MULTI-LAYER GARMENT AND METHODS OF MANUFACTURING THE SAME

Abstract

Multi-layered garments and methods of manufacturing the same are provided. Such multi-layered garments comprise at least an outer layer that forms a front portion and a back portion and defines an interior, and at least one inner layer positioned within the interior defined by the outer layer. The inner layer(s) are coupled with the outer layer via an exterior seam or using other adhering methods such that the inner-most inner layer does not have an abrasive surface. The front portion of the outer layer may be coupled with more inner layers as compared to the back portion of the outer layer. The methods for manufacturing the multi-layered garments include the steps of providing an outer layer and coupling at least one inner layer thereto. The methods may be designed to retrofit previously manufactured outer layers with at least one inner layer positioned within an interior defined by the outer layer.

Description

PRIORITY

The present application is related to and claims the priority benefit of U.S. Provisional Patent Application Ser. No. 62/350,200, filed Jun. 15, 2016. The disclosure of the aforementioned patent application is hereby incorporated by reference in its entirety into this disclosure.

BACKGROUND

There are numerous types of infant garments conventionally known including infant sleepers, onesies, bodysuits and the like. Most of these garments comprise a body portion for covering the child's body, with a least a pair of arm portions attached thereto for covering at least part of the child's arms and/or shoulders. Conventional sleepers, in particular, also comprise a pair of leg portions attached to the body portion that are designed to cover the child's legs. Additionally, some infant garments may also comprise foot portions integral with the distal ends of the leg portions for covering the infant's feet.

Infant garments can be designed to fit snuggly (as is often the case with sleepwear, for example) or to be loose fitting. Typically, these conventional garments are made from several pieces of material or fabric that are sewn together into a single layer and held closed by snaps, zippers, and/or other closure mechanisms. However, when an infant is sleeping it is often necessary to use an additional blanket to ensure the child does not become cold.

Along these lines, numerous products and methods have been developed over the years in an effort to prevent infants from kicking blankets off. For example, blankets configured to be secured to the bed are known. However, such designs present major drawbacks in that they are either too restrictive to the child or do not adequately cover or remain on the child (especially after a child reaches the age of approximately two to three months, where the infant begins to wiggle, squirm and kick). Additionally, and perhaps most importantly, conventional blankets or blankets designed to be secured to the bed greatly increase the risk that the child could get tangled in the material or strings or straps thereof, thereby leading to the danger of suffocation or choking. Indeed, it is currently conventional practice to place an infant in a crib without anything in it—even a blanket—to decrease the probability that the child will be a victim of Sudden Infant Death Syndrome (SIDS).

As such, wearable blankets positioned over the infant's sleeper are currently the garments of choice when placing a child in a crib. Conventional wearable blankets for infants (sometimes called a sleep sack or pouch) are designed to replace blankets and keep infants warm, without the increased risk of extra material and/or straps present within the crib. Such wearable blankets typically cover the baby's body and have a neck opening and armholes with or without sleeves and are fitted over the infant's sleeper, thereby enclosing the baby's torso and legs within the sack.

While conventional wearable blankets provide an extra layer of material to the infant with a decreased risk of choking or suffocation as compared to conventional blankets, they can still get displaced and twist around the child's lower torso and legs as a result of the child squirming and kicking, thus resulting in a constriction of movement. In some cases, the wearable blanket can even migrate up and over the baby's head or face to cause suffocation issues or slide off when the baby is lifted. Additionally, by virtue of its design, the child cannot safely or easily remove the blanket, which can cause the baby to overheat.

What is needed is an infant sleeping garment that provides warmth, but does not restrict the baby's movement, migrate, or become tangled, twisted or fall off when the baby squirms, kicks, or moves around. The sleeping garment should not require the use of potentially harmful fasteners, but should also provide a material that is soft and comfortable against the baby's skin.

BRIEF SUMMARY

The present disclosure provides novel garments and methods for manufacturing the same. In at least one embodiment, such garments comprise an infant bodysuit comprising an outer layer forming a body portion, and a first inner layer formed from a first plurality of woven fibers that are either absorptive or moisture-wicking. The first inner layer may comprise an outside-facing surface and an inside-facing surface, with the outside-facing surface positioned adjacent to the outer layer. The garments hereof may also comprise at least one second inner layer. Such second inner layer may be formed from a second plurality of woven fibers, with the at least one second inner layer positioned such that the first inner layer is between the at least one second inner layer and the outer layer.

In at least one embodiment, the first and/or second plurality of woven fibers of the first and/or second inner layer(s) may be absorptive and comprise at least a cotton fiber. Additionally or alternatively, the outer layer of the bodysuit may comprise a material that is moisture-wicking. In certain embodiments, both the outer layer and the first plurality of woven fibers of the first inner layer may comprise a cotton-based sheet material.

In certain embodiments, the outer layer of the bodysuit may include a pair of arm portions and a pair of leg portions or, alternatively, the outer layer may simply define a portion for fitting around the torso of a wearer. Where the outer layer comprises arm and leg portions, each pair of arm portions and leg portions may be affixed to the body portion of the outer layer by a seam, for example. Furthermore, the first inner layer may also be coupled with the outer layer at each of the seams.

In at least one exemplary embodiment of the inventive garments of the present disclosure, the outer layer of the garment may additionally define back portion and a front portion. Here, the inner layers may also be divided between the front and back portions of the outer layer, such that the configuration of the front portion of the garment may be different than that of the garment's back portion. For example, in at least one embodiment, the first inner layer may be adjacent to the front portion of the outer layer, but not the back portion of the outer layer such that the back portion of the outer layer remains unlined. Alternatively, the back portion may comprise one or more inner layers, but the front portion may comprise a greater number of inner layers than does the back portion. By way of a non-limiting example, the front portion of the outer layer of the bodysuit may comprise at least one second inner layer formed from a second plurality of woven fibers, whereas the back portion only comprises a single inner layer. There, in at least one embodiment, the at least one second inner layer may be positioned such that the first inner layer is between the at least one second inner layer and the front portion of the outer layer.

Certain embodiments of the present disclosure provide a garment comprising an outer layer forming a front portion, a back portion, and defining an interior; a first inner layer formed from a first plurality of first woven fibers, the first inner layer sized and shaped for attachment to the front portion of the outer layer and positioned within the interior defined by the outer layer; and at least one second inner layer formed from a second plurality of woven fibers, the at least one second inner layer sized and shaped for attachment to the first inner layer and positioned within the interior defined by the outer layer such that the first inner layer is between the at least one second inner layer and the outer layer. There, the second plurality of woven fibers may be absorptive or moisture-wicking, while the front portion of the outer layer comprises a porous fabric.

An inner-most surface of the at least one second inner layer may comprise a soft fabric or material. Additionally or alternatively, the front portion of the outer layer and the first inner layer may be integrally formed such that there is no open space between the front portion of the outer layer and the first inner layer.

The first inner layer and the at least one second inner layer may be attached to the front portion of the outer layer at a seam. In at least one embodiment, the first inner layer and one or more of the at least one second layers are affixed together with adhesive.

Embodiments of the garment may also comprise at least one third inner layer formed from a third plurality of woven fibers. In such embodiments, the at least one third inner layer may be sized and shaped for attachment to the back portion of the outer layer and positioned within the interior defined by the outer layer, with the at least one second inner layer of the front portion comprises a fabric-weight that is greater than a fabric-weight of the at least one third layer of the back portion of the outer layer.

Methods for manufacturing the infant bodysuits and/or garments of the present disclosure are also provided. In at least one exemplary embodiment, such a method may comprise the steps of: providing an outer layer that forms a body portion, the body portion defining an interior; and coupling a first inner layer with the outer layer such that the first inner layer is positioned within the interior defined by the body portion of the outer layer and forms a first inner-most surface within the interior. In at least one embodiment, the first inner layer may comprise a plurality of woven fibers that are absorptive or moisture-wicking. Notably, the outer layer may be prefabricated and comprise any commercially available infant bodysuit or other garment.

Furthermore, in at least one embodiment, the step of coupling a first inner layer with the outer layer may further comprise sewing the first inner layer to the outer layer at one or more seams. Additionally or alternatively, the step of coupling a first inner layer with the outer layer may further comprise adhering at least a portion of an outer-most surface of the first inner layer with the outer layer using an adhesive.

Additional embodiments of the method comprise the step of coupling at least a second inner layer with the first inner-most surface of the first inner layer such that the at least one second inner layer is positioned within the interior defined by the body portion of the outer layer. There, the at least one second inner layer may comprise a plurality of woven fibers that are absorptive or moisture-wicking.

Where the body portion of the outer layer further comprises a front portion and a back portion, the method may further comprise the step of coupling a second inner layer with only the first inner layer positioned in the front portion of the outer layer. The second inner layer comprises a cotton-based material and the first inner layer positioned in the front portion of the outer layer comprises a heavy-weight fabric.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a front view of at least one exemplary embodiment of a multi-layered garment of the present disclosure;

FIG. 2 shows an exploded view of portions of outer and inner layers of the garment of FIG. 1;

FIG. 3 shows an exploded view of portions of outer and inner layers of an exemplary embodiment of a multi-layered garment of the present disclosure; and

FIG. 4 shows an exploded view of portions of outer and inner layers of at least one exemplary embodiment of a multi-layered garment of the present disclosure;

FIG. 5 shows a front view of the multi-layered garment of FIG. 4;

FIG. 6 shows a flow chart representing a method of manufacturing the garment of FIGS. 1 3, and/or 5 according to an exemplary embodiment of the present disclosure. an exemplary embodiment representative of the color key of the present disclosure; and

An overview of the features, functions and/or configurations of the elements depicted in the various figures will now be presented. It should be appreciated that not all of the features of the figures are necessarily described as some of these non-discussed features, as well as other discussed features, are inherent from the figures themselves. Other non-discussed features may be inherent in component geometry and/or configuration.

DETAILED DESCRIPTION

For the purposes of promoting an understanding of the principles of the present disclosure, reference will now be made to the embodiments illustrated in the drawings, and specific language and details will be used to describe the same. It will nevertheless be understood that no limitation of the scope of this disclosure is intended, with any additional alterations, modifications, and further applications of the principles of this disclosure being contemplated hereby as would normally occur to one skilled in the craft. Accordingly, this disclosure is intended to cover alternatives, modifications, and equivalents as may be included within the spirit and scope of this application. While this technology may be illustrated and described in one or more preferred embodiments, the garments, methods, and techniques hereof may comprise many different configurations, forms, materials, and accessories.

In regards to applications of the following description, numerous specific details are set forth in order to provide a thorough understanding of the present disclosure. Particular examples may be implemented without some or all of these specific details. In other instances, well-known methods (for example, the various steps of manufacturing a garment) have not been described in detail so as to not unnecessarily obscure the present disclosure.

The disclosure of the present application provides novel garments comprising at least two layers of fabric on at least a portion of the garment, with the inner-most layer comprising a soft fabric that comprises either absorptive or wicking properties, as desired. In at least one exemplary embodiment, the garment comprises a multiple-layered infant sleeper that eliminates the need for blankets, extra layers, and/or the use of a wearable blanket. While the garments described herein are described in connection with infant sleepwear, it will be understood that the inventive concepts hereof are not limited to this application alone and can instead be applied to any garments and/or apparel where it may be beneficial to provide multiple layers without bulk or to provide warmth without the risk of overheating.

FIG. 1 illustrates at least one exemplary embodiment of a garment 100 of the present disclosure. As shown in FIG. 1, garment 100 comprises an infant sleeper having an outer layer 102 and an inner layer 104 sewn (or otherwise coupled) together at one or more seams 108. As with conventional sleepers, the garment 100 comprises a body portion 12 for covering the wearer's body, a pair of arm portions 14 attached thereto for covering at least part of the wearer's arms and/or shoulders, and a pair of leg portions 16 attached to the body portion 12 that are designed to cover the wearer's legs (note, however, that the inventive concepts disclosed herein are not limited to garments comprising all of these components). As is known in the art, the garment 100 may also comprise one or more fasteners 110 (such as buttons, zippers, snaps, etc.) to secure the garment 100 in place when worn.

FIG. 2 shows an exploded view of the outer and inner layers 102, 104 relative to each other as applied to the garment 100. For reference, skin 10 of a wearer is shown to illustrate the orientation of the garment 100 and its layers 102, 104 when being worn.

The outer layer 102 may comprise any type of fabric suitable for use with apparel including, for example, cotton, fleece, wool, cotton-polyester, polyester, silk, rayon, fabric blends, and the like. Additionally, the outer layer 102 may comprise a non-flammable (or fire retardant) and/or soft fabric of a type often preferred for use with infant sleepwear; however, due to the unique multi-layer design of the garment 100, the outer layer 102 need not necessarily be soft or selected for comfort. Indeed, the outer layer 102 may comprise a more durable fabric or material without concern for how it will feel against the wearer's skin.

At least one inner layer 104 of the garment 100 lines at least a portion of the inside surface of the outer layer 102. In at least one exemplary embodiment, a single inner layer 104 lines the entire inside surface of the outer layer 102 such that the inside-facing surface 106 of the inner layer 104 is the only material in contact with the wearer's skin. Notwithstanding the foregoing embodiment, it will be appreciated that the inner layer 104 may alternatively only line portions of the garment 100 if desired (for example, where the garment 100 comprises feet and/or sleeves, the inner layer 104 need not necessarily cover the entire inner surfaces thereof, or an inner layer 104 may only line the front of the garment 100 as described in further detail below in connection with garment 400).

The inner layer 104 may comprise a soft fabric or material such as cotton, organic fibers, fleece, cotton-polyester, polyester, silk, linen, rayon, and the like. As previously noted, it is the inside-facing surface 106 of the inner-most inner layer 104 that will be in contact with the wearer's skin so the inner-most inner layer 104 is preferably manufactured from a soft material that additionally comprises certain properties to help regulate the wearer's body temperature and/or to absorb or remove (wick) moisture, oils, and/or dead skin cells from the wearer's skin. In this manner, the inner layer 104 not only provides an extra soft layer of material for warmth and comfort (thereby eliminating the need for additional blankets or clothing), but also prevents the wearer from becoming overheated and uncomfortable.

The material or fabric of the inner layer 104 need not be as durable as that of the outer layer 102 as, when worn, the outer layer 104 will receive the brunt of the wear and exposure. Accordingly, the inner layer(s) 104 may be selected for comfort and its moisture absorption/wicking or other properties, rather than durability.

In at least one exemplary embodiment of the garment 100, the inner layer 104 comprises a high quality cotton sheet material or threads capable of absorbing moisture present on the wearer's skin (e.g., such as Liquid Cotton Sheets or another high-quality cotton-based material utilizing, in at least one embodiment, at least 300 thread count single inclusions that has the hand and sheen of silk and the soft, and the dampness permeableness of premium cotton.) This provides a soft surface against the wearer's skin and, effectively, functions much as a sheet does on a bed without the risk of the sheet being wrapped around the wearer (as it is anchored to the outer layer 102). Additionally or alternatively, the inner layer 104 may comprise a jersey cotton material, an Egyptian cotton material, a bamboo material, a mercerized cotton, a cotton-blend, other absorbent material(s) comprising modal/micromodal, tencel, and/or other viscose-based fibers, or any other material that may be desirable.

In at least one alternative embodiment, the inner layer 104 of the garment 100 may be made of a fluid-wicking material or fabric that, when the inside-facing surface 106 is in contact with moisture on a wearer's skin, draws the moisture into it by the process of wicking. Examples of such fluid-wicking materials include fabrics, threads, and/or synthetic fibers such as polyester, nylon, polyester-blends, etc. that are woven in such a way that moisture is forced into and through gaps in the weave so it can find the outer shell of the material. The weave itself makes the material highly permeable and the materials/fibers of the fabric may also be treated with a solution that results in the fabric becoming less absorbent.

Once the moisture is wicked by the inside-facing surface 106, the moisture travels into the base of the inner layer 104 (or even, in at least one embodiment, into outer layer 102) where it then is allowed to evaporate from the threads/material. This moisture-wicking and evaporative process not only keeps the wearer's skin dry and comfortable, but also acts to cool the skin. In certain embodiments where the inner layer 104 comprises a material having moisture-wicking properties, the outer layer 102 may comprise a porous material or fabric such that any moisture wicked away from the wearer's skin by the inner layer 104 is allowed to evaporate. Additionally or alternatively, the material(s) of the outer layer 102 may comprise moisture-wicking or even absorbent properties to further wick or absorb, respectively, any moisture delivered thereto by the inner layer 104.

While only one inner layer 104 is illustrated and described in the embodiments shown in FIGS. 1 and 2, any number of inner layers 104 may be employed. FIG. 3 shows an exploded, perspective view of a portion of a garment 200 comprising an outer layer 102 and three inner layers 104a, 104b, 104c. Where the garment 200 comprises more than one inner layer 104, the only requirement with respect to the material selection of the inner layers 104 is that the inside-facing surface 106 of the most interior inner layer 104 (i.e. the surface that will be in contact with the wearer's skin—here inner layer 104c) comprises a soft fabric or material. Furthermore, each of the multiple inner layers 104a, 104b, 104c need not comprise the same material or fabric.

As previously noted, the inner and outer layers 102, 104 may be attached together at the seams 108. While certain examples of seam 108 lines are illustrated in FIG. 1, it will be appreciated that seams 108 may be positioned in any area on the garment 100 that may be appropriate or desired. In at least one embodiment, a space may be present between the layers 102, 104 in areas other than at the seams 108. In additional embodiments, the layers 102, 104 of the garment 100 may be integrally formed and/or adhered together using an adhesive or the like such that one or more of the layers 102, 104 are adhered/anchored together along all or part of their lengths. In any case, the attachment between the inner and outer layers 102, 104 prevents the bunching and twisting of the materials that is seen with conventional garments and blankets.

At least one exemplary embodiment of a varied-layer garment 400 of the present disclosure is shown in FIGS. 4 and 5. A perspective view of a portion of the garment 400 is shown in FIG. 4. Here, the garment 400 has a different number of layers on its front portion (i.e. the portion configured to cover a wearer's anterior side) than its back portion 402 (i.e. the portion configured to cover a wearer's 410 posterior side). For example, the back portion 402 of the varied-layer garment 400 may comprise only an outer layer 102, while the front portion 404 of the varied-layer garment 300 (i.e. the portion configured to cover a wearer's 410 anterior side) may comprise both inner and outer layers 102, 104 (and any number of inner layers 104). Alternatively, the back portion 402 may comprise both inner and outer layers 102, 104, but the back portion 402 has fewer inner layers 104 than those of the front portion 404. These layers 102, 104 may comprise any material and be formed as previously described herein in conjunction with garments 100 and 200, and in at least one exemplary embodiment, one or more of the inner and outer layers 102, 104 comprise a liquid cotton or other cotton-based material.

Referring now to FIG. 5, the outer layer 102 of the varied-layer garment 400 may comprise a first piece that defines the back portion 402 of the garment 400 and a second piece that defines the front portion 404 of the garment 400, with the inner layer(s) 104 only attached to the front portion 404 part of the outer layer 102 at the one or more seams 108 and/or via an adhesive or other affixing medium. In at least one exemplary embodiment, one or more seams 108 run along a frontal plane of the garment 400 such that even the front portions 404 of any arm portions 14 and/or leg portions 16 such that the back portions 404 thereof only comprise the outer layer 102 and the front portions 402 thereof comprise the outer and inner layers 102, 104.

Functionally, because of its fewer layers, this varied-layer design enables the back portion 402 of the garment 400 to be thinner and breathable, thereby retaining less heat adjacent to the wearer's 410 body than does the front portion 404. This is particularly useful when the garment 400 is used with infants that are typically positioned on their backs to sleep. Due to the contact between an infant's back and the underlying blankets or linens of the bed or crib, less layers are necessary on the back portion 404 to retain heat and maintain the wearer 410 at a comfortable temperature. However, especially when sleeping without a blanket (as is advised for infants), additional layers on the front portion 404 are useful as heat more readily escapes in this direction. Accordingly, the incorporation of more layers on the front portion 404 as compared to the back portion 402 increases the thickness thereof for added warmth and comfort.

Whether or not the front and back portions 404, 402 of the garment 400 comprise the same number of layers 102, 104, the front portion 404 of garment 400 may comprise one or more inner layers 104 made of a different material than are the layers 102, 104 of the back portion 402. In at least one exemplary embodiment, one or more of the front portion's 404 inner layer(s) 104 may comprise a thicker/heavier-weight material than that of the material used in the inner layer(s) 104 of the back portion 402. Similar to the embodiments of the garment 400 where the front portion 404 has more inner layers 104 than the back portion 402, in application, when one or more layers 104 of the front portion 404 comprise heavy-weight fabric or material, the front portion 404 will retain more heat against the wearer's body as compared to the back portion 402 (i.e. exhibit an increased heat retention effect).

By way of a non-limiting example, a back portion 402 of the garment 400 may comprise an outer layer 102 and a first inner layer 104 made of a cotton-based material, whereas the front portion 404 may comprise the outer layer 102, a first inner layer 104 made of wool, a wool-blend, or fleece, and a second inner-most layer 104 made of a cotton-based material. There, the first inner layer 104 of the front portion 404 that has a heavy fabric- or material-weight facilitates heat retention, while the breathable first inner layer 104 of the back portion 402 promotes comfort and/or moisture-wicking. It will be appreciated that no limitation is intended with respect to the types of materials that may be used with the garment 400 and any material that provides the desired characteristic(s) (or combinations of different material/fabric types) may be used.

Furthermore, it is not uncommon for caregivers to apply light pressure to an infant's chest in an effort to provide a soothing effect; indeed, this is one of the theories behind swaddling infants. In line with this theory, the garments 100, 200, 400 of the present disclosure may be constructed to provide additional weight on the front portion 404 such that, when the baby is supine (i.e. on its back), the weight of the front portion 404 applies a gentle pressure to the baby's chest, thereby providing a soothing effect. Accordingly, in at least one embodiment, the number of and/or material(s) used for one or more of the inner layers 104 of the front portion 404 may be customized to add actual weight to the garment 400, while the materials and number of layers 104 of the back portion 402 are selected for breathability, etc. Additionally, actual weights may be affixed to one of more of the layers 102, 104 of the front portion 404 to achieve the desired effect.

Now referring to FIG. 6, a flow chart representative of a method 600 of manufacturing the garments 100, 200 of the present disclosure is shown. At step 302 the outer layer 102 of the garment 100, 200, 400 may be formed (via cutting, sewing, or otherwise) into the appropriate pattern and/or shape. For example, in at least one embodiment, the body portion 12 and any arm and/or leg portions 14, 16 are formed out of the outer layer 102. It will be appreciated that the separate portions 12, 14, and/or 16 may be formed out of the outer layer 102 independent of each other and not yet attached, or all such portions 12, 14, and/or 16 may be attached to each other via seems 108 at step 302. In at least one exemplary embodiment, the outer layer 102 may comprise a previously fabricated infant sleeper or the like and the method 600 entails retrofitting the same with the inner layer(s) 104 as described herein to form the garment 100, 200, 400.

At step 304, corresponding inner layer(s) 104 are coupled with the body portion 12 that was formed out of the outer layer 102 at step 302. The outer and inner layers 102, 104 may be coupled with each other via sewed seams 108, adhesive, snaps, mechanical based fastening products (such as hook and loop fasteners, for example), any other coupling means now known in the art or hereinafter developed, and/or any combination of the foregoing, provided that: 1) the inner layer(s) 104 and outer layer 102 are securely attached to each other, and 2) the inside-facing surface 106 of the inner-most inner layer 104 does not include any abrasive areas or surfaces that may irritate a wearer's skin. In at least one exemplary embodiment of the method 600, the outer and inner layers 102, 104 are coupled with each other via sewed seams 108 formed by soft thread at least at a location where the body portion 12 will be attached to the arm portions 14 of the garment 100, 200, 400 and where the fasteners 110 will be attached. Where a garment 400 comprises front and back portions 404, 402 having different configurations, the corresponding inner layer(s) 104 are coupled with the appropriate portions 404, 402 at step 304, as desired.

At step 306, the process of step 304 is repeated for any arm portions 14 of the garment 100, 200, 400—i.e. the inner layer(s) 104 are coupled with the arm portions 14 that were formed out of the outer layer 102 at step 302. Additionally, if the garment 100, 200, 400 comprises separate leg portions 16, the process is again repeated at step 308 for any leg portions 14 of the garment 100, 200, 400. Note, however, that where the leg portions 16 are integral with and/or comprised of the same piece of outer layer 102 as the body portion 12, then the leg portions 16 may be lined with inner layer(s) 104 at step 304 in conjunction with the lining of the body portion 12 (and/or the front and back portions 404, 402 as applicable) if so desired.

At step 310 of the method 600, all of the portions 12, 14, 16, 402, and/or 404 are attached to each other to form the finished garment 100, 200, 400. In embodiments where the garment 100, 200, 400 comprises one or more fasteners 110 or weights (not shown), such fasteners 110 and/or weights may also be attached to the garment 100, 200, 400 at any or all of steps 304-310, as may be appropriate or desired. Furthermore, applique, embroidery, or any other decorative embellishments may be applied to the outer layer 102 of the garment 100, 200, 400 at any step of the method 600 or, alternatively, the outer layer 102 may be provided with such embellishments already formed thereon or attached thereto.

While embodiments of inventive garments and methods hereof have been described in considerable detail herein, the embodiments are merely offered by way of non-limiting examples of the disclosure described herein. It will therefore be understood that various changes and modifications may be made, and equivalents may be substituted for elements thereof, without departing from the scope of the disclosure. Indeed, this disclosure is not intended to be exhaustive or to limit the scope of the disclosure.

Further, in describing representative embodiments, the disclosure presents a method and/or process as a particular sequence of steps. However, to the extent that the method or process does not rely on the particular order of steps set forth herein, the method or process should not be limited to the particular sequence of steps described. Other sequences of steps may be possible. Therefore, the particular order of the steps disclosed herein should not be construed as limitations of the present disclosure. In addition, disclosure directed to a method and/or process should not be limited to the performance of their steps in the order written. Such sequences may be varied and still remain within the scope of the present disclosure.

Claims

1. An infant bodysuit comprising:

an outer layer forming a body portion; and

a first inner layer formed from a first plurality of woven fibers, the first inner layer comprising an outside-facing surface and an inside-facing surface, the outside-facing surface positioned adjacent to the outer layer;

wherein the first plurality of woven fibers of the first inner layer are either absorptive or moisture-wicking.

2. The infant bodysuit of claim 1, wherein the outer layer further forms a pair of arm portions and a pair of leg portions, each of the pair of arm portions and the pair of leg portions are affixed to the body portion of the outer layer by a seam, and the first inner layer is coupled with the outer layer at each of the seams.

3. The infant bodysuit of claim 1, wherein the first plurality of woven fibers are absorptive and comprise at least a cotton fiber.

4. The infant bodysuit of claim 1, wherein the outer layer comprises a material that is moisture-wicking.

5. The infant bodysuit of claim 1, further comprising at least one second inner layer formed from a second plurality of woven fibers, the at least one second inner layer positioned such that the first inner layer is between the at least one second inner layer and the outer layer.

6. The infant bodysuit of claim 1, wherein the outer layer defines a back portion and a front portion, and the first inner layer is adjacent to the front portion of the outer layer, but not the back portion of the outer layer.

7. The infant bodysuit of claim 6, further comprising at least one second inner layer formed from a second plurality of woven fibers, the at least one second inner layer positioned such that the first inner layer is between the at least one second inner layer and the front portion of the outer layer.

8. The infant bodysuit of claim 3, wherein the outer layer and the first plurality of woven fibers of the first inner layer both comprise a cotton-based sheet material.

9. A garment comprising:

an outer layer forming a front portion, a back portion, and defining an interior;

a first inner layer formed from a first plurality of first woven fibers, the first inner layer sized and shaped for attachment to the front portion of the outer layer and positioned within the interior defined by the outer layer; and

at least one second inner layer formed from a second plurality of woven fibers, the at least one second inner layer sized and shaped for attachment to the first inner layer and positioned within the interior defined by the outer layer such that the first inner layer is between the at least one second inner layer and the outer layer;

wherein the second plurality of woven fibers are absorptive or moisture-wicking and the front portion of the outer layer comprises a porous fabric.

10. The garment of claim 9, wherein the first inner layer and the at least one second inner layer are attached to the front portion of the outer layer at a seam.

11. The garment of claim 10, wherein the first inner layer and one or more of the at least one second layers are affixed together with adhesive.

12. The garment of claim 9, further comprising at least one third inner layer formed from a third plurality of woven fibers, the at least one third inner layer sized and shaped for attachment to the back portion of the outer layer and positioned within the interior defined by the outer layer, and

wherein the at least one second inner layer of the front portion comprises a fabric-weight that is greater than a fabric-weight of the at least one third layer of the back portion of the outer layer.

13. The garment of claim 9, wherein an inner-most surface of the at least one second inner layer comprises a soft fabric or material.

14. The garment of claim 13, wherein the front portion of the outer layer and the first inner layer are integrally formed such that there is no open space between the front portion of the outer layer and the first inner layer.

15. A method of manufacturing an infant bodysuit, the method comprising the steps of:

providing an outer layer that forms a body portion, the body portion defining an interior; and

coupling a first inner layer with the outer layer such that the first inner layer is positioned within the interior defined by the body portion of the outer layer and forms a first inner-most surface within the interior;

wherein the first inner layer comprises a plurality of woven fibers that are absorptive or moisture-wicking.

16. The method of claim 15, wherein the body portion of the outer layer further comprises a front portion and a back portion, and the method further comprises the step of coupling a second inner layer with only the first inner layer positioned in the front portion of the outer layer.

17. The method of claim 15, wherein the step of coupling a first inner layer with the outer layer further comprises sewing the first inner layer to the outer layer at one or more seams.

18. The method of claim 15, wherein the step of coupling a first inner layer with the outer layer further comprises adhering at least a portion of an outer-most surface of the first inner layer with the outer layer using an adhesive.

19. The method of claim 16, wherein the second inner layer comprises a cotton-based material and the first inner layer positioned in the front portion of the outer layer comprises a heavy-weight fabric.

20. The method of claim 15, further comprising the step of coupling at least a second inner layer with the first inner-most surface of the first inner layer such that the at least one second inner layer is positioned within the interior defined by the body portion of the outer layer, and wherein the at least one second inner layer comprises a plurality of woven fibers that are absorptive or moisture-wicking.