiff, bonded shaping region without adding unnecessary extra thickness that would cause the shaping region of the garment to be visible when the shaping garment is worn underneath an outer garment.

FIG. 1 and FIG. 2 depict a lower body garment 100. The lower body garment 100 has a main body 102 assembled from multiple panels, which are interconnected by seams and/or closures (e.g., buttons, snaps, zippers, hook-and-loop fasteners, etc.) to form an encircling garment. In some aspects, the garment can be assembled from any number of horizontal and/or vertical panels or segments, the design and assembly of which could be identified by one of ordinary skill in the art based on the type and style of the garment. In other aspects, a portion or all of the garment can be circularly knit.

The main body 102 includes an X-shaped panel 104 which surrounds the abdominal region and thigh region of the wearer. The X-shaped panel 104 includes bottom arms 106a, 106b and top arms 108a, 108b. The bottom arms 106a, 106b meet the top arms 108a, 108b approximately at the navel of the wearer. In other aspects, the top arms can meet the bottom arms at any point along the front of the wearer's torso, for example, above the navel of the wearer, at the navel of the wearer, below the navel of the wearer, or above the crotch area of the wearer.

On both the left and right sides of the X-shaped panel, the bottom arms 106a, 106b form a side angle 107 with the top arms 108a, 108b. This side angle 107 is noted in FIG. 1 in dashed lines and is understood to be symmetrical on the left and right sides of the X-shaped panel. While the arms of the X-shaped panel may intersect at a side angle 107 ranging from about 30° to about 130°, the angle of intersection modifies both the shaping effect and the resulting appearance of the garment. A smaller side angle 107 (e.g., about 30°-60°) concentrates shaping forces more vertically along the torso, thereby producing stronger abdominal compression and a visibly elongated waistline. A larger side angle 107 (e.g., about 90°-130°) distributes shaping forces diagonally across the torso and hips, smoothing lateral transitions and minimizing lines of demarcation under outer clothing. An intermediate side angle 107 (e.g., about 65°-95°) balances vertical lift and diagonal smoothing, providing simultaneous waist-narrowing and hip-smoothing effects.

In some aspects, the side angle 107 can be at least about 30° (e.g., at least about 35°, at least about 40°, at least about 45°, at least about 50°, at least about 55°, at least about 60°, at least about 65°, at least about 70°, at least about 75°, at least about 80°, at least about 85°, at least about 90°, at least about 95°, at least about 100°, at least about 105°, at least about 110°, at least about 115°, at least about 120°, at least about 125°, at least about 130°). In some aspects, the side angle 107 can be up to about 130° (e.g., up to about 125°, up to about 120°, up to about 115°, up to about 110°, up to about 105°, up to about 100°, up to about 95°, up to about 90°, up to about 85°, up to about 80°, up to about 75°, up to about 70°, up to about 65°, up to about 60°, up to about 55°, up to about 50°, up to about 45°, up to about 40°, up to about 35°, up to about 30°).

It is considered that the side angle 107 can be an angle ranging from any of the minimum values described above to any of the maximum values described above. For example, in some aspects, the side angle 107 can be from about 30° to about 130° (e.g., from about 35° to about 125°, from about 40° to about 120°, from about 45° to about 115°, from about 50° to about 110°, from about 55° to about 105°, from about 60° to about 100°, from about 65°to about 95°, from about 70° to about 90°, from about 75° to about 85°, from about 30° to about 80°, from about 35° to about 75°, from about 40° to about 70°, from about 45° to about 65°, from about 50° to about 60°, from about 80° to about 130°, from about 85° to about 125°, from about 90° to about 120°, from about 95° to about 115°, from about 100° to about 110°).

The bottom arms 106a, 106b can extend around the outside of the wearer's thighs, underneath the wearer's buttocks, and toward the wearer's inner thighs. In some aspects, the bottom arms can end at the rear, middle, or front of the wearer's inner thighs. This thigh wrapping advantageously provides a sleek shaping effect to the abdomen, buttocks, and thighs simultaneously. Around-thigh extension delivers circumferential compression, slimming the thighs while maintaining comfort. Under-buttock extension provides a lifting effect, accentuating buttock contour and reducing sagging. Toward-inner-thigh extension creates a smoothing effect in the thigh gap area, reducing fabric chafing and providing a continuous silhouette beneath clothing. It is understood that the precise location of the bottom arms is merely depicted as an example and may be modified as desired. For example, the placement of the bottom arms under the wearer's buttocks can be moved up or down to customize the lifting and/or shaping effect conferred to the buttocks. Higher placement on the wearer enhances buttock lift, whereas lower placement provides more thigh shaping and elongation of the leg line.

The bottom arms 106a, 106b form a bottom angle 110 with each other. This bottom angle 110 is noted in FIG. 1 in dashed lines. In some aspects, the bottom angle 110 can be at least about 30° (e.g., at least about 35°, at least about 40°, at least about 45°, at least about 50°, at least about 55°, at least about 60°, at least about 65°, at least about 70°, at least about 75°, at least about 80°, at least about 85°, at least about 90°, at least about 95°, at least about 100°, at least about 105°, at least about 110°, at least about 115°, at least about 120°, at least about 125°, at least about 130°). In some aspects, the bottom angle 110 can be up to about 130° (e.g., up to about 125°, up to about 120°, up to about 115°, up to about 110°, up to about 105°, up to about 100°, up to about 95°, up to about 90°, up to about 85°, up to about 80°, up to about 75°, up to about 70°, up to about 65°, up to about 60°, up to about 55°, up to about 50°, up to about 45°, up to about 40°, up to about 35°, up to about 30°).

It is considered that the bottom angle 110 can be an angle ranging from any of the minimum values described above to any of the maximum values described above. For example, in some aspects, the bottom angle 110 can be from about 30° to about 130° (e.g., from about 35° to about 125°, from about 40°to about 120°, from about 45° to about 115°, from about 50° to about 110°, from about 55° to about 105°, from about 60° to about 100°, from about 65° to about 95°, from about 70° to about 90°, from about 75° to about 85°, from about 30° to about 80°, from about 35° to about 75°, from about 40° to about 70°, from about 45° to about 65°, from about 50° to about 60°, from about 80° to about 130°, from about 85° to about 125°, from about 90° to about 120°, from about 95° to about 115°, from about 100° to about 110°).

The top arms 108a, 108b fully extend up to the upper encircling edge 112 of the garment 100. In other aspects, only a portion of the top arms may extend to the upper encircling edge of the garment (e.g., the top portions of the top arms may extend to the upper encircling edge of the garment), and a portion of the top arms may not extend to the upper encircling edge of the garment (e.g., the side portions of the top arms may cut off vertically and not extend to the upper encircling edge of the garment) (for example, the aspect shown in FIG. 5). In yet other aspects, the top arms may extend to any point below the upper encircling edge of the garment. In some specific aspects, the garment may include a waistband on the inside or outside of the garment, and the top arms may extend across or underneath some or all of the waistband (i.e., partially or completely to the upper encircling edge of the garment). In other specific aspects, the garment may include a waistband on the inside or outside of the garment, and the top arms may extend to the bottom edge of the waistband. In some aspects, all or part of the top arms extend completely around the upper encircling edge, ending on the rear side of the garment (for example, as shown in FIG. 11). Each arrangement of the top arms confers benefits. Full extension to the upper encircling edge 112 increases structural stability at the waist, resists rolling or slippage, and enhances waist definition. Termination below the upper encircling edge 112 reduces bulk at the waistline, enabling a smooth finish beneath fitted tops while still delivering targeted abdominal shaping. Partial or complete extension beneath a waistband creates a reinforced zone that anchors the garment in place, preventing waistband digging and providing a continuous shaping band. Full wraparound to the rear (see FIG. 11-12) produces a smoothing strip 1105 across the upper back and flanks, reducing bulging and providing enhanced posture support.

The top arms 108a, 108b form a top angle 114 with each other. This top angle 114 is noted in FIG. 1 in dashed lines. In some aspects, the top angle 114 can be at least about 30°(e.g., at least about 35°, at least about 40°, at least about 45°, at least about 50°, at least about 55°, at least about 60°, at least about 65°, at least about 70°, at least about 75°, at least about 80°, at least about 85°, at least about 90°, at least about 95°, at least about 100°, at least about 105°, at least about 110°, at least about 115°, at least about 120°, at least about 125°, at least about 130°). In some aspects, the top angle 114 can be up to about 130° (e.g., up to about 125°, up to about 120°, up to about 115°, up to about 110°, up to about 105°, up to about 100°, up to about 95°, up to about 90°, up to about 85°, up to about 80°, up to about 75°, up to about 70°, up to about 65°, up to about 60°, up to about 55°, up to about 50°, up to about 45°, up to about 40°, up to about 35°, up to about 30°).

It is considered that the top angle 114 can be an angle ranging from any of the minimum values described above to any of the maximum values described above. For example, in some aspects, the top angle 114 can be from about 30° to about 130° (e.g., from about 35° to about 125°, from about 40° to about 120°, from about 45° to about 115°, from about 50° to about 110°, from about 55° to about 105°, from about 60° to about 100°, from about 65° to about 95°, from about 70° to about 90°, from about 75° to about 85°, from about 30° to about 80°, from about 35° to about 75°, from about 40° to about 70°, from about 45° to about 65°, from about 50° to about 60°, from about 80° to about 130°, from about 85° to about 125°, from about 90° to about 120°, from about 95° to about 115°, from about 100° to about 110°).

In lower body garment 100, the upper edge 112 of the garment 100 sits below the bust of the wearer. In other aspects, the upper edge of the garment can sit at any point along the wearer's torso, for example, above the bust of the wearer, at the bust of the wearer, below the bust of the wearer, above the navel of the wearer, at the navel of the wearer, or below the navel of the wearer. For example, FIG. 3 and FIG. 4 depict a lower body garment 300 where the upper edge 312 of the garment 300 sits at the navel of the wearer. The top arms 308a, 308b extend up to the upper edge 312 of the garment 300. In other aspects, the top arms may extend to any point below the upper edge of the garment. In some specific aspects, the garment may include a waistband on the inside or outside of the garment, and the top arms may extend across or underneath some or all of the waistband (i.e., partially or completely to the upper edge of the garment). In other specific aspects, the garment may include a waistband on the inside or outside of the garment, and the top arms may extend to the bottom edge of the waistband.

The lower body garment 100 and the lower body garment 300 are formed as shorts. However, it is considered that a garment in accordance with the present disclosure formed as a lower body garment can be any length and/or style. For example, in some aspects, the garment can be formed as shorts, pants, a skirt, or a skort. In some aspects, the legs of the garment can be upper-thigh length, mid-thigh length, knee length, calf-length, ⅞ length, or ankle length. In some aspects, the legs of the garment can include tight-fitting portions and/or loose-fitting portions.

Furthermore, a garment in accordance with the present disclosure need not necessarily be formed as a lower body garment. Lower-body garments (FIGS. 1-4, 7, 11-12) primarily target shaping of the abdomen, hips, and thighs, delivering slimming and lift in localized regions. Full-body garments (FIGS. 5-6, 8, 10) distribute shaping forces across the torso, combining abdominal compression with bust support and posture alignment. Such embodiments reduce garment shifting and provide proportional shaping from bust to thigh. For example, FIG. 5 and FIG. 6 depict a full body garment 500. The full body garment 500 has a main body 502 assembled from multiple panels, which are interconnected by seams and/or closures (e.g., buttons, snaps, zippers, hook-and-loop fasteners, etc.) to form an encircling garment. In some aspects, the garment can be assembled from any number of horizontal and/or vertical panels or segments, the design and assembly of which could be identified one of ordinary skill in the art based on the type and style of the garment. In other aspects, a portion or all of the garment can be circularly knit.

The main body 502 includes an X-shaped panel 504 which surrounds the abdominal region and thigh region of the wearer. The X-shaped panel 504 includes bottom arms 506a, 506b and top arms 508a, 508b. The bottom arms 506a, 506b meet the top arms 508a, 508b approximately at the navel of the wearer. In other aspects, the top arms can meet the bottom arms at any point along the front of the wearer's torso, for example, above the navel of the wearer, at the navel of the wearer, below the navel of the wearer, or at the crotch area of the wearer.

On both the left and right sides of the X-shaped panel, the bottom arms 506a, 506b form a side angle 507 with the top arms 508a, 508b. This side angle 507 is noted in FIG. 5 in dashed lines and is understood to be symmetrical on the left and right sides of the X-shaped panel. In some aspects, the side angle 507 can be at least about 30° (e.g., at least about 35°, at least about 40°, at least about 45°, at least about 50°, at least about 55°, at least about 60°, at least about 65°, at least about 70°, at least about 75°, at least about 80°, at least about 85°, at least about 90°, at least about 95°, at least about 100°, at least about 105°, at least about 110°, at least about 115°, at least about 120°, at least about 125°, at least about 130°). In some aspects, the side angle 507 can be up to about 130° (e.g., up to about 125°, up to about 120°, up to about 115°, up to about 110°, up to about 105°, up to about 100°, up to about 95°, up to about 90°, up to about 85°, up to about 80°, up to about 75°, up to about 70°, up to about 65°, up to about 60°, up to about 55°, up to about 50°, up to about 45°, up to about 40°, up to about 35°, up to about 30°).

It is considered that the side angle 507 can be an angle ranging from any of the minimum values described above to any of the maximum values described above. For example, in some aspects, the side angle 507 can be from about 30° to about 130° (e.g., from about 35° to about 125°, from about 40° to about 120°, from about 45° to about 115°, from about 50° to about 110°, from about 55° to about 105°, from about 60° to about 100°, from about 65° to about 95°, from about 70° to about 90°, from about 75° to about 85°, from about 30° to about 80°, from about 35° to about 75°, from about 40° to about 70°, from about 45° to about 65°, from about 50° to about 60°, from about 80° to about 130°, from about 85° to about 125°, from about 90° to about 120°, from about 95° to about 115°, from about 100° to about 110°).

The bottom arms 506a, 506b extend around the outside of the wearer's thighs, underneath the wearer's buttocks, and to the wearer's inner thighs. This thigh wrapping advantageously provides a sleek shaping effect to the abdomen, buttocks, and thighs simultaneously. It is understood that the precise location of the bottom arms is merely depicted as an example and may be modified as desired. For example, the placement of the bottom arms under the wearer's buttocks can be moved up or down to customize the lifting and/or shaping effect conferred to the buttocks. In some aspects, the bottom arms can end at the rear, middle, or front of the wearer's inner thighs.

The bottom arms 506a, 506b form a bottom angle 510 with each other. This bottom angle 510 is noted in FIG. 5 in dashed lines. In some aspects, the bottom angle 510 can be at least about 30° (e.g., at least about 35°, at least about 40°, at least about 45°, at least about 50°, at least about 55°, at least about 60°, at least about 65°, at least about 70°, at least about 75°, at least about 80°, at least about 85°, at least about 90°, at least about 95°, at least about 100°, at least about 105°, at least about 110°, at least about 115°, at least about 120°, at least about 125°, at least about 130°). In some aspects, the bottom angle 510 can be up to about 130° (e.g., up to about 125°, up to about 120°, up to about 115°, up to about 110°, up to about 105°, up to about 100°, up to about 95°, up to about 90°, up to about 85°, up to about 80°, up to about 75°, up to about 70°, up to about 65°, up to about 60°, up to about 55°, up to about 50°, up to about 45°, up to about 40°, up to about 35°, up to about 30°).

It is considered that the bottom angle 510 can be an angle ranging from any of the minimum values described above to any of the maximum values described above. For example, in some aspects, the bottom angle 510 can be from about 30° to about 130° (e.g., from about 35° to about 125°, from about 40° to about 120°, from about 45° to about 115°, from about 50° to about 110°, from about 55° to about 105°, from about 60° to about 100°, from about 65° to about 95°, from about 70° to about 90°, from about 75° to about 85°, from about 30° to about 80°, from about 35° to about 75°, from about 40° to about 70°, from about 45° to about 65°, from about 50° to about 60°, from about 80° to about 130°, from about 85° to about 125°, from about 90° to about 120°, from about 95° to about 115°, from about 100° to about 110°).

The top arms 508a, 508b partially extend up to the upper encircling edge 512 and partially across the straps 516 of the garment 500 (n.b., the upper encircling edge 512 is considered to cut across and exclude the straps 516, and is noted in dashed lines in FIG. 5 and FIG. 6 for clarity). The top portions 518a, 518b of the top arms 508a, 508b extend to the upper encircling edge 512 and partially across the straps 516 of the garment 500 (e.g., to the strap length adjusters 522), and the side portions 520a, 520b of the top arms cut off vertically and do not extend to the upper encircling edge 512 of the garment 500. In some aspects, the side portions 520a, 520b of the top arms 508a, 508b may cut off at the front, middle, or rear of the wearer's sides. In some aspects, the side portions 520a, 520b of the top arms 508a, 508b may cut off at side seams of the garment. In some aspects, the side portions 520a, 520b of the top arms 508a, 508b may not cut off vertically and, instead, cut off at an angle. In other aspects, the top arms 508a, 508b may fully extend to the upper encircling edge of the garment (i.e., both side portions 520a, 520b and top portions 518a, 518b fully extend to the upper encircling edge 512 of the garment). In yet other aspects, the top arms may extend to any point below the upper encircling edge of the garment. In some specific aspects, the garment may include a band on the inside or outside of the upper edge of the garment, and the top arms may extend across or underneath some or all of the band (i.e., partially or completely to the upper encircling edge of the garment). In other specific aspects, the garment may include a band on the inside or outside of the upper edge of the garment, and the top arms may extend to the bottom edge of the band.

In some aspects, all or part of the top arms extend partially or completely around the rear side 1103 of the garment. For example, as shown in FIG. 11 and FIG. 12, top portions 1118a, 1118b of the top arms 1108a, 1108b meet the upper encircling edge 1112 on the front side 1101 of the garment 1100 and continue to meet the upper encircling edge 1112 as the top arms 1108a, 1108b extend around to the rear side 1103 of the garment 1100. The side portions 1120a, 1120b of the top arms 1108a, 1108b also continue around to the rear side 1103 of the garment 1100. As such, the top arms 1108a, 1108b extend completely around and meet each other on the rear side 1103 of the garment, forming a continuous smoothing strip 1105 under the upper encircling edge 112. In the aspect shown in FIG. 11 and FIG. 12, the top arms 1108a, 1108b meet each other at an angle, such that the smoothing strip 1105 narrows as it approaches the center 1109 of the rear side 1103 of the garment 1100. In other aspects, the smoothing strip 1105 may maintain a continuous width as it approaches the center 1109 of the rear side 1103 of the garment 1100, or it may widen as it approaches the center 1109 of the rear side 1103 of the garment 1100. Note that the continuous smoothing strip 1105 stiffens the garment 1100 at the waist region, reducing garment roll-down or slipping and enhancing smoothing across the upper back. This stiffening is due to the process of bonding the top arms 1108a, 1108b to the underlying fabric—a process that results in a double layer of fabric and the adhesive in the bonded region. A continuous smoothing strip configuration substitutes for or improves upon conventional waistbands.

In other aspects, the top arms 1108a, 1108b may extend only partially around the rear side 1103 of the garment, stopping short of meeting each other and therefore creating an interrupted strip. An interrupted strip permits localized abdominal shaping without introducing excess stiffness across the back, thereby enhancing flexibility and wearer comfort.

Turning back to FIG. 5, the top arms 508a, 508b form a top angle 514 with each other. This top angle 514 is noted in FIG. 5 in dashed lines. In some aspects, the top angle 514 can be at least about 30° (e.g., at least about 35°, at least about 40°, at least about 45°, at least about 50°, at least about 55°, at least about 60°, at least about 65°, at least about 70°, at least about 75°, at least about 80°, at least about 85°, at least about 90°, at least about 95°, at least about 100°, at least about 105°, at least about 110°, at least about 115°, at least about 120°, at least about 125°, at least about 130°). In some aspects, the top angle 514 can be up to about 130° (e.g., up to about 125°, up to about 120°, up to about 115°, up to about 110°, up to about 105°, up to about 100°, up to about 95°, up to about 90°, up to about 85°, up to about 80°, up to about 75°, up to about 70°, up to about 65°, up to about 60°, up to about 55°, up to about 50°, up to about 45°, up to about 40°, up to about 35°, up to about 30°).

It is considered that the top angle 514 can be an angle ranging from any of the minimum values described above to any of the maximum values described above. For example, in some aspects, the top angle 514 can be from about 30° to about 130° (e.g., from about 35° to about 125°, from about 40° to about 120°, from about 45° to about 115°, from about 50° to about 110°, from about 55° to about 105°, from about 60° to about 100°, from about 65° to about 95°, from about 70° to about 90°, from about 75° to about 85°, from about 30° to about 80°, from about 35° to about 75°, from about 40° to about 70°, from about 45° to about 65°, from about 50° to about 60°, from about 80° to about 130°, from about 85° to about 125°, from about 90° to about 120°, from about 95° to about 115°, from about 100° to about 110°).

In the front of full body garment 500, the upper encircling edge 512 of the garment 500 sits below the bust of the wearer. In other aspects, the upper encircling edge of the garment can sit at any point along the front of the wearer's torso, for example, above the bust of the wearer, at the bust of the wearer, below the bust of the wearer, above the navel of the wearer, at the navel of the wearer, or below the navel of the wearer. For example, FIG. 10 depicts an example full body garment 1000 having a bottom portion formed as pants and with an upper encircling edge 1012 that sits above the bust of the wearer. Turning back to FIG. 5 and the rear of full body garment 500, the upper encircling edge 512 of the garment 500 sits at the upper back of the wearer. In other aspects, the upper encircling edge of the garment can sit at any point along the rear of the wearer's torso, for example, above the shoulder blades of the wearer, at the shoulder blades of the wearer, below the shoulder blades of the wearer, at the upper back of the wearer, at the midback of the wearer, or at the lower back of the wearer.

The bottom portion of the full body garment 500 is formed as shorts. However, it is considered that a garment in accordance with the present disclosure formed as a full body garment can have a bottom portion of any length and/or style. For example, in some aspects, the bottom portion of the garment can be formed as shorts, pants, a skirt, or a skort. In some aspects, the legs of the garment can be upper-thigh length, mid-thigh length, knee length, calf-length, ⅞ length, or ankle length. In some aspects, the legs of the garment can include tight-fitting portions and/or loose-fitting portions.

The full body garment 500 is sleeveless, however, it is considered that a garment in accordance with the present disclosure formed as a full body garment can have any length and style of sleeves. For example, in some aspects, the garment can have long sleeves, three-quarter-length sleeves, mid-length sleeves, elbow length sleeves, above-elbow-length sleeves, short sleeves, cap sleeves, or no sleeves (i.e., sleeveless). In other aspects, the garment can be strapless. In some aspects, the sleeves can include tight-fitting portions and/or loose-fitting portions.

Any of the disclosed garments (e.g., 100, 300, 500, 700, 800, and/or 1000) can be formed with any pant length and fit. For example, FIG. 7 depicts an example lower body garment 700 formed as pants, and FIG. 8 and FIG. 10 depict example full body garments 800, 1000 having bottom portions formed as pants. In some aspects, the legs of the garment can be upper-thigh length, mid-thigh length, knee length, calf-length, ⅞ length, or ankle length. In some aspects, the legs of the garment can include tight-fitting portions and/or loose-fitting portions.

The X-shaped panel (e.g., 104, 304, 504, 704, 804, and/or 1004) is bonded to the main body (e.g., 102, 302, 502, 702, 802, and/or 1002), thereby forming a shaping region defined by the region where the X-shaped panel overlaps the main body. As used herein, the term “shaping region” refers to an area of a garment having two layers of fabric in direct contact with one another which are adhered or bonded together. A shaping region can provide a shaping effect to any part of a wearer's body (e.g., abdomen, back, bust, buttocks, arms, hips, legs, etc.) as the double layer of fabric and the adhesive can increase the stiffness of the shaping region, thereby increasing the extent to which the shaping region can resist deformation by the wearer's body. A shaping region may have additional layers of fabric and/or adhesive on one or both sides of said shaping region. In some aspects, the X-shaped panel can be bonded to the main body across the entire area where the X-shaped panel and the main body overlap. In other aspects, the X-shaped panel can be bonded to the main body across only a portion of the area where the X-shaped panel and the main body overlap (e.g., along the edges of the X-shaped panel and/or in the center of the X-shaped panel). The method of bonding the X-shaped panel to the main body is discussed in further detail below. The shaping region formed by the bonded X-shaped panel exhibits desirable elongation, modulus, and recovery values. Lower elongation ranges (20-40%) correspond to high-compression garments providing maximal shaping. Higher elongation ranges (50-70%) correspond to moderate shaping garments optimized for comfort and freedom of movement. Percent recovery values approaching 100% ensure that the shaping panel retains its contouring effect after repeated wear and laundering.

The shaping region can provide a shaping effect to any part of a wearer's body (e.g., abdomen, back, bust, buttocks, hips, legs, etc.) as the double layer of fabric and the adhesive can increase the stiffness of the shaping region, thereby increasing the extent to which the shaping region can resist deformation by the wearer's body. For example, in some aspects, using ASTM D4964 test method at a 50 N load, the shaping region can have an elongation of at least about 20% (e.g., at least about 25%, at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, at least about 60%, at least about 65%, at least about 70%). In some aspects, using ASTM D4964 test method at a 50 N load, the shaping region can have an elongation of up to about 70% (e.g., up to about 65%, up to about 60%, up to about 55%, up to about 50%, up to about 45%, up to about 40%, up to about 35%, up to about 30%, up to about 25%, up to about 20%).

It is considered that the shaping region can have an elongation ranging from any of the minimum values described above to any of the maximum values described above. For example, in some aspects, using ASTM D4964 test method at a 50 N load, the shaping region can have an elongation of from about 20% to about 70% (e.g., from about 25% to about 65%, from about 30% to about 60%, from about 35% to about 55%, from about 40% to about 50%, from about 20% to about 45%, from about 25% to about 40%, from about 30% to about 35%, from about 45% to about 70%, from about 50% to about 65%, from about 55% to about 60%).

In some aspects, using ASTM D4964 test method at a 50 N load and 30% elongation, the shaping region can have a modulus of at least about 15 N (e.g., at least about 16 N, at least about 18 N, at least about 20 N, at least about 22 N, at least about 24 N, at least about 26 N, at least about 28 N, at least about 30 N, at least about 32 N, at least about 34 N, at least about 36 N, at least about 38 N, at least about 40 N, at least about 42 N, at least about 44 N, at least about 46 N, at least about 48 N, at least about 50 N). In some aspects, using ASTM D4964 test method at a 50 N load and 30% elongation, the shaping region can have a modulus of up to about 50 N (e.g., up to about 48 N, up to about 46 N, up to about 44 N, up to about 42 N, up to about 40 N, up to about 38 N, up to about 36 N, up to about 34 N, up to about 32 N, up to about 30 N, up to about 28 N, up to about 26 N, up to about 24 N, up to about 22 N, up to about 20 N, up to about 18 N, up to about 16 N, up to about 15 N).

It is considered that the shaping region can have a modulus ranging from any of the minimum values described above to any of the maximum values described above. For example, in some aspects, using ASTM D4964 test method at a 50 N load and 30% elongation, the shaping region can have a modulus of from about 15 N to about 50 N (e.g., from about 16 N to about 48 N, from about 18 N to about 46 N, from about 20 N to about 44 N, from about 22 N to about 42 N, from about 24 N to about 40 N, from about 26 N to about 38 N, from about 28 N to about 36 N, from about 30 N to about 34 N, from about 15 N to about 30 N, from about 16 N to about 28 N, from about 18 N to about 26 N, from about 20 N to about 24 N, from about 30 N to about 50 N, from about 32 N to about 48 N, from about 34 N to about 46 N, from about 36 N to about 44 N, from about 38 N to about 42 N).

In some aspects, using ASTM D4964 test method at a 50 N load, the shaping region can have a percent recovery of at least about 80% (e.g., at least about 81%, at least about 82%, at least about 83%, at least about 84%, at least about 85%, at least about 86%, at least about 87%, at least about 88%, at least about 89%, at least about 90%, at least about 91%, at least about 92%, at least about 93%, at least about 94%, at least about 95%, at least about 96%, at least about 97%, at least about 98%, at least about 99%, about 100%). In some aspects, using ASTM D4964 test method at a 50 N load, the shaping region can have a percent recovery of up to about 100% (e.g., up to about 99%, up to about 98%, up to about 97%, up to about 96%, up to about 95%, up to about 94%, up to about 93%, up to about 92%, up to about 91%, up to about 90%, up to about 89%, up to about 88%, up to about 87%, up to about 86%, up to about 85%, up to about 84%, up to about 83%, up to about 82%, up to about 81%, up to about 80%).

It is considered that the shaping region can have a percent recovery ranging from any of the minimum values described above to any of the maximum values described above. For example, in some aspects, using ASTM D4964 test method at a 50 N load, the shaping region can have a percent recovery of from about 80% to about 100% (e.g., from about 81% to about 99%, from about 82% to about 98%, from about 83% to about 97%, from about 84% to about 96%, from about 85% to about 95%, from about 86% to about 94%, from about 87% to about 93%, from about 88% to about 92%, from about 89% to about 91%, from about 80% to about 90%, from about 81% to about 89%, from about 82% to about 88%, from about 83% to about 87%, from about 84% to about 86%, from about 90% to about 100%, from about 91% to about 99%, from about 92% to about 98%, from about 93% to about 97%, from about 94% to about 96%).

In some aspects, the elongation of the shaping region can be reduced by at least about 20% (e.g., at least about 25%, at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, at least about 60%, at least about 65%, at least about 70%) compared to the elongation of the unbonded first fabric and/or second fabric. In some aspects, the elongation of the shaping region can be reduced by up to about 70% (e.g., up to about 65%, up to about 60%, up to about 55%, up to about 50%, up to about 45%, up to about 40%, up to about 35%, up to about 30%, up to about 25%, up to about 20%) compared to the elongation of the unbonded first fabric and/or second fabric.

It is considered that the elongation of the shaping region can be reduced by a percentage ranging from any of the minimum values described above to any of the maximum values described above. For example, in some aspects, the elongation of the shaping region can be reduced by from about 20% to about 70% (e.g., from about 25% to about 65%, from about 30% to about 60%, from about 35% to about 55%, from about 40% to about 50%, from about 20% to about 45%, from about 25% to about 40%, from about 30% to about 35%, from about 45% to about 70%, from about 50% to about 65%, from about 55% to about 60%) compared to the elongation of the unbonded first fabric and/or second fabric.

In some aspects, the modulus of the shaping region can be increased by at least about 50% (e.g., at least about 60%, at least about 70%, at least about 80%, at least about 90%, at least about 100%, at least about 125%, at least about 150%, at least about 175%, at least about 200%, at least about 225%, at least about 250%, at least about 275%, at least about 300%, at least about 350%, at least about 400%, at least about 450%, at least about 500%, at least about 550%, at least about 600%, at least about 650%, at least about 700%, at least about 750%, at least about 800%, at least about 850%, at least about 900%, at least about 950%, at least about 1000%, at least about 1100%, at least about 1200%, at least about 1300%, at least about 1400%, at least about 1500%) compared to the modulus of the unbonded first fabric and/or second fabric. In some aspects, the modulus of the shaping region can be increased by up to about 1500% (e.g., up to about 1400%, up to about 1300%, up to about 1200%, up to about 1100%, up to about 1000%, up to about 950%, up to about 900%, up to about 850%, up to about 800%, up to about 750%, up to about 700%, up to about 650%, up to about 600%, up to about 550%, up to about 500%, up to about 450%, up to about 400%, up to about 350%, up to about 300%, up to about 275%, up to about 250%, up to about 225%, up to about 200%, up to about 175%, up to about 150%, up to about 125%, up to about 100%, up to about 90%, up to about 80%, up to about 70%, up to about 60%, up to about 50%) compared to the modulus of the unbonded first fabric and/or second fabric.

It is considered that the modulus of the shaping region can be increased by a percentage ranging from any of the minimum values described above to any of the maximum values described above. For example, in some aspects, the modulus of the shaping region can be increased by from about 50% to about 1500% (e.g., from about 60% to about 1400%, from about 70% to about 1300%, from about 80% to about 1200%, from about 90% to about 1100%, from about 100% to about 1000%, from about 125% to about 950%, from about 150% to about 900%, from about 175% to about 850%, from about 200% to about 800%, from about 225% to about 750%, from about 250% to about 700%, from about 275% to about 650%, from about 300% to about 600%, from about 350% to about 550%, from about 400% to about 500%, from about 50% to about 450%, from about 60% to about 400%, from about 70% to about 350%, from about 80% to about 300%, from about 90% to about 275%, from about 100% to about 250%, from about 125% to about 225%, from about 150% to about 200%, from about 50% to about 200%, from about 60% to about 175%, from about 70% to about 150%, from about 80% to about 125%, from about 90% to about 100%, from about 200% to about 1500%, from about 225% to about 1400%, from about 250% to about 1300%, from about 275% to about 1200%, from about 300% to about 1100%, from about 350% to about 1000%, from about 400% to about 950%, from about 450% to about 900%, from about 500% to about 850%, from about 550% to about 800%, from about 600% to about 750%, from about 650% to about 700%) compared to the modulus of the unbonded first fabric and/or second fabric.

Furthermore, the disclosed garments can have these shaping benefits without significantly impacting the flexibility or comfort of the garment. For example, in some aspects, the recovery of the shaping region can be altered (i.e., increased or decreased) by about 15% or less (e.g., about 14% or less, about 13% or less, about 12% or less, about 11% or less, about 10% or less, about 9% or less, about 8% or less, about 7% or less, about 6% or less, about 5% or less, about 4% or less, about 3% or less, about 2% or less, about 1% or less, about 0.5% or less, about 0%) compared to the recovery of the unbonded first fabric and/or second fabric.

The disclosed methods of applying shaping regions are relatively simple and inexpensive compared to more conventional methods of incorporating shaping regions. Methods of joining two or more fabric layers may include bonding the fabric layers together using heat and pressure applied, for example, by a roller fuse or a flat press. The bonding process can be carried out without the need for stitching, thereby forming a seamless connection between the fabric layers. The methods disclosed herein can utilize relatively thin outer fabrics to yield a clean and smooth aesthetic, which is beneficial for shapewear as it is less likely to show through under the clothing. Furthermore, the methods disclosed herein can be applied to a broad range of underlying fabrics, which may be an advantage over certain conventional methods that are more difficult to apply to, for example, a mesh inner fabric.

FIG. 9A depicts an example method 900a for forming a shapewear garment (e.g., lower body garment 100, lower body garment 300, full body garment 500, lower body garment 700, and/or full body garment 800). First, a first fabric is coated 902 with an adhesive. In some aspects, the first fabric can include a knit fabric. In other aspects, the first fabric can include satin. As used herein, the term “satin” refers to a weave or fabric having a first set of yarns interwoven with a second set of yarns with at least two floats between interlacings such that the first set of yarns dominate one surface of the fabric and the second set of yarns dominate the other surface of the fabric. For example, in some aspects, the first fabric can include antique satin, baronet satin, charmeuse satin, cuttanee satin, double-faced satin, duchess satin, faconne satin, farmer's satin, gattar satin, messaline, polysatin, slipper satin, sultan satin, surf satin, or any combination thereof. In some aspects, the first fabric can have a 4-harness satin weave, a 5-harness satin weave, or an 8-harness satin weave. In some aspects, the satin can be woven. In other aspects, the satin can be knit.

In some aspects, the adhesive can include a thermoplastic. For example, in some such aspects, the adhesive can include thermoplastic elastomer (TPE), thermoplastic polyurethanes (TPU), thermoplastic polyamide elastomer (TPA), or any combination thereof. In some aspects, the adhesive can include a thermoplastic film, a fusible interlining, or a combination thereof. In some aspects, the adhesive can be thermally activated. In some aspects, the adhesive can be applied in a regular pattern, for example, a dot-matrix pattern. In other aspects, the adhesive can be applied as a random pattern or distribution. In yet other aspects, the adhesive can be applied as a substantially continuous layer.

In some aspects, at least about 30% (e.g., at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, at least about 80%, at least about 85%, at least about 90%, at least about 95%, about 100%) of the surface area of the first fabric can be covered with the adhesive. In some aspects, up to about 100% (e.g., up to about 95%, up to about 90%, up to about 85%, up to about 80%, up to about 75%, up to about 70%, up to about 65%, up to about 60%, up to about 55%, up to about 50%, up to about 45%, up to about 40%, up to about 35%, up to about 30%) of the surface area of the first fabric can be covered with the adhesive.

It is considered that a portion of the surface area of the first fabric ranging from any of the minimum values described above to any of the maximum values described above. For example, in some aspects, from about 30% to about 100% (e.g., from about 35% to about 95%, from about 40% to about 90%, from about 45% to about 85%, from about 50% to about 80%, from about 55% to about 75%, from about 60% to about 70%, from about 30% to about 65%, from about 35% to about 60%, from about 40% to about 55%, from about 45% to about 50%, from about 65% to about 100%, from about 70% to about 95%, from about 75% to about 90%, from about 80% to about 85%) of the surface area of the first fabric can be covered with the adhesive.

Next, the adhesive is cured 904 on the first fabric. In some aspects, the adhesive can be cured by a UV light. In other aspects, the adhesive can be cured by cooling (e.g., by applying no light or temperature to the adhesive, or by decreasing the temperature of the adhesive, for example, with air flow). In some aspects, the adhesive can be allowed to cool for at least about 30 minutes (e.g., at least about 40 minutes, at least about 50 minutes, at least about 1 hour, at least about 1.5 hours, at least about 2 hours, at least about 2.5 hours, at least about 3 hours, at least about 3.5 hours, at least about 4 hours, at least about 4.5 hours, at least about 5 hours, at least about 6 hours, at least about 7 hours, at least about 8 hours, at least about 9 hours, at least about 10 hours, at least about 12 hours, at least about 14 hours, at least about 16 hours, at least about 18 hours, at least about 20 hours, at least about 22 hours, at least about 24 hours). In some aspects, the adhesive can be allowed to cool for up to about 24 hours (e.g., up to about 22 hours, up to about 20 hours, up to about 18 hours, up to about 16 hours, up to about 14 hours, up to about 12 hours, up to about 10 hours, up to about 9 hours, up to about 8 hours, up to about 7 hours, up to about 6 hours, up to about 5 hours, up to about 4.5 hours, up to about 4 hours, up to about 3.5 hours, up to about 3 hours, up to about 2.5 hours, up to about 2 hours, up to about 1.5 hours, up to about 1 hour, up to about 50 minutes, up to about 40 minutes, up to about 30 minutes).

It is considered that the adhesive can be allowed to cool for a duration ranging from any of the minimum values described above to any of the maximum values described above. For example, in some aspects, the adhesive can be allowed to cool for from about 30 minutes to about 24 hours (e.g., from about 40 minutes to about 22 hours, from about 50 minutes to about 20 hours, from about 1 hour to about 18 hours, from about 1.5 hours to about 16 hours, from about 2 hours to about 14 hours, from about 2.5 hours to about 12 hours, from about 3 hours to about 10 hours, from about 3.5 hours to about 9 hours, from about 4 hours to about 8 hours, from about 4.5 hours to about 7 hours, from about 5 hours to about 6 hours, from about 30 minutes to about 6 hours, from about 40 minutes to about 5 hours, from about 50 minutes to about 4.5 hours, from about 1 hour to about 4 hours, from about 1.5 hours to about 3.5 hours, from about 2 hours to about 3 hours, from about 5 hours to about 24 hours, from about 6 hours to about 22 hours, from about 7 hours to about 20 hours, from about 8 hours to about 18 hours, from about 9 hours to about 16 hours, from about 10 hours to about 14 hours).

In some aspects, the adhesive can be allowed to cool for about 30 minutes or less (e.g., about 25 minutes or less, about 20 minutes or less, about 15 minutes or less, about 10 minutes or less, about 5 minutes or less). In other aspects, the adhesive can be allowed to cool for about 24 hours or more (e.g., about 28 hours or more, about 32 hours or more, about 36 hours or more, about 40 hours or more, about 44 hours or more, about 48 hours or more, about 56 hours or more, about 64 hours or more, about 72 hours or more). In some aspects, this step may be omitted and the adhesive may not be allowed to cool.

Next, an X-shaped panel is cut 906 from the first fabric with the cured adhesive. In some examples, this can be executed by a rotary knife, a laser, or a straight knife.

It is considered that the first three steps can occur in any order. For example, FIG. 9B depicts an example method 900b in which the X-shaped panel is cut from the first fabric before the adhesive is applied. As another example, FIG. 9C depicts an example method 900c in which the X-shaped panel is cut from the first fabric after the adhesive is applied but before the adhesive is cured.

Next, the X-shaped panel is bonded 908 to a second fabric using the adhesive, thereby forming a shaping region. In some aspects, the second fabric can include a knit fabric. In other aspects, the second fabric can include mesh. For example, in some aspects, the second fabric can include polyester mesh, nylon mesh, tulle, power mesh, powernet, or any combination thereof. Second fabrics that include mesh provide the structural foundation for both comfort and adhesion, and are selected to balance breathability, elasticity, and adhesive compatibility.

A second fabric that includes mesh demonstrates a combination of knitting gauge, stitch density, stitch construction, yarn type, and finishing processes that yield a substrate particularly well-suited for bonding operations. A higher knitting gauge, higher stitch density, and shorter floats generally produce smaller interstices, reducing the likelihood that adhesive penetrates through to contact the skin or creates visible markings when the garment is worn under clothing. Conversely, lower gauge or density fabrics, or fabrics having longer floats, may provide greater openness but can lead to visible adhesive bleed-through. The stitch construction of a mesh second fabric also contributes to the character of the interstices. Stitch construction is defined by the float length, or the number of needle spaces the yarn traverses before forming a loop. Longer floats in opposing directions increase surface area and yield larger interstices, while shorter floats create a tighter structure with fewer or smaller interstices. The stitch construction can be optimized to achieve a balance of openness (for breathability) and compactness (for bonding and stability). Persons of ordinary skill in the art will recognize that variations in gauge, stitch density, stitch construction, yarn properties, and finishing can yield fabrics with equivalent bonding performance. For example, increasing or decreasing gauge by a few needle counts, altering stitch density by a few courses or wales per inch, or varying the elastane denier can adjust the interstice dimensions without fundamentally impairing performance. Thus, a range of fabric parameters may be employed to achieve similar functional outcomes, including reduced adhesive visibility, improved adhesion stability, and enhanced wearer comfort.

The knitting gauge of the mesh fabric influences the size of the interstices between yarns and therefore determines both the openness and stability of the fabric structure. In one example, the mesh fabric can exhibit a knitting gauge of 32 needles per inch, which corresponds to a fine-gauge mesh suitable for intimate apparel and shapewear applications. The stitch density is 41 courses per inch (cpi) by 51 wales per inch (wpi), which defines the number of stitches in the lengthwise and widthwise directions. Together, these parameters result in a fine, high-density mesh with controlled interstice size. The example mesh fabric can utilize, for example, a combination of 20-6 nylon yarns and 140 denier Lycra® elastane yarns. The nylon provides strength, abrasion resistance, and dimensional stability, while the Lycra contributes high elongation and recovery. The multi-filament structure of the yarns also influences the size and shape of the interstices by affecting how the yarns pack together during knitting. Yarn diameter, filament count, yarn texture, fiber cross section, and feed rate into the knitting machine can be adjusted to further control these parameters. The example mesh fabric can exhibit elongation of about 190% in the length direction and about 130% in the width direction, with recovery values of about 97% and 96%, respectively. These values indicate excellent resilience and dimensional stability. Such properties ensure that when bonded to an adhesive-coated shaping panel, the second fabric can stretch and recover in harmony with the first fabric, reducing distortion, sagging, or bagging after repeated use.

Post-knitting finishing processes (e.g., heat setting, washing, or calendaring) may shrink, swell, or otherwise alter the fibers, thereby modifying the effective size of the interstices of a second fabric that includes mesh. Various finishing processes can be applied to stabilize and close interstices sufficiently to minimize adhesive bleed-through while preserving air permeability.

In some examples, the X-shaped panel can be bonded to the second fabric by a roller fuse or flat press at a temperature sufficient to soften or activate the bonding medium. In some aspects, the roller fuse or flat press can operate at a temperature of at least about 130° C. (e.g., at least about 135° C., at least about 140° C., at least about 145° C., at least about 150° C., at least about 155° C., at least about 160° C., at least about 165° C., at least about 170° C., at least about 175° C., at least about 180° C.). In some aspects, the roller fuse or flat press can operate at a temperature of up to about 180° C. (e.g., up to about 175° C., up to about 170° C., up to about 165° C., up to about 160° C., up to about 155° C., up to about 150° C., up to about 145° C., up to about 140° C., up to about 135° C., up to about 130° C.).

It is considered that the roller fuse or flat press can operate at a temperature ranging from any of the minimum values described above to any of the maximum values described above. For example, in some aspects, the roller fuse or flat press can operate at a temperature of from about 130° C. to about 180° C. (e.g., from about 135° C. to about 175° C., from about 140° C. to about 170° C., from about 145° C. to about 165° C., from about 150° C. to about 160° C., from about 130° C. to about 155° C., from about 135° C. to about 150° C., from about 140° C. to about 145° C., from about 155° C. to about 180° C., from about 160° C. to about 175° C., from about 165° C. to about 170° C.).

The process may further include applying pressure concurrently with heat to ensure intimate contact between the fabric layers and uniform distribution of the bonding medium. In some aspects, the roller fuse or flat press exerts a pressure in a range from about 2 bar to about 5 bar. The applied pressure facilitates penetration of the bonding medium into pores, interstices, or surface structures of the fabric layers, thereby enhancing adhesion and mechanical anchoring. In some aspects, the roller fuse or flat press can exert a pressure of at least about 2 bar (e.g., at least about 2.25 bar, at least about 2.5 bar, at least about 2.75 bar, at least about 3 bar, at least about 3.25 bar, at least about 3.5 bar, at least about 3.75 bar, at least about 4 bar, at least about 4.25 bar, at least about 4.5 bar, at least about 4.75 bar, at least about 5 bar). In some aspects, the roller fuse or flat press can exert a pressure of up to about 5 bar (e.g., up to about 4.75 bar, up to about 4.5 bar, up to about 4.25 bar, up to about 4 bar, up to about 3.75 bar, up to about 3.5 bar, up to about 3.25 bar, up to about 3 bar, up to about 2.75 bar, up to about 2.5 bar, up to about 2.25 bar, up to about 2 bar). It is considered that the roller fuse or flat press can exert a pressure ranging from any of the minimum values described above to any of the maximum values described above. For example, in some aspects, the roller fuse or flat press can exert a pressure of from about 2 bar to about 5 bar (e.g., from about 2.25 bar to about 4.75 bar, from about 2.5 bar to about 4.5 bar, from about 2.75 bar to about 4.25 bar, from about 3 bar to about 4 bar, from about 3.25 bar to about 3.75 bar, from about 2 bar to about 3.5 bar, from about 2.25 bar to about 3.25 bar, from about 2.5 bar to about 3 bar, from about 3.5 bar to about 5 bar, from about 3.75 bar to about 4.75 bar, from about 4 bar to about 4.5 bar).

In some aspects, bonding the X-shaped panel to the second fabric can have a duration (e.g., the amount of time for which temperature and/or pressure are applied to the X-shaped panel and the second fabric) of at least about 10 seconds (e.g., at least about 11 seconds, at least about 12 seconds, at least about 13 seconds, at least about 14 seconds, at least about 15 seconds, at least about 16 seconds, at least about 17 seconds, at least about 18 seconds, at least about 19 seconds, at least about 20 seconds, at least about 21 seconds, at least about 22 seconds, at least about 23 seconds, at least about 24 seconds, at least about 25 seconds, at least about 26 seconds, at least about 27 seconds, at least about 28 seconds, at least about 29 seconds, at least about 30 seconds, at least about 31 seconds, at least about 32 seconds, at least about 33 seconds, at least about 34 seconds, at least about 35 seconds). In some aspects, bonding the X-shaped panel to the second fabric can have a duration of up to about 35 seconds (e.g., up to about 34 seconds, up to about 33 seconds, up to about 32 seconds, up to about 31 seconds, up to about 30 seconds, up to about 29 seconds, up to about 28 seconds, up to about 27 seconds, up to about 26 seconds, up to about 25 seconds, up to about 24 seconds, up to about 23 seconds, up to about 22 seconds, up to about 21 seconds, up to about 20 seconds, up to about 19 seconds, up to about 18 seconds, up to about 17 seconds, up to about 16 seconds, up to about 15 seconds, up to about 14 seconds, up to about 13 seconds, up to about 12 seconds, up to about 11 seconds, up to about 10 seconds).

It is considered that bonding the X-shaped panel to the second fabric can have a duration ranging from any of the minimum values described above to any of the maximum values described above. For example, in some aspects, bonding the X-shaped panel to the second fabric can have a duration of from about 10 seconds to about 35 seconds (e.g., from about 11 seconds to about 34 seconds, from about 12 seconds to about 33 seconds, from about 13 seconds to about 32 seconds, from about 14 seconds to about 31 seconds, from about 15 seconds to about 30 seconds, from about 16 seconds to about 29 seconds, from about 17 seconds to about 28 seconds, from about 18 seconds to about 27 seconds, from about 19 seconds to about 26 seconds, from about 20 seconds to about 25 seconds, from about 21 seconds to about 24 seconds, from about 22 seconds to about 23 seconds, from about 10 seconds to about 23 seconds, from about 11 seconds to about 22 seconds, from about 12 seconds to about 21 seconds, from about 13 seconds to about 20 seconds, from about 14 seconds to about 19 seconds, from about 15 seconds to about 18 seconds, from about 16 seconds to about 17 seconds, from about 22 seconds to about 35 seconds, from about 23 seconds to about 34 seconds, from about 24 seconds to about 33 seconds, from about 25 seconds to about 32 seconds, from about 26 seconds to about 31 seconds, from about 27 seconds to about 30 seconds, from about 28 seconds to about 29 seconds).

In one aspect, the roller fuse may comprise opposing heated rollers that rotate in a continuous manner to simultaneously compress and heat the fabric layers as they are passed through the nip region between the rollers. This configuration is particularly suitable for continuous bonding of fabric webs or long sections of material. In another aspect, the flat press may comprise heated platens that are brought into contact with the stacked fabric layers under controlled temperature and pressure conditions. The flat press configuration may be advantageous for localized bonding or batch operations.

Following application of heat and pressure, the bonded fabric assembly may be cooled, thereby solidifying the bonding medium and forming a durable attachment between the fabric layers. The resulting bonded region can be resistant to delamination under ordinary conditions of wear, laundering, and stretching.

Finally, the shapewear garment (e.g., lower body garment 100, lower body garment 300, full body garment 500, lower body garment 700, and/or full body garment 800) is formed 910 from the second fabric. In some aspects, this can include i) cutting the second fabric to pattern; and ii) sewing the pattern together to form the shapewear garment.

EXAMPLES

Example 1

Forming an Example Shapewear Garment

To construct the X-shaped panel, rolls of satin fabric are run through a machine that applies the liquid adhesive in a dot-matrix pattern. The adhesive is cooled, and the fabric is re-rolled. The roll with the adhesive is allowed time to cure before being cut to pattern. Next, the cut pieces are pre-bonded to the mesh fabric. For a full body garment, the neckline and armhole satin strips are pre-bonded to the mesh pattern pieces. For a lower body garment, the waist elastic is pre-bonded to the waist opening. The front pre-bonded assembly and their pair of side back assemblies are finally bonded. The final-bonded pieces are then final cut to pattern before being sewn together to make the finished garment. First, the side panels are sewn to the front panel, and the center back is closed using a 2-needle overlock. Next, for a full body garment, the straps are attached to the bonded front assembly by looping the front strap platform through the plastic ring and tacking with a zigzag tacker. The straps are attached to the bonded back assembling by looping the strap on top of the front assembly and tacking each strap two times with a zigzag tacker. Finally, each seam closing is reinforced with a zigzag tacker.

The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications, variations, and/or combinations of the features disclosed herein will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The implementation was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various implementations with various modifications as are suited to the particular use contemplated.

EXAMPLE ASPECTS

Aspect 1. A method of making a shapewear garment, the method comprising: a) applying an adhesive to a first fabric; b) curing said adhesive on the first fabric; c) cutting an X-shaped panel from the first fabric; d) bonding said X-shaped panel to a second fabric using the adhesive, thereby forming a shaping region; and e) forming the shapewear garment from the second fabric.

Aspect 2. The method of any aspects herein, particularly Aspect 1, wherein the first fabric comprises a knit fabric.

Aspect 3. The method of any aspects herein, particularly Aspect 1, wherein the first fabric comprises satin.

Aspect 4. The method of any aspects herein, particularly Aspects 1-3, wherein the adhesive comprises thermoplastic elastomer (TPE), thermoplastic polyurethanes (TPU), thermoplastic polyamide elastomer (TPA), or any combination thereof.

Aspect 5. The method of any aspects herein, particularly Aspects 1-4, wherein the adhesive is thermally activated.

Aspect 6. The method of any aspects herein, particularly Aspects 1-5, wherein step a) comprises applying the adhesive in a dot-matrix pattern.

Aspect 7. The method of any aspects herein, particularly Aspects 1-6, wherein step a) comprises covering from about 30% to about 100% of the surface area of the first fabric with the adhesive.

Aspect 8. The method of any aspects herein, particularly Aspects 1-7, wherein step b) comprises allowing the adhesive to cool for from about 30 minutes to about 24 hours.

Aspect 9. The method of any aspects herein, particularly Aspects 1-8, wherein step c) is executed by a rotary knife, a laser, or a straight knife.

Aspect 10. The method of any aspects herein, particularly Aspects 1-9, wherein the second fabric comprises a knit fabric.

Aspect 11. The method of any aspects herein, particularly Aspects 1-9, wherein the second fabric comprises mesh.

Aspect 12. The method of any aspects herein, particularly Aspects 1-11, wherein step d) is executed by a roller fuse or flat press.

Aspect 13. The method of any aspects herein, particularly Aspect 12, wherein the roller fuse or flat press operates at a temperature of from about 130° C. to about 180° C.

Aspect 14. The method of any aspects herein, particularly Aspects 12-13, wherein the roller fuse or flat press exerts a pressure of from about 2 bar to about 5 bar.

Aspect 15. The method of any aspects herein, particularly Aspects 12-14, wherein step d) has a duration of from about 10 seconds to about 25 seconds.

Aspect 16. The method of any aspects herein, particularly Aspects 1-15, wherein step e) comprises: i) cutting the second fabric to pattern; and ii) sewing the pattern together to form the shapewear garment.

Aspect 17. A garment made by the method of any aspects herein, particularly Aspects 1-16.

Aspect 18. The garment of any aspects herein, particularly Aspect 17, wherein top arms of the X-shaped panel extend to an upper edge of the garment.

Aspect 19. The garment of any aspects herein, particularly Aspect 18, wherein the top arms of the X-shaped panel extend completely around the upper edge of the garment.

Aspect 20. The garment of any aspects herein, particularly Aspect 19, wherein the garment comprises a waistband on the inside or outside of the garment, and the top arms of the X-shaped panel extend across or underneath all of the waistband.

Aspect 21. The garment of any aspects herein, particularly Aspects 17-20, wherein bottom arms of the X-shaped panel extend around a wearer's thighs.

Aspect 22. The garment of any aspects herein, particularly Aspect 21, wherein bottom arms of the X-shaped panel extend under a wearer's buttocks and to a wearer's inner thighs.

Aspect 23. The garment of any aspects herein, particularly Aspects 17-22, wherein the shaping region has an elongation of from about 20% to about 70%.

Aspect 24. The garment of any aspects herein, particularly Aspects 17-23, wherein the shaping region has a modulus of from about 15 N to about 50 N.

Aspect 25. The garment of any aspects herein, particularly Aspects 17-24, wherein the shaping region has a percent recovery of from about 80% to about 100%.

Aspect 26. The garment of any aspects herein, particularly Aspects 17-25, wherein the garment is shorts or pants.

Aspect 27. The garment of any aspects herein, particularly Aspects 17-25, wherein the garment is a body suit.