Briefs for Male Wearers and Method for Manufacturing Same

The present application is a continuation-in-part of U.S. Non-Provisional application Ser. No. 18/821,426, filed Aug. 30, 2024, entitled “BRIEFS FOR MALE WEARERS AND METHOD FOR MANUFACTURING SAME”, which is a continuation-in-part of U.S. Non-Provisional application Ser. No. 17/246,215, filed Apr. 30, 2021, entitled “SEAMLESS MALE GARMENT”, which claims priority from U.S. Provisional Application No. 63/018,175, filed Apr. 30, 2020, entitled “SEAMLESS MALE GARMENT”, each of which are incorporated by reference herein in its entirety.

Conventional undergarments, such as briefs, are uncomfortable for the wearer as they exhibit low breathability. Further, presence of seams in undergarments exacerbates wearer discomfort. Moreover, conventional undergarments lack the ability to conform to one or more of the wearer's body parts, for example, the wearer's buttocks.

Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of embodiments.

The apparatus and method components have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments so as not to obscure the description with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.

The embodiments described herein are related to a brief for a wearer, such as a male wearer or a female wearer. More particularly, the embodiments described herein are related to a method for manufacturing the brief. In some embodiments, the brief provides for a pouch to enclose genitals of a male wearer. The pouch provides improved breathability to the wearer's genitals. Also, in other embodiments, the brief provides for a molded sac to accommodate and conform to buttocks of the wearer when the brief is worn by the wearer. The molded sac also ensures a retention of the brief around the waist of the wearer.

In one aspect, a method for manufacturing a brief for a wearer is described. The method includes using a first stretchable fabric and a second stretchable fabric. The first stretchable fabric defines a first leg portion, a second leg portion, and a first crotch portion extending between the first leg portion and the second leg portion. The second stretchable fabric is adherable to the first stretchable fabric. The second stretchable fabric defines a third leg portion, a fourth leg portion, and a second crotch portion integrally and contiguously extending between the third leg portion and the fourth leg portion. The second stretchable fabric defines a gluteal portion extending at least in part across each of the third leg portion, the fourth leg portion, and the second crotch portion. The method includes placing the second stretchable fabric into a die assembly such that the gluteal portion sits between a core and a cavity of the die assembly. The core includes a profile of buttocks of the wearer. Further, the method includes mating the core with the cavity to cause the core to push a section of the gluteal portion into the cavity such that the section is stretched from a non-stretched state to a stretched state with respect to a remaining section of the gluteal portion. The section includes a synthetic compound. The method also includes applying heat and pressure at the section to cause a volume of the synthetic compound to melt while retaining the section in the stretched state. Furthermore, the method includes cooling the section such that a melted volume of the synthetic compound is infused or incorporated into a remainder of the section and solidified therewithin to cause the section to acquire a shape as that acquired in the stretched state and be retained in the shape to form a molded sac seamlessly integrated with the remaining section of the gluteal portion. The molded sac is configured to accommodate and conform to buttocks of the wearer when the brief is worn by the wearer.

In another aspect, a brief for a wearer is described. The brief includes a first stretchable fabric and a second stretchable fabric. The first stretchable fabric defines a first leg portion, a second leg portion, and a first crotch portion extending between the first leg portion and the second leg portion. The second stretchable fabric is adhered to the first stretchable fabric and includes a satin weave synthetic composite fabric including elongated nano fibers. The second stretchable fabric defines a third leg portion, a fourth leg portion, a second crotch portion integrally and contiguously extending between the third leg portion and the fourth leg portion. A gluteal portion extends at least in part across each of the third leg portion, the fourth leg portion, and the second crotch portion. The gluteal portion defines a molded sac configured to accommodate and conform to buttocks of the wearer when the brief is worn by the wearer. The molded sac is formed by a section of the gluteal portion that is stretched outwardly to a stretched state to define a bulge with respect to a remaining section of the gluteal portion. Also, the molded sac is seamlessly integral with the remaining section of the gluteal portion. A first fabric region of the second stretchable fabric other than the molded sac defines first holes and a second fabric region of the second stretchable fabric within the molded sac defines second holes. The first holes define a diameter in a range of 0.01 millimeters (mm) to 0.024 mm in between warp and filament yarn. The second holes define a diameter in a range of 0.025 mm to 0.05 mm in between warp and filament yarn.

Reference will now be made in detail to specific embodiments or features, examples of which are illustrated in the accompanying drawings. Generally, corresponding reference numbers may be used throughout the drawings to refer to the same or corresponding parts, for example,,′,″,andcould refer to one or more comparable components used in the same and/or different depicted embodiments.

Referring to, a garment, and, more particularly, a briefis described by way of reference to various isometric views. The briefcorresponds to an undergarment wearable by a male wearer(see) directly over the wearer's body such that portions of the briefcomes in contact with the wearer's body. Although aspects in the present disclosure have been described in relation to the brief, said aspects are applicable to a variety of other garments, such as men's swimwear, men's shorts, men's sweatpants, men's trousers, men's pants, men's underpants, and/or the like apparels usable by men. Furthermore, some aspects of the present description are also applicable to women's undergarments, as will become apparent from the description further below. According to one of the aspects, the briefincludes a pouchconfigured to enclose genitals of the male wearerwhen the briefis worn by the male wearer.

The briefincludes a first panel(which is a front panel of the brief) and a second panel(which is a rear panel of the brief). In an embodiment, each of the first paneland the second panelis made from the same fabric material. Alternatively, in an embodiment, the first paneland the second panelare made from different fabric materials. As an example, at least one of the first paneland the second panelincludes, but is not limited to, a fabric which includes a satin weave synthetic composite fabric having elongated nano fibers. The fabric forming each of the first paneland the second panelis a stretchable fabric that enables the briefto adjust and conform to a body structure of the male wearer. For the purposes of the present disclosure, the first panelis referred to as a first stretchable fabric. Similarly, the second panelis referred to as a second stretchable fabric.

In further detail, the first stretchable fabricdefines a first leg portion, a second leg portion, and a first crotch portionintegrally and contiguously extending between the first leg portionand the second leg portion. Similar portions are available in the second stretchable fabric, as well. The first crotch portiondefines the pouchto enclose the genitals of the male wearerwhen the briefis worn by the male wearer. To this end, the first crotch portiondefines a first sectionand a second section. In this regard, reference is also made towhich illustrates the first stretchable fabricin a state prior to the formation of the pouch. In, the first stretchable fabricincludes the first sectionand a second section′. It will be noted that similar reference numeralsand′, as used here, refer to the same region of the first crotch portionwith the distinction that ‘’ relates to a state (for example, a stretched state) of said region subsequent to the formation of the pouch, while ‘′’ relates to a state (for example, a non-stretched state) of said region prior to the formation of the pouch. Aspects of the present description describe the formation of the pouch(and thus of the second section) from the second section′ by way of an exemplary method for manufacturing the brief. Said method will be described further below. Also, as shown in, the first sectionis external to the second section, or, alternatively, is devoid of the second section. In other words, the first sectionis a remaining section of the first crotch portionseparate and apart from the second section.

As is viewed from various views of the briefin, as the pouchis converted and obtained from the second section′ of the first crotch portion, the pouchis formed integrally to the first sectionof the first crotch portion. Moreover, the pouchdefines no seams with the first section. More particularly, for the formation of the pouch, the second section′ is stretched outwardly to a stretched state to define a bulge, BU, with respect to the remaining section or the first sectionof the first crotch portion. As the second section′ is merely stretched away from the first crotch portionand is not an add-on to the first crotch portion, the pouchis integral (for example, seamlessly integral) with the remaining section or the first sectionof the first crotch portion. A fabric matrix corresponding to the first section(and optionally additionally corresponding to one or more of the first leg portionand the second leg portion) defines a plurality of first holes. A fabric matrix corresponding to the pouchdefines a plurality of second holes. According to some embodiments, the dimensional sizes of the second holes are larger than the dimensional sizes of the first holes.

According to some embodiments, the first holes define a diameter anywhere in a first range of 0.01 mm to 0.024 mm in between warp and filament yarn. According to some embodiments, the second holes define a diameter anywhere in a second range of 0.025 mm to 0.05 mm in between warp and filament yarn. In some examples, the lower limit of 0.025 mm of the second range for the second holes of the pouchis optimal for application in men's garments that are related to sports activities, while the upper limit of 0.05 mm of the second range for the second holes of the pouchis optimal for application in men's garments such as a recovery underwear.

With the relatively larger second holes in the pouch, the second holes serve as aeration holes of the pouchthat allows relatively more air to pass across the fabric matrix of the pouchwhen the briefis worn by the male wearer. This makes the pouch(formed by the second section′) more breathable than the first sectionand/or also more breathable than other portions of the first stretchable fabricand, in some embodiments, optionally additionally, the second stretchable fabric. Apart from providing greater breathability, the larger, second holes also provide for lowering humidity and improved heat dissipation from a groin area of the male wearer, thus enabling the wearer's genitals to remain at an optimal temperature range. While the bulge, BU, defined by the pouchprovides adequate space for the wearer's genitals to be accommodated within the brief, the bulge, BU, also appropriately supports the wearer's genitals, in turn promoting wearer comfort and sperm health.

In some embodiments, one or more of the first stretchable fabricand the second stretchable fabric(or the satin weave synthetic composite fabric of one or more of the first stretchable fabricand the second stretchable fabric) is formed from a polyamide weave transformed into a satin weave and thinned out. Moreover, in some embodiments, one or more of the first stretchable fabricand the second stretchable fabric, with the satin weave synthetic composite fabric, includes elongated nano fibers having a length anywhere between ten (10) to hundred (100) microns. In some embodiments, the satin weave synthetic composite fabric of one or more of the first stretchable fabricand the second stretchable fabricincludes polyester. Further, in some embodiments, the first crotch portionincludes a synthetic compound, associated with the polyester. In one example, the synthetic compound takes up to fifteen percent (15%) of the weight in the first stretchable fabricor in the brief. In some embodiments, a portion (for example, a non-synthetic part) of the brief, which is devoid of the synthetic compound, takes up to eighty five percent (85%) of the weight in the first stretchable fabricor in the brief.

As an example, both the first sectionand the second section(and understandably the second section′) include the synthetic compound. However, it will be appreciated that the pouch(or the second sectionformed by the second section′) includes a melted, infused, and solidified volume of the synthetic compound. The solidified volume of the synthetic compound enables the pouchto be retained in the stretched state, with the bulge, BU. A manner in which the synthetic compound is melted, infused, and solidified, will be described later in the present description. In some embodiments, the synthetic compound includes or corresponds to polyethylene terephthalate (PET).

With continued reference to, and also in conjunction with, the first leg portiondefines a first side edgeand the second leg portiondefines a second side edge. Further, the first crotch portiondefines a first crotch periphery. With the second stretchable fabricbeing similar (for example, in shape) to the first stretchable fabric, the second stretchable fabricdefines similar leg portions, for example, a third leg portionand a fourth leg portion(also see). The third leg portiondefines a third side edgeand the fourth leg portiondefines a fourth side edge. Also, the second stretchable fabricincludes a second crotch portionintegrally and contiguously extending between the third leg portionand the fourth leg portion. The second crotch portiondefines a second crotch periphery. While it is notable that the portions in the first stretchable fabricand the second stretchable fabricare similar, they need not be identical. This is because each of the first stretchable fabricand the second stretchable fabricare configured to adapt and conform to different parts of wearer's body.

In some embodiments, one or more of the first stretchable fabricand the second stretchable fabricis a synthetic composite fabric of approximately eighty six percent (86%) Creora® Polyamide and approximately fourteen percent (14%) Spandex® or Lyrca®. The term ‘approximately’, as used here, accounts for tolerances when manufacturing the brief. In some embodiments, one or more of the first stretchable fabricand the second stretchable fabricincludes elongated nano fibers making up each corresponding thread and which allows for greater strength and stretch recovery of the corresponding fabric. In some embodiments, one or more of the first stretchable fabricand the second stretchable fabricis made using a conventional polyamide weave that is transformed to a satin weaved and thinned out, as described above. In some embodiments, one or more of the first stretchable fabricand the second stretchable fabrichas a thickness anywhere within the range of 0.0045-0.0048 millimeters (mm).

Referring toand, an exemplary method for manufacturing the briefis described. The method is also described by way of a flowchartillustrated in. The method described in conjunction with,, and the flowchartillustrated in, mainly includes description corresponding to a formation of the first stretchable fabric. This is because, alongside the first stretchable fabric, the briefis envisioned to include any suitable second stretchable fabric, which need not necessarily be the second stretchable fabric. The flowchartincludes different stages of the method for manufacturing the brief, and the stages are indicated by various blocks,,,, and. The stages need not necessarily be viewed to be in any chronological order. The method starts at block.

At block, a base fabric(for example, a relatively enlarged flat piece of stretchable fabric) (see) is used and a profile of the first stretchable fabricis generated on the base fabric. Such profile generation, in an embodiment, is performed by using one or more of a template, a stencil, and/or the like devices, associated with the briefand which is then used to form the brief. A suitable tool (not shown) is then applied to shear or cut out and remove the first stretchable fabricfrom the base fabricsuch that the first stretchable fabricis formed, independent of the base fabric. The first stretchable fabric, as obtained, defines the aforementioned the first leg portion, the second leg portion, and the first crotch portion(see). The first stretchable fabricis used for the production of the brief. Although not limited, the first stretchable fabric, as obtained from the base fabric, in an embodiment, is obtained as a flat piece of stretchable fabric, for example, which is devoid of any three-dimensional (3D) contours and/or shapes and/or structures. Also, one or both of the base fabricand/or the first stretchable fabricis heat pressed on steel rollers,to reduce a coefficient of friction of the first stretchable fabricand/or of the brief. In some embodiments, the description corresponding to the first stretchable fabric, as described in relation with the block, is suitably applicable for the second stretchable fabric, as well, for the production of the second stretchable fabric. The method proceeds to block.

At block, the first stretchable fabricis placed into a die assembly(see). In this regard, the die assemblyincludes a cavity, an intermediate station, and a core. The intermediate stationis arranged in between the cavityand the core. The cavityis formed in a first support partof the die assembly; the intermediate stationis formed in a second support partof the die assembly; and the coreis formed in a third support partof the die assembly.

With reference to, the intermediate stationdefines a through-slot, and a placement of the first stretchable fabricinto the die assemblymeans that the first stretchable fabricis laid onto the intermediate stationsuch that the first crotch portionlies over the through-slot, and/or, in other words, the first crotch portionfully overlaps the through-slot. Also, at said block, the placement of the first stretchable fabricinto the die assemblymeans that the first crotch portionof the first stretchable fabricsits between the coreand the cavityof the die assembly, with one sideof the first crotch portionfacing the coreand the other sideof the first crotch portionfacing the cavity. In this regard, and as shown in, for example, the coreis defined or positioned below the cavityand lies in alignment to the each of the cavityand the through-slot. The method proceeds to block.

At block, the die assemblyis operated to mate the corewith the cavity. During the mating of the corewith the cavity, the corepasses through the through-slotsuch that the coreis able to ingress or enter into the cavity(see direction, A,) from below. By way of having the coreenter into the cavity, or by way of mating the corewith the cavity, with the first stretchable fabricand/or on the first crotch portionarranged in between the coreand the cavity, an exemplary molding operation on the first stretchable fabricand/or on the first crotch portionof the first stretchable fabricis performed.

When operating the die assemblyfor mating the corewith the cavityor prior to the mating the corewith the cavity, one of the first support partand the second support partis moved (see direction, B,) towards the other of the first support partand the second support partsuch that the first support partand the second support partcome into physical contact with each other. In so doing, one support part (for example, the first support part) impinges against the other support part (for example, the second support part) and the first stretchable fabric(and, more particularly, the remaining section or the first sectionof the first crotch portion, positioned in between the first support partand the second support part) is clinched and/or restrained (for example, tightly) between portions of the first support partand the second support part. At this point, the second section′ remains exposed to the coreand to the cavity.

With reference to, as part of a continued operation of the die assembly, or as the coreenters into the cavity(for example, for mating with the cavity), the corepushes the second section′ of the first crotch portioninto the cavitysuch that the second section′ is stretched from the non-stretched state (as it was when lying unattended and/or undisturbed on the second support part or the intermediate stationat block) to the stretched state. The non-stretched state of the second section′ is visualized fromand the stretched state of the second section′ is visualized from. In other words, the second section′ is pushed to the stretched state with respect to the remaining section or the first sectionof the first crotch portion. The remaining section or the first section, at this point, continues to stay clinched and restrained between portions of the first support partand the second support part, as described above. The method proceeds to block.

At block, once the corefully enters into the cavityand is mated with the cavity(referred to as a ‘mated state’ of the core), the coreexerts pressure against the cavitysuch that the pressure is transferred and thus applied to the second section′ received between the coreand the cavity. This pressure application causes the second section′ to sit snugly and/or tightly within the cavity(see), urging the second section′ to take a shape of the cavity. In some embodiments, simultaneously with the application of pressure, heat is applied to the second section′, as well. Both the application of heat and pressure causes a volume of the synthetic compound (see), for example, a volume of PET of the second section′, to be subject to phase change and/or to melt. The melting occurs while retaining the second section′ in the stretched state and with the second section′ sitting tightly within the cavity, as the second section′ is pushed by the coreinto the cavity.

In some embodiments, the heat is supplied to the second section′ through the core. To this end, and as an example, the coreincludes features, such as one or more heating elementsthat convert any supplied energy, at least in part, into heat, and through which heat is applied and/or imparted to the second section′. As an example, a source from where energy is supplied for the production of heat at the corecorresponds to any heat source, for example, an electrical heat source (not shown). In some embodiments, heat application is uniform about a bodyof the core. In so doing, a physical state (for example, an initial solid state) of the synthetic compound, present in and across the second section′ of the first crotch portion, is uniformly altered or melted. In other words, a temperature at an outer surfaceof the coreis varied evenly across an expanse of said outer surfaceof the core. In so doing, a phase change of the synthetic compound in and across the second section′ of the first crotch portionis attained uniformly throughout the second section′. In some embodiments, the temperature is evenly varied at the outer surfaceof the coreby having the heating elementsevenly distributed across the expanse of the outer surfaceof the core. Although not limited, the second section′ is retained in the stretched state for an entire duration of the melting of the synthetic compound.

In some embodiments, a temperature value during an application of the heat is anywhere between 330.2 degrees Fahrenheit to 402 degrees Fahrenheit. In some embodiments, a pressure value during an application of the pressure is anywhere between 3.899 pounds per square inch to 7.024 pounds per square inch. In some embodiments, the heat is applied for a period of at least 10.05 seconds from start and up to a maximum of 13.03 seconds. In some embodiments, the pressure is applied for a period of at least 10.05 seconds from start and up to a maximum of 13.03 seconds. In some embodiments, the period for heat and pressure application is same when they are applied simultaneously. In some embodiments, the period for each of the heat and the pressure application varies or changes within or with respect to the ranges provided above according to a material of the first stretchable fabric. The method proceeds to block.

At block, after the heat and pressure have been applied in accordance with the ranges provided above, the heat application is halted and the operation switches to the cool the second section′ such that the volume of the synthetic compound that is melted (referred to as a ‘melted volume’) (see) at blockis infused or incorporated back into the second section′ (for example, into a remainder of the second section′). The synthetic compound is then left to be solidified therewithin (referred to as a ‘solidified volume’) (see). Such cooling and the ensuing solidification cause the second section′ to be retained in a shape, for example, as that or similar to what was acquired in the stretched state, thereby forming the second sectionand thus the pouchin the first crotch portion.

The solidification enables the pouchto be retained in said shape, for example, with the bulge, BU. Further, the pouch, as formed from the same fabric as that of the first crotch portion, is seamlessly merged and/or integrated with the remaining section or with the first sectionof the first crotch portion. This is beneficial over cases where a different fabric piece is applied and which is stitched to the first crotch portionto form a pouch, similar to the pouch, as stitching a different fabric externally to any section of the first crotch portioninevitably defines a seam (for example, a suture-based seam) at the first crotch portion. During use by the male wearer, such suture-based seams are observed to undesirably cause chaffing of a skin of the male wearer. The method ends at block, although a variety of other processes are contemplatable by someone skilled in the art in subsequence to block.

In some embodiments, the cooling is performed while retaining the second section′ in the stretched state. At this point, ‘retaining the second section′ in the stretched state’ means that the either the corecontinues to be in the mated state with the cavityto keep the second section′ in the stretched state, or, that the coremoves away from the cavityto an unmated state but the second section′ continues to remain in the stretched state owing to the heat and pressure applied to the second section′ at blockand/or owing to the melting of the synthetic compound at the second section′ at block.

In some embodiments, cooling is provided by natural convection. For example, natural convention includes the allowance of a natural flow of air across the second section′ (for example, immediately) after the melting of the synthetic compound or immediately after the period for which the heat and/or the pressure is applied. In some embodiments, the solidification of the synthetic compound incorporated into the second section′ takes about thirty (30) seconds. Additionally, or optionally, cooling is provided by one or more additional systems associated with the die assembly. As an example, the coreincludes cooling channelsthrough which a cooled fluid, such as cooled air, is passed and transferred (or applied) to the second section′ such that the volume of the synthetic compound that is melted (or the melted volume) is solidified, while retaining the second section′ in the stretched state and thus turning the same into the second sectionand/or the pouch.

In some embodiments, the second section′ is stretched from the non-stretched state to the stretched state to increase sizes of holes defined in the second section(or in the fabric matrix of the second section) from relatively smaller hole sizes to relatively larger hole sizes. As an example, holes in the second sectionare switched from being the first holes to the second holes—more specifically, as the second section′ is stretched to the stretched state, diameter of the holes in the second section′ moves from being anywhere between 0.01 mm to 0.024 mm in between warp and filament yarn to anywhere between 0.025 mm to 0.05 mm in between warp and filament yarn. Also, when the melted volume of the synthetic compound is infused or incorporated into the second section′ (or into the remainder of the second section′) and solidified therewithin, the larger sizes of holes, as achieved in the stretched state of the second section′ or as achieved in the second section, are retained so, without returning to the hole size they were in when in the non-stretched state.

Referring to, to form the brief, each of the first stretchable fabricand the second stretchable fabricis used. More particularly, the first side edgewith the third side edgeare overlapped over each other and a first adhesive volumebetween the first side edgeand the third side edgeis used to fuse and join the first side edgewith the third side edge. This enables the formation of a first suture-less and seamless jointof the brief. Similarly, the second side edgewith the fourth side edgeare overlapped over each other and a second adhesive volume (not shown but is similar to the first adhesive volume) is used between the second side edgeand the fourth side edgeto fuse and join the second side edgewith the fourth side edge. This enables the formation of a second suture-less and seamless jointof the brief, laterally oppositely to the first suture-less and seamless jointof the brief. Examples of the adhesive include, but are not limited to, hotmelt adhesives, ethyl vinyl acetate, polyamide-based hot melt adhesives, and the like.

Moreover, the first crotch peripheryand the second crotch peripheryare also overlapped with each other and a third adhesive volume (not shown but is similar to the first adhesive volume) is used between the first crotch peripheryand the second crotch peripheryto fuse and join the first crotch peripherywith the second crotch periphery. This enables the formation of a third suture-less and seamless jointof the brief. In so doing, and with the first stretchable fabricand the second stretchable fabricbeing heat pressed (for example, the base fabric(see) is heat pressed prior to its placing into the die assembly) the briefas formed, possess a smooth and/or a body friendly texture and contours for the male wearer.

Referring toand, an exemplary method of manufacturing a brief(see) is described. The method is also described by way of a flowchartillustrated in. While it is possible for the briefand the briefto refer to one and the same brief, the method described in conjunction with,, and, mainly includes description corresponding to a formation of the second stretchable fabric. This is because, alongside the second stretchable fabric, the briefis envisioned to include any suitable first stretchable fabric, which need not necessarily be the first stretchable fabric.

Effectively, separate descriptions for the formations of the first stretchable fabricand the second stretchable fabricby way of the flowcharts,are provided for covering different aspects of the present description. It is however possible for the formations of the first stretchable fabricand the second stretchable fabricto be performed in a suitable continuum and/or in an appropriate sequence, as contemplatable by someone skilled in the art based on the present description, to manufacture a single common brief having both the first stretchable fabricand the second stretchable fabric. Such a common brief can take the form of any one or both the briefand/or the brief. Therefore, stages or blocks associated with the flowchartand stages or blocks associated with the flowchartcan both form part of the same, continuous manufacturing method to produce a common brief having both the first stretchable fabricand the second stretchable fabric. As the briefand briefcan be similar to each other and/or are one and same, similar or same reference numerals (and nomenclatures) are used for the briefand the brief, wherever possible.

It will be noted that the formation of the second stretchable fabricincludes the molding of a sac (also referred to as a molded sac, see) from the same fabric as that of the second stretchable fabric, thus making the molded sacintegral to the second stretchable fabric. The molded sacis configured to accommodate and conform to buttocks of a wearer (for example, the male wearer) when the briefis worn by the male wearer. The method for manufacturing the briefdescribed in conjunction with the flowchart, describing mainly the formation of the of the second stretchable fabric, is applicable to both male garments and female garments. Therefore, references to the male wearerused while describing the formation of the second stretchable fabricis purely exemplary. In view of the same, the reference ‘male wearer’ will be referred to as a ‘wearer’, hereinafter.

Similar to the flowchart, the flowchartalso includes different stages of the method for manufacturing the brief, and the stages are indicated by various blocks,,,,, and. The stages need not necessarily be viewed to be in any chronological order. The method starts at block.

At block, the method includes the use of the first stretchable fabric(see) to manufacture the brief. As described and illustrated in, and also in conjunction with the description and illustrations provided corresponding to, the first stretchable fabricdefines the first leg portion, the second leg portion, and the first crotch portion. The first crotch portionextends between the first leg portionand the second leg portion. Given the formation of the first stretchable fabricis described in detail above, the same is not repeated or described again for brevity. Alternatively, the method, at block, includes the use of another stretchable fabric (similar to the first stretchable fabric) to manufacture the brief. The method proceeds to block.

At block, and referring to, a base fabric(for example, a relatively enlarged flat piece of stretchable fabric) is used and a profile of the second stretchable fabricis generated on the base fabric. Such profile generation, in some embodiments, is performed by using one or more of a template, a stencil, and/or the like devices, associated with the briefor the second stretchable fabricof the briefand which is then used to form the brief. A suitable tool (not shown) is then applied to shear or cut out and remove the second stretchable fabricfrom the base fabricsuch that the second stretchable fabricis formed, independent of the base fabric. As also described and illustrated in, the second stretchable fabric, as obtained, defines the third leg portion, the fourth leg portion, and the second crotch portion. Additionally, the second stretchable fabricdefines a gluteal portion(also see) extending at least in part across each of the third leg portion, the fourth leg portion, and the second crotch portion. The gluteal portionis configured to abut and/or rest against a gluteal anatomy of the wearerwhen the briefis worn by the wearer.

With continued reference to, although not limited, the second stretchable fabric, as obtained from the base fabricis obtained as a flat piece of stretchable fabric devoid of any three-dimensional (3D) contours and/or shapes and/or structures. Further, one or both of the base fabricand/or the second stretchable fabricis heat pressed on steel rollers,to reduce a coefficient of friction of the second stretchable fabricof the brief. Material characteristics and/or properties for the second stretchable fabricare similar to the material characteristics and/or properties as described for the first stretchable fabric.

Referring to, the second stretchable fabric(and/or the gluteal portionof the second stretchable fabric) defines a third sectionand a fourth section′. It will be appreciated that the second stretchable fabricshown inillustrates a state prior to the formation of the molded sac, and two similar reference numerals, as used here, for the fourth section, namely, ‘’ and ‘′’, refer to the same region of the gluteal portionwith the distinction that ‘’ relates to a state (for example, a stretched state) of said region subsequent to the formation of the molded sac, and ‘″’ relates to a state (for example, a non-stretched state) of said region prior to the formation of the molded sac. Aspects of the present description describe the formation of the molded sac(and thus of the fourth section) from the fourth section′ by way of the exemplary method for manufacturing the briefdescribed in conjunction withand also the flowchartin. Further, as shown in, the third sectionis external to the fourth section′, or, alternatively, is devoid of the fourth section′. In other words, the third sectionis a remaining section of the gluteal portionseparate and apart from the fourth section′.

The satin weave synthetic composite fabric of the second stretchable fabricincludes polyester. In some embodiments, the gluteal portionincludes a synthetic compound associated with the polyester. As an example, the synthetic compound takes up to fifteen percent (15%) of the weight in the second stretchable fabricor in the brief. Also, in some embodiments, a portion (for example, a non-synthetic part) of the second stretchable fabricor of the brief, which is devoid of the synthetic compound, takes up to eighty five percent (85%) of the weight in the second stretchable fabricor in the brief.

The gluteal portion, or, alternatively, both the third sectionand the fourth section(and understandably the fourth section′) include the synthetic compound. It will be appreciated that the molded sac(or the fourth sectionformed by the fourth section′) includes a melted, infused, and solidified volume of the synthetic compound. The solidified volume of the synthetic compound enables the molded sacto be retained in the stretched state, with a bulge, BB (see). A manner in which the synthetic compound is melted, infused, and solidified, will be described later in the present description. In some embodiments, the synthetic compound includes or corresponds to polyethylene terephthalate (PET). The method proceeds to block.

At block, the second stretchable fabricis placed into a die assembly(see). As shown in, the die assemblyis different from the die assembly(although their functioning, as discussed below, is generally similar). Accordingly, different reference numbers are used to describe the die assemblyso as to distinguish the die assemblyfrom the die assembly. The die assemblyincludes a cavity, an intermediate station, and a core. The coreincludes a profile of the buttocks of the wearerand the cavityincludes a profile complementary to the profile of the core, which allows the coreto be received into the cavityduring the manufacturing of the brief. The intermediate stationis arranged in between the cavityand the core. The cavityis formed in a first support partof the die assembly; the intermediate stationis formed in a second support partof the die assembly; and the coreis formed in a third support partof the die assembly, as shown in.

With continued reference to, the intermediate stationdefines a through-slot, and a placement of the second stretchable fabricinto the die assemblymeans that the second stretchable fabricis laid onto the intermediate stationsuch that the gluteal portion(or the fourth section′ of the gluteal portion) lies over the through-slot, and/or, in other words, the gluteal portion(or the fourth section′ of the gluteal portion) fully overlaps the through-slot. Also, at said block, the placement of the second stretchable fabricinto the die assemblymeans that the gluteal portionsits between the coreand the cavityof the die assembly, with one sideof the gluteal portionfacing the coreand the other sideof the gluteal portionfacing the cavity. As an example, and as shown in, the coreis defined or positioned below the cavityand lies in alignment to the each of the cavityand the through-slot. The method proceeds to block.

At block, the die assemblyis operated to mate the corewith the cavity. During the mating of the corewith the cavity, the corepasses through the through-slotsuch that the coreis able to ingress or enter into the cavity(see direction, C,) from below. By way of having the coreenter into the cavity, or by way of mating the corewith the cavity, a section (for example, the fourth section′) of the gluteal portionis pushed into the cavitycausing the fourth section′ to be stretched from a non-stretched state to a stretched state with respect to a remaining section (for example, the third section) of the gluteal portion. With the second stretchable fabricand/or on the fourth section′ of the gluteal portionbeing arranged in between the coreand the cavity, an exemplary molding operation on the second stretchable fabricand/or on the fourth section′ of the second stretchable fabricis thus performed.

When operating the die assemblyfor mating the corewith the cavityor prior to the mating the corewith the cavity, one of the first support partand the second support partis moved (see direction, D,) towards the other of the first support partand the second support partsuch that the first support partand the second support partcome into physical contact with each other. In so doing, one support part (for example, the first support part) impinges against the other support part (for example, the second support part) and the gluteal portion(and, more particularly, the third sectionof the gluteal portion, positioned in between the first support partand the second support part) is clinched and/or restrained (for example, tightly) between portions of the first support partand the second support part. At this point, the fourth section′ remains exposed to the coreand to the cavity.

With reference to, as part of a continued operation of the die assembly, or as the coreenters into the cavity(for example, for mating with the cavity), the corepushes the fourth section′ of the gluteal portioninto the cavitysuch that the fourth section′ is stretched from the non-stretched state (as it was when lying unattended and/or undisturbed on the second support partor the intermediate stationat block) to the stretched state. The non-stretched state of the fourth section′ is visualized fromand the stretched state of the fourth sectionis visualized from. In other words, the fourth section′ is pushed to the stretched state with respect to the remaining section or the third sectionof the gluteal portion. The remaining section or the third section, at this point, continues to stay clinched and restrained between portions of the first support partand the second support part, as described above. The method proceeds to block.