Abstract: A tennis vest is formed from a circularly knit fabric tube having an extended turned welt at a bottom region of the vest to form outer and inner plies. The plies are sewn together along longitudinal lines to form two pockets. A pair of openings are knitted into the outer ply, each opening associated with one pocket. The pockets and openings are sized to accommodate a tennis ball in each pocket. The pockets are preferably located on a rear side of the garment.

Abstract: A brassiere for extending around a wearer's torso and supporting the wearer's breasts. The brassiere includes a torso strap supporting a pair of breast cups which in turn support the wearer's breasts. The breast cups are constructed of a two-ply fabric, preferably a circularly knit fabric, and each of the breast cups has a fold line positioned along at least a portion of its top edge so as to improve wearer comfort and reduce seams visible through clothing. Also, an underwire may be attached to an exterior side of one of the plies of the two-ply material of each of the breast cups to provide extra support. Optionally, the fold may be knit to have a thinner material than the remaining plies to facilitate formation of a smooth folded upper edge of the breast cup with a finished appearance.

Abstract: A brassiere for extending around a wearer's torso and supporting the wearer's breasts. The brassiere includes a torso strap supporting a pair of breast cups which in turn support the wearer's breasts. The breast cups are constructed of a two-ply fabric, preferably a circularly knit fabric, and each of the breast cups has a fold line positioned along at least a portion of its top edge so as to improve wearer comfort and reduce seams visible through clothing. Also, an underwire may be attached to an exterior side of one of the plies of the two-ply material of each of the breast cups to provide extra support. Optionally, the fold may be knit to have a thinner material than the remaining plies to facilitate formation of a smooth folded upper edge of the breast cup with a finished appearance.

Abstract: A tennis vest is formed from a circularly knit fabric tube having an extended turned welt at a bottom region of the vest to form outer and inner plies. The plies are sewn together along longitudinal lines to form two pockets. A pair of openings are knitted into the outer ply, each opening associated with one pocket. The pockets and openings are sized to accommodate a tennis ball in each pocket. The pockets are preferably located on a rear side of the garment.

Abstract: A circularly knit garment is provided, the garment comprising a circularly knit fabric body having an inner surface adapted to be disposed adjacent to a wearer's skin when the garment is worn. The garment further includes at least one discrete electrically-conductive region formed at the inner surface of the body during the circular knitting thereof in such as manner as to contact the wearer's skin when the garment is worn. The at least one electrically-conductive region is comprised of electrically-conductive threads, wherein the electrically-conductive threads are knit into the body such that the electrically-conductive threads at the inner surface are confined to the at least one electrically-conductive region. The at least one electrically-conductive region is further adapted to cooperate with the wearer's skin to conduct an electrical signal therebetween. An associated blank and a method of making such a garment are also provided.

Abstract: A two-ply support garment such as a brassiere, panty, or the like, is made by positioning a piece of heat-bondable polymer film between two fabric plies of a two-ply fabric blank in one or more selected areas that will become portions of the garment, heating the film to bond the plies to the opposite faces of the film in the one or more selected areas, and fashioning a two-ply garment from the blank. A brassiere embodiment includes the film in partial regions of the cups, in a central panel between the cups, and in side panels of the brassiere.

Abstract: Elastic and/or decorative trim is attached along an edge of a fabric body of a garment without sewing. The trim comprises a textile material containing fibers of thermoplastic material. The fabric edge to which the trim is attached can be any type of fabric, not necessarily containing any thermoplastic fibers. The trim is attached by wrapping the trim around the fabric edge so that the edge is sandwiched between two opposing portions of the trim, and then localized regions of the trim are heated, preferably ultrasonically, to cause the thermoplastic material in the trim to become plastic and flow together from the opposing portions, thus penetrating through the fabric edge. The thermoplastic material is then allowed to cool and solidify, thereby attaching the trim to the fabric edge. Also disclosed are garments having ultrasonically formed joints between two or more fabric panels.

Abstract: A two-ply support garment such as a brassiere, panty, or the like, is made by positioning a piece of heat-bondable polymer film between two fabric plies of a two-ply fabric blank in one or more selected areas that will become portions of the garment, heating the film to bond the plies to the opposite faces of the film in the one or more selected areas, and fashioning a two-ply garment from the blank. A brassiere embodiment includes the film in partial regions of the cups, in a central panel between the cups, and in side panels of the brassiere.

Abstract: Elastic and/or decorative trim is attached along an edge of a fabric body of a garment without sewing. The trim comprises a textile material containing fibers of thermoplastic material. The fabric edge to which the trim is attached can be any type of fabric, not necessarily containing any thermoplastic fibers. The trim is attached by wrapping the trim around the fabric edge so that the edge is sandwiched between two opposing portions of the trim, and then localized regions of the trim are heated, preferably ultrasonically, to cause the thermoplastic material in the trim to become plastic and flow together from the opposing portions, thus penetrating through the fabric edge. The thermoplastic material is then allowed to cool and solidify, thereby attaching the trim to the fabric edge. Also disclosed are garments having ultrasonically formed joints between two or more fabric panels.

Abstract: A brassiere fashioned from a circularly knit fabric blank has a central panel between the breast cups that has a greater resistance to stretching than the remainder of the body of the brassiere. The brassiere preferably is formed from a blank that is knit to have two pairs of breast cups that are arranged in mirror image about a fold region at which the blank is folded to place one set of breast cups in overlying relationship with the other set of breast cups such that the resulting brassiere is a two-ply structure. The brassiere can be formed in either non-underwire or underwire form. When included, the underwires are attached either to an exterior side of one of the plies, or alternatively between the plies. The blank can be circularly knit as a two-ply tubular structure similar to a long turned welt.

Abstract: Multiple garments such as panties, briefs, bodysuits, teddys, and brassieres are produced from a single circularly knit fabric tube. Multiple garments of differing silhouettes can be produced from the same tube. The garment includes a tubular portion for encircling the torso of a wearer, and at least one non-tubular portion for forming a crotch or gusset and/or one or two shoulder straps. The non-tubular portions of two adjacent garments are cut from the same lengthwise-extending portion of the tube. The tube in one embodiment has at least one gusset panel formed therein at one longitudinal location along the tube when two garments are to be produced from the tube, and at a plurality of longitudinal locations along the tube when more than two garments are to be produced from the tube. The gusset panel has a different knit construction from the rest of the tube.

Abstract: A brassiere fashioned from a circularly knit fabric blank has a central panel between the breast cups that has a greater resistance to stretching than the remainder of the body of the brassiere. The brassiere preferably is formed from a blank that is knit to have two pairs of breast cups that are arranged in mirror image about a fold region at which the blank is folded to place one set of breast cups in overlying relationship with the other set of breast cups such that the resulting brassiere is a two-ply structure. The brassiere can be formed in either non-underwire or underwire form. When included, the underwires are attached either to an exterior side of one of the plies, or alternatively between the plies. The blank can be circularly knit as a two-ply tubular structure similar to a long turned welt.