Costumes with semi-rigid fabric components and method of manufacture of same

• US RE37,533 E1
• Filed: 05/03/2000
• Issued: 01/29/2002
• Est. Priority Date: 04/03/1996
• Status: Expired due to Term

• Current Assignee: Rubie's Costume Company Incorporated
• Original Assignee: Rubie's Costume Company Incorporated
• Inventors: Beige, Marc P., Kearns, John G.
• Primary Examiner(s): Morris, Terrel
• Assistant Examiner(s): Pratt, Christopher C.
• Application Number:
  US09/566,231
• Time in Patent Office: 636 Days
• Field of Search: D 2/741, D 2/189, D 2/190, 428/102, 428/187, 442/221, 442/370, 264/571, 264/257, D21/189, D21/190
• US Class Current: 428/187
• CPC Class Codes: A41D 1/00 Garments for children A41D11/00
• CPC Class Codes: A41D 27/08 Trimmings; Ornaments
• CPC Class Codes: A41H 43/00 Other methods, machines or appliances
• CPC Class Codes: B29C 44/569 Shaping and joining components with different densities or hardness
• CPC Class Codes: B32B 1/00 Layered products having a non-planar shape
• CPC Class Codes: B32B 2262/0276 Polyester fibres
• CPC Class Codes: B32B 2305/18 Fabrics, textiles
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/245 another layer next to it being a foam layer
• CPC Class Codes: D06M 15/705 Embossing; Calendering; Pressing
• CPC Class Codes: D06M 17/06 Polymers of vinyl compounds
• CPC Class Codes: D06M 23/04 Processes in which the treating agent is applied in the form of a foam
• CPC Class Codes: D06M 23/14 Processes for the fixation or treatment of textile materials in three-dimensional forms
• CPC Class Codes: Y10S 264/78 Processes of molding using vacuum
• CPC Class Codes: Y10T 428/24033 including stitching and discrete fastener[s], coating or bond
• CPC Class Codes: Y10T 428/24636 Embodying mechanically interengaged strand[s], strand-portion[s] or strand-like strip[s] [e.g., weave, knit, etc.]
• CPC Class Codes: Y10T 428/24736 Ornamental design or indicia
• CPC Class Codes: Y10T 442/3325 Including a foamed layer or component
• CPC Class Codes: Y10T 442/647 Including a foamed layer or component

Abstract

A process for manufacturing a costume having semi-rigid costume components, and the costume itself. The semi-rigid costume components are capable of being sewn to fabric to form an integrated costume. An embodiment is shown in which the costume includes a semi-rigid muscular torso suitable for a superhero chestpiece. The sewn rigid component is formed from fusing a layer of fabric to a layer of foam and the resulting laminate is vacuum molded into a three-dimensional shape.

Claims

1. A method for manufacturing a component for a costume, comprising the steps of:

(a) providing a sheet of fabric and a separate foam sheet;

(b) fusing said sheet of fabric to said foam sheet to form a fused, laminated sheet; and

,

(c) vacuum molding said laminated sheet to form the a three-dimensional shape of a human, upper torso.

2. A method for manufacturing as claimed in claim 1, further comprising the step of applying stretchable ink to said laminated sheet.

3. A method for manufacturing as claimed in claim 2, wherein said stretchable ink is applied to said laminated sheet before said step of vacuum molding.

4. A method for manufacturing as claimed in claim 1, further comprising the step of gross die cutting a first section of said laminated material, and before said step of vacuum molding.

5. A method for manufacturing as claimed in claim 4, further comprising the step of performing a fine die cut on said vacuum molded, laminated sheet.

6. A method for manufacturing as claimed in claim 5, further comprising the step of sewing said component for a costume to fabric pieces to form a complete costume.

7. A method as claimed in claim 2 wherein said step of applying stretchable ink accommodates the differences in surface configuration of said laminated sheet before and after said step of vacuum molding, to present an integrated visual effect after said step of vacuum molding.

8. A method for manufacturing as claimed in claim 1 further comprising the step of sewing said component to fabric pieces to form a unitard-style costume.

9. A three-dimensional costume component representing the pectoral and/or abdominal muscles of a well-toned human comprising:

a) a fabric layer; and

b) a foam layer;

said fabric and foam layers being fused to form a laminated sheet which is vacuum molded.

10. A three-dimensional costume component as claimed in claim 9 further comprising a stretchable ink design printed on said fabric layer.

11. A three-dimensional costume component as claimed in claim 9 wherein said costume component is in the shape of an upper torso.

12. A three-dimensional costume component as claimed in claim 9 wherein said costume component is integrated into a unitard.

13. A three-dimensional costume component as claimed in claim 9 wherein said costume component is sewn to additional fabric to form an integrated costume.

14. A costume comprising:

a costume component, said costume component comprising a first layer of fabric and a second layer of foam fused to said fabric to form a laminated sheet, said laminated sheet being vacuum molded into a three-dimensional desired shape in the shape of an upper torso.

15. A costume as claimed in claim 14, wherein said first layer of fabric comprises polyester.

16. A costume as claimed in claim 14, in which said costume component further has stretchable ink applied to said fabric of said laminated sheet.

17. A costume as claimed in claim 14, in which said costume component is sewn to fabric pieces to form a unitard.

18. A costume as claimed in claim 14, in which said costume component comprises a chestpiece sewn to fabric, said chestpiece having stretchable ink on its surface.

19. A costume, said costume comprising a semi-rigid and three-dimensional upper-torso component, said upper torso component comprising a layer of fabric, heat laminated and fused to a layer of foam, said upper-torso component being vacuum formed into a three-dimensional shape of a well-toned human and sewn to other fabric components.

20. A costume as claimed in claim 19, in which said other fabric components together with said upper torso component form a unitard.

21. A costume as claimed in claim 19, in which said semi-rigid component has stretchable ink applied on its surface.

22. A method for manufacturing a component for a costume as claimed in claim 19 wherein said layer of foam comprises H-cell foam material.

23. A method for manufacturing a component for a costume, comprising the steps of:

(a) providing a sheet of fabric and a separate foam sheet;

(b) fusing said sheet of fabric to said foam sheet to form a fused, laminated sheet; and

,

(c) molding said laminated sheet to form a three-dimensional shape of a human upper torso.

24. A method for manufacturing as claimed in claim 23, further comprising the step of applying stretchable ink to said laminated sheet.

25. A method for manufacturing as claimed in claim 24, wherein said stretchable ink is applied to said laminated sheet before said step of molding.

26. A method as claimed in claim 24 wherein said step of applying stretchable ink accommodates the differences in surface configuration of said laminated sheet before and after said step of molding, to present an integrated visual effect after said step of molding.

27. A method for manufacturing as claimed in claim 23, further comprising the step of gross die cutting a first section of said laminated material, and before said step of molding.

28. A method for manufacturing as claimed in claim 27, further comprising the step of performing a fine die cut on said molded, laminated sheet.

29. A method for manufacturing as claimed in claim 28, further comprising the step of sewing said component for a costume to fabric pieces to form a complete costume.

30. A method as claimed in claim 29 wherein said sewing step comprises the use of conventional sewing techniques.

31. A method for manufacturing as claimed in claim 23 further comprising the step of sewing said component to fabric pieces to form a unitard-style costume.

32. A method for manufacturing a component for a costume claimed in claim 23, in which said sheet of fabric forms the top layer of said laminated sheet.

33. A three-dimensional costume component as claimed in claim 23 wherein said foam layer comprises H-cell foam material.

34. A method for manufacturing a component for a costume as claimed in claim 23 wherein said three-dimensional shape of said human upper torso is fabric-covered.

35. A costume component as claimed in claim 23 wherein said fusing step is performed by heat and pressure.

36. A three-dimensional costume component representing the pectoral and/or abdominal muscles of a well-toned human comprising:

a) fabric layer; and

b) a foam layer;

said fabric d foam layers being fused to form a laminated sheet which is molded.

37. A three-dimensional costume component as claimed in claim 36 further comprising a stretchable ink design printed on said fabric layer.

38. A three-dimensional costume component as claimed in claim 36 wherein said costume component is in the shape of an upper torso.

39. A three-dimensional costume component as claimed in claim 36 wherein said costume component is integrated into a unitard.

40. A three dimensional costume as claimed in claim 39 wherein said costume component is integrated into a unitard by conventional sewing.

41. A three-dimensional costume component as claimed in claim 36 wherein said costume component is sewn to additional fabric to form an integrated costume.

42. A three-dimensional costume component representing the pectoral and/or abdominal muscles of a well-toned human as claimed in claim 36 in which said fabric layer forms the top layer of said laminated sheet.

43. A three-dimensional costume component as claimed in claim 36 wherein said foam layer comprises H-cell foam material.

44. A three-dimensional costume component as claimed in claim 36 wherein said laminated sheet which is molded is fabric-covered.

45. A three dimensional costume component as claimed in claim 36 wherein said fusing is performed by heat and pressure.

46. A costume comprising:

47. A costume as claimed in claim 46, wherein said first layer of fabric comprises polyester.

48. A costume as claimed in claim 46, in which said costume component further has stretchable ink applied to said fabric of said laminated sheet.

49. A costume as claimed in claim 46, in which said costume comment is sewn to fabric pieces to form a unitard.

50. A costume as claimed in claim 46, in which said costume component comprises a chestpiece sewn to fabric, said chestpiece having stretchable ink on its surface.

51. A costume as claimed in claim 46 in which said first layer of fabric is the top layer of said laminated sheet.

52. A costume as claimed in claim 46 wherein said layer of foam comprises H-cell foam material.

53. A costume as claimed in claim 46 wherein said costume component is attachable by conventional sewing technique to at least one additional fabric-only piece.

54. A costume as claimed in claim 46 wherein said three-dimensional desired shape in the shape of an upper torso is fabric-covered.

55. A costume as claimed in claim 46 wherein said fusing is performed by heat and pressure.

56. A costume, said costume comprising a semi-rigid and three-dimensional upper-torso component, said upper torso component comprising a layer of fabric, heat laminated and fused to a layer of foam, said upper-torso component being formed into a three-dimensional shape of a well-toned human and sewn to other fabric components.

57. A costume as claimed in claim 56, in which said other fabric components together with said upper torso component form a unitard.

58. A costume as claimed in claim 56, in which said semi-rigid component has stretchable ink applied on its surface.

59. A costume as claimed in claim 56 wherein said layer of fabric is the top layer of said three-dimensional upper torso component.

60. A costume as claimed in claim 56 wherein said layer of foam comprises H-cell foam material.

61. A costume as claimed in claim 56 wherein said upper torso component is integrated to said other fabric components by conventional sewing techniques.

62. A costume as claimed in claim 56 wherein said upper-torso component is fabric-covered.

63. A costume as claimed in claim 56 wherein fusing is performed by heat and pressure.