BRIEFS FOR MALE WEARERS AND METHOD FOR MANUFACTURING SAME

Abstract

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

Claims

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

2. The method of claim 1, wherein the section is stretched from the non-stretched state to the stretched state to increase sizes of holes defined in the section from relatively smaller hole sizes to relatively larger hole sizes, when the melted volume of the synthetic compound is infused or incorporated into the section and solidified therewithin, the sizes of holes in the section are retained with the relatively larger hole sizes, the section of the gluteal portion sustains a stretching pressure when the section is stretched from the non-stretched state to the stretched state, and a percentage increase in the sizes of holes when the section is stretched from the non-stretched state to the stretched state is at least twice of a percentage rise in the stretching pressure.

3. The method of claim 1, wherein the first leg portion defines a first side edge, the second leg portion defines a second side edge, the third leg portion defines a third side edge, and the fourth leg portion defines a fourth side edge, the method further including: overlapping the first side edge with the third side edge and using a first adhesive volume therebetween to fuse and join the first side edge with the third side edge, thereby forming a first suture-less and seamless joint of the brief; and overlapping the second side edge with the fourth side edge and using a second adhesive volume therebetween to fuse and join the second side edge with the fourth side edge, thereby forming a second suture-less and seamless joint of the brief.

4. The method of claim 3, wherein the first crotch portion defines a first crotch periphery, the second crotch portion defines a second crotch periphery, the method further including: overlapping the first crotch periphery with the second crotch periphery and using a third adhesive volume therebetween to fuse and join the first crotch periphery with the second crotch periphery, thereby forming a third suture-less and seamless joint of the brief.

5. The method of claim 1 further including heat pressing the second stretchable fabric on steel rollers to reduce a coefficient of friction of the second stretchable fabric prior to placing the second stretchable fabric into the die assembly.

6. The method of claim 1, wherein the second stretchable fabric includes a satin weave synthetic composite fabric including elongated nano fibers having a length anywhere between ten (10) to hundred (100) microns.

7. The method of claim 1, wherein the second stretchable fabric is made using a polyamide weave that is transformed to a satin weave and thinned out.

8. The method of claim 1, wherein the second stretchable fabric includes polyester and the synthetic compound includes polyethylene terephthalate (PET).

9. The method of claim 1, wherein the second stretchable fabric includes a thickness anywhere between 0.0045-0.0048 millimeters (mm).

10. The method of claim 1, wherein the section of the second stretchable fabric defines a first fabric weight in a range of 70 and 100 grams per square meter, and the molded sac, formed from the section of the second stretchable fabric, defines a second fabric weight in a range of 65 percent to 75 percent of the first fabric weight.

11. The method of claim 1, wherein the cavity is formed in a first support part of the die assembly, the method including using a second support part of the die assembly to impinge against the first support part when or prior to mating the core with the cavity to clinch and restrain the remaining section of the gluteal portion in between the first support part and the second support part.

12. The method of claim 1, wherein a temperature value during an application of the heat is anywhere between 330.2 degrees Fahrenheit to 402 degrees Fahrenheit.

13. The method of claim 1, wherein a pressure value during an application of the pressure is anywhere between 3.899 to 7.024 pounds per square inch (psi).

14. The method of claim 1, wherein the heat is applied for a period of at least 10.05 seconds and up to a maximum of 13.03 seconds.

15. The method of claim 1, wherein the pressure is applied for a period of at least 10.05 seconds and up to a maximum of 13.03 seconds.

16. The method of claim 1, wherein cooling is applied to the section for a period of at least thirty (30) seconds, and when cooling is applied, the section is subjected to a temperature ranging between 71 degrees Fahrenheit to 76 degrees Fahrenheit.

17. The method of claim 1, wherein the heat and the pressure are applied simultaneously.

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

19. The brief of claim 18, wherein the satin weave synthetic composite fabric is formed from a polyamide weave transformed into a satin weave and thinned out, the satin weave synthetic composite fabric includes polyester and the molded sac includes a melted, infused, and solidified volume of a synthetic compound associated with the polyester, enabling the molded sac to be retained in the stretched state, and the synthetic compound includes polyethylene terephthalate (PET).

20. The brief of claim 18, wherein the first leg portion defines a first side edge, the second leg portion defines a second side edge, the third leg portion defines a third side edge, and the fourth leg portion defines a fourth side edge, the first side edge is overlapped with the third side edge and adhered thereto by a first adhesive volume applied therebetween to fuse and join the first side edge with the second side edge, thereby defining a first suture-less and seamless joint of the brief, and the second side edge is overlapped with the fourth side edge and adhered thereto by a second adhesive volume applied therebetween to fuse and join the second side edge with the fourth side edge, thereby defining a second suture-less and seamless joint of the brief.

21. The brief of claim 20, wherein the first crotch portion defines a first crotch periphery and the second crotch portion defines a second crotch periphery, and the first crotch periphery is overlapped with the second crotch periphery and adhered thereto by a third adhesive volume applied therebetween to fuse and join the first crotch periphery with the second crotch periphery, thereby defining a third suture-less and seamless joint of the brief.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0003] The accompanying figures, where like reference numerals refer to identical or functionally similar elements throughout the separate views, together with the detailed description below, are incorporated in and form part of the specification, and serve to further illustrate embodiments of concepts that include the claimed invention and explain various principles and advantages of those embodiments.

[0004] FIG. 1 is a front perspective view of an exemplary brief, which is a seamless male undergarment, for a male wearer, in accordance with some embodiments;

[0005] FIG. 2 is an exemplary side view of the brief of FIG. 1, in accordance with some embodiments;

[0006] FIG. 3 is an exemplary top view of the brief of FIG. 1, in accordance with some embodiments;

[0007] FIG. 4 is an exemplary front view of the brief of FIG. 1, in accordance with some embodiments;

[0008] FIG. 5 is an exemplary rear view of the brief of FIG. 1, in accordance with some embodiments;

[0009] FIG. 6 is an exemplary bottom view of the brief of FIG. 1, in accordance with some embodiments;

[0010] FIGS. 7A through 7I are views illustrating an exemplary method for manufacturing the brief, including exemplary steps to form a front panel of the brief, in accordance with some embodiments;

[0011] FIG. 8 is a view in which the front panel of the brief is adhered to, or is in an exemplary process of adhering to, a rear panel of the brief, in accordance with some embodiments;

[0012] FIG. 9 is a flowchart associated with the method for manufacturing the brief illustrated by way of FIGS. 7A through 7I, in accordance with some embodiments;

[0013] FIGS. 10A through 10I are views illustrating an exemplary method for manufacturing the brief, including exemplary steps to form a rear panel of the brief, in accordance with some embodiments;

[0014] FIG. 11 is a rear view of the brief once the rear panel is fully formed, in accordance with an embodiment; and

[0015] FIG. 12 is a flowchart associated with the method for manufacturing the brief illustrated by way of FIGS. 10A through 10I, in accordance with some embodiments.

[0016] 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.

[0017] 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.

DETAILED DESCRIPTION OF THE INVENTION

[0018] 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.

[0019] 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.

[0020] 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.

[0021] 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, 1, 1, 1, 101 and 201 could refer to one or more comparable components used in the same and/or different depicted embodiments.

[0022] Referring to FIGS. 1 through 6, a garment, and, more particularly, a brief 100 is described by way of reference to various isometric views. The brief 100 corresponds to an undergarment wearable by a male wearer 104 (see FIG. 1) directly over the wearer's body such that portions of the brief 100 comes in contact with the wearer's body. Although aspects in the present disclosure have been described in relation to the brief 100, 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 brief 100 includes a pouch 108 configured to enclose genitals of the male wearer 104 when the brief 100 is worn by the male wearer 104.

[0023] The brief 100 includes a first panel 112 (which is a front panel of the brief 100) and a second panel 116 (which is a rear panel of the brief 100). In an embodiment, each of the first panel 112 and the second panel 116 is made from the same fabric material. Alternatively, in an embodiment, the first panel 112 and the second panel 116 are made from different fabric materials. As an example, at least one of the first panel 112 and the second panel 116 includes, 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 panel 112 and the second panel 116 is a stretchable fabric that enables the brief 100 to adjust and conform to a body structure of the male wearer 104. For the purposes of the present disclosure, the first panel 112 is referred to as a first stretchable fabric 120. Similarly, the second panel 116 is referred to as a second stretchable fabric 124.

[0024] In further detail, the first stretchable fabric 120 defines a first leg portion 128, a second leg portion 132, and a first crotch portion 136 integrally and contiguously extending between the first leg portion 128 and the second leg portion 132. Similar portions are available in the second stretchable fabric 124, as well. The first crotch portion 136 defines the pouch 108 to enclose the genitals of the male wearer 104 when the brief 100 is worn by the male wearer 104. To this end, the first crotch portion 136 defines a first section 140 and a second section 144. In this regard, reference is also made to FIG. 7B which illustrates the first stretchable fabric 120 in a state prior to the formation of the pouch 108. In FIG. 7B, the first stretchable fabric 120 includes the first section 140 and a second section 144. It will be noted that similar reference numerals 144 and 144, as used here, refer to the same region of the first crotch portion 136 with the distinction that 144 relates to a state (for example, a stretched state) of said region subsequent to the formation of the pouch 108, while 144 relates to a state (for example, a non-stretched state) of said region prior to the formation of the pouch 108. Aspects of the present description describe the formation of the pouch 108 (and thus of the second section 144) from the second section 144 by way of an exemplary method for manufacturing the brief 100. Said method will be described further below. Also, as shown in FIGS. 1 through 6, the first section 140 is external to the second section 144, or, alternatively, is devoid of the second section 144. In other words, the first section 140 is a remaining section of the first crotch portion 136 separate and apart from the second section 144.

[0025] As is viewed from various views of the brief 100 in FIGS. 1 through 6, as the pouch 108 is converted and obtained from the second section 144 of the first crotch portion 136, the pouch 108 is formed integrally to the first section 140 of the first crotch portion 136. Moreover, the pouch 108 defines no seams with the first section 140. More particularly, for the formation of the pouch 108, the second section 144 is stretched outwardly to a stretched state to define a bulge, BU, with respect to the remaining section or the first section 140 of the first crotch portion 136. As the second section 144 is merely stretched away from the first crotch portion 136 and is not an add-on to the first crotch portion 136, the pouch 108 is integral (for example, seamlessly integral) with the remaining section or the first section 140 of the first crotch portion 136. A fabric matrix corresponding to the first section 140 (and optionally additionally corresponding to one or more of the first leg portion 128 and the second leg portion 132) defines a plurality of first holes. A fabric matrix corresponding to the pouch 108 defines 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.

[0026] 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 pouch 108 is 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 pouch 108 is optimal for application in men's garments such as a recovery underwear.

[0027] With the relatively larger second holes in the pouch 108, the second holes serve as aeration holes of the pouch 108 that allows relatively more air to pass across the fabric matrix of the pouch 108 when the brief 100 is worn by the male wearer 104. This makes the pouch 108 (formed by the second section 144) more breathable than the first section 140 and/or also more breathable than other portions of the first stretchable fabric 120 and, in some embodiments, optionally additionally, the second stretchable fabric 124. 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 104, thus enabling the wearer's genitals to remain at an optimal temperature range. While the bulge, BU, defined by the pouch 108 provides adequate space for the wearer's genitals to be accommodated within the brief 100, the bulge, BU, also appropriately supports the wearer's genitals, in turn promoting wearer comfort and sperm health.

[0028] In some embodiments, one or more of the first stretchable fabric 120 and the second stretchable fabric 124 (or the satin weave synthetic composite fabric of one or more of the first stretchable fabric 120 and the second stretchable fabric 124) 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 fabric 120 and the second stretchable fabric 124, 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 fabric 120 and the second stretchable fabric 124 includes polyester. Further, in some embodiments, the first crotch portion 136 includes 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 fabric 120 or in the brief 100. In some embodiments, a portion (for example, a non-synthetic part) of the brief 100, which is devoid of the synthetic compound, takes up to eighty five percent (85%) of the weight in the first stretchable fabric 120 or in the brief 100.

[0029] As an example, both the first section 140 and the second section 144 (and understandably the second section 144) include the synthetic compound. However, it will be appreciated that the pouch 108 (or the second section 144 formed by the second section 144) includes a melted, infused, and solidified volume of the synthetic compound. The solidified volume of the synthetic compound enables the pouch 108 to 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).

[0030] With continued reference to FIGS. 1 through 6, and also in conjunction with FIGS. 7B and 8, the first leg portion 128 defines a first side edge 148 and the second leg portion 132 defines a second side edge 152. Further, the first crotch portion 136 defines a first crotch periphery 156. With the second stretchable fabric 124 being similar (for example, in shape) to the first stretchable fabric 120, the second stretchable fabric 124 defines similar leg portions, for example, a third leg portion 160 and a fourth leg portion 164 (also see FIG. 3). The third leg portion 160 defines a third side edge 168 and the fourth leg portion 164 defines a fourth side edge 172. Also, the second stretchable fabric 124 includes a second crotch portion 176 integrally and contiguously extending between the third leg portion 160 and the fourth leg portion 164. The second crotch portion 176 defines a second crotch periphery 180. While it is notable that the portions in the first stretchable fabric 120 and the second stretchable fabric 124 are similar, they need not be identical. This is because each of the first stretchable fabric 120 and the second stretchable fabric 124 are configured to adapt and conform to different parts of wearer's body.

[0031] In some embodiments, one or more of the first stretchable fabric 120 and the second stretchable fabric 124 is 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 100. In some embodiments, one or more of the first stretchable fabric 120 and the second stretchable fabric 124 includes 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 fabric 120 and the second stretchable fabric 124 is 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 fabric 120 and the second stretchable fabric 124 has a thickness anywhere within the range of 0.0045-0.0048 millimeters (mm).

[0032] Referring to FIGS. 7A through 7I and FIG. 8, an exemplary method for manufacturing the brief 100 is described. The method is also described by way of a flowchart 900 illustrated in FIG. 9. The method described in conjunction with FIGS. 7A through 7I, FIG. 8, and the flowchart 900 illustrated in FIG. 9, mainly includes description corresponding to a formation of the first stretchable fabric 120. This is because, alongside the first stretchable fabric 120, the brief 100 is envisioned to include any suitable second stretchable fabric, which need not necessarily be the second stretchable fabric 124. The flowchart 900 includes different stages of the method for manufacturing the brief 100, and the stages are indicated by various blocks 902, 904, 906, 908, and 910. The stages need not necessarily be viewed to be in any chronological order. The method starts at block 902.

[0033] At block 902, a base fabric 184 (for example, a relatively enlarged flat piece of stretchable fabric) (see FIG. 7A) is used and a profile of the first stretchable fabric 120 is generated on the base fabric 184. 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 brief 100 and which is then used to form the brief 100. A suitable tool (not shown) is then applied to shear or cut out and remove the first stretchable fabric 120 from the base fabric 184 such that the first stretchable fabric 120 is formed, independent of the base fabric 184. The first stretchable fabric 120, as obtained, defines the aforementioned the first leg portion 128, the second leg portion 132, and the first crotch portion 136 (see FIG. 7B). The first stretchable fabric 120 is used for the production of the brief 100. Although not limited, the first stretchable fabric 120, as obtained from the base fabric 184, 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 fabric 184 and/or the first stretchable fabric 120 is heat pressed on steel rollers 188, 192 to reduce a coefficient of friction of the first stretchable fabric 120 and/or of the brief 100. In some embodiments, the description corresponding to the first stretchable fabric 120, as described in relation with the block 902, is suitably applicable for the second stretchable fabric 124, as well, for the production of the second stretchable fabric 124. The method proceeds to block 904.

[0034] At block 904, the first stretchable fabric 120 is placed into a die assembly 196 (see FIGS. 7C through 7I). In this regard, the die assembly 196 includes a cavity 200, an intermediate station 204, and a core 208. The intermediate station 204 is arranged in between the cavity 200 and the core 208. The cavity 200 is formed in a first support part 212 of the die assembly 196; the intermediate station 204 is formed in a second support part 216 of the die assembly 196; and the core 208 is formed in a third support part 220 of the die assembly 196.

[0035] With reference to FIGS. 7C through 7I, the intermediate station 204 defines a through-slot 224, and a placement of the first stretchable fabric 120 into the die assembly 196 means that the first stretchable fabric 120 is laid onto the intermediate station 204 such that the first crotch portion 136 lies over the through-slot 224, and/or, in other words, the first crotch portion 136 fully overlaps the through-slot 224. Also, at said block 904, the placement of the first stretchable fabric 120 into the die assembly 196 means that the first crotch portion 136 of the first stretchable fabric 120 sits between the core 208 and the cavity 200 of the die assembly 196, with one side 228 of the first crotch portion 136 facing the core 208 and the other side 232 of the first crotch portion 136 facing the cavity 200. In this regard, and as shown in FIG. 7C, for example, the core 208 is defined or positioned below the cavity 200 and lies in alignment to the each of the cavity 200 and the through-slot 224. The method proceeds to block 906.

[0036] At block 906, the die assembly 196 is operated to mate the core 208 with the cavity 200. During the mating of the core 208 with the cavity 200, the core 208 passes through the through-slot 224 such that the core 208 is able to ingress or enter into the cavity 200 (see direction, A, FIGS. 7E and 7F) from below. By way of having the core 208 enter into the cavity 200, or by way of mating the core 208 with the cavity 200, with the first stretchable fabric 120 and/or on the first crotch portion 136 arranged in between the core 208 and the cavity 200, an exemplary molding operation on the first stretchable fabric 120 and/or on the first crotch portion 136 of the first stretchable fabric 120 is performed.

[0037] When operating the die assembly 196 for mating the core 208 with the cavity 200 or prior to the mating the core 208 with the cavity 200, one of the first support part 212 and the second support part 216 is moved (see direction, B, FIG. 7D) towards the other of the first support part 212 and the second support part 216 such that the first support part 212 and the second support part 216 come into physical contact with each other. In so doing, one support part (for example, the first support part 212) impinges against the other support part (for example, the second support part 216) and the first stretchable fabric 120 (and, more particularly, the remaining section or the first section 140 of the first crotch portion 136, positioned in between the first support part 212 and the second support part 216) is clinched and/or restrained (for example, tightly) between portions of the first support part 212 and the second support part 216. At this point, the second section 144 remains exposed to the core 208 and to the cavity 200.

[0038] With reference to FIGS. 7E and 7F, as part of a continued operation of the die assembly 196, or as the core 208 enters into the cavity 200 (for example, for mating with the cavity 200), the core 208 pushes the second section 144 of the first crotch portion 136 into the cavity 200 such that the second section 144 is stretched from the non-stretched state (as it was when lying unattended and/or undisturbed on the second support part or the intermediate station 204 at block 904) to the stretched state. The non-stretched state of the second section 144 is visualized from FIG. 7D and the stretched state of the second section 144 is visualized from FIG. 7F through 7I. In other words, the second section 144 is pushed to the stretched state with respect to the remaining section or the first section 140 of the first crotch portion 136. The remaining section or the first section 140, at this point, continues to stay clinched and restrained between portions of the first support part 212 and the second support part 216, as described above. The method proceeds to block 908.

[0039] At block 908, once the core 208 fully enters into the cavity 200 and is mated with the cavity 200 (referred to as a mated state of the core 208), the core 208 exerts pressure against the cavity 200 such that the pressure is transferred and thus applied to the second section 144 received between the core 208 and the cavity 200. This pressure application causes the second section 144 to sit snugly and/or tightly within the cavity 200 (see FIG. 7F), urging the second section 144 to take a shape of the cavity 200. In some embodiments, simultaneously with the application of pressure, heat is applied to the second section 144, as well. Both the application of heat and pressure causes a volume of the synthetic compound (see FIG. 7G), for example, a volume of PET of the second section 144, to be subject to phase change and/or to melt. The melting occurs while retaining the second section 144 in the stretched state and with the second section 144 sitting tightly within the cavity 200, as the second section 144 is pushed by the core 208 into the cavity 200.

[0040] In some embodiments, the heat is supplied to the second section 144 through the core 208. To this end, and as an example, the core 208 includes features, such as one or more heating elements 236 that convert any supplied energy, at least in part, into heat, and through which heat is applied and/or imparted to the second section 144. As an example, a source from where energy is supplied for the production of heat at the core 208 corresponds to any heat source, for example, an electrical heat source (not shown). In some embodiments, heat application is uniform about a body 240 of the core 208. In so doing, a physical state (for example, an initial solid state) of the synthetic compound, present in and across the second section 144 of the first crotch portion 136, is uniformly altered or melted. In other words, a temperature at an outer surface 244 of the core 208 is varied evenly across an expanse of said outer surface 244 of the core 208. In so doing, a phase change of the synthetic compound in and across the second section 144 of the first crotch portion 136 is attained uniformly throughout the second section 144. In some embodiments, the temperature is evenly varied at the outer surface 244 of the core 208 by having the heating elements 236 evenly distributed across the expanse of the outer surface 244 of the core 208. Although not limited, the second section 144 is retained in the stretched state for an entire duration of the melting of the synthetic compound.

[0041] 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 120. The method proceeds to block 910.

[0042] At block 910, 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 144 such that the volume of the synthetic compound that is melted (referred to as a melted volume 260) (see FIG. 7G) at block 908 is infused or incorporated back into the second section 144 (for example, into a remainder of the second section 144). The synthetic compound is then left to be solidified therewithin (referred to as a solidified volume 272) (see FIGS. 7H and 7I). Such cooling and the ensuing solidification cause the second section 144 to be retained in a shape, for example, as that or similar to what was acquired in the stretched state, thereby forming the second section 144 and thus the pouch 108 in the first crotch portion 136.

[0043] The solidification enables the pouch 108 to be retained in said shape, for example, with the bulge, BU. Further, the pouch 108, as formed from the same fabric as that of the first crotch portion 136, is seamlessly merged and/or integrated with the remaining section or with the first section 140 of the first crotch portion 136. This is beneficial over cases where a different fabric piece is applied and which is stitched to the first crotch portion 136 to form a pouch, similar to the pouch 108, as stitching a different fabric externally to any section of the first crotch portion 136 inevitably defines a seam (for example, a suture-based seam) at the first crotch portion 136. During use by the male wearer 104, such suture-based seams are observed to undesirably cause chaffing of a skin of the male wearer 104. The method ends at block 910, although a variety of other processes are contemplatable by someone skilled in the art in subsequence to block 910.

[0044] In some embodiments, the cooling is performed while retaining the second section 144 in the stretched state. At this point, retaining the second section 144 in the stretched state means that the either the core 208 continues to be in the mated state with the cavity 200 to keep the second section 144 in the stretched state, or, that the core 208 moves away from the cavity 200 to an unmated state but the second section 144 continues to remain in the stretched state owing to the heat and pressure applied to the second section 144 at block 908 and/or owing to the melting of the synthetic compound at the second section 144 at block 908.

[0045] 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 144 (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 144 takes about thirty (30) seconds. Additionally, or optionally, cooling is provided by one or more additional systems associated with the die assembly 196. As an example, the core 208 includes cooling channels 248 through which a cooled fluid, such as cooled air, is passed and transferred (or applied) to the second section 144 such that the volume of the synthetic compound that is melted (or the melted volume) is solidified, while retaining the second section 144 in the stretched state and thus turning the same into the second section 144 and/or the pouch 108.

[0046] In some embodiments, the second section 144 is stretched from the non-stretched state to the stretched state to increase sizes of holes defined in the second section 144 (or in the fabric matrix of the second section 144) from relatively smaller hole sizes to relatively larger hole sizes. As an example, holes in the second section 144 are switched from being the first holes to the second holesmore specifically, as the second section 144 is stretched to the stretched state, diameter of the holes in the second section 144 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 144 (or into the remainder of the second section 144) and solidified therewithin, the larger sizes of holes, as achieved in the stretched state of the second section 144 or as achieved in the second section 144, are retained so, without returning to the hole size they were in when in the non-stretched state.

[0047] Referring to FIG. 8, to form the brief 100, each of the first stretchable fabric 120 and the second stretchable fabric 124 is used. More particularly, the first side edge 148 with the third side edge 168 are overlapped over each other and a first adhesive volume 252 between the first side edge 148 and the third side edge 168 is used to fuse and join the first side edge 148 with the third side edge 168. This enables the formation of a first suture-less and seamless joint 256 of the brief 100. Similarly, the second side edge 152 with the fourth side edge 172 are overlapped over each other and a second adhesive volume (not shown but is similar to the first adhesive volume 252) is used between the second side edge 152 and the fourth side edge 172 to fuse and join the second side edge 152 with the fourth side edge 172. This enables the formation of a second suture-less and seamless joint 264 of the brief 100, laterally oppositely to the first suture-less and seamless joint 256 of the brief 100. Examples of the adhesive include, but are not limited to, hotmelt adhesives, ethyl vinyl acetate, polyamide-based hot melt adhesives, and the like.

[0048] Moreover, the first crotch periphery 156 and the second crotch periphery 180 are also overlapped with each other and a third adhesive volume (not shown but is similar to the first adhesive volume 252) is used between the first crotch periphery 156 and the second crotch periphery 180 to fuse and join the first crotch periphery 156 with the second crotch periphery 180. This enables the formation of a third suture-less and seamless joint 268 of the brief 100. In so doing, and with the first stretchable fabric 120 and the second stretchable fabric 124 being heat pressed (for example, the base fabric 184 (see FIG. 7A) is heat pressed prior to its placing into the die assembly 196) the brief 100 as formed, possess a smooth and/or a body friendly texture and contours for the male wearer 104.

[0049] Referring to FIGS. 10A through 10I and FIG. 11, an exemplary method of manufacturing a brief 1100 (see FIG. 11) is described. The method is also described by way of a flowchart 1200 illustrated in FIG. 12. While it is possible for the brief 100 and the brief 1100 to refer to one and the same brief, the method described in conjunction with FIGS. 10A through 10I, FIG. 11, and FIG. 12, mainly includes description corresponding to a formation of the second stretchable fabric 124. This is because, alongside the second stretchable fabric 124, the brief 1100 is envisioned to include any suitable first stretchable fabric, which need not necessarily be the first stretchable fabric 120.

[0050] Effectively, separate descriptions for the formations of the first stretchable fabric 120 and the second stretchable fabric 124 by way of the flowcharts 900, 1200 are provided for covering different aspects of the present description. It is however possible for the formations of the first stretchable fabric 120 and the second stretchable fabric 124 to 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 fabric 120 and the second stretchable fabric 124. Such a common brief can take the form of any one or both the brief 100 and/or the brief 1100. Therefore, stages or blocks associated with the flowchart 900 and stages or blocks associated with the flowchart 1200 can both form part of the same, continuous manufacturing method to produce a common brief having both the first stretchable fabric 120 and the second stretchable fabric 124. As the brief 100 and brief 1100 can be similar to each other and/or are one and same, similar or same reference numerals (and nomenclatures) are used for the brief 100 and the brief 1100, wherever possible.

[0051] It will be noted that the formation of the second stretchable fabric 124 includes the molding of a sac (also referred to as a molded sac 1104, see FIG. 11) from the same fabric as that of the second stretchable fabric 124, thus making the molded sac 1104 integral to the second stretchable fabric 124. The molded sac 1104 is configured to accommodate and conform to buttocks of a wearer (for example, the male wearer 104) when the brief 1100 is worn by the male wearer 104. The method for manufacturing the brief 1100 described in conjunction with the flowchart 1200, describing mainly the formation of the of the second stretchable fabric 124, is applicable to both male garments and female garments. Therefore, references to the male wearer 104 used while describing the formation of the second stretchable fabric 124 is purely exemplary. In view of the same, the reference male wearer 104 will be referred to as a wearer 104, hereinafter.

[0052] Similar to the flowchart 900, the flowchart 1200 also includes different stages of the method for manufacturing the brief 1100, and the stages are indicated by various blocks 1202, 1204, 1206, 1208, 1210, and 1212. The stages need not necessarily be viewed to be in any chronological order. The method starts at block 1202.

[0053] At block 1202, the method includes the use of the first stretchable fabric 120 (see FIGS. 1 through 8) to manufacture the brief 1100. As described and illustrated in FIGS. 1 through 6, and also in conjunction with the description and illustrations provided corresponding to FIGS. 7A through 8, the first stretchable fabric 120 defines the first leg portion 128, the second leg portion 132, and the first crotch portion 136. The first crotch portion 136 extends between the first leg portion 128 and the second leg portion 132. Given the formation of the first stretchable fabric 120 is described in detail above, the same is not repeated or described again for brevity. Alternatively, the method, at block 1202, includes the use of another stretchable fabric (similar to the first stretchable fabric 120) to manufacture the brief 1100. The method proceeds to block 1204.

[0054] At block 1204, and referring to FIGS. 10A and 10B, a base fabric 1000 (for example, a relatively enlarged flat piece of stretchable fabric) is used and a profile of the second stretchable fabric 124 is generated on the base fabric 1000. 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 brief 1100 or the second stretchable fabric 124 of the brief 1100 and which is then used to form the brief 1100. A suitable tool (not shown) is then applied to shear or cut out and remove the second stretchable fabric 124 from the base fabric 1000 such that the second stretchable fabric 124 is formed, independent of the base fabric 1000. As also described and illustrated in FIGS. 1 through 6, the second stretchable fabric 124, as obtained, defines the third leg portion 160, the fourth leg portion 164, and the second crotch portion 176. Additionally, the second stretchable fabric 124 defines a gluteal portion 1004 (also see FIG. 11) extending at least in part across each of the third leg portion 160, the fourth leg portion 164, and the second crotch portion 176. The gluteal portion 1004 is configured to abut and/or rest against a gluteal anatomy of the wearer 104 when the brief 1100 is worn by the wearer 104.

[0055] With continued reference to FIGS. 10A and 10B, although not limited, the second stretchable fabric 124, as obtained from the base fabric 1000 is 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 fabric 1000 and/or the second stretchable fabric 124 is heat pressed on steel rollers 188, 192 to reduce a coefficient of friction of the second stretchable fabric 124 of the brief 1100. Material characteristics and/or properties for the second stretchable fabric 124 are similar to the material characteristics and/or properties as described for the first stretchable fabric 120.

[0056] Referring to FIG. 10B, the second stretchable fabric 124 (and/or the gluteal portion 1004 of the second stretchable fabric 124) defines a third section 1008 and a fourth section 1012. It will be appreciated that the second stretchable fabric 124 shown in FIG. 10B illustrates a state prior to the formation of the molded sac 1104, and two similar reference numerals, as used here, for the fourth section, namely, 1012 and 1012, refer to the same region of the gluteal portion 1004 with the distinction that 1012 relates to a state (for example, a stretched state) of said region subsequent to the formation of the molded sac 1104, and 1012 relates to a state (for example, a non-stretched state) of said region prior to the formation of the molded sac 1104. Aspects of the present description describe the formation of the molded sac 1104 (and thus of the fourth section 1012) from the fourth section 1012 by way of the exemplary method for manufacturing the brief 1100 described in conjunction with FIGS. 10A through 11 and also the flowchart 1200 in FIG. 12. Further, as shown in FIGS. 10B, the third section 1008 is external to the fourth section 1012, or, alternatively, is devoid of the fourth section 1012. In other words, the third section 1008 is a remaining section of the gluteal portion 1004 separate and apart from the fourth section 1012.

[0057] The satin weave synthetic composite fabric of the second stretchable fabric 124 includes polyester. In some embodiments, the gluteal portion 1004 includes 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 fabric 124 or in the brief 1100. Also, in some embodiments, a portion (for example, a non-synthetic part) of the second stretchable fabric 124 or of the brief 1100, which is devoid of the synthetic compound, takes up to eighty five percent (85%) of the weight in the second stretchable fabric 124 or in the brief 1100.

[0058] The gluteal portion 1004, or, alternatively, both the third section 1008 and the fourth section 1012 (and understandably the fourth section 1012) include the synthetic compound. It will be appreciated that the molded sac 1104 (or the fourth section 1012 formed by the fourth section 1012) includes a melted, infused, and solidified volume of the synthetic compound. The solidified volume of the synthetic compound enables the molded sac 1104 to be retained in the stretched state, with a bulge, BB (see FIG. 11). 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 1206.

[0059] At block 1206, the second stretchable fabric 124 is placed into a die assembly 1016 (see FIGS. 10C through 10I). As shown in FIGS. 10C through 10I, the die assembly 1016 is different from the die assembly 196 (although their functioning, as discussed below, is generally similar). Accordingly, different reference numbers are used to describe the die assembly 1016 so as to distinguish the die assembly 1016 from the die assembly 196. The die assembly 1016 includes a cavity 1020, an intermediate station 1024, and a core 1028. The core 1028 includes a profile of the buttocks of the wearer 104 and the cavity 1020 includes a profile complementary to the profile of the core 1028, which allows the core 1028 to be received into the cavity 1020 during the manufacturing of the brief 1100. The intermediate station 1024 is arranged in between the cavity 1020 and the core 1028. The cavity 1020 is formed in a first support part 1032 of the die assembly 1016; the intermediate station 1024 is formed in a second support part 1036 of the die assembly 1016; and the core 1028 is formed in a third support part 1040 of the die assembly 1016, as shown in FIGS. 10C through 10I.

[0060] With continued reference to FIGS. 10C through 10I, the intermediate station 1024 defines a through-slot 1044, and a placement of the second stretchable fabric 124 into the die assembly 1016 means that the second stretchable fabric 124 is laid onto the intermediate station 1024 such that the gluteal portion 1004 (or the fourth section 1012 of the gluteal portion 1004) lies over the through-slot 1044, and/or, in other words, the gluteal portion 1004 (or the fourth section 1012 of the gluteal portion 1004) fully overlaps the through-slot 1044. Also, at said block 1206, the placement of the second stretchable fabric 124 into the die assembly 1016 means that the gluteal portion 1004 sits between the core 1028 and the cavity 1020 of the die assembly 1016, with one side 1048 of the gluteal portion 1004 facing the core 1028 and the other side 1052 of the gluteal portion 1004 facing the cavity 1020. As an example, and as shown in FIG. 10C, the core 1028 is defined or positioned below the cavity 1020 and lies in alignment to the each of the cavity 1020 and the through-slot 1044. The method proceeds to block 1208.

[0061] At block 1208, the die assembly 1016 is operated to mate the core 1028 with the cavity 1020. During the mating of the core 1028 with the cavity 1020, the core 1028 passes through the through-slot 1044 such that the core 1028 is able to ingress or enter into the cavity 1020 (see direction, C, FIG. 10E) from below. By way of having the core 1028 enter into the cavity 1020, or by way of mating the core 1028 with the cavity 1020, a section (for example, the fourth section 1012) of the gluteal portion 1004 is pushed into the cavity 1020 causing the fourth section 1012 to be stretched from a non-stretched state to a stretched state with respect to a remaining section (for example, the third section 1008) of the gluteal portion 1004. With the second stretchable fabric 124 and/or on the fourth section 1012 of the gluteal portion 1004 being arranged in between the core 1028 and the cavity 1020, an exemplary molding operation on the second stretchable fabric 124 and/or on the fourth section 1012 of the second stretchable fabric 124 is thus performed.

[0062] When operating the die assembly 1016 for mating the core 1028 with the cavity 1020 or prior to the mating the core 1028 with the cavity 1020, one of the first support part 1032 and the second support part 1036 is moved (see direction, D, FIG. 10D) towards the other of the first support part 1032 and the second support part 1036 such that the first support part 1032 and the second support part 1036 come into physical contact with each other. In so doing, one support part (for example, the first support part 1032) impinges against the other support part (for example, the second support part 1036) and the gluteal portion 1004 (and, more particularly, the third section 1008 of the gluteal portion 1004, positioned in between the first support part 1032 and the second support part 1036) is clinched and/or restrained (for example, tightly) between portions of the first support part 1032 and the second support part 1036. At this point, the fourth section 1012 remains exposed to the core 1028 and to the cavity 1020.

[0063] With reference to FIGS. 10E and 10F, as part of a continued operation of the die assembly 1016, or as the core 1028 enters into the cavity 1020 (for example, for mating with the cavity 1020), the core 1028 pushes the fourth section 1012 of the gluteal portion 1004 into the cavity 1020 such that the fourth section 1012 is stretched from the non-stretched state (as it was when lying unattended and/or undisturbed on the second support part 1036 or the intermediate station 1024 at block 1206) to the stretched state. The non-stretched state of the fourth section 1012 is visualized from FIGS. 10C and 10D and the stretched state of the fourth section 1012 is visualized from FIGS. 10F through 10I. In other words, the fourth section 1012 is pushed to the stretched state with respect to the remaining section or the third section 1008 of the gluteal portion 1004. The remaining section or the third section 1008, at this point, continues to stay clinched and restrained between portions of the first support part 1032 and the second support part 1036, as described above. The method proceeds to block 1210.

[0064] At block 1210, once the core 1028 fully enters into the cavity 1020 and is mated with the cavity 1020 (referred to as a mated state of the core 1028), the core 1028 exerts pressure against the cavity 1020 such that the pressure is transferred and thus applied to the fourth section 1012 received between the core 1028 and the cavity 1020. This pressure application causes the fourth section 1012 to sit snugly and/or tightly within the cavity 1020 (see FIGS. 10F and 10G), urging the fourth section 1012 to take a shape of the cavity 1020. In some embodiments, simultaneously with the application of pressure, heat is applied to the fourth section 1012, as well. Both the application of heat and pressure causes a volume of the synthetic compound (see FIG. 10G), for example, a volume of polyethylene terephthalate (PET) of the fourth section 1012, to be subject to phase change and/or to melt. The melting occurs while retaining the fourth section 1012 in the stretched state and with the fourth section 1012 sitting tightly within the cavity 1020, as the fourth section 1012 is pushed by the core 1028 into the cavity 1020.

[0065] In some embodiments, the heat is supplied to the fourth section 1012 through the core 1028. To this end, and, as an example, the core 1028 includes features, such as one or more heating elements 1056 that convert any supplied energy, at least in part, into heat, and through which heat is applied and/or imparted to the fourth section 1012. As an example, a source from where energy is supplied for the production of heat at the core 1028 corresponds to any heat source, for example, an electrical heat source (not shown). In some embodiments, heat application is uniform about a body of the core 1028. In so doing, a physical state (for example, an initial solid state) of the synthetic compound, present in and across the fourth section 1012 of the gluteal portion 1004, is uniformly altered or melted. In other words, a temperature at an outer surface 1060 of the core 1028 is varied evenly across an expanse of said outer surface 1060 of the core 1028. In so doing, a phase change of the synthetic compound in and across the fourth section 1012 of the gluteal portion 1004 is attained uniformly throughout the fourth section 1012. In some embodiments, the temperature is evenly varied at the outer surface 1060 of the core 1028 by having the heating elements 1056 evenly distributed across the expanse of the outer surface 1060 of the core 1028. Although not limited, the fourth section 1012 is retained in the stretched state for an entire duration of the melting of the synthetic compound. In some embodiments, the fourth section 1012 is retained in the stretched state till the synthetic compound is solidified.

[0066] 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 second stretchable fabric 124. The method proceeds to block 1212.

[0067] At block 1212, after the heat and pressure have been applied (for example, in accordance with the ranges provided above) the heat application is halted and the operation switches to cool the fourth section 1012 such that the volume of the synthetic compound that is melted (referred to as a melted volume) (see FIG. 10G) at block 1210 is infused or incorporated back into the fourth section 1012 (for example, into a remainder of the fourth section 1012). The synthetic compound is then left to be solidified therewithin (referred to as a solidified volume) (see FIGS. 10H and 10I). Such cooling and the ensuing solidification cause the fourth section 1012 to acquire and be retained in a shape, for example, as that or similar to what was acquired in the stretched state, thereby fully forming the fourth section 1012 and thus the molded sac 1104 in the second stretchable fabric 124.

[0068] The solidification enables the molded sac 1104 to be retained in said shape, for example, with the bulge, BB, (see FIG. 11) with respect to the remaining section (or the third section 1008) of the gluteal portion 1004. Further, the molded sac 1104, as formed from the same fabric as that of the second stretchable fabric 124, is seamlessly merged and/or integrated with the remaining section or with the third section 1008 of the gluteal portion 1004. This is beneficial over cases where a different fabric piece is applied and which is stitched to the second stretchable fabric 124 to form a molded sac, similar to the molded sac 1104, as stitching a different fabric externally to any section of the second stretchable fabric 124 inevitably defines a seam (for example, a suture-based seam). During use by the wearer 104, such suture-based seams can undesirably cause chaffing of a skin of the wearer 104.

[0069] Concepts of the present description described in connection with the second stretchable fabric 124 are also applicable to a woman's garment, such as a woman's undergarment. Therefore, all references to the wearer 104, used in describing the method of manufacturing of the brief 1100, in conjunction with FIGS. 10A through 12 is exemplary. The method ends at block 1212, although a variety of other processes, contemplatable by someone skilled in the art, is performable on the brief 1100 in subsequence to block 1212.

[0070] In some embodiments, the cooling is performed while retaining the fourth section 1012 in the stretched state. At this point, retaining the fourth section 1012 in the stretched state means that the either the core 1028 continues to be in the mated state with the cavity 1020 to keep the fourth section 1012 in the stretched state, or, that the core 1028 moves away from the cavity 1020 to an unmated state but the fourth section 1012 continues to remain in the stretched state owing to the heat and pressure applied to the fourth section 1012 at block 1210 and/or owing to the melting of the synthetic compound at the fourth section 1012 at block 1210.

[0071] In some embodiments, cooling is provided by natural convection. For example, natural convention includes the allowance of a natural flow of air across the fourth section 1012 (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 fourth section 1012 takes about thirty (30) seconds. In other words, cooling is applied to the fourth section 1012 for a period of at least thirty (30) seconds. Further, when such a cooling is applied, the fourth section 1012 can be subjected to a temperature ranging between 71 degrees Fahrenheit to 76 degrees Fahrenheit. Additionally, or optionally, cooling is provided by one or more additional systems associated with the die assembly 1016. As an example, the core 1028 includes cooling channels 1064 through which a cooled fluid, such as cooled air, is passed and transferred (or applied) to the fourth section 1012 such that the volume of the synthetic compound that is melted (or the melted volume) is solidified, while retaining the fourth section 1012 in the stretched state and thus turning the same into the fourth section 1012 and/or the molded sac 1104.

[0072] In some embodiments, the fourth section 1012 is stretched from the non-stretched state to the stretched state to increase sizes of holes defined in the fourth section 1012 (or in the fabric matrix of the fourth section 1012 or the molded sac 1104) from relatively smaller hole sizes to relatively larger hole sizes. As an example, holes in the fourth section 1012 are switched from being first holes (or, for ease of reference, third holes) to second holes (or, for ease of reference, fourth holes)more specifically, as the fourth section 1012 is stretched to the stretched state, diameter of the holes in the stretched fourth section 1012 increase and move 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 fourth section 1012 (or into the remainder of the fourth section 1012) and solidified therewithin, the larger sizes of holes, as achieved in the stretched state of the fourth section 1012 or as achieved in the fourth section 1012, are retained so, without returning to the hole size they were in when in the non-stretched state. Effectively, when the melted volume of the synthetic compound is infused or incorporated into the fourth section 1012 and solidified therewithin, the sizes of holes in the fourth section 1012 are retained with the relatively larger hole sizes.

[0073] In other words, a first fabric region of the second stretchable fabric 124 other than the molded sac 1104 (or effectively the third section 1008) defines the third holes and a second fabric region of the second stretchable fabric 124 within the molded sac 1104 (or effectively the fourth section 1012) defines the relatively larger sized fourth holes. The relatively larger sized fourth holes in the molded sac 1104 enables enhanced and/or increased aeration through the molded sac 1104 than through the third section 1008the third holes defining a diameter in a range of 0.01 millimeters (mm) to 0.024 mm in between warp and filament yarn, while the fourth holes defining a diameter (or relatively increased diameter) in a range of 0.025 mm to 0.05 mm in between warp and filament yarn, as described above.

[0074] In some embodiments, the fourth section 1012 of the gluteal portion 1004 sustains a stretching pressure when the fourth section 1012 is stretched from the non-stretched state to the stretched state. As an example, the stretching pressure corresponds to a pressure needed by the core 1028 to enter into the cavity 1020 during the manufacturing of the brief 1100, and which is computable by way of any known or suitable pressure detection methods. As an example, the stretching pressure can correspond to an amount of actuation power needed by the core 1028 to enter into the cavity 1020. Thus, a detection of the actuation power can result in the determination of the stretching pressure. Like methods, now known or in the future developed, can be applied for stretching pressure determination. According to some embodiments, a percentage increase in the sizes of the holes (for example, the third holes) when the fourth section 1012 is stretched from the non-stretched state to the stretched state is at least twice of a percentage rise in the stretching pressure.

[0075] Optionally, or additionally, the percentage increase in the size of the holes (for example, the third holes) is computed based on a distance travelled by the core 1028 when stretching the fourth section 1012 from the non-stretched state to the stretched state. As an example, a percentage increase in the sizes of the holes (for example, the third holes) when the fourth section 1012 is stretched from the non-stretched state to the stretched state is at least twice of a percentage rise in the distance travelled by the core 1028 towards and/or into the cavity 1020. Also, in some embodiments, the fourth section 1012 of the second stretchable fabric 124 defines a first fabric weight in a range of 70 and 100 grams per square meter (GSM), and the molded sac 1104, formed from the fourth section 1012 of the second stretchable fabric 124, defines a second fabric weight in a range of 65 percent to 75 percent of the first fabric weight.

[0076] A manner of manufacturing the brief 1100 involving the coupling or adhering of the first stretchable fabric 120 with the second stretchable fabric 124 is similar or same to what has been described in connection with FIG. 8 above. Apart from achieving increased aeration through the molded sac 1104, the brief 1100, with the bulge, BB, enables the male wearer's buttocks to registered and slotted well into the brief 1100. As a result, the buttocks remain freely accommodated within the molded sac 1104, without impinging or pushing against any portion of the second stretchable fabric 124. This negates the second stretchable fabric 124 from pushing or inducing strain against a waist band associated with the brief 1100, in turn enabling the waist band (and thus the brief 1100) to remain securely fitted against the wearer's waist. This prevents the brief 1100 from slipping down and/or away from the body of the wearer 104. Aspects described in relation to the brief 1100 is applicable to both male garments and to female garments, and any reference to male and/or men and/or the wearer 104, used in connection with the description of the brief 1100, is exemplary.

[0077] In the foregoing specification, specific embodiments have been described. However, one of ordinary skill in the art appreciates that various modifications and changes can be made without departing from the scope of the invention as set forth in the claims below. Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of present teachings.

[0078] The benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential features or elements of any or all the claims. The invention is defined solely by the appended claims including any amendments made during the pendency of this application and all equivalents of those claims as issued.

[0079] Moreover, in this document, relational terms such as first and second, top and bottom, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms comprises, comprising, has, having, includes, including, contains, containing or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises, has, includes, contains a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element preceded by comprises . . . a, has . . . a, includes . . . a, contains . . . a does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises, has, includes, contains the element. The terms a and an are defined as one or more unless explicitly stated otherwise herein. The terms substantially, essentially, approximately, about or any other version thereof, are defined as being close to as understood by one of ordinary skill in the art, and in one non-limiting embodiment the term is defined to be within 10%, in another embodiment within 5%, in another embodiment within 1% and in another embodiment within 0.5%. The term coupled as used herein is defined as connected, although not necessarily directly and not necessarily mechanically. A device or structure that is configured in a certain way is configured in at least that way but may also be configured in ways that are not listed.

[0080] The Abstract of the Disclosure is provided to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description, it can be seen that various features are grouped together in various embodiments for the purpose of streamlining the description. This method is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separately claimed subject matter.