WO2001094674A2

WO2001094674A2 - Process for manufacturing shirts with inset sleeves

Info

Publication number: WO2001094674A2
Application number: PCT/US2001/018385
Authority: WO
Inventors: Joseph Richard Alberts; Michael Joseph Nelson; Brendon Frank Ribble
Original assignee: Kimberly-Clark Worldwide, Inc.
Priority date: 2000-06-07
Filing date: 2001-06-07
Publication date: 2001-12-13
Also published as: GB2380394A; KR20030017989A; AU2001271289A1; GB0300033D0; MXPA02012116A; WO2001094674A3; GB2380394B; DE10196321T5; KR100714954B1

Abstract

The present invention provides a continuous process for the manufacture of a garment. A web of fabric including opposing web side edges is provided. The intermittently cutting the web of fabric is intermittently cut, thereby forming edges defining neck openings in the web fabric. The web of fabric is cut thereby defining discrete garment-sized pieces. Each of the discrete garment-sized piece of the web of fabric includes at least one neck opening, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, two opposing garment end portions, and a pair of opposing piece side edges. The opposing piece side edges of the discrete garment-sized piece are proximate a pair of opposing garment bottom edges of the garment. The discrete garment-sized piece of the web of fabric is folded, whereby one of the garment bottom edges of the pair of opposing garment bottom edges is brought into contact with the other garment bottom edge. At least a portion of the pair of opposing garment side edges of the front panel is fastened to at least a portion of the pair of opposing garment side edges of the back panel to form a pair of garment side seams.

Description

PROCESS FOR MANUFACTURING SHIRTS WITH INSET SLEEVES

Background of the Invention

This invention pertains to a continuous process for the manufacture of garments such as shirts intended for everyday wear, and more particularly to a process for the continuous manufacture of tee-shirt type garments.

Manufacturers are always looking for new, cost-effective, high-speed continuous processes for manufacturing inexpensive clothing, both disposable and reusable garments, for everyday use. In addition, consumers are interested in dress and active wear that is comfortable and relatively inexpensive.

Previous methods used in clothing manufacture require pieces of fabric, such as cloth or woven material, to be cut from a larger bolt of the fabric into specific patterns. The pieces are then sewn together in a multi-step cut and piece process for assembly into finished articles of clothing. Such cut and piece processes are labor and time intensive. The process speeds typically depend on the speed of the final sewing stages of the cut and piece process.

Summary of the Invention

Thus, there is a need to provide an improved process for manufacturing garments, including washable and disposable garments. There is also a need to provide comfortable and inexpensive active wear garments. In addition, the garments need to be easy to put on and durable during wear. In response to these needs, an improved cost effective, high speed process for manufacturing shirts, tee-shirts, wraps, robes, gowns, jackets, coats, and the like has been discovered.

One embodiment of the present invention is a continuous process for the manufacture of a shirt-type garment to be worn about the upper body. Numerous features and advantages of the present invention will appear from the following description. In the description, reference is made to the accompanying drawings which illustrate desired embodiments of the invention. Such embodiments do not represent the full scope of the invention. Reference should, therefore, be made to the claims herein for interpreting the full scope of the invention.

Brief Description of the Drawings

The above-mentioned and other features of the present invention and the manner of attaining them will become more apparent, and the invention itself will be better understood by reference to the following description of the invention, taken in conjunction with the accompanying drawings, wherein:

Figure 1 is a diagram of one embodiment of the present invention.

Figure 2 is a diagram of another embodiment of the present invention.

Figure 3 is a top plan view of a garment made by the present invention in a pre- assembled flat configuration.

Figure 4 is a top plan view of a garment made by the present invention in a pre- assembled flat configuration.

Figure 5 is a perspective view of the front of a garment made by the present invention.

Figure 6 is a perspective view of the front of a garment made by the present invention.

Figure 7 is a back plan view of a garment made by the present invention in a post- assembled flat configuration.

Figure 8 is a front plan view of a garment made by the present invention in a post- assembled flat configuration. Figure 9 is a back plan view of a garment made by the present invention in a post- assembled flat configuration.

Figure 10 is a front plan view of a garment made by the present invention in a post- assembled flat configuration.

Figure 11 is a cross sectional view of a seam.

Figure 12 is a cross sectional view of a seam.

Figure 13 is a cross sectional view of a seam.

Figure 14 is a cross sectional view of a seam.

Figure 15 is a cross sectional view of a seam.

Figure 16 is a cross sectional view of a seam.

Figure 17 is a cross sectional view of the face to face orientation of the webs of fabric.

Figure 18 is a cross sectional view of the side by side orientation of the webs of fabric.

Figure 19 is a cross sectional view of a seam.

Figure 20 is a cross sectional view of a seam.

Figure 21 is a cross sectional view of a seam.

Figure 22 is a cross sectional view of a seam.

Figure 23 is a cross sectional view of a seam.

Figure 24 is a cross sectional view of a seam.

Figure 25 is a diagram of one embodiment of the present invention. Figure 26 is a diagram of another embodiment of the present invention.

Figure 27 is a perspective view of the front of a garment made by the present invention.

Figure 28 is a perspective view of the front of a garment made by the present invention.

Figure 29 is a back plan view of a garment made by the present invention in a post- assembled flat configuration.

Figure 30 is a front plan view of a garment made by the present invention in a post- assembled flat configuration.

Figure 31 is a back plan view of a garment made by the present invention in a post- assembled flat configuration.

Figure 32 is a front plan view of a garment made by the present invention in a post- assembled flat configuration.

Figure 33 is a top plan view of a garment made by the present invention in a pre- assembled flat configuration.

Figure 34 is a top plan view of a garment made by the present invention in a pre- assembled flat configuration.

Figure 35 is a cross sectional view of a seam.

Figure 36 is a cross sectional view of a seam.

Figure 37 is a cross sectional view of a seam.

Figure 38 is a cross sectional view of a seam.

Figure 39 is a cross sectional view of a seam. Figure 40 is a cross sectional view of a seam.

Figure 41 is a top plan view of a garment made by the present invention in a pre- assembled flat configuration.

Figure 42 is a cross sectional view of the face to face orientation of the webs of fabric.

Figure 43 is a cross sectional view of the side by side orientation of the webs of fabric.

Figure 44 is a cross sectional view of a seam.

Figure 45 is a cross sectional view of a seam.

Figure 46 is a cross sectional view of a seam.

Figure 47 is a cross sectional view of a seam.

Figure 48 is a cross sectional view of a seam.

Figure 49 is a cross sectional view of a seam.

Figure 50 is a diagram of one embodiment of the present invention.

Figure 51 is a diagram of another embodiment of the present invention.

Figure 52 is a perspective view of the front of a garment made by the present invention.

Figure 53 is a perspective view of the front of a garment made by the present invention.

Figure 54 is a back plan view of a garment made by the present invention in a post- assembled flat configuration.

Figure 55 is a front plan view of a garment made by the present invention in a post- assembled flat configuration. Figure 56 is a back plan view of a garment made by the present invention in a post- assembled flat configuration.

Figure 57 is a front plan view of a garment made by the present invention in a post- assembled flat configuration.

Figure 58 is a top plan view of a garment made by the present invention in a pre- assembled flat configuration.

Figure 59 is a top plan view of a garment made by the present invention in a pre- assembled flat configuration.

Figure 60 is a top plan view of a garment made by the present invention in a pre- assembled flat configuration.

Figure 61 is a cross sectional view of the face to face orientation of the webs of fabric.

Figure 62 is a cross sectional view of the side by side orientation of the webs of fabric.

Figure 63 is a top plan view of a garment made by the present invention in a pre- assembled flat configuration.

Figure 64 is a top plan view of a garment made by the present invention in a pre- assembled flat configuration.

Figure 65 is a top plan view of a garment made by the present invention in a pre- assembled flat configuration.

Figure 66 is a top plan view of a garment made by the present invention in a pre- assembled flat configuration.

Figure 67 is a cross sectional view of a seam.

Figure 68 is a cross sectional view of a seam. Figure 69 is a cross sectional view of a seam.

Figure 70 is a cross sectional view of a seam.

Figure 71 is a cross sectional view of a seam.

Figure 72 is a cross sectional view of a seam.

Figure 73 is a cross sectional view of a seam.

Figure 74 is a cross sectional view of a seam.

Figure 75 is a cross sectional view of a seam.

Figure 76 is a cross sectional view of a seam.

Figure 77 is a cross sectional view of a seam.

Figure 78 is a cross sectional view of a seam.

Figure 79 is a diagram of one embodiment of the present invention.

Figure 80 is a diagram of another embodiment of the present invention.

Figure 81 is a top plan view of a garment made by the present invention in a pre- assembled flat configuration.

Figure 82 is a top plan view of a garment made by the present invention in a pre- assembled flat configuration.

Figure 83 is a top plan view of a garment made by the present invention in a pre- assembled flat configuration.

Figure 84 is a top plan view of a garment made by the present invention in a pre- assembled flat configuration. Figure 85 is a top plan view of a garment made by the present invention in a pre- assembled flat configuration.

Figure 86 is a cross sectional view of the face to face orientation of the webs of fabric.

Figure 87 is a cross sectional view of the side by side orientation of the webs of fabric.

Figure 88 is a perspective view of the front of a garment made by the present invention.

Figure 89 is a perspective view of the front of a garment made by the present invention.

Figure 90 is a back plan view of a garment made by the present invention in a post- assembled flat configuration.

Figure 91 is a front plan view of a garment made by the present invention in a post- assembled flat configuration.

Figure 92 is a back plan view of a garment made by the present invention in a post- assembled flat configuration.

Figure 93 is a front plan view of a garment made by the present invention in a post- assembled flat configuration.

Figure 94 is a cross sectional view of a seam.

Figure 95 is a cross sectional view of a seam.

Figure 96 is a cross sectional view of a seam.

Figure 97 is a cross sectional view of a seam.

Figure 98 is a cross sectional view of a seam.

Figure 99 is a cross sectional view of a seam. Figure 100 is a cross sectional view of a seam. Figure 101 is a cross sectional view of a seam. Figure 102 is a cross sectional view of a seam. Figure 103 is a cross sectional view of a seam. Figure 104 is a cross sectional view of a seam. Figure 105 is a cross sectional view of a seam.

Definitions

Within the context of this specification, each term or phrase below will include the following meaning or meanings:

(a) "Bonded" refers to the joining, adhering, connecting, attaching, or the like, of two elements. Two elements will be considered to be bonded together when they are bonded directly to one another or indirectly to one another, such as when each is directly bonded to intermediate elements. The act of bonding, joining, adhering, connecting, attaching, or the like, of two elements is understood to include the two elements, such as edges, or regions adjacent the elements, such as edges.

(b) "Bonded carded fabric or web", "bonded carded web", and "bonded carded fabric" refer to fabric or webs made from staple fibers which are sent through a combing or carding unit, which breaks apart and aligns the staple fibers in the machine direction to form a generally machine direction-oriented fibrous nonwoven web. Such fibers are usually purchased in bales which are placed in a picker which separates the fibers prior to the carding unit. Once the web or fabric is formed, it is then bonded by one or more of several known bonding methods. Once such bonding method is powder bonding, wherein a powdered adhesive is distributed through the web or fabric and then activated, usually by heating the fabric and adhesive with hot air. Another suitable bonding method is pattem boding, wherein heated calendar rolls or ultrasonic bonding equipment are used to bond the fibers together, usually in a localized bond pattern, though the fabric can be bonded across its entire surface if so desired. Another suitable and well-known bonding method, particularly when using bi-component staple fibers, is through-air bonding.

(c) "Cross machine direction" means a direction generally perpendicular to the machine direction.

(d) "Disposable" includes being disposed of after use, and not intended to be washed and reused.

(e) "Disposed", "disposed on", "disposed with", "disposed at", "disposed near", and variations thereof are intended to mean that one element can be integral or unitary with another element, or that one element can be a separate structure joined to or connected to or placed with or placed near another element.

(f) "Elasticity" and "elastic" include that property of a material by virtue of which it tends to substantially recover to its original size and shape after removal of a force causing deformation of the material.

(g) "Elastically connected" and "elastically connecting" refer to two elements being separated by and bonded to an elastic member, where the relative position of the two elements may change due to extension of the elastic member.

(h) "Elongation" includes the ratio of the extension of a material to the length of a material prior to the extension. Elongation is expressed in percent.

(i) "Extension", "extend", and "extended" include the change in length of a material due to stretching. Extension is expressed in units of length.

0^') "Fabric" is used to refer to all of the woven, knitted, and nonwoven webs. (k) "Flexible" refers to materials or fabrics that are compliant and readily conform to the general shape and contours of an individual's body.

(I) "Force" includes a physical influence exerted by one body on another which produces acceleration of bodies that are free to move and deformation of bodies that are not free to move. Force is expressed in grams-force.

(m) "Foreshortened" and "foreshortening" include to shorten beforehand, that is, before a subsequent step.

(n) "Front" and "back" are used to designate relationships relative to the garment itself, rather than to suggest any position the garment assumes when it is positioned on a wearer.

(o) "Gatherable" material is one which, when bonded to the reticular web with the latter under tension, will gather, with the formation of puckers or gathers, to accommodate contraction of the reticulated web upon release of the tensioning forces.

(p) "Machine direction" means the direction in which it is produced or the length of fabric moving in the direction of the machine operations.

(q) "Meltblown fibers" means fibers formed by extruding a molten thermoplastic material through a plurality of fine, usually circular, die capillaries as molten threads or filaments into converging high velocity, usually hot gas (e.g. air) streams which attenuate the filaments of molten thermoplastic material to reduce their diameter, which may be to microfiber diameter. Thereafter, the meltblown fibers are carried by the high velocity gas stream and are deposited on a collecting surface to form a web of randomly disbursed meltblown fibers. Such a process is disclosed, for example in U.S. Patent No. 3,849,241 to Butin, et al. Meltblown fibers are microfibers which may be continuous or discontinuous, are generally smaller than

10 microns in average diameter, and are generally tacky when deposited onto a collecting surface.

(r) "Member" when used in the singular can have the dual meaning of a single element or a plurality of elements. (s) "Multi-layer laminate" means a laminate wherein some of the layers are spunbond and some are meltblown such as a spunbond/meltblown/spunbond (SMS) laminate and other as disclosed in U.S. Patent No. 4,041 ,203 to Brock et al., U.S. Patent No. 5,169,706 to Collier et al., U.S. Patent No. 5,145,727 to Potts et al., U.S. Patent No.

5,178,931 to Perkins, et al., and U.S. Patent No. 5,188,885 to Timmons et al. Such a laminate may be made by sequentially depositing onto a moving forming belt first a spunbond fabric layer, then a meltblown fabric layer and last another spunbond layer and then bonding the laminate in a manner described below. Alternatively, the fabric layers may be made individually, collected in rolls, and combined in a separate bonding step. Such fabrics usually have a basis weight of from about 0.1 to 12 osy (6 to 400 gsm), or more particularly from about 0.75 to about 3 osy. Multilayer laminates may also have various numbers of meltblown layers or multiple spunbond layers in may different configurations and may include other materials like films or coform materials.

(t) "Neckable material" means any material which can be necked.

(u) "Necked material" refers to any material which has been constricted in at least one dimension by processes such as, for example, drawing or gathering.

(v) "Non-elastic" or "inelastic" refers to any material that does not fall within the definition of "elastic".

(w) "Nonwoven fabric or web", "nonwoven web", and "nonwoven fabric" mean a web having a structure of individual fibers or threads which are interlaid, but not in an identifiable manner as in a knitted fabric. Nonwoven fabrics or webs have been formed from many processes such as, for example, meltblowing processes, spunbonding processes, and bonded carded web processes. The basis weight of nonwoven fabrics is usually expressed in ounces of material per square yard (osy) or grams per square meter (gsm) and the fiber diameters are usually expressed in microns.

(x) "Operatively joined" with reference to the attachment of an elastic member to another element means that the elastic member when attached to or connected to or treated with heat with the element gives that element elastic properties. With reference to the attachment of a non-elastic member to another element, it means that the member and element can be attached in any suitable manner that permits or allows them to perform the intended or described function of the joinder. The joining, attaching, connecting or the like can be either directly, such as joining either member directly to an element, or can be indirectly by means of another member or element disposed between the first member and the first element.

(y) "Pattern" includes any geometric or non-geometric form that can include, among others, a series of connected or unconnected lines or curves, a series of parallel or nonparallel or intersecting lines or curves, a series of linear or curvilinear lines, and the like, or any combinations thereof. The pattern can include a repeating form and/or non-repeating form.

(z) "Rupture" includes the breaking or tearing apart of a material. In tensile testing, rupture refers to the total separation of a material into two parts, either all at once or in stages, or the development of a hole in some materials.

(aa) "Stretch bonded" refers to an elastomeric strand being bonded to another member while the elastomeric strand is elongated at least about 25 percent of its relaxed length. Desirably, the term "stretch bonded" refers to the situation wherein the elastomeric strand is elongated at least about 50 percent, more desirably at least about 300 percent, of its relaxed length when it is bonded to the other member.

(bb) "Stretch bonded laminate" ("SBL") refers to a composite material having at least two layers in which one layer is a gatherable layer and the other layer is a stretchable, that is, elastic, layer. The layers are joined together when the stretchable layer is in a stretched condition so that upon relaxing the layers, the gatherable layer is gathered.

(cc) "Spunbonded fibers" refers to small diameter fibers which are formed by extruding molten thermoplastic material as filaments from a plurality of fine, usually circular capillaries or spinneret with the diameter of the extruded filaments then being rapidly reduced as by, for example, in U.S. Patent No. 4,340,563 to Appel et al., and U.S. Patent No. 3,692,618 to Dorschner et al., U.S. Patent No. 3, 802,817 to Matsuki et al., U.S. Patents No. 3,338,992 and 3,341 ,394 to Kinney, U.S. Patent No. 3,502,763 to Hartman, and U.S. Patent No. 3,542,615 to Dobo et a\. Spunbond fibers are generally not tacky when they are deposited onto a collecting surface. Spunbond fibers are generally continuous and have average diameters (from a sample of at least 10) larger than 7 microns, more particularly, between about 10 and 20 microns.

(dd) "Tension" includes a uni-axial force tending to cause the extension of a body or the balancing force within that body resisting the extension.

(ee) "Two-dimensional" refers to a garment, such as a diaper, that can be opened and laid in a flat condition without destructively tearing any structure. This type of garment does not have continuous leg and waist openings when opened and laid flat, and requires a fastening device, such as adhesive tapes, to attach the garment about the wearer.

(ff) "Three-dimensional" refers to a finished garment similar to shorts or pants in that they have continuous leg and waist openings that are bounded by the material of which the garment is made. This type of garment can be opened and laid flat only by destructively tearing it. This type of garment may or may not have manually tearable seams.

(gg) "Ultimate elongation" includes the elongation at the point of rupture.

These definitions are not intended to be limiting and these terms may be defined with additional language in the remaining portion of the specification.

Detailed Description

The garment 10 is illustrated in Figures 1 and 5. The garment 10 includes opposing inner and outer surfaces 11 and 13, respectively. Within this application, the term "garment" is understood to mean shirt, tee-shirt, wrap, robe, gown, jacket, coat, or any type of upper body covering garment having variable lengths of the garment 10 itself and the sleeves (if any) as well as a variety of neck openings and garment openings, such as plackets. According to the preferred embodiment, see Figure 3, the garment 10 desirably comprises at least a front panel 20 and a back panel 30. The front panel 20 has a pair of garment side edges 22 and 24, a garment bottom edge 26 and a shoulder region 28 positioned between the garment side edges 22 and 24. The back panel 30 has a pair of garment side edges 32 and 34, a garment bottom edge 36 and a shoulder region 38 positioned between the garment side edges 32 and 34.

The garment side edge 22 is joined to the garment side edge 32 to form the garment side seam 40. The garment side edge 24 is joined to the garment side edge 34 to form the garment side seam 42. A portion of the garment side seams 40 and 42 are left unbonded or not joined, preferably in the shoulder regions 28 and 38, defining two opposing arm openings 72 and 74.

Arm coverings or sleeves 76 and 78 may be attached to the garment end edges 80 and 82 of the sleeves 76 and 78, respectively, so as to surround, at least partially, the arm openings 72 and 74 to the arm opening edges 73 and 75, respectively, of the garment 10. In some embodiments, only one sleeve 76 or 78 may be included in the finished garment 10. The attachment of the sleeves 76 and 78 may be made non- refastenable by means as discussed below. In the alternative, the attachment of the sleeves 76 and 78 may be made refastenable by means as discussed below. The length of the sleeves 76 and 78 may vary from a length intended to at least cover the entire arm of the wearer to a caplet length or shorter. The sleeve opening end edges 84 and 86 of the sleeves 76 and 78, respectively, may be hemmed. For easier manufacture, the sleeve opening end edges 84 and 86 may be left unhemmed, facilitating easy machine cutoff.

In the embodiments of the garments 10 that do not include the sleeves 76 and 78, the unattached portion of the garment side edges 22 and 32 and the garment side edges 24, and 34, more specifically the arm opening edges 73 and 75 defining the arm openings 72 and 74, respectively, can be hemmed. For easier manufacture, the arm opening edges 73 and 75, defining the arm openings 72 and 74, may be left unhemmed, facilitating easy machine cutoff.

A neck opening 90, defined about its perimeter by edge 92, is located in at least one of the shoulder regions 28 and 38. The neck opening 90 is typically centered between the garment side edges 22 and 24 and the garment side edges 32 and 34, although such placement of the neck opening 90 is not required. The neck opening 90 may take on a variety of sizes and shapes, such as circular, oval, triangular, square, rectangular, multi-faceted, asymmetric or irregular, or the like. While the placement of the neck opening 90 may be symmetrical between the shoulder regions 28 and 38, as well as between the garment side edges 22 and 24 and the garment side edges 32 and 34, typically, the placement of the neck opening 90 is configured so that a larger portion of the neck opening 90 is located in the front shoulder region 28.

Additionally, while the shape of the neck opening 90 can be symmetrical, typically, the shape of the neck opening 90 is asymmetrical as dictated by fashion and comfort. In some embodiments of the garment 10, the edge 92 of the neck opening 90 can be hemmed. For easier manufacture, the edge 92 of the neck opening 90 may be left unhemmed, facilitating easy machine cutoff.

Various styles of a collar 94 can also be attached to the edge 92 of the neck opening 90. The attachment of the collar 94 may be made non-refastenable by means as discussed below. In the alternative, the attachment of the collar 94 may be made refastenable by means as discussed below. The collars 94 include, but are not limited to, turtlenecks, mock turtlenecks, cowls, shirt collars, tee-shirt shirt ribbed edging, decorative edging, and the like known in the garment industry.

The garment bottom edges 26 and 36 of the garment 10 may also be hemmed.

For easier manufacture, the garment bottom edges 26 and 36 of the garment 10 may be left unhemmed, facilitating easy machine cutoff.

The front panel 20, the back panel 30, or both may be cut or otherwise opened to form a slit 45 or 65 (shown in Figure 5) such as a placket. The garment 10, including one or both slits 45 and 65, can be used as a wrap, gown, robe, or the like. The slit 45 has two edges 57 and 61. The slit 65 has two edges 66 and 67. Various fastening means, such as adhesive and mechanical type fasteners 95, see the discussion below, may be used to refastenably attach or secure the edges 57 and 61 or the edges 66 and 67 together to form reclosable or refastenable garments 10. The slits 45 and 65 of the front and back panels 20 and 30, respectively, may extend from the edge 92 of the neck opening 90 to the garment bottom edges 26 and 36, respectively. In the alternative, the slits 45 and 65 may extend over only a portion of the panels 20 and 30 between the edge 92 of the neck opening 90 to the garment bottom edges 26 and 36, respectively. When the garment 10 comprises both a slit 45 in the front panel 20 and a slit 65 in the back panel 30, the slits 45 and 65 may be similar or dissimilar in size, structure, shape, and the like. It is understood that the term 'similar' as used herein is interpreted to include identical and varying levels of similarity. It is also understood that the term 'dissimilar' as used herein is interpreted to include different and varying levels of dissimilarity.

An alternate embodiment of the invention is illustrated in Figure 4. The garment 210 includes opposing inner and outer surfaces 211 and 213. According to this embodiment, the garment 210 desirably comprises at least a right front panel 220, a left front panel 221 , a right back panel 230, and a left back panel 231. The right front panel 220 has a garment side edge 222, a side edge 224, a garment bottom edge 226 and a shoulder region 228 positioned between the garment side edge 222 and the side edge 224. The left front panel 221 has a side edge 223, a garment side edge 225, a garment bottom edge 227 and a shoulder region 229 positioned between the side edge 223 and the garment side edge 225. The right back panel 230 has a garment side edge 232, a side edge 234, a garment bottom edge 236 and a shoulder region 238 positioned between the garment side edge 232 and the side edge 234. The left back panel 231 has a side edge 233, a garment side edge 235, a garment bottom edge 237 and a shoulder region 239 positioned between the side edge 233 and the garment side edge 235.

At least a portion of the side edge 224 is joined to at least a portion of the side edge 223 to form the center seam 252, the front shoulder region 254, and the front panel 250. At least a portion of the side edge 234 is joined to at least a portion of the side edge 233 to form the center seam 256, the back shoulder region 258, and the back panel 260. The garment side edge 222 is joined to the garment side edge 232 to form the side seam 240. The garment side edge 225 is joined to the garment side edge 235 to form the garment side seam 242. A portion of the garment side seams 240 and 242 are left unbonded or not joined, in the shoulder regions 254 and 258, defining two opposing arm openings 272 and 274.

In another embodiment of the present invention, the side edges 223 and 224 or a portion thereof (or, in the alternative or in addition, side edges 233 and 234 or a portion thereof) may be left unjoined, thereby forming a placket (or, alternatively, plackets) in the garment 210. The garment 210 can be used in this form as a wrap, gown, or robe, or the like. Various closure devices, discussed below, could be utilized to form a reclosable or refastenable center seam 252 or 256 or portions thereof. In other embodiments, the center seams 252 and 256, or portions thereof, may be constructed as non-refastenable seams. The center seams 252 and 256 may be constructed on a continuous or intermittent basis.

In some embodiments of the garment 210, one or both of the center seams 252 and

256 may be non-refastenable. Non-refastenable center seams 252 and 256 may be formed by any suitable means such as ultrasonic sealing, adhesive bonding, heat sealing, sewing, tape, or the like known in the art. The non-refastenable center seams 252 and 256 may be constructed on a continuous or intermittent basis. One suitable method of forming such center seams 252 and 256 is disclosed in U.S. Patent No. 4,938,753 issued July 3, 1990, to Van Gompel et al., which is incorporated herein by reference. The center seams 252 and 256 may be bonded together to form non-refastenable center seams 252 and 256.

In various embodiments of the garment 210, one or both of the center seams 252 and 256 may be refastenable. The refastenable means for securing edges include adhesive and mechanical type fasteners 295. The adhesive and mechanical type fasteners include buttons and button holes, snaps, buckles, clasps, hooks and loops, end extensions, tabs, tape, and the like which are designed or adapted to interlock or engage some type of complementary device or the inner surface 211 or the outer surface 213 of the garment 210. The refastenable center seams 252 and 256 may be constructed on a continuous or intermittent basis. In addition, elasticized fasteners may also be used in assuring better fit of the garment 210.

In various embodiments of the present invention, the front panel 250, the back panel 260, or both panels 250 and 260 may be cut or otherwise opened to form a slit 245 or 300 (shown in Figure 6) such as a placket. The garment 210 including one or both slits 245 and 300 can be used as a wrap, gown, robe, or the like. The slit 245 has two edges 257 and 261. The slit 300 has two edges 301 and 302. Various fastening means, such as adhesive and mechanical type fasteners 295, see the discussion below, may be used to refastenably attach or secure the edges 257 and 261 and the edges 301 and 302 to form reclosable or refastenable garments 210. The slits 245 and 300 of the front and back panels 250 and 260, respectively, may extend from the edge 292 of the neck opening 290 to the garment bottom edges 259 and 269, respectively. In the alternative, the slits 245 and 300 may extend over only a portion of the panels 250 and 260 between the edge 292 of the neck opening 290 to the garment bottom edges 259 and 269, respectively. When the garment 210 comprises both a slit 245 in the front panel 250 and a slit 300 in the back panel 250, the slits 245 and 300 may be similar or dissimilar in size, structure, shape, and the like. It is understood that the term 'similar' as used herein is interpreted to include identical and varying levels of similarity. It is also understood that the term 'dissimilar' as used herein is interpreted to include different and varying levels of dissimilarity.

In some embodiments, the edges 257 and 261 of the slit 245 and the edges 301 and 302 of the slit 300 may be refastenably attached or secured to each other. Various fastening means, such as adhesive and mechanical type fasteners 295, see the discussion above, may be used to refastenably attach or secure the edges 257 and 261 or the edges 301 and 302 together of the slits 245 and 300, respectively.

Arm coverings or sleeves 276 and 278 may be attached to the garment end edges 280 and 282 of the sleeves 276 and 278, respectively, so as to surround, at least partially, the arm openings 272 and 274, to the arm opening edges 273 and 275, respectively, of the garment 210. In some embodiments, only one sleeve 276 or 278 may be included in the finished garment 210. The attachment of the sleeves 276 and 278 may be made non- refastenable by means as discussed below. In the alternative, the attachment of the sleeves 276 and 278 may be made refastenable by means as discussed below. The length of the sleeves 276 and 278 may vary from a length intended to cover at least the entire arm of the wearer to a caplet length or shorter. The sleeve opening end edges 284 and 286 of the sleeves 276 and 278, respectively, may be hemmed. For easier manufacture, the sleeve opening end edges 284 and 286 may be left unhemmed, facilitating easy machine cutoff.

In the embodiments of the garments 210 that do not include the sleeves 276 and 278, the unattached portion of the garment side edges 222 and 232 and the garment side edges 225 and 235, more specifically the arm opening edges 273 and 275 defining the arm openings 272 and 274, respectively, can be hemmed. For easier manufacture, the unattached portion of the garment side edges 222 and 232 and the garment side edges 225 and 235, defining the arm openings 272 and 274, may be left unhemmed, facilitating easy machine cutoff. A neck opening 290, defined about its perimeter by edge 292, is located in at least one of the shoulder regions 254 and 258. The neck opening 290 is typically centered between the garment side edges 222 and 232 and the garment side edges 225 and 235, although such placement of the neck opening 290 is not required. The neck opening 290 may take on a variety of sizes and shapes, such as circular, oval, triangular, square, rectangular, multi-faceted, asymmetric or irregular, or the like. While the placement of the neck opening 290 may be symmetrical between the shoulder regions 254 and 258, as well as between the garment side edges 222 and 232 and the garment side edges 225 and 235, typically, the placement of the neck opening 290 is configured so that a larger portion of the neck opening 290 is located in the front shoulder region 254.

Additionally, while the shape of the neck opening 290 can be symmetrical, typically, the shape of the neck opening 290 is asymmetrical as dictated by fashion and comfort. In some embodiments of the garment 210, the edge 292 of the neck opening 290 can be hemmed. For easier manufacture, the edge 292 of the neck opening 290 may be left unhemmed, facilitating easy machine cutoff.

Various styles of a collar 294 can also be attached to the edge 292 of the neck opening 290. The attachment of the collar 294 may be made non-refastenable by means as discussed below. In the alternative, the attachment of the collar 294 may be made refastenable by means as discussed below. The collars 294 include, but are not limited to, turtlenecks, mock turtlenecks, cowls, shirt collars, tee-shirt shirt ribbed edging, decorative edging, and the like known in the garment industry.

The garment bottom edges 226, 227, 236, and 237 of the garment 210 may also be hemmed. For easier manufacture, the garment bottom edges 226, 227, 236, and 237 of the garment 210 may be left unhemmed, facilitating easy machine cutoff.

Another embodiment of the present invention is a continuous process for the manufacture of a garment 10 (see Figures 1 and 2) for wearing about the upper body comprising at least a front panel 20, a back panel 30, a neck opening 90 defined about its perimeter by edge 92, arm openings 72 and 74 defined about their perimeters by arm opening edges 73 and 75, respectively, a lower body opening 44 defined about its perimeter by garment bottom edges 26 and 36. The garment 10 comprises an inner surface 11 and an outer surface 13. The garment 10 may comprise a single layer web of fabric 15 or may comprise a multi-layer laminate web of fabric 15. In some embodiments of the present invention, the garment 10 may comprise multiple layers of the web of fabric 15. In some embodiments, the garment 10 may comprise multiple layers of the web of fabric 15. The present invention requires at least one web of fabric 15 in a single continuous process to create the garment 10.

In one embodiment of the present invention (see Figure 1), one web of fabric 15 of sufficient width of fabric to make the garment 10 is provided to produce the garment 10. The desired web of fabric 15 is nonwoven although any disposable or washable fabric can be used. (See the discussion below). The web of fabric 15 is typically unwound from a roll or other source. (Not shown).

The web of fabric 15 is desirably compliant and soft feeling to the wearer. The following description of materials from which the web of fabric 15 may be formed would also be used for the materials to form the inner surface 11 and the outer surface 13 of a multi-layer laminate web of fabric 15.

The web of fabric 15 may be any suitable material, such as a woven material, a nonwoven material, a fibrous or a polymeric film material and may be, although they need not necessarily be, an elastic material or of a stretchable nature. Suitable fibrous webs may utilize any suitable natural and/or synthetic fibers, for example, woven or nonwoven webs of fibers made of acrylic polymers, polyester, polyamide, glass, polyolefins, e.g., polyethylene and polypropylene, cellulosic derivatives such as rayon, cotton, silk, wool, pulp, paper and the like, as well as blends or combinations of any two or more of the foregoing. The web of fabric 15 may also comprise polymeric film layers such as polyethylene, polypropylene, polyamide, polyester, acrylic polymers, and compatible mixtures, blends and copolymers thereof.

The web of fabric 15 may be liquid pervious, permitting liquids to readily penetrate into its thickness, or impervious, resistant to the penetration of liquids into its thickness. The web of fabric 15 may be made from a wide range of materials, such as natural fibers (e.g. rayon, wood, or cotton fibers), synthetic fibers (e.g. polyester or polypropylene fibers), or from a combination of natural and synthetic fibers or reticulated foams and apertured plastic films. The web of fabric 15 may be woven, nonwoven, or film such as spunbonded, carded, or the like. A suitable web of fabric 15 may be carded, and thermally bonded by means well known to those skilled in the fabric art.

Alternatively, the web of fabric 15 may be derived from a spunbonded web. In a desired embodiment, the web of fabric 15 is spunbonded polypropylene nonwoven, meltblown polypropylene nonwoven and spunbonded polypropylene nonwoven laminate (SMS). The total basis weight is from about 0.4 to about 1.0 osy (more desirably 0.6 osy) and is made with about 86% spunbonded nonwoven and 14% meltblown nonwoven. A pigment such as titanium dioxide may be incorporated into the web of fabric 15. Such a spunbonded meltblown nonwoven laminate material is available from Kimberly-Clark

Corporation, Roswell, GA. The basis weight of the SMS material may vary from about 0.4 to about 1.0 osy.

In other desired embodiments, the web of fabric 15 is spunbonded polypropylene nonwoven with a wire-weave bond pattern having a grab tensile of 19 pounds as measured by ASTM D1682 and D1776, a Taber 40 cycle abrasion rating of 3.0 as measured by ASTM D1175 and Handle-O-Meter MD value of 6.6 grams and CD value of 4.4 grams using TAPPI method T402. Such a spunbonded material is available from Kimberly-Clark Corporation, Roswell, GA. The web of fabric 15 has a weight of from about 0.5 oz. per square yard (osy) to about 1.5 osy, desirably about 0.7 osy.

The web of fabric 15 may be constructed of a single spunbonded polypropylene nonwoven web having a basis weight of about 0.5 oz/yd² (17 gsm) to about 1.5 oz/yd² (51 gsm). In the structure of the garment 10, the web of fabric 15 desirably comprises a material having a basis weight of from about 0.5 oz/yd² (1 gsm) to about 1.5 oz/yd² (51 gsm). Lesser or greater basis weights may be used in the other regions of the garment 10, such as the sleeves 76 and 78, the cuffs 85 and 87, and the collar 94. Since the garment 10 is typically intended for active wear, the web of fabric 15 or portions thereof, can be made of materials having a basis weight that is abrasion resistant.

The web of fabric 15 may be any soft and flexible sheet. The web of fabric 15 may permit submersion in fresh water or salt water or treated water (chlorinated or brominated) and still retain its integrity. The web of fabric 15 may comprise, for example, a nonwoven web or sheet of a spunbonded, meltblown, or bonded-carded web composed of synthetic polymer filaments, such as polypropylene, polyethylene, polyesters, or the like, or a web of natural polymer filaments such as rayon or cotton. The web of fabric 15 may be selectively embossed or perforated with discrete slits or holes extending therethrough.

The web of fabric 15 may be further dyed, pigmented, or imprinted with any suitable color. Desirably, the web of fabric 15 is dyed, pigmented, or printed with a material which does not irritate or bleed the color onto the skin of the wearer.

For embodiments wherein the web of fabric 15 is a multi-layer laminate, both the outer surface 13 and the inner surface 11 are desirably compliant and soft feeling to the wearer. The following description of materials from which the outer surface 13 may be formed may also be used to form the material of the inner surface 11.

The outer surface 13 may be any suitable gatherable material, such as a woven material, a nonwoven material, a fibrous or a polymeric film material and may be, although they need not necessarily be, an elastic material or of a stretchable nature. Suitable fibrous gatherable webs may utilize any suitable natural and/or synthetic fibers, for example, woven or nonwoven webs of fibers made of acrylic polymers, polyester, polyamide, glass, polyolefins, e.g., polyethylene and polypropylene, cellulosic derivatives such as rayon, cotton, silk, wool, pulp, paper and the like, as well as blends or combinations of any two or more of the foregoing. The gatherable webs may also comprise polymeric film layers such as polyethylene, polypropylene, polyamide, polyester, acrylic polymers, and compatible mixtures, blends and copolymers thereof.

The outer surface 13 may be liquid pervious, permitting liquids to readily penetrate into its thickness, or impervious, resistant to the penetration of liquids into its thickness. The outer surface 13 may be made from a wide range of materials, such as natural fibers (e.g. rayon, wood, or cotton fibers), synthetic fibers (e.g. polyester or polypropylene fibers), or from a combination of natural and synthetic fibers or reticulated foams and apertured plastic films. The outer surface 13 may be woven, nonwoven, or film such as spunbonded, carded, or the like. A suitable material for the outer surface 13 may be carded, and thermally bonded by means well known to those skilled in the fabric art.

Alternatively, the outer surface 13 may be derived from a spunbonded web. In a desired embodiment, the outer surface 13 is spunbonded polypropylene nonwoven, meltblown polypropylene nonwoven and spunbonded polypropylene nonwoven laminate (SMS). The total basis weight is from about 0.4 to about 1.0 osy (more desirably 0.6 osy) and is made with about 86% spunbonded nonwoven and 14% meltblown nonwoven. A pigment such as titanium dioxide may be incorporated into the outer surface 13 and the inner surface 1. Such spunbonded meltblown nonwoven laminate material is available from Kimberly-Clark Corporation, Roswell, GA. The basis weight of the SMS material may vary from about 0.4 to about 1.0 osy.

In other desired embodiments, the outer surface 13 is spunbonded polypropylene nonwoven with a wire-weave bond pattem having a grab tensile of 19 pounds as measured by ASTM D1682 and D1776, a Taber 40 cycle abrasion rating of 3.0 as measured by ASTM D1175 and Handle-O-Meter MD value of 6.6 grams and CD value of 4.4 grams using TAPPI method T402. Such spunbonded material is available from Kimberly-Clark Corporation, Roswell, GA. The outer surface 13 has a weight of from about 0.5 oz. per square yard (osy) to about 1.5 osy, desirably about 0.7 osy.

The outer surface 13 may be constructed of a single spunbonded polypropylene nonwoven web having a basis weight of about 0.5 oz yd² (17 gsm) to about 1.5 oz/yd² (51 gsm). In the structure of the garment 10, the outer surface 13 desirably comprises a material having a basis weight of from about 0.5 oz/yd² (17 gsm) to about 1.5 oz/yd² (51 gsm). Lesser or greater basis weights may be used in the other regions of the garment 10. Since the garment 10 is typically intended for active wear, the outer surface 13 or portions thereof, can be made of materials having a basis weight which is abrasion resistant.

The inner surface 11 may be any soft and flexible sheet. The inner surface 11 may permit submersion in fresh water or salt water or treated water (chlorinated or brominated) and still retain its integrity. The inner surface 11 may comprise, for example, a nonwoven web or sheet of a spunbonded, meltblown, or bonded-carded web composed of synthetic polymer filaments, such as polypropylene, polyethylene, polyesters, or the like, or a web of natural polymer filaments such as rayon or cotton. The inner surface 11 may be selectively embossed or perforated with discrete slits or holes extending therethrough. Suitable adhesives for adhering the laminate layers can be obtained from Findley Adhesives, Inc. of Wauwatosa, Wisconsin. The outer surface 13 and the inner surface 11 may be further dyed, pigmented, or imprinted with any suitable color. Desirably, the inner surface 11 is either dyed, pigmented, or printed with a material which does not irritate or bleed the color onto the skin of the wearer.

The web of fabric 15 includes a pair of opposing web side edges 46 and 47. A repeating series of pairs of opposing indentations 68 and 70 are cut into the web side edges 46 and 47 of the web of fabric 15 by a die cutter 14. (See Figure 1). The location of the opposing indentations 68 and 70 corresponds to the arm openings 72 and 74, defined by the arm opening edges 73 and 75, respectively, of the finished garment 10. The opposing indentations 68 and 70 may be produced by a die cut operation, an ultrasonic operation, or any other suitable method of operation. The material to be removed from the opposing indentations 68 and 70 may be removed by any method known in the art, desirably a vacuum source (not shown).

The opposing indentations 68 and 70 may take on a variety of sizes and shapes, such as slit, circular, oval, triangular, square, rectangular, multi-faceted, asymmetric or irregular, or the like. The pattem of the opposing indentations 68 and 70 is restricted only by fashion and the minimum amount of the web of fabric 15 that must remain having a sufficient integrity to withstand the remaining steps or operations of the process of manufacture. The arm openings 72 and 74, alternately, the opposing indentations 68 and 70 may be similar or dissimilar in shape, structure, size, and the like from each other within the finished garment 10.

In some embodiments, the operation of cutting the opposing indentations 68 and 70 into the web side edges 46 and 47 of the web of fabric 15 may be eliminated. As the pattem of the garment 10 is restricted only by fashion and the minimum amount of the web of fabric 15 that must remain having a sufficient integrity to withstand the operations or steps of the process of manufacture, one can simply design the garment 10 such that this operation of cutting the opposing indentations 68 and 70 into web side edges 46 and 47 (or, alternatively, the garment side edges 22 and 32 and the garment side edges 24 and 34) of the web of fabric 15 is not required. As discussed above, the arm openings 72 and 74 may be created by leaving a portion of the garment side edges 22 and 32 and the garment side edges 24 and 34, respectively, unattached. A repeating series of openings 89 is cut by the die cutter 14 into the web of fabric 15. The location of the opening 89 corresponds to the neck opening 90 in the finished garment 10. The openings 89 may be produced by a die cut operation, an ultrasonic operation, or any other suitable method of operation known in the art. It is understood that while Figure 1 shows the die cutter 14 cutting the opening 89 and the opposing indentations 68 and 70, these cutting operations could be performed by separate devices and at different stages within the manufacturing process. The material to be removed from the openings 89 may be removed by any method known in the art, desirably a vacuum source (not shown). The opening 89 may take on a variety of sizes and shapes, such as slit, circular, oval, triangular, square, rectangular, multi-faceted, asymmetric or irregular, or the like. The pattern of the opening 89 is restricted only by fashion and the minimum amount of the web of fabric 15 that must remain having a sufficient integrity to withstand the remaining steps or operations of the process of manufacture.

The placement of the opening 89 in relation to a pair of opposing indentations 68 and 70, while in a typical garment 10, the opening 89 is centrally located between the pair of opposing indentations 68 and 70, is restricted only by fashion and the minimum amount of the web of fabric 15 that must remain having sufficient integrity to withstand the remaining steps or operations of the process of manufacture. For example, the placement of the opening 89 between the pair of opposing indentations 68 and 70 may be symmetrically or asymmetrically located.

The web of fabric 15 is cut by a die cutter 71 into discrete garment-sized pieces 17 wherein each discrete garment-sized piece 17 contains at least one opening 89, one pair of opposing indentations 68 and 70, one pair of opposing web side edges 46 and 47, and opposing garment end portions 62 and 64. The location of the opposing web side edges 46 and 47 of the web of fabric 15 (or, alternatively, the discrete garment-sized piece 17) corresponds to the garment side edge 22 of the front panel 20 and garment side edge 32 of the back panel 30 and the garment side edge 24 of the front panel 20 and the garment side edge 34 of the back panel 30, respectively, in the finished garment 10. The opposing garment end portions 62 and 64 are adjacent to the garment bottom edge 26 of the front panel 20 and the garment bottom edge 36 of the back panel 30, respectively, in the finished garment 10. The location of the opposing piece side edges 35 and 37 of the discrete garment- sized piece 17 corresponds to the garment bottom edge 26 of the front panel 20 and the garment bottom edge 36 of the back panel 30, respectively, in the finished garment 10. It is understood that while the piece side edges 35 and 37 of the discrete garment-sized piece 17 may typically become the garment bottom edges 26 and 36 in the finished garment 10, fabric may be removed from or added to the piece side edges 35 and 37 of the discrete garment-sized piece 17 to create the garment bottom edges 26 and 36 in the finished garment 10.

Each discrete garment-sized piece 17 of the web of fabric 15 is transported, typically by vacuum screens, belts, or conveyors, through hemming, folding, and fastening operations (not shown). The folding operations are desirably carried out by tuckers and folders, as well as any other known means. The discrete garment-sized piece 17 of the web of fabric 15 is folded by a folder 96 so as to bring together the opposing garment end portions 62 and 64 such that web side edge 46 of the web of fabric 15 is folded on to itself forming the garment side edge 22 of the front panel 20 and the garment side edge 32 of the back panel 30. The web side edge 47 of the web of fabric 15 is folded on to itself forming the garment side edge 24 of the front panel 20 and the garment side edge 34 of the back panel 30.

The mating of the garment side edge 22 and the garment side edge 32 as well as the mating of the garment side edge 24 and the garment side edge 34 form the garment side seams 40 and 42, respectively, of the garment 10. It may be desirable to redirect (or reorient) the discrete garment-sized piece 17 of the web of fabric 15 to allow easy bonding of the garment side seams 40 and 42 of the garment 10. The turning operations are desirably carried out by turn rolls and turn tables, as well as any other known means. The discrete garment-sized piece 17 of the web of fabric 15 may be reoriented 90 degrees (not shown). It is understood that while the web side edges 46 and 47 may typically become the garment side edges 22 and 32 and the garment side edges 24 and 34, respectively, in the finished garment 10, fabric may be removed from or added to the web side edges 46 and 47 to create the garment side edges 22 and 32 and the garment side edges 24 and 34, respectively, in the finished garment 10.

In various embodiments of the present invention, one or both of the garment side seams 40 and 42 can be constructed as non-refastenable seams or as refastenable seams. Any excess material of the web of fabric 15 may be removed from the edges of the garment side seams 40 and 42 to reduce and smooth out the garment side seams 40 and 42. The non-refastenable garment side seams 40 and 42 may be formed by any suitable means such as ultrasonic sealing, adhesive bonding, tape, heat sealing, sewing, or any method of fastening known in the art. (Sewing equipment 118 is shown in Figure 1). The non-refastenable garment side seams 40 and 42 may be constructed on a continuous or intermittent basis. One suitable method of forming such garment side seams 40 and 42 is disclosed in U.S. Patent No. 4,938,753 issued July 3, 1990, to Van Gompel et al., which is incorporated herein by reference. The garment side seams 40 and 42 may be bonded together to form non-refastenable garment side seams 40 and 42.

In other embodiments of the present invention, the garment side edges 22 and 32 and the garment side edges 24 and 34 of the garment 10 may be held together in the finished garment 10 to form refastenable garment side seams 40 and 42, respectively. The refastenable means for securing the garment side edges 22 and 32 and the garment side edges 24 and 34 of the garment 10 include refastenable adhesive and mechanical type fasteners 95. The mechanical type fasteners 95 include buttons and button holes, snaps, buckles, clasps, hooks and loops, end extensions, tabs, tape, and the like which are designed or adapted to interlock or engage some type of a complementary device or the outer surface 13 or the inner surface 11 of the garment 10.

In addition, elasticized fasteners 95 may also be used in assuring better fit of the garment 10. If the garment 10 includes refastenable garment side seams 40 and 42, the refastenable means are desirably strategically placed on the web of fabric 15 before the web of fabric 15 is cut into discrete garment-sized pieces 17. The folding and redirection operations may be eliminated when refastenable garment side seams 40 and 42 are included in the garment 10. However, there may be packaging reasons for which one would still carry out these two steps.

The garment side seams 40 and 42 of the present invention may take on a variety of structures or configurations known in the art. One embodiment of the garment side seams 40 and 42 is an out-turned configuration as illustrated in Figure 12. Such configured garment side seams 40 and 42 are formed by securing together at least a portion of the out-turned portions of the garment side edges 22 and 32 and the garment side edges 24 and 34, respectively. The inner surface 11 of the garment side edges 22 and 24 of the front panel 20 and the garment side edges 32 and 34 of the back panel 30, respectively, are brought into contact with each other, respectively.

Another embodiment of the garment side seams 40 and 42 is an in-turned configuration as illustrated in Figure 13. Such configured garment side seams 40 and 42 are formed by securing together at least a portion of the in-turned portions of the garment side edges 22 and 32 and the garment side edges 24 and 34, respectively. The outer surface 13 of the garment side edges 22 and 24 of the front panel 20 and the garment side edges 32 and 34 of the back panel 30 are brought into contact with each other, respectively.

Another embodiment of the garment side seams 40 and 42 is an over-lapped configuration as illustrated in Figure 11. Such configured garment side seams 40 and 42 are formed by securing together at least a portion of the over-lapped portions of the garment side edges 22 and 32 and the garment side edges 24 and 34, respectively. The inner surface 11 of one of the garment side edges 22 and 32 and one of the garment side edges 24 and 34 are brought into contact with the outer surface 13 of the other side edge of each pair of side edges.

Another embodiment of the garment side seams 40 and 42 is an over-lapped configuration as illustrated in Figure 14. Such a configured garment side seam 40 is formed by folding the garment side edge 22 or the garment side edge 32. The outer surface 13 of the folded portion and the inner surface 11 of the unfolded portion of the garment side edge 22 or 32 and the corresponding portion of the front panel 20 or the back panel 30, respectively, is brought into contact with the inner surface 11 or the outer surface 13 of the non-folded garment side edge 32 or 22 and the corresponding portion of the back panel 30 or the front panel 20.

The garment side seam 42 is formed by folding back the garment side edge 24 or the garment side edge 34. The outer surface 13 of the folded portion and the inner surface 11 of the unfolded portion of the garment side edges 24 or 34 and the corresponding portion of the front panel 20 or the back panel 30, respectively, is brought into contact with the inner surface 11 or the outer surface 13 of the non-folded garment side edge 34 or 24 and the corresponding portion of the back panel 30 or the front panel 20. It is understood that the folding back of a garment side edge 22, 24, 32, or 34 could be performed such that the inner surface 11 would be exposed along the fold.

The garment end portions 62 and 64 of the discrete garment-sized pieces 17 of the web of fabric 15 may be hemmed in the finished garment 10. The garment end portions 62 and 64 can be hemmed by any method or style known in the art. In some embodiments, it may be desirable to leave the garment end portions 62 and 64 unhemmed. The garment bottom edges 26 and 36 of the discrete garment-sized pieces 17 of the web of fabric 15 may be hemmed in the finished garment 10. The garment bottom edges 26 and 36 can be hemmed by any method or style known in the art.

(Sewing equipment 117 is shown in Figure 1). In some embodiments, it may be desirable to leave the garment bottom edges 26 and 36 unhemmed.

As shown in Figures 7 and 8, the garment 10 may include sleeves 76 and 78. In some embodiments, only one sleeve 76 or 78 may be included in the finished garment 10. The sleeves 76 and 78 are made of pieces of a sleeve web fabric 77 and 79, the same or different from the material of the web of fabric 15. The pieces of a sleeve web fabric 77 and 79 are provided as sleeve-sized pieces 19 cut from a sleeve web of fabric 18. The pieces of a sleeve web fabric 77 and 79 may take on a variety of sizes and shapes, such as circular, oval, triangular, square, rectangular, multi-faceted, asymmetric or irregular, or the like. The pattem of the sleeve web fabric 77 and 79 is restricted only by fashion and the minimum amount of the material of the pieces of a sleeve web fabric 77 and 79 that is necessary to complete the remaining steps or operations of the process of manufacture. The sleeves 76 and 78, alternately the pieces of sleeve web fabric 77 and 79, may be similar or dissimilar in shape, structure, material, size, and the like from each other within the finished garment 10. In some embodiments, only one sleeve 76 and 78 may be included in the finished garment 10.

The piece of a sleeve web fabric 77 has a pair of sleeve side edges 81 and 83, a garment end edge 80, and a sleeve opening end edge 84 opposite the garment end edge 80. It is understood that the piece of the sleeve web fabric 77 could be provided as a tube having a garment end edge 80 and a sleeve opening end edge 84 opposite the garment end edge 80. It is also understood that the piece of the sleeve web fabric 77 could be made of multiple pieces of material or materials. The piece of the sleeve web fabric 77 is folded so as to bring together the opposing sleeve side edges 81 and 83 to form a sleeve seam 93 of the sleeve 76.

The piece of a sleeve web fabric 79 has a pair of sleeve side edges 88 and 91 , a garment end edge 82, and a sleeve opening end edge 86 opposite the garment end edge 82. It is understood that the piece of the sleeve web fabric 79 could be provided as a tube having a garment end edge 82 and a sleeve opening end edge 86 opposite the garment end edge 82. It is also understood that the piece of the sleeve web fabric 79 could be made of multiple pieces of material or materials. The piece of the sleeve web fabric 79 is folded so as to bring together the opposing sleeve side edges 88 and 91 to form a sleeve seam 97 of the sleeve 78.

It may be desirable to redirect (or reorient) the sleeve-sized pieces 19 of the sleeve web of fabric 18 to allow easy fastening of the sleeve seams 93 and 97 of the sleeves 76 and 78, respectively, of the garment 10. The turning operations are desirably carried out by turn rolls and turn tables, as well as any other known means. The pieces 19 of the sleeve web of fabric 18 (pieces of the sleeve web fabric 77 and 79) may be reoriented 90 degrees (not shown). The sleeve seams 93 and 97 can be non- refastenable seams or refastenable seams. Any excesses of the pieces of the sleeve web fabric 77 and 79 can be removed from their respective edges of the sleeve seams 93 and 97 to reduce and smooth out the sleeve seams 93 and 97. The non-refastenable sleeve seams 93 and 97 may be formed by any suitable means such as ultrasonic sealing, adhesive bonding, tape, heat sealing, sewing, or any method of fastening known in the art, as discussed above. The non-refastenable sleeve seams 93 and 97 may be constructed on a continuous or intermittent basis.

In other embodiments, the opposing pair of the sleeve side edges 81 and 83 and the opposing pair of the sleeve side edges 88 and 91 of the sleeves 76 and 78, respectively, may be held together in the finished garment 10 to form refastenable sleeve seams 93 and 97. The refastenable means for securing the opposing pair of the sleeve side edges 81 and 83 and the opposing pair of the sleeve side edges 88 and 91 of the sleeves 76 and 78, respectively, include refastenable adhesive and mechanical type fasteners 95. The adhesive and mechanical type fasteners 95 include buttons and button holes, snaps, buckles, clasps, hooks and loops, end extensions, tabs, tape, and the like which are designed or adapted to interlock or engage some type of a complementary device or the inner surface 11 or the outer surface 13 of the garment 10. The refastenable sleeve seams 93 and 97 may be constructed on a continuous or intermittent basis.

In addition, elasticized fasteners 95 may also be used in assuring better fit of the sleeves 76 and 78 of the garment 10. If the garment 10 includes refastenable sleeve seams 93 and 97, the refastenable means are desirably strategically placed on the pieces of the sleeve web fabric 77 and 79 before the sleeve web of fabric 18 is cut into discrete sleeve-sized pieces 19. The folding and redirection operations may be eliminated when refastenable sleeve seams 93 and 97 are included in the garment 10. However, there may be packaging reasons for which one would still carry out these two steps.

The sleeve seams 93 and 97 of the present invention may take on a variety of structures or configurations known in the art. One embodiment of the sleeve seams 93 and 97 is an out-turned configuration as illustrated in Figure 12. Such configured sleeve seams 93 and 97 are formed by securing together at least a portion of the out-turned portions of the sleeve side edges 81 and 83 and the sleeve side edges 88 and 91 of the sleeves 76 and 78, respectively. The inner surface 11 of the sleeve side edges 81 and 83 and the sleeve side edges 88 and 91 of the sleeves 76 and 78, respectively, are brought into contact with each other of the pair.

Another embodiment of the sleeve seams 93 and 97 is an in-turned configuration as illustrated in Figure 13. Such configured sleeve seams 93 and 97 are formed by securing together at least a portion of the in-turned portions of the sleeve side edges 81 and 83 and the sleeve side edges 88 and 91 of the sleeves 76 and 78, respectively. The outer surface 13 of the sleeve side edges 81 and 83 and the sleeve side edges 88 and 91 of sleeves 76 and 78, respectively, are brought into contact with each other of the pair.

Another embodiment of the sleeve seams 93 and 97 is an over-lapped configuration as illustrated in Figure 11. Such configured sleeve seams 93 and 97 are formed by securing together at least a portion of the over-lapped portions of the sleeve side edges 81 and 83 and the sleeve side edges 88 and 91 of the sleeves 76 and 78, respectively. The inner surface 11 of one of the sleeve side edges 81 or 83 and the sleeve side edges 88 or 91 of the sleeves 76 and 78, respectively, are brought into contact with the outer surface 13 of the other sleeve side edge 81 or 83 and the sleeve side edge 88 or 91 of the sleeve 76 and 78, respectively.

Another embodiment of the sleeve seams 93 and 97 is an over-lapped configuration as illustrated in Figure 14. Such configured sleeve seams 93 and 97 are formed by folding back the sleeve side edge 81 or 83 and the sleeve side edge 88 or 91 of the sleeves 76 and 78, respectively. The outer surface 13 of the folded portions and the inner surface of the unfolded portions of the sleeve side edge 81 or 83 and the sleeve side edge 88 or 91 and the corresponding portions of the sleeves 76 and 78, respectively, are brought into contact with the inner surface 11 or the outer surface 13 of the non-folded sleeve side edge 81 or 83 and the sleeve side edge 88 or 91 and the corresponding portions of the sleeves 76 and 78, respectively. It is understood that the folding back of a sleeve side edge 81 , 83, 88, or 91 could be performed such that the inner surface 11 would be exposed along the fold.

The garment end edges 80 and 82 of the pieces of the sleeve web fabric 77 and 79, respectively, may be attached to the arm opening edges 73 and 75 of the arm openings 72 and 74, respectively, of the garment 10. The attachment of the pieces of the sleeve web fabric 77 and 79 may be made non-refastenable by means as discussed above. (Sewing equipment 116 is shown in Figure 1). In the alternative, the attachment of the pieces of the sleeve web fabric 77 and 79 may be made refastenable by means as discussed above.

The sleeves 76 and 78 may be constructed before attachment to the garment 10. The garment end edges 80 and 82 of the sleeves 76 and 78, respectively, may be attached to the arm opening edges 73 and 75 of the arm openings 72 and 74, respectively, of the garment 10, forming arm opening seams 103 and 106, respectively. The attachment of the sleeves 76 and 78 may be made non-refastenable by means as discussed above. In the alternative, the attachment of the sleeves 76 and 78 may be made refastenable by means as discussed above. The arm opening seams 103 and 106 may be constructed on a continuous or intermittent basis.

The arm opening seams 103 and 106 of the present invention may take on a variety of structures or configurations. One embodiment of the arm opening seams 103 and 106 is an out-turned configuration as illustrated in Figure 12. Such configured arm opening seams 103 and 106 are formed by securing together at least a portion of the out- turned portions of the garment end edge 80 and the arm opening edge 73 and the garment end edge 82 and the arm opening edge 75, respectively, of the garment 10. The inner surface 11 of the garment end edges 80 and 82 of the sleeves 76 and 78, respectively, are brought into contact with the inner surface 11 of the arm opening edges 73 and 75, respectively.

Another embodiment of the arm opening seams 103 and 106 is an in-turned configuration as illustrated in Figure 13. Such configured arm opening seams 103 and 106 are formed by securing together at least a portion of the in-turned portions of the garment end edge 80 and the arm opening edge 73 and the garment end edge 82 and the arm opening edge 75, respectively, of the garment 10. The outer surface 13 of the garment end edges 80 and 82 of the sleeves 76 and 78, respectively, are brought into contact with the outer surface 13 of the arm opening edges 73 and 75, respectively.

Another embodiment of the arm opening seams 103 and 106 is an over-lapped configuration as illustrated in Figure 11. Such configured arm opening seams 103 and 106 are formed by securing together at least a portion of the over-lapped portions of the garment end edges 80 and the arm opening edge 73 and the garment end edge 82 and the arm opening edge 75, respectively, of the sleeves 76 and 78, respectively. The inner surface 11 of one of the garment end edge 80 or the arm opening edge 73 and the garment end edge 82 or the arm opening edge 75, is brought into contact with the outer surface 13 of the other garment end edge 80 or the arm opening edge 73 and the garment end edge 82 or the arm opening edge 75 of the sleeves 76 and 78, respectively.

Another embodiment of the arm opening seams 103 and 106 is an over-lapped configuration as illustrated in Figure 14. Such configured arm opening seams 103 and 106 are formed by folding back the garment end edge 80 or the arm opening edge 73 and the garment end edge 82 or the arm opening edge 75. The outer surface 13 of the folded portions and the inner surface 11 of the unfolded portions of the garment end edge 80 or the arm opening edge 73 and the garment end edge 82 or the arm opening edge 75 and the corresponding portions of the sleeves 76 and 78 or the front and back panels 20 and 30 are brought into contact with the inner surface 11 or the outer surface 13 of the unfolded garment end edge or arm opening edge and the corresponding portions of the sleeves 76 and 78 or the front and back panels 20 and 30. It is understood that the folding back of a garment end edge 80 or 82 or an arm opening edge 73 or 75 could be performed such that the inner surface 11 would be exposed along the fold.

The sleeve opening end edges 84 and 86 of the sleeves 76 and 78, respectively, (in the alternative, the sleeve opening end edges 84 and 86 of the pieces of the sleeve web fabric 77 and 79) can be hemmed by any method or style known in the art. In some embodiments, it may be desirable to leave the sleeve opening end edges 84 and 86 unhemmed.

In other embodiments, cuffs 85 and 87 may be attached to the sleeve opening end edges 84 and 86, respectively, of the sleeves 76 and 78, respectively, of the garment 10, forming cuff seams 108 and 110, respectively. The attachment of the cuffs 85 and 87 may be made non-refastenable by means as discussed above. In the alternative, the attachment of the cuffs 85 and 87 may be made refastenable by means as discussed above. The cuff seams 108 and 110 may be constructed on a continuous or intermittent basis. The cuffs 85 and 87 may take on a variety of sizes and shapes. The cuffs 85 and 87 may be similar or dissimilar in shape, structure, material, size, and the like from each other within the finished garment 10. The pattern of the cuffs 85 and 87 is restricted only by the fashion and the minimum amount of the material of the cuffs 85 and 87 that is necessary to complete the remaining steps or operations of the process of manufacture.

The cuff seams 108 and 110 of the present invention may take on a variety of structures or configurations known in the art. One embodiment of the cuff seams 108 and 110 is an out-turned configuration as illustrated in Figure 12. Such configured cuff seams 108 and 110 are formed by securing together at least a portion of the out-turned portions of the cuff edge 107 and the sleeve opening end edge 84 and the cuff edge 109 and the sleeve opening end edge 86, respectively, of the garment 10. The inner surface 11 of the cuff edges 107 and 109 of the cuffs 85 and 87, respectively, are brought into contact with the inner surface 11 of the sleeve opening edges 84 and 86 of the sleeves 76 and 78, respectively.

Another embodiment of the cuff seams 108 and 110 is an in-turned configuration as illustrated in Figure 13. Such configured cuff seams 108 and 110 are formed by securing together at least a portion of the in-turned portions of the cuff edge 107 and the sleeve opening edge 84 and the cuff edge 109 and the sleeve opening edge 86, respectively, of the garment 10. The outer surface 13 of the cuff edges 107 and 109 of the sleeves 76 and 78 are brought into contact with the outer surface 13 of the sleeve opening edges 84 and 86, respectively.

Another embodiment of the cuff seams 108 and 110 is an over-lapped configuration as illustrated in Figure 11. Such configured cuff seams 108 and 110 are formed by securing together at least a portion of the over-lapped portions of the cuff edge 107 and the sleeve opening edge 84 and the cuff edge 109 and the sleeve opening edge

86 of the sleeves 76 and 78, respectively. The inner surface 11 of one of the cuff edge 107 or the sleeve opening edge 84 and the cuff edge 109 or the sleeve opening edge 86, is brought into contact with the outer surface 13 of the other cuff edge 107 or the sleeve opening edge 84 and the cuff edge 109 or the sleeve opening edge 86 of the sleeves 76 and 78, respectively.

Another embodiment of the cuff seams 108 and 110 is an over-lapped configuration as illustrated in Figure 14. Such configured cuff seams 108 and 110 are formed by folding back the cuff edge 107 or the sleeve opening end edge 84 and the cuff edge 109 or the sleeve opening end edge 86 of the sleeves 76 and 78, respectively. The outer surface 13 of the folded portions and the inner surface 11 of the unfolded portions of the cuff edge 107 or the sleeve opening end edge 84 and the cuff edge 109^" or the sleeve opening end edge 86 and the corresponding portions of the cuffs 85 and 87 or the sleeves 76 and 78 are brought into contact with the inner surface 11 or the outer surface 13 of the unfolded cuff edge 107 or 109 or the sleeve opening end edge 84 or 86 and the corresponding portions of the cuffs 85 and 87 or the sleeves 76 and 78. It is understood that the folding back of a cuff edge 107 or 109 or a sleeve opening end edge 84 or 86 could be performed such that the inner surface 11 would be exposed along the fold.

The materials used for the cuffs 85 and 87 may be the same as the materials used for the other portions of the garment 10. In some embodiments, it is desirable that the materials used for the cuffs 85 and 87 have an elastic element such that the cuffs 85 and

87 will conform to the portion of the wearer's arms that come into contact with the cuffs 85 and 87. The edge 92 of the neck opening 90 can be hemmed by any method or style known in the art. In some embodiments, it may be desirable to leave the edge 92 of the neck opening 90 unhemmed.

In other embodiments, a collar 94 may be attached to the edge 92 of the neck opening 90 of the garment 10, thereby forming a collar seam 112. The attachment of the collar 94 may be made non-refastenable by means as discussed above. (Sewing equipment 115 is shown in Figure 1). In the alternative, the attachment of the collar 94 may be made refastenable by means as discussed above. The collar seam 112 may be constructed on a continuous or intermittent basis. The collar 94 may take on a variety of sizes and shapes. The pattern of the collar 94 is restricted only by the fashion and the minimum amount of the material of the collar 94 that is necessary to complete the remaining steps or operations of the process of manufacture.

The collar seam 12 of the present invention may take on a variety of structures or configurations known in the art. One embodiment of the collar seam 112 is an out-turned configuration as illustrated in Figure 12. Such a configured collar seam 112 is formed by securing together at least a portion of the out-turned portions of the collar edge 111 of the collar 94 and the edge 92 of the neck opening 90 of the garment 10. The inner surface 11 of the collar edge 111 of the collar 94 is brought into contact with the inner surface 11 of the edge 92 of the neck opening 90.

Another embodiment of the collar seam 112 is an in-turned configuration as illustrated in Figure 13. Such a configured collar seam 112 is formed by securing together at least a portion of the in-turned portions of the collar edge 111 of the collar 94 and the edge 92 of the neck opening 90 of the garment 10. The outer surface 13 of the collar edge 111 of the collar 94 is brought into contact with the outer surface 13 of the edge 92 of the neck opening 90.

Another embodiment of the collar seam 112 is an over-lapped configuration as illustrated in Figure 11. Such a configured collar seam 112 is formed by securing together at least a portion of the over-lapped portions of the collar edge 111 of the collar 94 and the edge 92 of the neck opening 90 of the garment 10. The inner surface 11 of the collar edge 111 of the collar 94 or the edge 92 of the neck opening 90 is brought into contact with the outer surface 13 of the other, the collar edge 111 or the edge 92. Another embodiment of the collar seam 112 is an over-lapped configuration as illustrated in Figure 14. Such a configured collar seam 112 is formed by folding back the collar edge 111 of the collar 94 or the edge 92 of the neck opening 90. The outer surface 13 of the folded portions and the inner surface 11 of the unfolded portions of the collar edge 111 of the collar 94 or the edge 92 of the neck opening 90 and the corresponding portions of the collar 94 or the front and back panels 20 and 30 are brought into contact with the inner surface 11 or the outer surface 13 of the unfolded collar edge 111 of the collar 94 or the edge 92 of the neck opening 90 and the corresponding portions of the collar 94 or the front and back panels 20 and 30. It is understood that the folding back of the collar edge 111 of the collar 94 or the edge 92 of the neck opening 90 could be performed such that the inner surface 11 would be exposed along the fold.

Another embodiment of the collar seam 112 is an over-lapped configuration as illustrated in Figure 15. Such a configured collar seam 112 is formed by folding the collar 94 about or over the edge 92 of the neck opening 90. The collar edges 111 of the collar 94 may be folded under, bringing the outer surface 13 of the collar 94 into contact with the edge 92 of the neck opening and any portion of the adjacent material of the front panel 20, the back panel 30, or both as desired. The collar edges 111 may be left exposed by not being folding under.

Another embodiment of the collar seam 112 is an over-lapped configuration as illustrated in Figure 16. Such a configured collar seam 112 is formed by folding the collar edge 111 such that the inner surface 11 of the collar 94 is brought into contact with itself. The edge 92 of the neck opening 90 is folded such that the outer surface 13 of the front panel 20, the back panel 30, or both are brought into contact with itself. The collar edge 111 is inserted into the fold of the edge 92 of the neck opening 90. The edge 92 of the neck opening 90 is inserted into the fold of the collar edge 111. In another embodiment, the collar edge 111 is folded such that the outer surface 13 of the collar 94 is brought into contact with itself. The edge 92 of the neck opening 90 is folded such that the inner surface 11 of the front panel 20, the back panel 30, or both are brought into contact with itself. This configured collar seam 112 may be used with any seam describe herein.

The materials used for the collar 94 may be the same as the materials used for the other portions of the garment 10. In some embodiments, it is desirable that the materials used for the collar 94 have an elastic element such that the collar 94 will conform to the portion of the wearer's neck that comes into contact with the collar 94.

In various embodiments of the present invention, the front panel 20, the back panel 30, or both panels 20 and 30 may be cut or otherwise opened to form a slit 45 or 65 such as a placket. The slit 45 has two edges 57 and 61. The slit 65 has two edges 66 and 67. The slits 45 and 65 of the front and back panels 20 and 30, respectively, may extend from the edge 92 of the neck opening 90 to the garment bottom edges 26 and 36, respectively. In the alternative, the slits 45 and 65 may extend over only a portion of the panels 20 and 30 between the edge 92 of the neck opening 90 to the garment bottom edges 26 and 36, respectively. When the garment 10 comprises both a slit 45 in the front panel 20 and a slit 65 in the back panel 30, the slits 45 and 65 may be similar or dissimilar in size, structure, shape, and the like.

In some embodiments, the edges 57 and 61 of the slit 45 and the edges 66 and 67 of the slit 65 may be refastenably attached or secured to each other. The edges 57 and 61 may be secured together to form a front seam 113. The edges 66 and 67 may be secured to form a back seam 114. Various fastening means, such as adhesive and mechanical type fasteners 95, see the discussion above, may be used to refastenably attach or secure the edges 57 and 61 or the edges 66 and 67 together of the slits 45 and 65, respectively.

Another embodiment of the present invention is a continuous process for the manufacture of a garment 210 (see Figure 2) for wearing about the upper body comprising at least a front panel 250, a back panel 260, a neck opening 290 defined about its perimeter by edge 292, arm openings 272 and 274 defined about their perimeters by arm opening edges 273 and 275, respectively, a lower body opening 244 defined about its perimeter by garment bottom edges 259 and 269. The garment 210 comprises an inner surface 211 and an outer surface 213. The garment 210 may comprise a single layer webs of fabric 215 and 216, multi-layer laminate webs of fabric 215 and 216, or a combination of a single layer web of fabric and a multi-layer laminate web of fabric 215 and 216. In some embodiments, the garment 210 may comprise multiple layers of the webs of fabric 215 and 216 or various combinations of fabric. In one embodiment of the present invention (See Figure 2), two webs of fabric 215 and 216 of sufficient width of fabric to make the garment 210 is provided. The desired webs of fabric 215 and 216 are nonwoven although any disposable or washable fabric can be used. (See the discussion below). The webs of fabric 215 and 216 are typically unwound from rolls (not shown).

The webs of fabric 215 and 216 are desirably compliant and soft feeling to the wearer. The following description of materials from which the webs of fabric 215 and 216 may be formed would also be used for the materials to form the inner surface 211 and the outer surface 213 of multi-layer laminate webs of fabric 215 or 216.

The webs of fabric 215 and 216 may be any suitable material, such as a woven material, a nonwoven material, a fibrous or a polymeric film material and may be, although they need not necessarily be, an elastic material or of a stretchable nature. Suitable fibrous webs may utilize any suitable natural and/or synthetic fibers, for example, woven or nonwoven webs of fibers made of acrylic polymers, polyester, polyamide, glass, polyolefins, e.g., polyethylene and polypropylene, cellulosic derivatives such as rayon, cotton, silk, wool, pulp, paper and the like, as well as blends or combinations of any two or more of the foregoing. The webs of fabric 215 and 216 may also comprise polymeric film layers such as polyethylene, polypropylene, polyamide, polyester, acrylic polymers, and compatible mixtures, blends and copolymers thereof.

The webs of fabric 215 or 216 may be liquid pervious, permitting liquids to readily penetrate into its thickness, or impervious, resistant to the penetration of liquids into its thickness. The webs of fabric 215 and 216 may be made from a wide range of materials, such as natural fibers (e.g. rayon, wood, or cotton fibers), synthetic fibers (e.g. polyester or polypropylene fibers), or from a combination of natural and synthetic fibers or reticulated foams and apertured plastic films. The webs of fabric 215 and 216 may be woven, nonwoven, or film such as spunbonded, carded, or the like. The suitable webs of fabric 215 and 216 may be carded and thermally bonded by means well known to those skilled in the fabric art.

Alternatively, the webs of fabric 215 and 216 may be derived from a spunbonded web. In a desired embodiment, the webs of fabric 215 and 216 are spunbonded polypropylene nonwoven, meltblown polypropylene nonwoven and spunbonded polypropylene nonwoven laminate (SMS). The total basis weight is from about 0.4 to about 1.0 osy (more desirably 0.6 osy) and is made with about 86% spunbonded nonwoven and 14% meltblown nonwoven. A pigment such as titanium dioxide may be incorporated into the webs of fabric 215 and 216. Such a spunbonded meltblown nonwoven laminate material is available from Kimberly-Clark Corporation, Roswell, GA. The basis weight of the SMS material may vary from about 0.4 to about 1.0 osy.

In other desired embodiments, the webs of fabric 215 and 216 are spunbonded polypropylene nonwoven with a wire-weave bond pattern having a grab tensile of 19 pounds as measured by ASTM D1682 and D1776, a Taber 40 cycle abrasion rating of 3.0 as measured by ASTM D1175 and Handle-O-Meter MD value of 6.6 grams and CD value of 4.4 grams using TAPPI method T402. Such a spunbonded material is available from Kimberly-Clark Corporation, Roswell, GA. The webs of fabric 215 and 216 have a weight of from about 0.5 oz. per square yard (osy) to about 1.5 osy, desirably about 0.7 osy.

The webs of fabric 215 and 216 may be constructed of a single spunbonded polypropylene nonwoven web having a basis weight of about 0.5 oz/yd² (17 gsm) to about 1.5 oz/yd² (51 gsm). In the structure of the garment 210, the webs of fabric 215 and 216 desirably comprise a material having a basis weight of from about 0.5 oz/yd² (17 gsm) to about 1.5 oz yd² (51 gsm). Lesser or greater basis weights may be used in the other regions of the garment 210, such as the sleeves 276 and 278, the cuffs 285 and 287, and the collar 294. Since the garment 210 is typically intended for active wear, the webs of fabric 215 and 216 or portions thereof, can be made of materials having a basis weight that is abrasion resistant.

The webs of fabric 215 and 216 may be any soft and flexible sheet. The webs of fabric 215 and 216 may permit submersion in fresh water or salt water or treated water (chlorinated or brominated) and still retain its integrity. The webs of fabric 215 and 216 may comprise, for example, a nonwoven web or sheet of a spunbonded, meltblown, or bonded-carded web composed of synthetic polymer filaments, such as polypropylene, polyethylene, polyesters or the like, or a web of natural polymer filaments such as rayon or cotton. The webs of fabric 215 and 216 may be selectively embossed or perforated with discrete slits or holes extending therethrough. The webs of fabric 215 and 216 may be further dyed, pigmented, or imprinted with any suitable color. Desirably, the webs of fabric 215 and 216 are dyed, pigmented, or printed with a material which does not irritate or bleed the color onto the skin of the wearer.

The webs of fabric 215 and 216 may be made of the same material or may be made of different materials. In addition, the webs of fabric 215 and 216 may be both made of single layered materials, both multi-layered materials, or one of single layered materials and the other of multi-layered materials.

For embodiments wherein the webs of fabric 215 and 216 are a multi-layer laminate, both the outer surface 213 and the inner surface 211 are desirably compliant and soft feeling to the wearer. The following description of materials from which the outer surface 213 may be formed may also be used to form the material of the inner surface 211.

The outer surface 213 may be any suitable gatherable material, such as a woven material, a nonwoven material, a fibrous or a polymeric film material and may be, although it need not necessarily be, an elastic material or of a stretchable nature. Suitable fibrous gatherable webs may utilize any suitable natural and/or synthetic fibers, for example, woven or nonwoven webs of fibers made of acrylic polymers, polyester, polyamide, glass, polyolefins, e.g., polyethylene and polypropylene, cellulosic derivatives such as rayon, cotton, silk, wool, pulp, paper and the like, as well as blends or combinations of any two or more of the foregoing. The gatherable webs may also comprise polymeric film layers such as polyethylene, polypropylene, polyamide, polyester, acrylic polymers, and compatible mixtures, blends and copolymers thereof.

The outer surface 213 may be liquid pervious, permitting liquids to readily penetrate into its thickness, or impervious, resistant to the penetration of liquids into its thickness. The outer surface 213 may be made from a wide range of materials, such as natural fibers (e.g. rayon, wood, or cotton fibers), synthetic fibers (e.g. polyester or polypropylene fibers), or from a combination of natural and synthetic fibers or reticulated foams and apertured plastic films. The outer surface 213 may be woven, nonwoven, or film such as spunbonded, carded, or the like. A suitable material for the outer surface 213 may be carded and thermally bonded by means well known to those skilled in the fabric art. Alternatively, the outer surface 213 may be derived from a spunbonded web. In a desired embodiment, the outer surface 213 is spunbonded polypropylene nonwoven, meltblown polypropylene nonwoven and spunbonded polypropylene nonwoven laminate (SMS). The total basis weight is from about 0.4 to about 1.0 osy (more desirably 0.6 osy) and is made with about 86% spunbonded nonwoven and 14% meltblown nonwoven. A pigment such as titanium dioxide may be incorporated into the outer surface 213 and the inner surface 211. Such spunbonded meltblown nonwoven laminate material is available from Kimberly-Clark Corporation, Roswell, GA. The basis weight of the SMS material may vary from about 0.4 to about 1.0 osy.

In other desired embodiments, the outer surface 213 is spunbonded polypropylene nonwoven with a wire-weave bond pattem having a grab tensile of 19 pounds as measured by ASTM D1682 and D1776, a Taber 40 cycle abrasion rating of 3.0 as measured by ASTM D1175 and Handle-O-Meter MD value of 6.6 grams and CD value of 4.4 grams using TAPPI method T402. Such spunbonded material is available from Kimberly-Clark Corporation, Roswell, GA. The outer surface 213 has a weight of from about 0.5 oz. per square yard (osy) to about 1.5 osy, desirably about 0.7 osy.

The outer surface 213 may be constructed of a single spunbonded polypropylene nonwoven web having a basis weight of about 0.5 oz/yd² (17 gsm) to about 1.5 oz yd² (51 gsm). In the structure of the garment 210, the outer surface 213 desirably comprises a material having a basis weight of from about 0.5 oz/yd² (17 gsm) to about 1.5 oz/yd² (51 gsm). Lesser or greater basis weights may be used in the other regions of the garment 210. Since the garment 210 is typically intended for active wear, the outer surface 213 or portions thereof, can be made of materials having a basis weight which is abrasion resistant.

The inner surface 211 may be any soft and flexible sheet. The inner surface 211 may permit submersion in fresh water or salt water or treated water (chlorinated or brominated) and still retain its integrity. The inner surface 211 may comprise, for example, a nonwoven web or sheet of a spunbonded, meltblown, or bonded-carded web composed of synthetic polymer filaments, such as polypropylene, polyethylene, polyesters, or the like, or a web of natural polymer filaments such as rayon or cotton. The inner surface 211 may be selectively embossed or perforated with discrete slits or holes extending therethrough. Suitable adhesives for adhering the laminate layers can be obtained from Findley Adhesives, Inc. of Wauwatosa, Wisconsin.

The outer surface 213 and the inner surface 211 may be further dyed, pigmented, or imprinted with any suitable color. Desirably, the inner surface 211 is either dyed, pigmented, or printed with a material which does not irritate or bleed the color onto the skin of the wearer.

The web of fabric 215 includes a pair of opposing web side edges 246 and 247. A repeating series of indentations 268 are cut into the web side edge 246 of the web of fabric 215 by a die cutter 214. (See Figure 2). The location of the indentations 268 corresponds to the arm openings 272 of the finished garment 210. The indentations 268 may be produced by a die cut operation, an ultrasonic operation, or any other suitable method of operation. The material to be removed from the indentations 268 may be removed by any method known in the art, desirably a vacuum source (not shown).

The indentations 268 may take on a variety of sizes and shapes, such as slit, circular, oval, triangular, square, rectangular, multi-faceted, asymmetric or irregular, or the like. The pattern of the indentations 268 is restricted only by fashion and the minimum amount of the web of fabric 215 that must remain having a sufficient integrity to withstand the remaining steps or operations of the process of manufacture. The indentations 268 may be similar or dissimilar in shape, structure, size, and the like from each other or from the indentations 270 within the finished garment 210.

The web of fabric 216 includes a pair of opposing web side edges 248 and 249. A repeating series of indentations 270 are cut into the web side edge 249 of the web of fabric 216 by the die cutter 214. (See Figure 2). The location of the indentations 270 corresponds to the arm openings 274 of the finished garment 210. The indentations 270 may be produced by a die cut operation, an ultrasonic operation, or any other suitable method of operation.

The indentations 270 may take on a variety of sizes and shapes, such as slit, circular, oval, triangular, square, rectangular, multi-faceted, asymmetric or irregular, or the like. The material to be removed from the indentation 270 may be removed by any method known in the art, desirably a vacuum source (not shown). The pattern of the indentations 270 is restricted only by fashion and the minimum amount of the web of fabric 216 that must remain having a sufficient integrity td withstand the remaining steps or operations of the process of manufacture. The indentations 270 may be similar or dissimilar in shape, structure, size, and the like from each other or from the indentations 268 within the finished garment 210. Alternately, the arm openings 272 and 274 may be similar or dissimilar from each other.

In one type of embodiment of the present invention (see Figure 2), the two webs of fabric 215 and 216 of sufficient width of fabric to make the garment 210 are combined. The desired fabric is nonwoven although any disposable or washable fabric can be used. The two webs of fabric 215 and 216 are unwound from rolls (not shown) and brought together in a side by side orientation (see Figure 18) and fastened together at the web side edge 247 of the web of fabric 215 and the web side edge 248 of the web of fabric 216, defining a center seam 251 on the composite web of fabric 253. In some embodiments, portions of the center seam 251 may be left unfastened by intermittently fastening the web side edges 247 and 248 of the webs of fabric 215 and 216, respectively. In other embodiments, the center seam 251 may be constructed on a continuous basis. The desired method of fastening is ultrasonic sealing, although other methods of fastening, such as heat sealing, adhesives, tape, sewing, or any other method of fastening known in the art can be used.

In another type of embodiments, the two webs of fabric 215 and 216 to make the garment 210 are combined to produce the garments 210. The two webs of fabric 215 and 216 are unwound from rolls and brought together in a face to face (or, alternatively, back to back) orientation and fastened together at the web side edge 247 of the web of fabric 215 and the web side edge 248 of the web of fabric 216, defining the center seam 254 of the composite web of fabric 253. (See Figure 17).

The opposing indentations 268 and 270 of the web side edges 246 and 249 of the webs of fabric 215 and 216, respectively, may be cut into the web side edges 246 and 249 before or after the two webs of fabric 215 and 216 are fastened together to form the composite web of fabric 253. The material to be removed from the opposing indentations 268 and 270 may be removed by any method known in the art, desirably a vacuum source. As the pattern of the garment 210 is restricted only by fashion and the minimum amount of the webs of fabric 215 and 216 (or, alternatively, the composite web of fabric 253) that must remain having a sufficient integrity to withstand the operations or steps of the process of manufacture, one can simply design the garment 210 such that this operation of cutting the opposing indentations 268 and 270 into the web side edges 246 and 249 (or, alternatively, the garment side edges 222 and 232 and the garment side edges 225 and 235) of the webs of fabric 215 and 216, respectively, (or, alternatively, the composite web of fabric 253) is not required. The arm opening 272 and 274 may be created by leaving a portion of the garment side edges 222 and 232 and the garment side edges 225 and 235, respectively, unattached.

When the webs of fabric 215 and 216 are combined to form the composite web of fabric 253, the opposing indentations 268 and 270 are typically positioned or arranged such that the opposing indentations 268 and 270 form a repeating series of pairs of opposing indentations 268 and 270. However, such a placement or arrangement is not required in the present invention. The placement of the opposing indentations 268 and 270 in relation to each other, while in a typical garment 210, the opposing indentations 268 and 270 are located to be directly opposing, is restricted only by fashion and the minimum amount of the webs of fabric 215 and 216 (or, alternatively, the composite web of fabric 253) that must remain having sufficient integrity to withstand the remaining steps or operations of the process of manufacture.

A repeating series of openings 289 are cut by the die cutter 214 into at least one of the webs of fabric 215 and 216 (or, alternatively, the composite web of fabric 253). It is understood that while Figure 2 shows the die cutter 214 cutting the opening 289 and the opposing indentations 268 and 270, these cutting operations could be performed by separate devices and at different stages within the manufacturing process. The location of the opening 289 corresponds to the neck opening 290 in the finished garment 210. The openings 289 may be produced by a die cut operation, an ultrasonic operation, or any other suitable method of operation. The openings 289 may be cut into at least one of the webs of fabric 215 and 216 before or after the webs of fabric 215 and 216 are combined to form the composite web of fabric 253.

The opening 289 may take on a variety of sizes and shapes, such as slit, circular, oval, triangular, square, rectangular, multi-faceted, asymmetric or irregular, or the like. The material to be removed from the openings 289 may be removed by any method known in the art, desirably a vacuum source. The pattern of the openings 289 is restricted only by fashion and the minimum amount of the webs of fabric 215 and 216 (or, alternatively, the composite web of fabric 253) that must remain having a sufficient integrity to withstand the remaining steps or operations of the process of manufacture.

In alternative embodiments of the present invention, the openings 289 may be comprised of the indentations 305a cut into the web side edge 247 of the web of fabric 215 and the indentations 305b cut into the web side edge 248 of the web of fabric 216 prior to the combining of the webs of fabric 215 and 216 to form the composite web of fabric 253. An indentation 305a and an indentation 305b are combined to form the opening 289.

The placement of the opening 289 in relation to a pair of opposing indentations 268 and 270, while in a typical garment 210, the opening 289 is centrally located between the pair of opposing indentations 268 and 270, is restricted only by fashion and the minimum amount of the webs of fabric 215 and 216 (or, alternatively, the composite web of fabric 253) that must remain having sufficient integrity to withstand the remaining steps or operations of the process of manufacture. For example, the placement of the opening 289 between the pair of opposing indentations 268 and 270 may be symmetrically or asymmetrically located.

The composite web fabric 253 is cut by a die cutter 271 into discrete garment- sized pieces 255 wherein each discrete garment-sized piece 255 contains at least one opening 289, one pair of opposing indentations 268 and 270, one pair of opposing web side edges 246 and 249, and opposing garment end portions 266 and 267. The location of the opposing web side edges 246 and 249 of the composite web of fabric 253 corresponds to the garment side edge 222 of the right front panel 220 (or, alternatively, the front panel 250) and the garment side edge 232 of the right back panel 230 (or, alternatively, the back panel 260), and the garment side edge 225 of the left front panel 221 (or, alternatively, the front panel 250) and the garment side edge 235 of the left back panel 231 (or, alternatively, the back panel 260), respectively, in the finished garment 210. It is understood that while the web side edges 246 and 249 may typically become the garment side edges 222 and 232 and the garment side edges 225 and 235, respectively, in the finished garment 210, fabric may be removed from or added to the web side edges 246 and 249 to create the garment side edges 222 and 232 and the garment side edges 225 and 235, respectively, in the finished garment 210. The opposing garment end portions 266 and 267 are adjacent to the garment bottom edge 259 of the front panel 250 and the garment bottom edge 269 of the back panel 260, respectively, in the finished garment 210.

The location of the opposing piece side edges 241 and 243 of the discrete garment-sized piece 255 corresponds to the garment bottom edge 259 of the front panel 250 and the garment bottom edge 269 of the back panel 260, respectively, in the finished garment 210. It is understood that while the piece side edges 241 and 243 of the discrete garment-sized piece 255 may typically become the garment bottom edges 259 and 269 in the finished garment 210, fabric may be removed from or added to the piece side edges 241 and 243 of the discrete garment-sized piece 255 to create the garment bottom edges 259 and 269 in the finished garment 210.

The webs of fabric 215 and 216 may be cut into discrete garment-sized pieces 217 and 218, respectively, before the webs of fabric 215 and 216 are combined to form the composite web of fabric 253. The garment-sized pieces 217 and 218 of the webs of fabric 215 and 216 are fastened together to form the discrete garment-sized piece 255 of the composite web of fabric 253. The garment-sized pieces 217 and 218 are combined to form the discrete garment-sized piece 255 such that each discrete garment-sized piece 255 contains at least an opening 289, one pair of opposing indentations 268 and 270, one pair of opposing web side edges 246 and 249, and opposing garment end portions 266 and 267, as described above.

The garment-sized pieces 217 and 218 of the webs of fabric 215 and 216 may be folded before or after the garment-sized pieces 217 and 218 are fastened together to form the discrete garment-sized piece 255 of the composite web of fabric 253. The folding operations are desirably carried out by tuckers and folders, as well as any other known means. The garment-sized piece 217 is folded by a folder 296 so as to bring together the opposing garment end portions 262 and 264 such that the garment-sized piece 217 is folded onto itself forming a right front panel 220 and a right back panel 230. The web side edge 246 folds onto itself, forming the garment side edge 222 of the right front panel 220 and the garment side edge 232 of the right back panel 230. The web side edge 247 folds onto itself, forming the side edge 224 of the right front panel 220 and the side edge 234 of the right back panel 230. The garment-sized piece 217 contains at least one indentation 268, the web side edge 246, and the opposing garment end portions 262 and 264. The garment-sized piece 218 is folded by the folder 296 so as to bring together the opposing garment end portions 263 and 265 such that the garment-sized piece 218 is folded onto itself forming a left front panel 221 and a left back panel 231. The folding operations are desirably carried out by tuckers and folders, as well as any other known means. The web side edge 248 folds onto itself, forming the side edge 223 of the left front panel 221 and the side edge 233 of the left back panel 231. The web side edge 249 folds onto itself, forming the garment side edge 225 of the left front panel 221 and the garment side edge 235 of the left back panel 231. The folding operations are desirably carried out by tuckers and folders, as well as any other known means. The garment-sized piece 218 contains at least one indentation 270, the web side edge 247, and the opposing garment end portions 263 and 265. It is understood that the folding operations on the garment-sized pieces 217 and 218, while shown in Figure 2 to be carried out simultaneously by one folder 296, these folding operations could be performed by separate devices and at different stages within the manufacturing process.

The side edges 224 and 223 of the right and left front panels 220 and 221 , respectively, are fastened together to form a portion of the center seam 251 and the front panel 250. The side edges 234 and 233 of the right and left back panels 230 and 231, respectively, are fastened together to form a portion of the center seam 251 and the back panel 260.

The center seam 251, or portions thereof, can be constructed as a non- refastenable seam, as a refastenable seam, or as a combination of a non-refastenable seam and a refastenable seam. Any excess material from the webs of fabric 215 and 216 may be removed from the side edges 223, 224, 233, and 234 of the center seam 251 to reduce and smooth out the center seam 251. The non-refastenable center seam 251 may be formed by any suitable means such as ultrasonic sealing, adhesive bonding, tape, heat sealing, sewing, or any method of fastening known in the art. The non-refastenable center seam 251 may be constructed on a continuous or intermittent basis. One suitable method of forming such a center seam 251 is disclosed in U.S. Patent No. 4,938,753 issued July 3, 1990, to Van Gompel et al., which is incorporated herein by reference. See the discussion above for center seams 252 and 256. In other embodiments of the present invention, the side edges 223 and 224 and the side edges 233 and 234 of the garment 210 may be held together in the finished garment 210 to form the refastenable center seam 251. The refastenable means for securing the side edges 223 and 224 and the side edges 233 and 234 of the garment 210 include refastenable adhesive and mechanical type fasteners 295. The adhesive and mechanical type fasteners 295 include buttons and button holes, snaps, buckles, clasps, hooks and loops, end extensions, tabs, tape, and the like which are designed or adapted to interlock or engage some type of a complementary device or the outer surface 213 or the inner surface 211 of the garment 210. A refastenable center seam 251 may be constructed on a continuous or intermittent basis.

In addition, elasticized fasteners 295 may also be used in assuring better fit of the garment 210. If the garment 210 includes a refastenable center seam 251 , the refastenable means are desirably strategically placed on the webs of fabric 215 and 216 before the webs of fabric 215 and 216 are cut into discrete garment-sized pieces 217 and 218. The folding and redirection operations may be eliminated when a refastenable center seam 251 is included in the garment 210. However, there may be packaging reasons for which one would still carry out these two steps.

The center seam 251 of the present invention may take on a variety of structures or configurations known in the art. One embodiment of the center seam 251 is an out- turned configuration as illustrated in Figure 20. Such a configured center seam 251 is formed by securing together at least a portion of the out-turned portions of the side edges 223 and 224 and the side edges 233 and 234, respectively. The inner surface 211 of the right and left front panels 220 and 221 and inner surface 211 of the right and left back panels 230 and 231 , respectively, are brought into contact with each other.

Another embodiment of the center seam 251 is an in-turned configuration as illustrated in Figure 21. Such a configured center seam 251 is formed by securing together at least a portion of the in-turned portions of the side edges 223 and 224 and the side edges 233 and 234, respectively. The outer surface 213 of the right and left front panels 220 and 221 and the outer surface of the right and left back panels 230 and 231, respectively, are brought into contact with each other. Another embodiment of the center seam 251 is an over-lapped configuration as illustrated in Figure 19. Such a configured center seam 251 is formed by securing together at least a portion of the over-lapped portions of the side edges 223 and 224 and the side edges 233, and 234, respectively. The inner surface 211 of one of the right or left front panels 220 and 221 and the inner surface 211 of the right or left back panels 230 and 231 are brought into contact with the outer surface 213 of the other panel of each pair.

Another embodiment of the center seam 251 is an over-lapped configuration as illustrated in Figure 22. Such a configured center seam 251 is formed by folding back the side edges 224 and 234 (or, alternatively, the side edges 223 and 233). The outer surface 213 of the folded portion and the inner surface 211 of the unfolded portion of the side edges 224 and 234 and the corresponding portions of the right front and right back panels 220 and 230, respectively, (or, alternatively, of the side edges 223 and 233 and the corresponding portions of the left front and left back panels 221 and 231 , respectively) is brought into contact with the inner surface 211 or the outer surface 213 of the side edges 223 and 233 and the corresponding portions of the left front and left back panels 221 and 231, respectively (or, alternatively, of the side edges 224 and 234 and the corresponding portions of the right front and right back panels 220 and 230). It is understood that the folding back of a side edges; such as 223, 224, 233, and 234, could be performed such that the inner surface 211 would be exposed along the fold.

The locations of the garment end portion 262 of the right front panel 220 and the garment end portion 263 of the left front panel 221 correspond to the garment end portion 266 of the front panel 250 in the finished garment 210. The locations of the garment end portion 264 of the right back panel 230 and the garment end portion 265 of the left back panel 231 correspond to the garment end portion 267 of the back panel 260 in the finished garment 210.

In the embodiments where the webs of fabric 215 and 216 or the garment-sized pieces 217 and 218 are fastened together prior to the folding step, each discrete garment- sized piece 255 of the composite web of fabric 253 is transported, typically by vacuum screens, belts, or conveyors, through hemming, folding, and fastening operations. The folding operations are desirably carried out by tuckers and folders, as well as any other known means. The discrete garment-sized piece 255 of the composite web of fabric 253 is folded by the folder 296 so as to bring together the opposing garment end portions 266 and 267 such that the web side edge 246 of the composite web of fabric 253 is folded on to itself, forming the garment side edge 222 of the front panel 250 and the garment side edge 232 of the back panel 260. The web side edge 249 of the composite web of fabric 253 is folded on to itself, forming the garment side edge 225 of the front panel 250 and the garment side edge 235 of the back panel 260.

The mating of the garment side edge 222 and the garment side edge 232 as well as the mating of the garment side edge 225 and the garment side edge 235 form the garment side seams 240 and 242, respectively, of the garment 210. It may be desirable to redirect (or reorient) the discrete garment-sized piece 255 of the composite web of fabric 253 to allow easy bonding of the garment side seams 240 and 242 of the garment 210. The turning operations are desirably carried out by turn rolls and turn tables, as well as any other known means. The discrete garment-sized piece 255 of the composite web of fabric 253 may be reoriented 90 degrees (not shown). It is understood that while the web side edges 246 and 249 may typically become the garment side edges 222 and 232 and the garment side edges 225 and 235, respectively, in the finished garments 210, fabric may be removed from or added to the web side edges 246 and 249 to create the garment side edges 222 and 232 and the garment side edges 225 and 235, respectively, in the finished garments 210.

In various embodiments of the present invention, one or both of the garment side seams 240 and 242 can be constructed as non-refastenable seams or as refastenable seams. Any excess material from the webs of fabric 215 and 216 may be removed from the edges of the garment side seams 240 and 242 to reduce and smooth out the garment side seams 240 and 242. The non-refastenable garment side seams 240 and 242 may be formed by any suitable means such as ultrasonic sealing, adhesive bonding, tape, heat sealing, sewing, or any method of fastening known in the art. (Sewing equipment 318 is shown in Figure 2). The non-refastenable garment side seams 240 and 242 may be constructed on a continuous or intermittent basis. One suitable method of forming such garment side seams 240 and 242 is disclosed in U.S. Patent No. 4,938,753 issued July 3, 1990, to Van Gompel et al., which is incorporated herein by reference. The garment side seams 240 and 242 may be bonded together to form non-refastenable garment side seams 240 and 242. In other embodiments of the present invention, the garment side edges 222 and 232 and the garment side edges 225 and 235 of the garment 210 may be held together in the finished garment 210 to form refastenable garment side seams 240 and 242, respectively. The refastenable means for securing the garment side edges 222 and 232 and the garment side edges 225 and 235 of the garment 210 include refastenable adhesive and mechanical type fasteners 295. The adhesive and mechanical type fasteners 295 include buttons and button holes, snaps, buckles, clasps, hooks and loops, end extensions, tabs, tape, and the like which are designed or adapted to interlock or engage some type of a complementary device or the outer surface 213 or the inner surface 211 of the garment 210. The refastenable garment side seams 240 and 242 may be constructed on a continuous or intermittent basis.

In addition, elasticized fasteners 295 may also be used in assuring better fit of the garment 210. If the garment 210 includes refastenable garment side seams 240 and 242, the refastenable means are desirably strategically placed on the webs of fabric 215 and 216 before the webs of fabric 215 and 216 are cut into discrete garment-sized pieces 217 and 218. The folding and redirection operations may be eliminated when a refastenable garment side seams 240 and 242 are included in the garment 210. However, there may be packaging reasons for which one would still carry out these two steps.

The garment side seams 240 and 242 of the present invention may take on a variety of structures or configurations known in the art. One embodiment of the garment side seams 240 and 242 is an out-turned configuration as illustrated in Figure 20. Such configured garment side seams 240 and 242 are formed by securing together at least a portion of the out-turned portions of the garment side edges 222 and 232 and the garment side edges 225 and 235, respectively. The inner surface 211 of the garment side edges 222 and 225 of the front panel 250 and the garment side edges 232 and 235 of the back panel 260, respectively, are brought into contact with each other for each pair of side edges.

Another embodiment of the garment side seams 240 and 242 is an in-turned configuration as illustrated in Figure 21. Such configured garment side seams 240 and 242 are formed by securing together at least a portion of the in-turned portions of the garment side edges 222 and 232 and the garment side edges 225 and 235, respectively. The outer surface 213 of the garment side edges 222 and 225 of the front panel 250 and the garment side edges 232 and 235 of the back panel 260, respectively, are brought into contact with each other for each pair of side edges.

Another embodiment of the garment side seams 240 and 242 is an over-lapped configuration as illustrated in Figure 19. Such configured garment side seams 240 and 242 are formed by securing together at least a portion of the over-lapped portions of the garment side edges 222 and 232 and the garment side edges 225 and 235, respectively. The inner surface 211 of one of the garment side edges 222 and 232 and one of the garment side edges 225 and 235 are brought into contact with the outer surface 213 of the other side edges of each pair of side edges.

Another embodiment of the garment side seams 240 and 242 is an over-lapped configuration as illustrated in Figure 22. Such a configured garment side seam 240 is formed by folding back the garment side edge 222 or the garment side edge 232. The outer surface 213 of the folded portion and the inner surface 211 of the unfolded portion of the garment side edge 222 or 232 and the corresponding portion of the front panel 220 (or, the front panel 250) or the back panel 230 (or, the back panel 260), respectively, is brought into contact with the inner surface 211 or the outer surface 213 of the non-folded garment side edge and the corresponding portion of the front panel 220 (or, the front panel 250) or the back panel 230 (or, the back panel 260).

The garment side seam 242 is formed by folding back the garment side edge 225 or the garment side edge 235. The outer surface 213 of the folded portion and the inner surface 211 of the unfolded portion of the garment side edge 225 or 235 and the corresponding portion of the front panel 221 (or, the front panel 250) or the back panel 231 (or, the back panel 260), respectively, is brought into contact with the inner surface 211 or the outer surface 213 of the non-folded garment side edge and the corresponding portion of the front panel 221 (or, the front panel 250) or the back panel 231 (or, the back panel 260). It is understood that the folding back of a garment side edge 222, 232, 225, or 235, could be performed such that the inner surface 211 would be exposed along the fold.

The garment end portions 266 and 267 of the discrete garment-sized piece 255 of the composite web of fabric 253 may be hemmed in the finished garment 210. In some embodiments, it may be desirable to hem the garment end portions 262, 263, 264, and 265 of the garment-sized pieces 217 and 218 of the webs of fabric 215 and 216, respectively, before fastening the garment-sized pieces 217 and 218 together to form the discrete garment-sized piece 255 of the composite web of fabric 253. The garment end portions 266 and 267 of the discrete garment-sized piece 255 (or, alternatively, garment end portions 262, 263, 264, and 265 of the garment-sized pieces 217 and 218) can be hemmed by any method or style known in the art. In some embodiments, it may be desirable to leave the garment end portions 266 and 267 of the discrete garment-sized piece 255 (or, alternatively, garment end portions 262, 263, 264, and 265 of the garment- sized pieces 217 and 218) unhemmed.

The garment bottom edges 259 and 269 of the discrete garment-sized piece 255 of the composite web of fabric 253 may be hemmed in the finished garment 210. In some embodiments, it may be desirable to hem the garment bottom edges 226, 227, 236, and 237 of the garment-sized pieces 217 and 218 of the webs of fabric 215 and 216, respectively, before fastening the garment-sized pieces 217 and 218 together to form the discrete garment-sized piece 255 of the composite web of fabric 253. The garment bottom edges 259 and 269 of the discrete garment-sized piece 255 (or, alternatively, the garment bottom edges 226, 227, 236, and 237 of the garment-sized pieces 217 and 218) can be hemmed by any method or style known in the art. (Sewing equipment 317 is shown in Figure 2). In some embodiments, it may be desirable to leave the garment bottom edges 259 and 269 of the discrete garment-sized piece 255 (or, alternatively, the garment bottom edges 226, 227, 236, and 237 of the garment-sized pieces 217 and 218) unhemmed.

In some embodiments of the present invention, the garment 210 includes sleeves

276 and 278. (See Figures 9 and 10). The sleeves 276 and 278 are made of pieces of the sleeve web fabric 277 and 279, the same or different from the material of the webs of fabric 215 and 216. In some embodiments, only one sleeve 276 or 278 may be included in the finished garment 210. The pieces of the sleeve web fabric 277 and 279 are provided as sleeve-sized pieces 219 cut from the sleeve web of fabric 212. The pieces of the sleeve web fabric 277 and 279 may take on a variety of sizes and shapes, such as circular, oval, triangular, square, rectangular, multi-faceted, asymmetric or irregular, or the like. The pattern is restricted only by fashion and the minimum amount of the material of the pieces of the sleeve web fabric 277 and 279 that is necessary to complete the remaining steps or operations of the process of manufacture. The sleeves 276 and 278, alternately the pieces of sleeve web fabric 277 and 279, may be similar or dissimilar in shape, structure, material, size, and the like from each other within the finished garment 210.

The piece of a sleeve web fabric 277 has a pair of sleeve side edges 281 and 283, a garment end edge 280, and a sleeve opening end edge 284 opposite the garment end edge 280. It is understood that the piece of the sleeve web fabric 277 could be provided as a tube having a garment end edge 280 and a sleeve opening end edge 284 opposite the garment end edge 280. It is also understood that the piece of the sleeve web fabric 277 could be made of multiple pieces of material or materials. The piece of the sleeve web fabric 277 is folded so as to bring together the opposing sleeve side edges 281 and 283 to form a sleeve seam 293 of the sleeve 276.

The piece of a sleeve web fabric 279 has a pair of sleeve side edges 288 and 291 , a garment end edge 282, and a sleeve opening end edge 286 opposite the garment end edge 282. It is understood that the piece of the sleeve web fabric 279 could be provided as a tube having a garment end edge 282 and a sleeve opening end edge 286 opposite the garment end edge 282. It is also understood that the piece of the sleeve web fabric 279 could be made of multiple pieces of material or materials. The piece of the sleeve web fabric 279 is folded so as to bring together the opposing sleeve side edges 288 and 291 to form a sleeve seam 297 of the sleeve 278.

It may be desirable to redirect (or reorient) the sleeve-sized pieces 219 of the sleeve web of fabric 212 to allow easy fastening of the sleeve seams 293 and 297 of the sleeves 276 and 278, respectively, of the garment 210. The turning operations are desirably carried out by turn rolls and turn tables, as well as any other known means. The pieces 219 of the sleeve web of fabric 212 (pieces of the sleeve web fabric 277 and 279) may be reoriented 90 degrees (not shown). The sleeve seams 293 and 297 can be non- refastenable seams or refastenable seams. Any excess material of the pieces of the sleeve web fabric 277 and 279 can be removed from their respective edges of the sleeve seams 293 and 297 to reduce and smooth out the sleeve seams 293 and 297. The non- refastenable sleeve seams 293 and 297 may be formed by any suitable means such as ultrasonic sealing, adhesive bonding, tape, heat sealing, sewing, or any method of fastening known in the art, as discussed above. The non-refastenable sleeve seams 293 and 297 may be constructed on a continuous or intermittent basis. In other embodiments, the opposing pair of the sleeve side edges 281 and 283 and the opposing pair of the sleeve side edges 288 and 291 of the sleeves 276 and 278, respectively, may be held together in the finished garment 210 to form refastenable sleeve seams 293 and 297. The refastenable means for securing the opposing pair of the sleeve side edges 281 and 283 and the opposing pair of the sleeve side edges 288 and 291 of the sleeves 276 and 278, respectively, include refastenable adhesive and mechanical type fasteners 295. The adhesive and mechanical type fasteners 295 include buttons and button holes, snaps, buckles, clasps, hooks and loops, end extensions, tabs, tape, and the like which are designed or adapted to interlock or engage some type of a complementary device or the inner surface 211 or the outer surface 213 of the garment 210. The refastenable sleeve seams 293 and 297 may be constructed on a continuous or intermittent basis.

In addition, elasticized fasteners 295 may also be used in assuring better fit of the sleeves 276 and 278 of the garment 210. If the garment 210 includes refastenable sleeve seams 293 and 297, the refastenable means are desirably strategically placed on the pieces of the sleeve web fabric 277 and 279 before the sleeve web of fabric 212 is cut into discrete sleeve-sized pieces 219. The folding and redirection operations may be eliminated when refastenable sleeve seams 293 and 297 are included in the garment 210. However, there may be packaging reasons for which one would still carry out these two steps.

The sleeve seams 293 and 297 of the present invention may take on a variety of structures or configurations known in the art. One embodiment of the sleeve seams 293 and 297 is an out-turned configuration as illustrated in Figure 20. Such configured sleeve seams 293 and 297 are formed by securing together at least a portion of the out-turned portions of the sleeve side edges 281 and 283 and the sleeve side edges 288 and 291 of the sleeves 276 and 278, respectively. The inner surface 211 of the sleeve side edges 281 and 283 and the sleeve side edges 288 and 291 of the sleeves 276 and 278, respectively, are brought into contact with each other of the pair.

Another embodiment of the sleeve seams 293 and 297 is an in-turned configuration as illustrated in Figure 21. Such configured sleeve seams 293 and 297 are formed by securing together at least a portion of the in-turned portions of the sleeve side edges 281 and 283 and the sleeve side edges 288 and 291 of the sleeves 276 and 278,. respectively. The outer surface 213 of the sleeve side edges 281 and 283 and the sleeve side edges 288 and 291 of sleeves 276 and 278, respectively, are brought into contact with each other of the pair.

Another embodiment of the sleeve seams 293 and 297 is an over-lapped configuration as illustrated in Figure 19. Such configured sleeve seams 293 and 297 are formed by securing together at least a portion of the over-lapped portions of the sleeve side edges 281 and 283 and the sleeve side edges 288 and 291 of the sleeves 276 and 278, respectively. The inner surface 211 of one of the sleeve side edges 281 or 283 and the sleeve side edges 288 or 291 of the sleeves 276 and 278, respectively, is brought into contact with the outer surface 213 of the other sleeve side edge 281 or 283 and the sleeve side edge 288 or 291 of the sleeve 276 and 278, respectively.

Another embodiment of the sleeve seams 293 and 297 is an over-lapped configuration as illustrated in Figure 22. Such configured sleeve seams 293 and 297 are formed by folding back the sleeve side edges 281 or 283 and the sleeve side edges 288 and 291 of the sleeves 276 and 278, respectively. The outer surface 213 of the folded portions and the inner surface 211 of the unfolded portions of the sleeve side edges 281 or 283 and the sleeve side edges 288 or 291 and the corresponding portions of the sleeves 276 and 278, respectively, are brought into contact with the inner surface 211 or the outer surface 213 of the non-folded sleeve side edge 283 or 281 and the sleeve side edge 291 or 288 and the corresponding portions of the sleeves 276 and 278, respectively. It is understood that the folding back of a sleeve side edge 281 , 283, 288, or 291 could be performed such that the inner surface 211 would be exposed along the fold.

The garment end edges 280 and 282 of the pieces of the sleeve web fabric 277 and 279, respectively, may be attached to the arm opening edges 273 and 275 of the arm openings 272 and 274, respectively, of the garment 210. (Sewing equipment 316 is shown in Figure 2). The attachment of the pieces of the sleeve web fabric 277 and 279 may be made non-refastenable by means as discussed above. In the alternative, the attachment of the pieces of the sleeve web fabric 277 and 279 may be made refastenable by means as discussed above. The sleeves 276 and 278 may be constructed before attachment to the garment 210. The garment end edges 280 and 282 of the sleeves 276 and 278, respectively, may be attached to the arm opening edges 273 and 275 of the arm openings 272 and 274, respectively, of the garment 210, forming arm opening seams 303 and 306, respectively. The attachment of the sleeves 276 and 278 may be made non-refastenable by means as discussed above. In the alternative, the attachment of the sleeves 276 and 278 may be made refastenable by means as discussed above. The arm opening seams 303 and 306 may be constructed on a continuous or intermittent basis.

The arm opening seams 303 and 306 of the present invention may take on a variety of structures or configurations. One embodiment of the arm opening seams 303 and 306 is an out-turned configuration as illustrated in Figure 20. Such configured arm opening seams 303 and 306 are formed by securing together at least a portion of the out- turned portions of the garment end edge 280 and the arm opening edge 273 and the garment end edge 282 and the arm opening edge 275, respectively, of the garment 210. The inner surface 211 of the garment end edges 280 and 282 of the sleeves 276 and 278, respectively, are brought into contact with the inner surface 211 of the arm opening edges 273 and 275, respectively.

Another embodiment of the arm opening seams 303 and 306 is an in-turned configuration as illustrated in Figure 21. Such configured arm opening seams 303 and 306 are formed by securing together at least a portion of the in-turned portions of the garment end edge 280 and the arm opening edge 273 and the garment end edge 282 and the arm opening edge 275, respectively, of the garment 210. The outer surface 213 of the garment end edges 280 and 282 of the sleeves 276 and 278 are brought into contact with the outer surface 213 of the arm opening edges 273 and 275, respectively.

Another embodiment of the arm opening seams 303 and 306 is an over-lapped configuration as illustrated in Figure 19. Such configured arm opening seams 303 and 306 are formed by securing together at least a portion of the over-lapped portions of the garment end edges 280 and the arm opening edge 273 and the garment end edge 282 and the arm opening edge 275, respectively, of the sleeves 276 and 278, respectively. The inner surface 211 of one of the garment end edge 280 or the arm opening edge 273 and the garment end edge 282 or the arm opening edge 275, is brought into contact with the outer surface 213 of the other garment end edge 280 or the arm opening edge 273 and the garment end edge 282 or the arm opening edge 275 of the sleeves 276 and 278, respectively.

Another embodiment of the arm opening seams 303 and 306 is an over-lapped configuration as illustrated in Figure 22. Such configured arm opening seams 303 and 306 are formed by folding back the garment end edge 280 or the arm opening edge 273 and the garment end edge 282 or the arm opening edge 275. The outer surface 213 of the folded portions and the inner surface 211 of the unfolded portions of the garment end edge 280 or the arm opening edge 273 and the garment end edge 282 or the arm opening edge 275 and the corresponding portions of the sleeves 276 and 278 or the front and back panels 250 and 260 are brought into contact with the inner surface 211 or the outer surface 213 of the unfolded garment end edge 282 or 280 or arm opening edge 275 or 273 and the corresponding portions of the sleeves 276 and 278 or the front and back panels 250 and 260. It is understood that the folding back of a garment end edge 280 or 282 or an arm opening edge 273 or 275 could be performed such that the inner surface 211 would be exposed along the fold.

The sleeve opening end edges 284 and 286 of the sleeves 276 and 278, respectively, (in the alternative, the sleeve opening end edges 284 and 286 of the pieces of the sleeve web fabric 277 and 279) can be hemmed by any method or style known in the art. In some embodiments, it may be desirable to leave the sleeve opening end edges

284 and 286 unhemmed.

In other embodiments, cuffs 285 and 287 may be attached to the sleeve opening end edges 284 and 286, respectively, of the sleeves 276 and 278, respectively, of the garment 210, forming cuff seams 308 and 310, respectively. The attachment of the cuffs

285 and 287 may be made non-refastenable by means as discussed above. In the alternative, the attachment of the cuffs 285 and 287 may be made refastenable by means as discussed above. The cuff seams 308 and 310 may be constructed on a continuous or intermittent basis. The cuffs 285 and 287 may take on a variety of sizes and shapes. The cuffs 285 and 287 may be similar or dissimilar in shape, structure, material, size, and the like from each other within the finished garment 210. The pattern of the cuffs 285 and 287 is restricted only by the fashion and the minimum amount of the material of the cuffs 285 and 287 that is necessary to complete the remaining steps or operations of the process of manufacture. The cuff seams 308 and 310 of the present invention may take on a variety of structures or configurations known in the art. One embodiment of the cuff seams 308 and 310 is an out-turned configuration as illustrated in Figure 20. Such configured cuff seams 308 and 310 are formed by securing together at least a portion of the out-turned portions of the cuff edge 307 and the sleeve opening end edge 284 and the cuff edge 309 and the sleeve opening end edge 286, respectively, of the garment 210. The inner surface 211 of the cuff edges 307 and 309 of the cuffs 285 and 287, respectively, are brought into contact with the inner surface 211 of the sleeve opening edges 284 and 286 of the sleeves 276 and 278, respectively.

Another embodiment of the cuff seams 308 and 310 is an in-turned configuration as illustrated in Figure 21. Such configured cuff seams 308 and 310 are formed by securing together at least a portion of the in-turned portions of the cuff edge 307 and the sleeve opening edge 284 and the cuff edge 309 and the sleeve opening edge 286, respectively, of the garment 210. The outer surface 213 of the cuff edges 307 and 309 of the cuffs 285 and 287, respectively, are brought into contact with the outer surface 213 of the sleeve opening edges 284 and 286 of the sleeves 276 and 278, respectively.

Another embodiment of the cuff seams 308 and 310 is an over-lapped configuration as illustrated in Figure 19. Such configured cuff seams 308 and 310 are formed by securing together at least a portion of the over-lapped portions of the cuff edge 307 and the sleeve opening edge 284 and the cuff edge 309 and the sleeve opening edge 286 of the sleeves 276 and 278, respectively. The inner surface 211 of one of the cuff edge 307 or the sleeve opening edge 284 and the cuff edge 309 or the sleeve opening edge 286, is brought into contact with the outer surface 213 of the other cuff edge 307 or the sleeve opening edge 284 and the cuff edge 309 or the sleeve opening edge 286 of the sleeves 276 and 278, respectively.

Another embodiment of the cuff seams 308 and 310 is an over-lapped configuration as illustrated in Figure 22. Such configured cuff seams 308 and 310 are formed by folding back the cuff edge 307 or the sleeve opening end edge 284 and the cuff edge 309 or the sleeve opening end edge 286 of the sleeves 276 and 278, respectively. The outer surface 213 of the folded portions and the inner surface 211 of the unfolded portions of the cuff edge 307 or the sleeve opening end edge 284 and the cuff edge 309 or the sleeve opening end edge 286 and the corresponding portions of the cuffs 285 and 287 or the sleeves 276 and 278 are brought into contact with the inner surface 211 or the outer surface 213 of the unfolded cuff edge 307 and 309 or the sleeve opening end edge 284 and 286 and the corresponding portions of the cuffs 285 and 287 or the sleeves 276 and 278. It is understood that the folding back of a cuff edge 307 or 309 or a sleeve opening end edge 284 or 286 could be performed such that the inner surface 211 would be exposed along the fold.

The materials used for the cuffs 285 and 287 may be the same as the materials used for the other portions of the garment 210. In some embodiments, it is desirable that the materials used for the cuffs 285 and 287 have an elastic element such that the cuffs 285 and 287 will conform to the portion of the wearer's arms that come into contact with the cuffs 285 and 287.

The edge 292 of the neck opening 290 can be hemmed by any method or style known in the art. In some embodiments, it may be desirable to leave the edge 292 of the neck opening 290 unhemmed.

In other embodiments, a collar 294 may be attached to the edge 292 of the neck opening 290 of the garment 210, thereby forming a collar seam 312. The attachment of the collar 294 may be made non-refastenable by means as discussed above. (Sewing equipment 318 is shown in Figure 2). In the alternative, the attachment of the collar 294 may be made refastenable by means as discussed above. The collar seam 312 may be constructed on a continuous or intermittent basis. The collar 294 may take on a variety of sizes and shapes. The pattern of the collar 294 is restricted only by the fashion and the minimum amount of the material of the collar 294 that is necessary to complete the remaining steps or operations of the process of manufacture.

The collar seam 312 of the present invention may take on a variety of structures or configurations known in the art. (Sewing equipment 315 is shown in Figure 2). One embodiment of the collar seam 312 is an out-turned configuration as illustrated in Figure 20. Such a configured collar seam 312 is formed by securing together at least a portion of the out-turned portions of the collar edge 311 of the collar 294 and the edge 292 of the neck opening 290 of the garment 210. The inner surface 211 of the collar edge 311 of the collar 294 is brought into contact with the inner surface 211 of the edge 292 of the neck opening 290.

Another embodiment of the collar seam 312 is an in-turned configuration as illustrated in Figure 21. Such a configured collar seam 312 is formed by securing together at least a portion of the in-turned portions of the collar edge 311 of the collar 294 and the edge 292 of the neck opening 290 of the garment 210. The outer surface 213 of the collar edge 311 of the collar 294 is brought into contact with the outer surface 213 of the edge 292 of the neck opening 290.

Another embodiment of the collar seam 312 is an over-lapped configuration as illustrated in Figure 19. Such a configured collar seam 312 is formed by securing together at least a portion of the over-lapped portions of the collar edge 311 of the collar 294 and the edge 292 of the neck opening 290 of the garment 210. The inner surface 211 of the collar edge 311 of the collar 294 or the edge 292 of the neck opening 290 is brought into contact with the outer surface 213 of the other, the collar edge 311 of the collar 294 or the edge 292 of the neck opening 290.

Another embodiment of the collar seam 312 is an over-lapped configuration as illustrated in Figure 22. Such a configured collar seam 312 is formed by folding back the collar edge 311 of the collar 294 or the edge 292 of the neck opening 290. The outer surface 213 of the folded portions and the inner surface 211 of the unfolded portions of the collar edge 311 of the collar 294 or the edge 292 of the neck opening 290 and the corresponding portions of the collar 294 or the front and back panels 250 and 260 are brought into contact with the inner surface 211 or the outer surface 213 of the unfolded collar edge 311 of the collar 294 or the edge 292 of the neck opening 290 and the corresponding portions of the collar 294 or the front and back panels 250 and 260. It is understood that the folding back of the collar edge 311 of the collar 294 or the edge 292 of the neck opening 290 could be performed such that the inner surface 211 would be exposed along the fold.

Another embodiment of the collar seam 312 is an over-lapped configuration as illustrated in Figure 23. Such a configured collar seam 312 is formed by folding the collar 294 about or over the edge 292 of the neck opening 290. The collar edges 311 of the collar 294 may be folded under bringing the outer surface 213 of the collar 294 into contact with the edge 292 of the neck opening and any portion of the adjacent material of the front panel 250, the back panel 260, or both as desired. The collar edges 311 may be left exposed by not being folding under.

Another embodiment of the collar seam 312 is an over-lapped configuration as illustrated in Figure 24. Such a configured collar seam 312 is formed by folding the collar edge 311 such that the inner surface 211 of the collar 294 is brought into contact with itself. The edge 292 of the neck opening 290 is folded such that the outer surface 213 of the front panel 250, the back panel 260, or both are brought into contact with itself. The collar edge 311 is inserted into the fold of the edge 292 of the neck opening 290. The edge 292 of the neck opening 290 is inserted into the fold of the collar edge 311. In another embodiment, the collar edge 311 is folded such that the outer surface 213 of the collar 294 is brought into contact with itself. The edge 292 of the neck opening 290 is folded such that the inner surface 211 of the front panel 250, the back panel 260, or both are brought into contact with itself. This configured collar seam 312 may be used with any seam describe herein.

The materials used for the collar 294 may be the same as the materials used for the other portions of the garment 210. In some embodiments, it is desirable that the materials used for the collar 294 have an elastic element such that the collar 294 will conform to the portion of the wearer's neck that comes into contact with the collar 294.

In other embodiments of the present invention, the front panel 250, the back panel 260, or both panels 250 and 260 may be cut or otherwise opened to form a slit 245 or 300 (shown in Figure 6) such as a placket. The garment 210 including one or both slits 245 and 300 can be used as a wrap, gown, robe, or the like. The slit 245 has two edges 257 and 261. The slit 300 has two edges 301 and 302. The slits 245 and 300 of the front and back panels 250 and 260, respectively, may extend from the edge 292 of the neck opening 290 to the garment bottom edges 259 and 269, respectively. In the alternative, the slits 245 and 300 may extend over only a portion of the panels 250 and 260 between the edge 292 of the neck opening 290 to the garment bottom edges 259 and 269, respectively. When the garment 210 comprises both a slit 245 in the front panel 250 and a slit 300 in the back panel 260, the slits 245 and 301 may be similar or dissimilar in size, structure, shape, and the like. The slits 245 and 300 may or may not coincide with the side edges 223 and 224 and the side edges 233 and 234, respectively. In some embodiments, the edges 257 and 261 of the slit 245 and the edges 301 and 302 of the slit 300 may be refastenably attached or secured to each other. The edges 257 and 261 may be secured together to form a front seam 313. The edges 301 and 302 may be secured to form a back seam 314. Various fastening means, such as adhesive and mechanical type fasteners 295, see the discussion above, may be used to refastenably attach or secure the edges 257 and 261 or the edges 301 and 302 together of the slits 245 and 300, respectively.

One embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a web of fabric including opposing web side edges; intermittently cutting the web of fabric, forming edges defining neck openings in the web fabric; cutting the web of fabric, defining discrete garment-sized pieces wherein each of the discrete garment-sized pieces of the web of fabric includes at least one neck opening, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, two opposing ' garment end portions, and a pair of opposing piece side edges wherein the opposing piece side edges of the discrete garment-sized piece are proximate a pair of opposing garment bottom edges of the garment; folding the discrete garment-sized piece of the web of fabric whereby one of the garment bottom edges of the pair of opposing garment bottom edges is brought into contact with the other garment bottom edge; and, fastening at least a portion of the pair of opposing garment side edges of the front panel to at least a portion of the pair of opposing garment side edges of the back panel to form a pair of garment side seams.

The web of fabric may be intermittently cut thereby forming arm opening edges defining pairs of opposing arm openings in the web of fabric. The discrete garment-sized pieces of the web of fabric may include at least one pair of the arm opening edges. At least a portion of at least one of the opposing garment bottom edges may be hemmed. Pieces of sleeve web fabric may be provided wherein each of the pieces of the sleeve web fabric includes at least a pair of opposing sleeve side edges, a garment end edge having a shape complementary to at least a portion of the shape of at least one of the arm opening edges of the arm openings and an opposing sleeve opening end edge. At least a portion of the garment end edge of each of the piece of the sleeve web fabric may be applied and fastened to at least a portion of one of the arm opening edges of the arm openings. At least a portion of at least one of the sleeve opening end edges of the pieces of the sleeve web fabric may be hemmed.

The neck opening in the discrete garment-sized piece may be intermediate at least one of the pairs of opposing arm opening edges. A collar may be provided. At least a portion of the collar may be fastened to at least a portion of the edge of the neck opening. At least a portion of the collar may be a ribbed knit collar. At least a portion of at least one of the garment side seams may be refastenable. At least a portion of at least one of the garment side seams may be non-refastenable. At least a portion of the edge of the neck opening may be hemmed. At least a portion of at least one of the arm opening edges of the arm openings may be hemmed.

Pieces of sleeve web fabric may be provided wherein each of the pieces of the sleeve web fabric includes at least a garment end edge having at least a portion of a shape complementary to at least a portion of the shape of a portion of the opposing garment side edges of the front panel, or the back panel, or of both the front and back panels, and an opposing sleeve opening end edge. At least a portion of the garment end edge of each of the piece of the sleeve web fabric may be applied and fastened to at least a portion of one of the garment side edges defining the arm opening. At least a portion at least one of the sleeve opening end edges of the pieces of the sleeve web fabric may be hemmed. The front panel may be slit at least a portion of the distance between the edge of the neck opening and the garment bottom edge thereby defining a pair of edges of a slit. At least a portion of the edges of the slit may be fastened to form a front seam. At least a portion of the front seam may be refastenable. At least a portion of the front seam may be non-refastenable. The back panel may be slit at least a portion of the distance between the edge of the neck opening and the garment bottom edge thereby defining a pair of edges of a slit. At least a portion of the edges of the slit may be fastened to form a back seam. At least a portion of the back seam may be refastenable. At least a portion of the back seam may be non-refastenable.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a web of fabric including opposing web side edges; intermittently cutting the web of fabric, forming arm opening edges defining arm openings and edges defining neck openings in the web fabric; cutting the web of fabric, defining discrete garment-sized pieces wherein each of the discrete garment-sized pieces of the web of fabric includes at least one neck opening, one pair of opposing arm opening edges, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, two opposing garment end portions, and a pair of opposing piece side edges wherein the opposing piece side edges of the discrete garment-sized piece are proximate a pair of opposing garment bottom edges of the garment; folding the discrete garment-sized piece of the web of fabric whereby one of the garment bottom edges of the pair of opposing garment bottom edges is brought into contact with the other garment bottom edge; and, fastening at least a portion of the pair of opposing garment side edges of the front panel to at least a portion the pair of opposing garment side edges of the back panel to form a pair of garment side seams.

At least a portion of at least one of the opposing garment bottom edges may be hemmed. Pieces of sleeve web fabric may be provided wherein each of the pieces of the sleeve web fabric includes at least a pair of opposing sleeve side edges, a garment end edge having at least a portion of a shape complementary to at least a portion of the shape of at least one of the arm opening edges of the arm openings and an opposing sleeve opening end edge. At least a portion of the garment end edge of each of the piece of the sleeve web fabric may be applied and fastened to at least a portion of one of the arm opening edges of the arm openings. At least a portion of at least one of the sleeve opening end edges of the pieces of the sleeve web fabric may be hemmed. The neck opening in the discrete garment-sized piece may be intermediate at least one of the pairs of opposing arm opening edges.

A collar may be provided. At least a portion of the collar may be fastened to at least a portion of the edge of the neck opening. At least a portion of the collar may be a ribbed knit collar. At least a portion of at least one of the garment side seams may be refastenable. At least a portion of at least one of the garment side seams may be non- refastenable. At least a portion of the edge of the neck opening may be hemmed. At least a portion of at least one of the arm opening edges of the arm openings may be hemmed.

The front panel may be slit at least a portion of the distance between the edge of the neck opening and the garment bottom edge thereby defining a pair of edges of a slit. At least a portion of the edges of the slit may be fastened to form a front seam. At least a portion of the front seam may be refastenable. At least a portion of the front seam may be non-refastenable. The back panel may be slit at least a portion of the distance between the edge of the neck opening and the garment bottom edge thereby defining a pair of edges of a slit. At least a portion of the edges of the slit may be fastened to form a back seam. At least a portion of the back seam may be refastenable. At least a portion of the back seam may be non-refastenable.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a web of fabric including opposing web side edges; intermittently cutting the web of fabric, forming arm opening edges defining pairs of opposing arm openings in the web of fabric; intermittently cutting the web of fabric, forming edges defining neck openings in the web of fabric; providing pieces of sleeve web fabric, wherein each of the pieces of sleeve web fabric includes at least a garment end edge having at least a portion of a shape complementary to at least a portion of the shape of at least one of the arm opening edges of the arm openings, a pair of opposing sleeve side edges, and an opposing sleeve opening end edge; applying and fastening at least a portion of the garment end edge of each of the piece of the sleeve web fabric to at least a portion of the arm opening edge of one of the arm openings; hemming at least a portion of at least one of the sleeve opening end edges of the pieces of the sleeve web fabric; cutting the web of fabric, defining discrete garment-sized pieces wherein each of the discrete garment-sized piece of the web of fabric includes at least a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, a pair of the arm opening edges of the arm openings, one of the neck openings, two opposing garment end portions, and a pair of opposing piece side edges wherein the opposing piece side edges of the discrete garment-sized piece are proximate a pair of opposing garment bottom edges of the garment; hemming at least a portion of at least one of the opposing garment bottom edges; folding the discrete garment-sized piece of the web of fabric whereby one of the garment bottom edges of the pair of opposing garment bottom edges is brought into contact with the other garment bottom edge; and, fastening at least a portion of the pair of opposing garment side edges of the front panel to at least a portion of the pair of opposing garment side edges of the back panel to form a pair of garment side seams.

The web of fabric may be folded, defining an arrangement of having the web of fabric wherein the opposing web side edges are adjacent each other. The web of fabric may be unfolded after at least one of the steps of intermittently cutting the web of fabric. The discrete garment-sized piece of the web of fabric may be unfolded before the step of folding the discrete garment-sized piece of the web of fabric whereby the pair of opposing garment side edges of the front panel are brought into contact with the pair of opposing garment side edges of the back panel.

A collar may be provided. At least a portion of the collar may be fastened to at least a portion of the edge of the neck opening. At least a portion of the collar may be a ribbed knit collar. At least a portion of at least one of the garment side seams may be refastenable. At least a portion of at least one of the garment side seams may be non- refastenable. The neck opening in the discrete garment-sized piece may be intermediate at least one of the pairs of opposing arm opening edges. At least a portion of the edge of the neck opening may be hemmed. At least a portion of at least one of the arm opening edges of the opposing arm openings may be hemmed.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a web of fabric including an inner surface, an outer surface, and opposing side edges; intermittently cutting the web of fabric, forming arm opening edges defining pairs of opposing arm openings in the web of fabric; intermittently cutting the web of fabric, forming edges defining neck openings in the web of fabric; cutting the web of fabric, defining discrete garment-sized pieces wherein each of the discrete garment-sized piece of the web of fabric includes at least a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, a pair of the arm opening edges of the arm openings, one neck opening, two opposing garment end portions, and a pair of opposing piece side edges wherein the opposing piece side edges of the discrete garment-sized piece are proximate a pair of opposing garment bottom edges of the garment; hemming at least a portion of at least one of the opposing garment bottom edges; folding the discrete garment-sized piece of the web of fabric whereby one of the garment bottom edges of the pair of opposing garment side edges is brought into contact with the other garment bottom edge; and, fastening at least a portion of the pair of opposing garment side edges of the front panel to at least a portion of the pair of opposing garment side edges of the back panel to form a pair of garment side seams.

The web of fabric may be folded, defining an arrangement of having the web of fabric wherein the opposing web side edges are adjacent each other. The web of fabric may be folded after at least one of the steps of intermittently cutting the web of fabric. The discrete garment-sized piece of the web of fabric may be unfolded before the step of folding the discrete garment-sized piece of the web of fabric whereby the pair of opposing garment side edges of the front panel are brought into contact with the pair of opposing garment side edges of the back panel.

Pieces of sleeve web fabric may be provided wherein each of the pieces of the sleeve web fabric includes at least an inner surface, an outer surface, a garment end edge having at least a portion of a shape complementary to at least a portion of the shape of at least one of the arm opening edges of at least one of the arm openings, and an opposing sleeve opening end edge wherein the garment end edge is aligned with one of the arm opening edge of the arm opening and the outer surface of the piece of the sleeve web fabric is in contact with the outer surface of the web of fabric at least at the arm opening edge of the arm opening. At least a portion of the garment end edge of the piece of the sleeve web fabric may be applied and fastened to at least a portion of the arm opening edge of the arm opening. At least a portion of the sleeve opening end edge of the piece of the sleeve web fabric may be hemmed. The neck opening in the discrete garment-sized piece may be intermediate at least one of the pairs of the opposing arm opening edges. A collar may be provided. The collar may be fastened to at least a portion of the edge of the neck opening. At least a portion of the collar may be a ribbed knit collar. At least a portion of at least one of the garment side seams is refastenable. At least a portion of at least one of the garment side seams is non-refastenable.

At least a portion of the edge of the neck opening may be hemmed. At least a portion of at least one of the arm opening edges of the arm openings may be hemmed. The front panel may be slit at least a portion of the distance between the edge of the neck opening and the garment bottom edge thereby defining a pair of edges of a slit. At least a portion of the edges of the slit may be fastened to form a front seam. At least a portion of the front seam may be refastenable. At least a portion of the front seam may be non- refastenable. The back panel may be slit at least a portion of the distance between the edge of the neck opening and the garment bottom edge thereby defining a pair of edges of a slit. At least a portion of the edges of the slit may be fastened to form a back seam. At least a portion of the back seam may be refastenable. At least a portion of the back seam may be non-refastenable.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a first web of fabric including opposing web side edges; providing a second web of fabric including opposing web side edges; aligning the first and second webs of fabric together in a side by side orientation defining an arrangement fabric wherein one of the opposing web side edges of the first web of fabric is adjacent one of the opposing web side edge of the second web of fabric; fastening at least a portion of the adjacent web side edge of the first web of fabric to at least a portion of the adjacent web side edge of the second web of fabric in the side by side orientation, defining at least a portion of a center seam and a composite web of fabric having a pair of opposing web side edges; intermittently cutting the composite web of fabric, forming edges defining neck openings in the composite web of fabric; cutting the composite web of fabric, defining discrete garment-sized pieces wherein each of the discrete garment-sized piece of the composite web of fabric includes at least one neck opening, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, two opposing garment end portions, and a pair of opposing piece side edges wherein the opposing piece side edges of the discrete garment-sized piece are proximate a pair of opposing garment bottom edges of the garment; folding the discrete garment-sized piece of the composite web of fabric whereby one of the garment bottom edges of the pair of opposing garment bottom edges is brought into contact with the other garment bottom edge; and, fastening at least a portion of the pair of opposing garment side edges of the front panel to at least a portion of the pair of opposing garment side edges of the back panel to form a pair of garment side seams.

The composite web of fabric may be intermittently cut, forming arm opening edges defining pairs of opposing arm openings in the composite web of fabric. At least a portion of at least one of the opposing garment bottom edges may be hemmed. The discrete garment-sized pieces may include at least one pair of the arm opening edges. Pieces of sleeve web fabric may be provided wherein each of the pieces of the sleeve web fabric includes at least a garment end edge having at least a portion of a shape complementary to at least a portion of the shape of at least one of the arm opening edges of the arm openings and an opposing sleeve opening end edge. The garment end edge of each piece of the sleeve web fabric may be applied and fastened to one of the arm opening edges of the arm openings. At least a portion of at least one of the sleeve opening end edges of the pieces of the sleeve web fabric may be hemmed. At least one of the neck openings in the composite web of fabric may be intermediate a pair of the opposing arm opening edges. A collar may be provided. At least a portion of the collar may be fastened to at least a portion of the edge of the neck opening. At least a portion of the collar may be a ribbed knit collar. At least a portion of at least one of the garment side seams may be refastenable. At least a portion of at least one of the garment side seams may be non-refastenable. At least a portion of the edge of the neck opening may be hemmed. At least a portion of at least one of the arm opening edges of the arm openings may be hemmed.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a first web of fabric including opposing web side edges; providing a second web of fabric including opposing web side edges; aligning the first and second webs of fabric together in a side by side orientation defining an arrangement wherein one of the opposing web side edges of the first web of fabric is adjacent one of the opposing web side edges of the second web of fabric; fastening at least a portion of the adjacent web side edge of the first web of fabric to at least a portion of the adjacent web side edge of the second web of fabric in the side by side orientation, defining at least a portion of a center seam and a composite web of fabric having a pair of opposing web side edges; intermittently cutting the composite web of fabric, forming arm opening edges defining pairs of opposing arm openings in the composite web of fabric; intermittently cutting the composite web of fabric, forming edges defining neck openings in the composite web of fabric wherein the neck openings are intermediate the pairs of opposing arm opening edges; cutting the composite web of fabric, defining discrete garment-sized pieces wherein each of the discrete garment-sized piece of the composite web of fabric includes at least a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, one of the neck openings, at least one pair of the arm opening edges, two opposing garment end portions, and a pair of opposing piece side edges wherein the opposing piece side edges of the discrete garment-sized piece are proximate a pair of opposing garment bottom edges of the garment; folding the discrete garment-sized piece of the composite web of fabric whereby one of the garment bottom edges of the pair of opposing garment bottom edges is brought into contact with the other garment bottom edge; and, fastening at least a portion of the pair of opposing garment side edges of the front panel to at least a portion of the pair of opposing garment side edges of the back panel to form a pair of garment side seams.

At least a portion of at least one of the opposing garment bottom edges may be hemmed. Pieces of sleeve web fabric may be provided wherein each of the pieces of the sleeve web fabric includes at least a garment end edge having at least a portion of a shape complementary to at least a portion of the shape of at least a portion of the arm opening edge of the arm opening and an opposing sleeve opening end edge. At least a portion of the garment end edge of each of the pieces of the sleeve web fabric may be applied and fastened to at least a portion of one of the arm opening edges of the arm openings. At least a portion of at least one of the sleeve opening end edges of the pieces of the sleeve web fabric may be hemmed. At least one of the neck openings in the composite web of fabric may be intermediate a pair of the opposing arm opening edges. A collar may be provided. At least a portion of the collar may be fastened to at least a portion of the edge of the neck opening. At least a portion of the collar may be a ribbed knit collar. At least a portion of at least one of the garment side seams may be refastenable. At least a portion of at least one of the garment side seams may be non- refastenable. At least a portion of the edge of the neck opening may be hemmed. At least a portion of at least one of the arm opening edges of the arm openings may be hemmed.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a first web of fabric including opposing web side edges; providing a second web of fabric including opposing web side edges; aligning the first and second webs of fabric together in a side by side orientation defining an arrangement wherein one of the opposing web side edges of the first web of fabric is adjacent one of the opposing web side edges of the second web of fabric; fastening at least a portion of the adjacent web side edge of the first web of fabric to at least a portion of the adjacent web side edge of the second web of fabric in the side by side orientation, defining at least a portion of a center seam and a composite web of fabric having a pair of opposing web side edges; intermittently cutting the composite web of fabric, forming arm opening edges defining pairs of opposing arm openings in the composite web of fabric; intermittently cutting the composite web of fabric, forming edges defining neck openings in the composite web of fabric wherein the neck openings are intermediate the pairs of the opposing arm opening edges; providing pieces of sleeve web fabric, wherein each of the pieces of sleeve web fabric includes at least a garment end edge having at least a portion of a shape complementary to at least a portion of the shape of at least a portion of the arm opening edges of the arm openings and an opposing sleeve opening end edge; applying and fastening at least a portion of the garment end edge of each of the pieces of the sleeve web fabric to at least a portion of one of the edges of the arm openings; hemming at least a portion of at least one of the sleeve opening end edges of the pieces of the sleeve web fabric; cutting the composite web of fabric, defining discrete garment-sized pieces wherein each of the discrete garment-sized pieces of the composite web of fabric includes at least a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing side edges, one of the neck openings, one pair of the arm opening edges, two opposing garment end portions, and a pair of opposing piece side edges wherein the opposing piece side edges of the discrete garment-sized piece are proximate a pair of opposing garment bottom edges of the garment; hemming at least a portion of at least one of the opposing garment bottom edges; folding the discrete garment-sized piece of the composite web of fabric whereby one of the garment bottom edges of the pair of opposing garment side edges is brought into contact with the other garment bottom edge; and, fastening at least a portion of the pair of opposing garment side edges of the front panel to at least a portion of the pair of opposing garment side edges of the back panel to form a pair of garment side seams.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising: providing a first web of fabric including opposing web side edges, an inner surface, and an outer surface; providing a second web of fabric including opposing web side edges, an inner surface, and an outer surface; aligning the first and second webs of fabric together in a side by side orientation defining an arrangement wherein one of the opposing web side edges of the first web of fabric is adjacent one of the opposing web side edges of the second web of fabric; fastening at least a portion of the adjacent web side edge of the first web of fabric to at least a portion of the adjacent web side edge of the second web of fabric in the side by side orientation, defining at least a portion of a center seam and a composite web of fabric having a pair of opposing web side edges; intermittently cutting the composite web of fabric, forming arm opening edges defining pairs of opposing arm openings in the composite web of fabric; intermittently cutting the composite web of fabric, forming edges defining neck openings in the composite web of fabric wherein each neck opening is intermediate a pair of the opposing arm opening edges; cutting the composite web of fabric, defining discrete garment-sized pieces wherein each of the discrete garment-sized pieces of the composite web of fabric includes at least a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, one of the neck openings, one pair of the arm opening edges, two opposing garment end portions, and a pair of opposing piece side edges wherein the opposing piece side edges of the discrete garment-sized pieces are proximate a pair of opposing garment bottom edges of the garment; hemming at least a portion of at least one of the opposing garment bottom edges; folding the discrete garment-sized piece of the composite web of fabric whereby one of the garment bottom edges of the pair of opposing garment bottom edges is brought into contact with the other garment bottom edge; and, fastening at least a portion of the pair of opposing garment side edges of the front panel to at least a portion of the pair of opposing garment side edges of the back panel to form a pair of garment side seams.

Pieces of sleeve web fabric may be provided wherein each of the pieces of the sleeve web fabric includes at least an inner surface, an outer surface, a garment end edge having at least a portion of a shape complementary to at least a portion of the shape of at least a portion of the arm opening edge of at least one of the arm openings, and an opposing sleeve opening end edge wherein the garment end edge is aligned with one of the arm opening edges of the arm openings in the composite web of fabric and the outer surface of the piece of the sleeve web fabric is in contact with the outer surface of the composite web of fabric at least at at least a portion of the arm opening edge of the arm openings. At least a portion of the garment end edge of the piece of the sleeve web fabric may be applied and fastened to at least a portion of the arm opening edge of the arm opening. At least a portion of the sleeve opening end edge of the piece of the sleeve web fabric may be hemmed. At least one of the neck openings in the composite web of fabric may be intermediate at least one of the pairs of the opposing arm openings.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a first web of fabric including a first web side edge and a second web side edge; providing a second web of fabric including a first web side edge and a second web side edge; intermittently cutting the second web side edge of the first web of fabric, forming indentations; intermittently cutting the second web side edge of the second web of fabric, forming indentations; aligning the first and second webs of fabric together in a side by side orientation defining an arrangement wherein the second web side edge of the first web of fabric is adjacent the second web side edge of the second web of fabric and the indentations of the second web side edge of the first web of fabric are adjacent the indentations of the second web side edge of the second web of fabric thereby forming edges defining neck openings; fastening at least a portion of the second web side edge of the first web of fabric to at least a portion of the second web side edge of the second web of fabric in the side by side orientation, defining at least a portion of a center seam and a composite web of fabric having a pair of opposing web side edges; intermittently cutting the composite web of fabric, forming arm opening edges defining pairs of opposing arm openings in the composite web of fabric; cutting the composite web of fabric, defining discrete garment- sized pieces wherein each of the discrete garment-sized pieces of the composite web of fabric includes at least one of the neck openings, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, one pair of the arm opening edges, two garment end portions, and a pair of opposing piece side edges wherein the opposing piece side edges of the discrete garment-sized piece are proximate a pair of opposing garment bottom edges of the garment; folding the discrete garment-sized piece of the composite web of fabric whereby one of the garment bottom edges of the pair of opposing garment bottom edges is brought into contact with the other garment bottom edge; and, fastening at least a portion of the pair of opposing garment side edges of the front panel to at least a portion of the pair of opposing garment side edges of the back panel to form a pair of garment side seams.

Pieces of sleeve web fabric may be provided wherein each of the pieces of the sleeve web fabric includes at least an inner surface, an outer surface, a garment end edge having at least a portion of a shape complementary to at least a portion of the shape of at least a portion of the arm opening edge of at least one of the arm openings, and an opposing sleeve opening end edge wherein the garment end edge is aligned with one of the arm opening edges of the arm openings in the composite web of fabric and the outer surface of the piece of the sleeve web fabric is in contact with the outer surface of the composite web of fabric at least at at least a portion of the arm opening edge of the arm openings. At least a portion of the garment end edge of the piece of the sleeve web fabric may be applied and fastened to at least a portion of the arm opening edge of the arm opening. At least a portion of the sleeve opening end edge of the piece of the sleeve web fabric may be hemmed. At least one of the neck openings in the composite web of fabric may be intermediate at least one of the pairs of the opposing arm openings. At least a portion of at least one of the opposing garment bottom edges may be hemmed.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a first web of fabric including opposing web side edges; providing a second web of fabric including opposing web side edges; aligning the first and second webs of fabric together in a face to face orientation defining an arrangement wherein the opposing web side edges of the first web of fabric are adjacent the opposing web side edges of the second web of fabric thereby defining a first pair of adjacent web side edges and a second pair of adjacent web side edges; fastening at least a portion of the first pair of adjacent web side edges together in the face to face orientation, defining at least a portion of a center seam and a composite web of fabric having a pair of opposing web side edges formed from the second pair of adjacent web side edges; intermittently cutting the composite web of fabric, forming edges defining neck openings in the composite web of fabric; cutting the composite web of fabric, defining discrete garment-sized pieces wherein each of the discrete garment-sized piece of the composite web of fabric includes at least one of the neck openings, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, two opposing garment end portions, and a pair of opposing piece side edges wherein the opposing piece side edges of the discrete garment-sized piece are proximate a pair of opposing garment bottom edges of the garment; folding the discrete garment-sized piece of the composite web of fabric whereby one of the garment bottom edges of the pair of opposing garment side edges is brought into contact with the other garment bottom edge; and, fastening at least a portion of the pair of opposing garment side edges of the front panel to at least a portion of the pair of opposing garment side edges of the back panel to form a pair of garment side seams.

The composite web of fabric may be unfolded. The discrete garment-sized piece of the composite web of fabric may be unfolded. The composite web of fabric may be intermittently cut, forming arm opening edges defining pairs of opposing arm openings in the composite web of fabric. At least a portion of at least one of the opposing garment bottom edges may be hemmed. Pieces of sleeve web fabric may be provided wherein each of the pieces of the sleeve web fabric includes at least a garment end edge having at least a portion of a shape complementary to at least a portion of the shape of a portion of the opposing garment side edges of the front panel, or the back panel, or of both the front and back panels, and an opposing sleeve opening end edge. At least a portion of the garment end edge of each piece of the sleeve web fabric may be applied and fastened to at least a portion of one of the garment side edges defining the arm opening. At least a portion of at least one of the sleeve opening end edges of the pieces of the sleeve web fabric may be hemmed.

At least one of the neck openings in the composite web of fabric may be intermediate one of the pairs of the opposing arm opening edges. A collar may be provided. At least a portion of the collar may be fastened to at least a portion of the edge of the neck opening. At least a portion of the collar may be a ribbed knit collar. At least a portion of at least one of the garment side seams may be refastenable. At least a portion of at least one of the garment side seams may be non-refastenable.

The discrete garment-sized pieces may also include at least one pair of the arm opening edges. Pieces of sleeve web fabric may be provided wherein each of the pieces of the sleeve web fabric includes at least a garment end edge having at least a portion of a shape complementary to at least a portion of the shape of at least a portion of the arm opening edges of the opposing arm openings and an opposing sleeve opening end edge. At least a portion of the garment end edge of one piece of the sleeve web fabric may be applied and fastened to at least a portion of one of the arm opening edges of the arm openings. At least a portion of at least one of the sleeve opening end edges of the pieces of the sleeve web fabric may be hemmed.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a first web of fabric including opposing web side edges; providing a second web of fabric including opposing web side edges; aligning the first and second webs of fabric together in a face to face orientation, defining an arrangement wherein the opposing web side edges of the first web of fabric are adjacent the opposing web side edges of the second web of fabric, thereby defining a first pair of adjacent web side edges comprising one the web side edge of the first web of fabric and one the web side edge of the second web of fabric and a second pair of adjacent web side edges comprising one the web side edge of the first web of fabric and one the web side edge of the second web of fabric; fastening at least a portion of the first pair of adjacent web side edges together in a face to face orientation, defining at least a portion of a center seam and a composite web of fabric having a pair of opposing web side edges formed from the second pair of adjacent web side edges; intermittently cutting the composite web of fabric, forming arm opening edges defining pairs of opposing arm openings in the composite web of fabric; intermittently cutting the composite web of fabric, forming edges defining neck openings in the composite web of fabric wherein the neck openings are intermediate the pairs of the opposing arm opening edges; cutting the composite web of fabric, defining discrete garment-sized pieces wherein each of the discrete garment-sized piece of the composite web of fabric includes at least a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, the neck opening, at least one pair of the arm opening edges, two opposing garment end portions, and a pair of opposing piece side edges wherein the opposing piece side edges of the discrete garment-sized piece are proximate a pair of opposing garment bottom edges of the garment; folding the discrete garment-sized piece of the composite web of fabric whereby one of the garment bottom edges of the pair of opposing garment side edges is brought into contact with the other garment bottom edge; and, fastening at least a portion of the pair of opposing garment side edges of the front panel to at least a portion of the pair of opposing garment side edges of the back panel to form a pair of garment side seams.

The composite web of fabric may be unfolded. The discrete garment-sized piece of the composite web of fabric may be unfolded. At least a portion of at least one of the opposing garment bottom edges may be hemmed. Pieces of sleeve web fabric may be provided wherein each of the piece of the sleeve web fabric includes at least a garment end edge having at least a portion of a shape complementary to at least a portion of the shape of at least one of the arm opening edges of one of the arm openings and an opposing sleeve opening end edge. At least a portion of the garment end edge of each piece of the sleeve web fabric may be applied and fastened to at least a portion of one of the arm opening edges of the arm openings. At least a portion of at least one of the sleeve opening end edges of the pieces of the sleeve web fabric may be hemmed.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a first web of fabric including opposing web side edges; providing a second web of fabric including opposing web side edges; aligning the first and second webs of fabric together in a face to face orientation defining an arrangement wherein the opposing web side edges of the first web of fabric are adjacent the opposing web side edges of the second web of fabric, thereby defining a first pair of adjacent web side edges and a second pair of adjacent web side edges; fastening at least a portion of the first pair of adjacent web side edges together in the face to face orientation, defining at least a portion of a center seam and a composite web of fabric having a pair of opposing web side edges formed from the second pair of adjacent web side edges; intermittently cutting the composite web of fabric, forming arm opening edges defining pairs of opposing arm openings in the composite web of fabric; intermittently cutting the composite web of fabric, forming edges defining neck openings in the composite web of fabric wherein the neck openings are intermediate the pairs of the opposing arm opening edges; providing pieces of sleeve web fabric, wherein each of the pieces of sleeve web fabric includes at least a garment end edge having at least a portion of a shape complementary to at least a portion of the shape of the arm opening edges of the arm openings and an opposing sleeve opening end edge; applying and fastening at least a portion of the garment end edge of each piece of the sleeve web fabric to at least a portion of one of the arm openings; hemming at least a portion of at least one of the sleeve opening end edges of the pieces of the sleeve web fabric; cutting the composite web of fabric, defining discrete garment-sized pieces wherein each of the discrete garment-sized pieces of the composite web of fabric includes at least a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing side edges, one of the neck openings, at least one pair of the arm opening edges, two opposing garment end portions, and a pair of opposing piece side edges wherein the opposing piece side edges of the discrete garment-sized piece are proximate a pair of opposing garment bottom edges of the garment; hemming at least a portion of at least one of the opposing garment bottom edges; folding the discrete garment-sized piece of the composite web of fabric whereby one of the garment bottom edges of the pair of opposing garment bottom edges is brought into contact with the other garment bottom edge; and, fastening at least a portion of the pair of opposing garment side edges of the front panel to at least a portion of the pair of opposing garment side , edges of the back panel to form a pair of garment side seams.

The composite web of fabric may be unfolded. The discrete garment-sized piece of the composite web of fabric may be unfolded. A collar may be provided. At least a portion of the collar may be fastened to at least a portion of the edge of the neck opening. At least a portion of the collar may be a ribbed knit collar. At least a portion of at least one of the garment side seams may be refastenable. At least a portion of at least one of the garment side seams may be non-refastenable. At least a portion of the edge of the neck opening may be hemmed. At least a portion of at least one of the arm opening edges of the arm openings may be hemmed.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a first web of fabric including opposing web side edges, an inner surface, and an outer surface; providing a second web of fabric including opposing web side edges, an inner surface, and an outer surface; aligning the first and second webs of fabric together in a face to face orientation defining an arrangement wherein the opposing web side edges of the first web of fabric are adjacent the opposing web side edges of the second web of fabric, thereby defining a first pair of adjacent web side edges and a second pair of adjacent web side edges; fastening at least a portion of the first pair of web adjacent side edges together in the face to face orientation, defining at least a portion of a center seam and a composite web of fabric having a pair of opposing web side edges formed from the second pair of adjacent web side edges; intermittently cutting the composite web of fabric, forming arm opening edges defining pairs of opposing arm openings in the composite web of fabric; intermittently cutting the composite web of fabric, forming edges defining neck openings in the composite web of fabric wherein the neck openings are intermediate the pairs of the opposing arm opening edges; cutting the composite web of fabric, defining discrete garment-sized pieces wherein each of the discrete garment-sized piece of the composite web of fabric includes at least a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, one of the neck openings, one pair of the arm opening edges, two opposing garment end portions, and a pair of opposing piece side edges wherein the opposing piece side edges of the discrete garment-sized piece are proximate a pair of opposing garment bottom edges of the garment; hemming at least a portion of at least one of the opposing garment bottom edges; folding the discrete garment-sized piece of the composite web of fabric whereby one of the garment bottom edges of the pair of opposing garment bottom edges is brought into contact with the other garment bottom edge; and, fastening at least a portion of the pair of opposing garment side edges of the front panel to at least a portion of the pair of opposing garment side edges of the back panel to form a pair of garment side seams.

The composite web of fabric may be unfolded. The discrete garment-sized piece of the composite web of fabric may be unfolded. Pieces of sleeve web fabric may be provided wherein each of the pieces of the sleeve web fabric includes at least an inner surface, an outer surface, a garment end edge having at least a portion of a shape complementary to at least a portion of the shape of the arm opening edges of the arm openings, and an opposing sleeve opening end edge wherein the garment end edge is aligned with one of the arm opening edge of the arm openings in the composite web of fabric and the outer surface of the piece of the sleeve web fabric is in contact with the outer surface of the composite web of fabric at least at at least a portion of the arm opening edge of the arm openings. At least a portion of the garment end edge of the piece of the sleeve web fabric may be applied and fastened to at least a portion of the arm opening edge of the arm opening. At least a portion of at least one of the sleeve opening end edges of the pieces of the sleeve web fabric may be hemmed.

A collar may be provided. At least a portion of the collar may be fastened to at least a portion of the edge of the neck opening. At least a portion of the collar may be a ribbed knit collar. At least a portion of at least one of the garment side seams may be refastenable. At least a portion of at least one of the garment side seams may be non- refastenable. At least a portion of the edge of the opening may be hemmed. At least a portion of at least one of the arm opening edges of the openings may be hemmed.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a first web of fabric including a first web side edge and a second web side edge; providing a second web of fabric including a first web side edge and a second web side edge; intermittently cutting the second web side edge of the first web of fabric, forming indentations; intermittently cutting the second web side edge of the second web of fabric, forming indentations; aligning the first and second webs of fabric together in a face to face orientation, defining an arrangement wherein the first web side edge of the first web of fabric is adjacent the first web side edge of the second web of fabric and the second web side edge of the first web of fabric is adjacent the second web side edge of the second web of fabric wherein the indentations of the second web side edge of the first web of fabric are adjacent the indentations of the second web side edge of the second web of fabric thereby forming edges defining neck openings; fastening at least a portion of the second web side edge of the first web of fabric to at least a portion of the second web side edge of the second web of fabric in the face to face orientation, defining at least a portion of a center seam and a composite web of fabric having a pair of opposing web side edges formed from the first web side edges of the first web of fabric and the first web side edges; intermittently cutting the composite web of fabric, forming arm opening edges defining pairs of opposing arm openings in the composite web of fabric; cutting the composite web of fabric, defining discrete garment-sized pieces wherein each of the discrete garment-sized pieces of the composite web of fabric includes at least one the neck opening, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, one pair of the arm opening edges, two garment end portions, and a pair of opposing piece side edges wherein the opposing piece side edges of the discrete garment-sized piece are proximate a pair of opposing garment bottom edges of the garment; folding the discrete garment-sized piece of the composite web of fabric whereby one of the garment bottom edges of the pair of opposing garment bottom edges is brought into contact with the other garment bottom edge; and, fastening at least a portion of the pair of opposing garment side edges of the front panel to at least a portion of the pair of opposing garment side edges of the back panel to form a pair of garment side seams.

The composite web of fabric may be unfolded. The discrete garment-sized piece of the composite web of fabric may be unfolded. Pieces of sleeve web fabric may be provided wherein each of the pieces of the sleeve web fabric includes at least an inner surface, an outer surface, a garment end edge having at least a portion of a shape complementary to at least a portion of the shape of the arm opening edges of the arm openings, and an opposing sleeve opening end edge wherein the garment end edge is aligned with one of the arm opening edge of the arm openings in the composite web of fabric and the outer surface of the piece of the sleeve web fabric is in contact with the outer surface of the composite web of fabric at least at at least a portion of the arm opening edge of the arm openings. At least a portion of the garment end edge of the piece of the sleeve web fabric may be applied and fastened to at least a portion of the arm opening edge of the arm opening. At least a portion of at least one of the sleeve opening end edges of the pieces of the sleeve web fabric may be hemmed. At least a portion of at least one of the opposing garment bottom edges may be hemmed.

Another embodiment of the garment 410 is illustrated in Figures 25 and 27. The garment 410 includes opposing inner and outer surfaces 411 and 413, respectively. Within this application, the term "garment" is understood to mean shirt, tee-shirt, wrap, robe, gown, jacket, coat, or any type of upper body covering garment having variable lengths of the garment 410 itself and the sleeves (if any) as well as a variety of neck openings and garment openings, such as plackets. According to the preferred embodiment, see Figures 31 and 32, the garment 410 desirably comprises at least a front panel 418 and a back panel 423. The front panel 418 has a pair of garment side edges 419 and 420, a garment bottom edge 421 and a shoulder region 422 positioned between the garment side edges 419 and 420. The back panel 423 has a pair of garment side edges 424 and 425, a garment bottom edge 427 and a shoulder region 429 positioned between the garment side edges 424 and 425.

The garment side edge 419 is joined to the garment side edge 424 to form the garment side seam 430. The garment side edge 420 is joined to the garment side edge 425 to form the garment side seam 431. A portion of the garment side seams 430 and 431 is left unbonded or not joined, preferably in the shoulder regions 422 and 429, defining two opposing arm openings 445 and 447.

The finished garment 410 may include sleeves 449 and 451 so as to surround, at least partially, the arm openings 445 and 447, respectively, of the garment 410. In some embodiments, only one sleeve 449 or 451 may be included in the finished garment 410. The length of the sleeves 449 and 451 may vary from a length intended to at least cover the entire arm of the wearer to a caplet length or shorter. The sleeve opening end edges 454 and 456 of the sleeves 449 and 451 , respectively, may be hemmed. For easier manufacture, the sleeve opening end edges 454 and 456 may be left unhemmed, facilitating easy machine cutoff.

In the embodiments of the garments 410 that do not include the sleeves 449 and 451, the unattached portions of the garment side edges 419 and 424 and the garment side edges 420, and 425, more specifically the arm opening edges 446 and 448 defining the arm openings 445 and 447, respectively, can be hemmed. For easier manufacture, the arm opening edges 446 and 448, defining the arm openings 445 and 447, may be left unhemmed, facilitating easy machine cutoff.

A neck opening 460, defined about its perimeter by edge 462, is located in at least one of the shoulder regions 422 and 429. The neck opening 460 is typically centered between the garment side edges 419, 420, 424, and 425, although such placement of the neck opening 460 is not required. The neck opening 460 may take on a variety of sizes and shapes, such as circular, oval, triangular, square, rectangular, multi-faceted, asymmetric or irregular, or the like. While the placement of the neck opening 460 may be symmetrical between the shoulder regions 422 and 429, as well as between the garment side edges 419, 420, 424, and 425, typically, the placement of the neck opening 460 is configured so that a larger portion of the neck opening 460 is located in the front shoulder region 422.

Additionally, while the shape of the neck opening 460 can be symmetrical, typically, the shape of the neck opening 460 is asymmetrical as dictated by fashion and comfort. In some embodiments of the garment 410, the edge 462 of the neck opening 460 can be hemmed. For easier manufacture, the edge 462 of the neck opening 460 may be left unhemmed, facilitating easy machine cutoff.

Various styles of a collar 464 can also be attached to the edge 462 of the neck opening 460. The attachment of the collar 464 may be made non-refastenable by means as discussed below. In the alternative, the attachment of the collar 464 may be made refastenable by means as discussed below. The collars 464 include, but are not limited to, turtlenecks, mock turtlenecks, cowls, shirt collars, tee-shirt shirt ribbed edging, decorative edging, and the like known in the garment industry.

The garment bottom edges 421 and 427 of the garment 410 may also be hemmed. (Sewing equipment 480 is shown in Figure 25). For easier manufacture, the garment bottom edges 421 and 427 of the garment 410 may be left unhemmed, facilitating easy machine cutoff.

The front panel 418, the back panel 423, or both may be cut or otherwise opened to form a slit 433 or 440 (shown in Figure 27) such as a placket. The garment 410, including one or both slits 433 and 440, can be used as a wrap, gown, robe, or the like. The slit 433 has two edges 436 and 437. The slit 440 has two edges 441 and 442. Various fastening means, such as adhesive and mechanical type fasteners 465, see the discussion below, may be used to refastenably attach or secure the edges 436 and 437 or the edges 441 and 442 together to form reclosable or refastenable garments 410. The slits 433 and 440 of the front and back panels 418 and 423, respectively, may extend from the edge 462 of the neck opening 460 to the garment bottom edges 421 and 427, respectively, in the alternative, the slits 433 and 440 may extend over only a portion of the panels 418 and 423 between the edge 462 of the neck opening 460 to the garment bottom edges 421 and 427, respectively. When the garment 410 comprises both a slit 433 in the front panel 418 and a slit 440 in the back panel 423, the slits 433 and 440 may be similar or dissimilar in size, structure, shape, and the like. It is understood that the term 'similar' as used herein is interpreted to include identical and varying levels of similarity. It is also understood that the term 'dissimilar' as used herein is interpreted to include different and varying levels of dissimilarity.

An altemate embodiment of the invention is illustrated in Figures 29 and 30. The garment 482 includes opposing inner and outer surfaces 483 and 484. According to this embodiment, the garment 482 desirably comprises a right front panel 490, a left front panel 491, a right back panel 500, and a left back panel 501. The right front panel 490 has a garment side edge 492 and a side edge 494, a garment bottom edge 496 and a shoulder region 498 positioned between the garment side edge 492 and the side edge 494. The left front panel 491 has a side edge 493 and a garment side edge 495, a garment bottom edge 497 and a shoulder region 499 positioned between the side edge 493 and the garment side edge 495. The right back panel 500 has a garment side edge 502 and a side edge 504, a garment bottom edge 506 and a shoulder region 508 positioned between the garment side edge 502 and the side edge 504. The left back panel 501 has a side edge 503 and a garment side edge 505, a garment bottom edge 507 and a shoulder region 509 positioned between the side edge 503 and the garment side edge 505.

At least a portion of the side edge 494 is joined to at least a portion of the side edge 493 to form a center seam 520, a front shoulder region 522, and a front panel 518. At least a portion of the side edge 504 is joined to at least a portion of the side edge 503 to form a center seam 524, a back shoulder region 526, and a back panel 528. The garment side edge 492 is joined to the garment side edge 502 to form a garment side seam 510. The garment side edge 495 is joined to the garment side edge 505 to form a garment side seam 511. A portion of the garment side seams 510 and 511 are left unbonded or not joined, in the shoulder regions 522 and 526, defining two opposing arm openings 540 and 542.

In another embodiment of the present invention, the side edges 493 and 494 or a portion thereof (or, alternatively, in the alternative or in addition, side edges 503 and 504 or a portion thereof) may be left unjoined, thereby forming a placket (or, alternatively, plackets) in the garment 482. The garment 482 having at least a portion of the center seams 520 and 524 left unattached can be used in this form as a wrap, gown, or robe, or the like. Various closure devices, discussed below, could be utilized to form reclosable or refastenable center seams 520 or 524 or portions thereof. In other embodiments, the center seams 520 and 524, or portions thereof, may be constructed as non-refastenable seams.

In some embodiments of the garment 482, one or both of the center seams 520 and 524 may be non-refastenable. Non-refastenable center seams 520 and 524 may be formed by any suitable means such as ultrasonic sealing, adhesive bonding, heat sealing, sewing, tape, or the like known in the art. The non-refastenable center seams 520 and 524 may be constructed on a continuous or intermittent basis. One suitable method of forming such center seams 520 and 524 is disclosed in U.S. Patent No. 4,938,753 issued July 3, 1990, to Van Gompel et al., which is incorporated herein by reference. The center seams 520 and 524 may be bonded together to form non-refastenable center seams 520 and 524.

In various embodiments of the garment 482, one or both of the center seams 520 and 524 may be refastenable. The refastenable means for securing edges include adhesive and mechanical type fasteners 564. The adhesive and mechanical type fasteners include buttons and button holes, snaps, buckles, clasps, hooks and loops, end extensions, tabs, tape, and the like which are designed or adapted to interlock or engage some type of complementary device or the inner surface 483 or outer surface 484 of the garment 482. The refastenable center seams 520 and 524 may be constructed on a continuous or intermittent basis. In addition, elasticized fasteners may also be used in assuring better fit of the garment 482.

In various embodiments of the present invention, the front panel 518, the back panel 528, or both panels 518 and 528 may be cut or otherwise opened to form a slit 513 or 568 (shown in Figure 28) such as a placket. The garment 482 including one or both slits 513 and 568 can be used as a wrap, gown, robe, or the like. The slit 513 has two edges 525 and 529. The slit 568 has two edges 569 and 570. Various fastening means, such as adhesive and mechanical type fasteners 564, see the discussion below, may be used to refastenably attach or secure the edges 525 and 529 and the edges 569 and 570 to form reclosable or refastenable garments 482. The slits 513 and 568 of the front and back panels 518 and 528, respectively, may extend from the edge 561 of the neck opening 559 to the garment bottom edges 527 and 536, respectively. In the alternative, the slits 513 and 568 may extend over only a portion of the panels 490 and 500 between the edge 561 of the neck opening 559 to the garment bottom edges 527 and 536, respectively. When the garment 482 comprises both a slit 513 in the front panel 518 and a slit 568 in the back panel 528, the slits 513 and 568 may be similar or dissimilar in size, structure, shape, and the like. It is understood that the term 'similar' as used herein is interpreted to include identical and varying levels of similarity. It is also understood that the term 'dissimilar' as used herein is interpreted to include different and varying levels of dissimilarity. In some embodiments, the edges 525 and 529 of the slit 513 and the edges 569 and 570 of the slit 568 may be refastenably attached or secured to each other. Various fastening means, such as adhesive and mechanical type fasteners 564, see the discussion above, may be used to refastenably attach or secure the edges 525 and 529 or the edges 569 and 570 together of the slits 513 and 568, respectively.

The finished garment 482 may include sleeves 544 and 547 so as to surround, at least partially, the arm openings 540 and 542, respectively, of the garment 482. In some embodiments, only one sleeve 544 or 547 may be included in the finished garment 482. The length of the sleeves 544 and 547 may vary from a length intended to cover at least the entire arm of the wearer to a caplet length or shorter. The sleeve opening end edges 553 and 555 of the sleeves 544 and 547, respectively, may be hemmed. For easier manufacture, the sleeve opening end edges 553 and 555 may be left unhemmed, facilitating easy machine cutoff.

In the embodiments of the garments 482 that do not include the sleeves 544 and 547, the unattached portions of the garment side edges 492 and 502 and the garment side edges 495 and 505, more specifically the arm opening edges 541 and 543 defining the arm openings 540 and 542, respectively, can be hemmed. For easier manufacture, the unattached portion of the arm opening edges 541 and 543, defining the arm openings 540 and 542, may be left unhemmed, facilitating easy machine cutoff.

A neck opening 559, defined about its perimeter by edge 561 , is located in at least one of the shoulder regions 522 and 526. The neck opening 559 is typically centered between the garment side edges 492 and 502 and the garment side edges 495 and 505, although such placement of the neck opening 559 is not required. The neck opening 559 may take on a variety of sizes and shapes, such as circular, oval, triangular, square, rectangular, multi-faceted, asymmetric or irregular, or the like. While the placement of the neck opening 559 may be symmetrical between the shoulder regions 522 and 526, as well as between the garment side edges 492 and 502 and the garment side edges 495 and 505, typically, the placement of the neck opening 559 is configured so that a larger portion of the neck opening 559 is located in the front shoulder region 522. Additionally, while the shape of the neck opening 559 can be symmetrical, typically, the shape of the neck opening 559 is asymmetrical as dictated by fashion and comfort. In some embodiments of the garment 482, the edge 561 of the neck opening 559 can be hemmed. For easier manufacture, the edge 561 of the neck opening 559 may be left unhemmed, facilitating easy machine cutoff.

Various styles of a collar 563 can also be attached to the edge 561 of the neck opening 559. The attachment of the collar 563 may be made non-refastenable by means as discussed below. In the alternative, the attachment of the collar 563 may be made refastenable by means as discussed below. The collars 563 include, but are not limited to, turtlenecks, mock turtlenecks, cowls, shirt collars, tee-shirt ribbed edging, decorative edging, and the like known in the garment industry.

The garment bottom edges 496, 497, 506, and 507 of the garment 482 may also be hemmed. For easier manufacture, the garment bottom edges 496, 497, 506, and 507 of the garment 482 may be left unhemmed, facilitating easy machine cutoff.

Another embodiment of the present invention is a continuous process for the manufacture of a garment 410 (see Figures 25 and 27) for wearing about the upper body comprising at least a front panel 418, a back panel 423, a neck opening 460 defined about its perimeter by edge 462, arm openings 445 and 447 defined about their perimeters by arm opening edges 446 and 448, respectively, a lower body opening 432 defined about its perimeter by garment bottom edges 421 and 427. The garment 410 comprises an inner surface 411 and an outer surface 413. The garment 410 may comprise a single layer web of fabric 415 or may comprise a multi-layer laminate web of fabric 415. In some embodiments of the present invention, the garment 410 may comprise multiple layers of the web of fabric 415. In some embodiments, the garment 410 may comprise multiple layers of the web of fabric 415. The present invention requires at least one web of fabric 415 in a single continuous process to create garments 410.

In one embodiment of the present invention (see Figure 25), one web of fabric 415 of sufficient width of fabric to make the garment 410 is provided to produce the garments 410. The desired web of fabric 415 is nonwoven although any disposable or washable fabric can be used. (See the discussion below). The web of fabric 415 is typically unwound from a roll or other source. (Not shown). The web of fabric 415 is desirably compliant and soft feeling to the wearer. The following description of materials from which the web of fabric 415 may be formed would also be used for the materials to form the inner surface 411 and the outer surface 413 of a multi-layer laminate web of fabric 415.

The web of fabric 415 may be any suitable material as earlier described for the web of fabric 15.

The web of fabric 415 may be constructed of a single spunbonded polypropylene nonwoven web having a basis weight of about 0.5 oz/yd² (17 gsm) to about 1.5 oz/yd² (51 gsm). In the structure of the garment 410, the web of fabric 415 desirably comprises a material having a basis weight of from about 0.5 oz/yd² (17 gsm) to about 1.5 oz/yd² (51 gsm). Lesser or greater basis weights may be used in the other regions of the garment 410, such as the sleeves 446 and 448, the cuffs 455 and 457, and the collar 464. Since the garment 410 is typically intended for active wear, the web of fabric 415 or portions thereof, can be made of materials having a basis weight that is abrasion resistant.

For embodiments wherein the web of fabric 415 is a multi-layer laminate, both the outer surface 413 and the inner surface 411 are desirably compliant and soft feeling to the wearer. The following description of materials from which the outer surface 413 may be formed may also be used to form the material of the inner surface 411.

The outer surface 413 may be any suitable gatherable material as earlier described for the outer surface 13.

Alternatively, the outer surface 413 may be derived from a spunbonded web. In a desired embodiment, the outer surface 413 is spunbonded polypropylene nonwoven, meltblown polypropylene nonwoven and spunbonded polypropylene nonwoven laminate (SMS). The total basis weight is from about 0.4 to about 1.0 osy (more desirably 0.6 osy) and is made with about 86% spunbonded nonwoven and 14% meltblown nonwoven. A pigment such as titanium dioxide may be incorporated into the outer surface 413 and the inner surface 411. Such spunbonded meltblown nonwoven laminate material is available from Kimberly-Clark Corporation, Roswell, GA. The basis weight of the SMS material may vary from about 0.4 to about 1.0 osy. The inner surface 411 may be any soft and flexible sheet as earlier described for the inner surface 11.

The outer surface 413 and the inner surface 411 may be further dyed, pigmented, or imprinted with any suitable color. Desirably, the inner surface 411 is either dyed, pigmented, or printed with a material which does not irritate or bleed the color onto the skin of the wearer.

Another embodiment of the present invention is a continuous process for the manufacture of a garment 410 (see Figures 25 and 27) for wearing about the upper body comprising at least a front panel 418, a back panel 423, a neck opening 460 defined about its perimeter by edge 462, sleeve flaps 468 and 469, and a lower body opening 432 defined about its perimeter by garment bottom edges 421 and 427. The garment 410 comprises an inner surface 411 and an outer surface 413. The garment 410 may comprise a single layer web of fabric 415 or may comprise a multi-layer laminate web of fabric 415. The materials comprising the web of fabric 415 have been discussed above. In some embodiments, the garment 410 may comprise multiple layers of the web of fabric 415.

The web of fabric 415 of sufficient width of fabric to make the garment 410 is provided to produce the garments 410. The desired web of fabric 415 is nonwoven although any disposable or washable fabric can be used. (See the discussion above). The web of fabric 415 is typically unwound from a roll or other source. (Not shown).

The web of fabric 415 includes a pair of opposing web side edges 434 and 435. A repeating series of pairs of opposing indentations 443 and 444 are cut into the web side edges 434 and 435 of the web of fabric 415 by the die cutter 414. (See Figure 25). The location of the opposing indentations 443 and 444 correspond to the garment side edges 419 and 420, and the garment side edges 424 and 425, respectively, of the finished garment 410. The opposing indentations 443 and 444 may be produced by a die cut operation, an ultrasonic operation, or any other suitable method of operation. The material to be removed from the opposing indentations 443 and 444 may be removed by any method known in the art, desirably a vacuum source (not shown). The opposing indentations 443 and 444 may take on a variety of sizes and shapes, such as oval, triangular, square, rectangular, multi-faceted, asymmetric or irregular, or the like. The pattern of the opposing indentations 443 and 444 is restricted only by fashion and the minimum amount of web of fabric 415 that must remain having a sufficient integrity to withstand the remaining steps or operations of the process of manufacture. The opposing indentations 443 and 444 may be similar or dissimilar in shape, structure, size, and the like from each other within the finished garment 410.

In some embodiments, the operation of cutting the opposing indentations 443 and 444 into the web side edges 434 and 435 of the web of fabric 415 may be eliminated. As the pattern of the garment 410 is restricted only by fashion and the minimum amount of web of fabric 415 that must remain having a sufficient integrity to withstand the operations or steps of the process of manufacture, one can simply design the garment 410 such that this operation of cutting the opposing indentations 443 and 444 into the web side edges 434 and 435 (or, alternatively, the garment side edges 419 and 420 and the garment side edges 424 and 425) the web of fabric 415 is not required. As discussed above, the arm openings 445 and 447 may be created by leaving a portion of the garment side edges 419 and 424 and the garment side edges 420 and 425, respectively, unattached.

A repeating series of openings 459 are cut by the die cutter 414 into the web of fabric 415. The location of the opening 459 corresponds to the neck opening 460 in the finished garment 410. The openings 459 may be produced by a die cut operation, an ultrasonic operation, or any other suitable method of operation known in the art. It is understood that while Figure 25 shows the die cutter 414 cutting the opening 459 and the opposing indentations 443 and 444, these cutting operations could be performed by separate devices and at different stages within the manufacturing process. The material to be removed from the openings 459 may be removed by any method known in the art, desirably a vacuum source (not shown). The opening 459 may take on a variety of sizes and shapes, such as slit, circular, oval, triangular, square, rectangular, multi-faceted, asymmetric or irregular, or the like. The pattem of the opening 459 is restricted only by fashion and the minimum amount of web of fabric 415 that must remain having a sufficient integrity to withstand the remaining steps or operations of the process of manufacture.

The placement of the opening 459 in relation to two pairs of opposing indentations 443 and 444, while in a typical garment 410, the opening 459 is centrally located between the two pairs of opposing indentations 443 and 444, is restricted only by fashion and the minimum amount of web of fabric 415 that must remain having sufficient integrity to withstand the remaining steps or operations of the process of manufacture. For example, the placement of the opening 459 between the two pairs of opposing indentations 443 and 444 may be symmetrically or asymmetrically located.

The web of fabric 415 is cut by a die cutter 417 into discrete garment-sized pieces 416 wherein each discrete garment-sized piece 416 contains at least one opening 459, two pairs of opposing indentations 443 and 444, one pair of opposing web side edges 434 and 435, one pair of opposing garment bottom edges 421 and 427, and opposing garment end portions 438 and 439. The location of the opposing web side edges 434 and 435 of the web of fabric 415 corresponds to a sleeve opening end edge 454 of a sleeve flap 468 proximate the garment side edge 419 of the front panel 418 and garment side edge 424 of the back panel 423 and a sleeve opening end edge 456 of a sleeve flap 469 proximate the garment side edge 420 of the front panel 418 and the garment side edge 425 of the back panel 423, respectively, in the finished garment 410. It is understood that while the opposing web side edges 434 and 435 of the web of fabric 415 (or, alternatively, the discrete garment-sized piece 416) may typically become the sleeve opening end . edges 454 and 456 in the finished garment 410, fabric may be removed from or added to the web side edges 434 and 435 to create the sleeve opening end edges 454 and 456 in the finished garment 410.

The opposing garment end portions 438 and 439 are adjacent to the garment bottom edge 421 of the front panel 418 and the garment bottom edge 427 of the back panel 423, respectively, in the finished garment 410. The location of the opposing piece side edges 426 and 428 of the discrete garment-sized piece 416 correspond to the garment bottom edge 421 of the front panel 418 and the garment bottom edge 427 of the back panel 423, respectively, in the finished garment 410. It is understood that while the opposing piece side edges 426 and 428 of the discrete garment-sized piece 416 may typically become the garment bottom edges 421 and 427 in the finished garment 410, fabric may be removed from or added to the piece side edges 426 and 428 to create the garment bottom edges 421 and 427 in the finished garment 410.

Each discrete garment-sized piece 416 of the web of fabric 415 is transported, typically by vacuum screens, belts, or conveyors, through hemming, folding, and fastening operations (not shown). The folding operations are desirably carried out by tuckers and folders, as well as any other known means. The discrete garment-sized piece 416 of the web of fabric 415 is folded by a folder 450 so as to bring together the opposing garment end portions 438 and 439 such that web side edge 434 of the web of fabric 415 is folded on to itself, bringing the garment side edge 419 of the front panel 418 and the garment side edge 424 of the back panel 423 together. The web side edge 435 of the web of fabric 415 is folded on to itself, bringing the garment side edge 420 of the front panel 418 and the garment side edge 425 of the back panel 423 together.

The mating of the garment side edge 419 and the garment side edge 424 as well as the mating of the garment side edge 420 and the garment side edge 425 form the garment side seams 430 and 431, respectively, of the garment 410. It may be desirable to redirect (or reorient) the discrete garment-sized piece 416 of the web of fabric to allow easy bonding of the garment side seams 430 and 431 of the garment 410. The turning operations are desirably carried out by turn rolls and turn tables, as well as any other known means. The discrete garment-sized piece 416 of the web of fabric 415 may be reoriented 90 degrees (not shown).

In various embodiments of the present invention, one or both of the garment side seams 430 and 431 can be constructed as non-refastenable seams or as refastenable seams. Any excess material of the web of fabric 415 may be removed from the edges of the garment side seams 430 and 431 to reduce and smooth out the garment side seams 430 and 431. The non-refastenable garment side seams 430 and 431 may be formed by any suitable means such as ultrasonic sealing, adhesive bonding, tape, heat sealing, sewing, or any method of fastening known in the art. (Sewing equipment 481 is shown in Figure 25). The non-refastenable garment side seams 430 and 431 may be constructed on a continuous or intermittent basis. One suitable method of forming such garment side seams 430 and 431 is disclosed in U.S. Patent No. 4,938,753 issued July 3, 1990, to Van Gompel et al., which is incorporated herein by reference. The garment side seams 430 and 431 may be bonded together to form non-refastenable garment side seams 430 and 431.

In other embodiments of the present invention, the garment side edges 419 and 424 and the garment side edges 420 and 425 of the garment 410 may be held together in the finished garment 410 to form refastenable garment side seams 430 and 42, respectively. The refastenable means for securing the garment side edges 419 and 424 and the garment side edges 420 and 425 of the garment 410 include refastenable adhesive and mechanical type fasteners 465. The adhesive and mechanical type fasteners 465 include buttons and button holes, snaps, buckles, clasps, hooks and loops, end extensions, tabs, tape, and the like which are designed or adapted to interlock or engage some type of a complementary device or the outer surface 413 or the inner surface 411 of the garment 410.

In addition, elasticized fasteners 465 may also be used in assuring better fit of the garment 410. If the garment 410 includes refastenable garment side seams 430 and 431, the refastenable means are desirably strategically placed on the web of fabric 415 before the web of fabric 415 is cut into discrete garment-sized pieces 416. The folding and redirection operations may be eliminated when refastenable garment side seams 430 and 431 are included in the garment 410. However, there may be packaging reasons for which one would still carry out these two steps.

The garment side seams 430 and 431 of the present invention may take on a variety of structures or configurations known in the art. One embodiment of the garment side seams 430 and 431 is an out-turned configuration as illustrated in Figure 36. Such configured garment side seams 430 and 431 are formed by securing together at least a portion of the out-turned portions of the garment side edges 419 and 424 and the garment side edges 420 and 425, respectively. The inner surface 411 of the garment side edges 419 and 420 of the front panel 418 and the garment side edges 424 and 425 of the back panel 423, respectively, are brought into contact with each other, respectively.

Another embodiment of the garment side seams 430 and 431 is an in-turned configuration as illustrated in Figure 37. Such configured garment side seams 430 and 431 are formed by securing together at least a portion of the in-turned portions of the garment side edges 419 and 424 and the garment side edges 420 and 425, respectively. The outer surface 413 of the garment side edges 419 and 420 of the front panel 418 and the garment side edges 424 and 425 of the back panel 423 are brought into contact with each other, respectively.

Another embodiment of the garment side seams 430 and 431 is an over-lapped configuration as illustrated in Figure 35. Such configured garment side seams 430 and 431 are formed by securing together at least a portion of the over-lapped portions of the garment side edges 419 and 424 and the garment side edges 420 and 425, respectively. The inner surface 411 of one of the garment side edges 419 and 424 and one of the garment side edges 420 and 425 are brought into contact with the outer surface 413 of the other side edge of each pair of side edges.

Another embodiment of the garment side seams 430 and 431 is an over-lapped configuration as illustrated in Figure 38. Such a configured garment side seam 430 is formed by folding the garment side edge 419 or the garment side edge 424. The outer surface 413 of the folded portion and the inner surface 411 of the unfolded portion of the garment side edge 419 or 424 and the corresponding portion of the front panel 418 or the back panel 423, respectively, are brought into contact with the inner surface 411 or the outer surface 413 of the non-folded garment side edge 424 or 419 and the corresponding portion of the back panel 423 or the front panel 418.

The garment side seam 431 is formed by folding back the garment side edge 420 or the garment side edge 425. The outer surface 413 of the folded portion and the inner surface 411 of the unfolded portion of the garment side edges 420 or 425 and the corresponding portion of the front panel 418 or the back panel 423, respectively, are brought into contact with the inner surface 411 or the outer surface 413 of the non-folded garment side edge 425 or 420 and the corresponding portion of the back panel 423 or the front panel 418. It is understood that the folding back of a garment side edge 419, 420, 424, or 425 could be performed such that the inner surface 411 would be exposed along the fold.

The garment end portions 438 and 439 of the discrete garment-sized pieces 416 web of fabric 415 may be hemmed in the finished garment 410. The garment end portions 438 and 439 can be hemmed by any method or style known in the art. In some embodiments, it may be desirable to leave the garment end portions 438 and 439 unhemmed. The garment bottom edges 421 and 427 of the discrete garment-sized pieces 416 web of fabric 415 may be hemmed in the finished garment 410. The garment bottom edges 421 and 427 can be hemmed by any method or style known in the art. In some embodiments, it may be desirable to leave the garment bottom edges 421 and 427 unhemmed. As shown in Figure 33, the garment 410 includes sleeve flaps 468 and 469. The sleeve flaps 468 and 469 may take on a variety of sizes and shapes, such as circular, oval, triangular, square, rectangular, multi-faceted, asymmetric or irregular, or the like. The pattern of the sleeve flaps 468 and 469 is restricted only by fashion and the minimum amount of the material of the sleeve flaps 468 and 469 that is necessary to complete the remaining steps or operations of the process of manufacture. In some embodiments, only one sleeve 449 or 451 may be included in the finished garment 410. The sleeves 449 and 451, alternately the sleeve flaps 468 and 469, may be similar or dissimilar in shape, structure, material, size, and the like from each other within the finished garment 410.

The sleeve flap 468 has a pair of sleeve side edges 452 and 453, and a sleeve opening end edge 454 extending between the sleeve side edges 452 and 453. It is understood that the sleeve flap 468 could be made of multiple pieces of material or materials. The sleeve flap 468 is folded so as to bring together the opposing sleeve side edges 452 and 453 to form a sleeve seam 463 of the sleeve 449.

The sleeve flap 469 has a pair of sleeve side edges 458 and 461, and a sleeve opening end edge 456 extending between the sleeve side edges 458 and 461. It is understood that the sleeve flap 469 could be made of multiple pieces of material or materials. The sleeve flap 469 is folded so as to bring together the opposing sleeve side edges 458 and 461 to form a sleeve seam 467 of the sleeve 451.

It may be desirable to redirect (or reorient) the discrete garment-sized pieces 416 to allow easy fastening of the sleeve seams 463 and 467 of the sleeves 449 and 451 , respectively, of the garment 410. The discrete garment-sized pieces 416 may be reoriented 90 degrees (not shown). The sleeve seams 463 and 467 can be non- refastenable seams or refastenable seams. Any excess material of the fabric pieces 468 and 469 can be removed from their respective edges of the sleeve seams 463 and 467 to reduce and smooth out the sleeve seams 463 and 467. The non-refastenable sleeve seams 463 and 467 may be formed by any suitable means such as ultrasonic sealing, adhesive bonding, tape, heat sealing, sewing, or other methods of fastening as known in the art, as discussed above. The non-refastenable sleeve seams 463 and 467 may be constructed on a continuous or intermittent basis. In other embodiments, the opposing pair of the sleeve side edges 452 and 453 and the opposing pair of the sleeve side edges 458 and 461 of the sleeves 449 and 451 , respectively, may be held together in the finished garment 410 to form refastenable sleeve seams 463 and 467. The refastenable means for securing the opposing pair of the sleeve side edges 452 and 453 and the opposing pair of the sleeve side edges 458 and 461 of the sleeves 449 and 451 , respectively, include refastenable adhesive and mechanical type fasteners 465. The adhesive and mechanical type fasteners 465 include buttons and button holes, snaps, buckles, clasps, hooks and loops, end extensions, tabs, tape, and the like which are designed or adapted to interlock or engage some type of a complementary device or the inner surface 411 or the outer surface 413 of the garment 410. The refastenable sleeve seams 463 and 467 may be constructed on a continuous or intermittent basis.

In addition, elasticized fasteners may also be used in assuring better fit of the sleeves 449 and 451 of the garment 410. If the garment 410 includes refastenable sleeve seams 463 and 467, the refastenable means are desirably strategically placed on the sleeve flaps 468 and 469 before or after the web of fabric 415 is cut into discrete garment- sized pieces 416 of the web of fabric 415. The folding and redirection operations may be eliminated when refastenable sleeve seams 463 and 467 are included in the garment 410. However, there may be packaging reasons for which one would still carry out these two steps.

The sleeve seams 463 and 467 of the present invention may take on a variety of structures or configurations known in the art. One embodiment of the sleeve seams 463 and 467 is an out-turned configuration as illustrated in Figure 36. Such configured sleeve seams 463 and 467 are formed by securing together at least a portion of the out-turned portions of the sleeve side edges 452 and 453 and the sleeve side edges 458 and 461 of the sleeve flaps 468 and 469, respectively. The inner surface 411 of the sleeve side edges 452 and 453 and the sleeve side edges 458 and 461 of the sleeve flaps 468 and 469, respectively, are brought into contact with each other of the pair.

Another embodiment of the sleeve seams 463 and 467 is an in-turned configuration as illustrated in Figure 37. Such configured sleeve seams 463 and 467 are formed by securing together at least a portion of the in-turned portions of the sleeve side edges 452 and 453 and the sleeve side edges 458 and 461 of the sleeve flaps 468 and 469, respectively. The outer surface 413 of the sleeve side edges 452 and 453 and the sleeve side edges 458 and 461 of sleeve flaps 468 and 469, respectively, are brought into contact with each other of the pair.

Another embodiment of the sleeve seams 463 and 467 is an over-lapped configuration as illustrated in Figure 35. Such configured sleeve seams 463 and 467 are formed by securing together at least a portion of the over-lapped portions of the sleeve side edges 452 and 453 and the sleeve side edges 458 and 461 of the sleeve flaps 468 and 469, respectively. The inner surface 411 of one of the sleeve side edges 452 or 453 and the sleeve side edges 458 or 461 of the sleeve flaps 468 and 469, respectively, are brought into contact with the outer surface 413 of the other sleeve side edge 452 or 453 and the sleeve side edge 458 or 461 of the sleeve flap 468 and 469, respectively.

Another embodiment of the sleeve seams 463 and 467 is an over-lapped configuration as illustrated in Figure 38. Such configured sleeve seams 463 and 467 are formed by folding back the sleeve side edge 452 or 453 and the sleeve side edge 458 or 461 of the sleeve flaps 468 and 469, respectively. The outer surface 413 of the folded portions and the inner surface of the unfolded portions of the sleeve side edge 452 or 453 and the sleeve side edge 458 or 461 and the corresponding portions of the sleeve flaps 468 and 469, respectively, are brought into contact with the inner surface 411 or the outer surface 413 of the non-folded sleeve side edges 452 or 453 and the sleeve side edges 458 or 461 and the corresponding portions of the sleeves flaps 468 and 469, respectively. It is understood that the folding back of a sleeve side edge 452, 453, 458, or 461 could be performed such that the inner surface 411 would be exposed along the fold.

The sleeve opening end edges 454 and 456 of the sleeves 449 and 451 , respectively, (in the alternative, the sleeve opening end edges 454 and 456 of the sleeve flaps 468 and 469, respectively) can be hemmed by any method or style known in the art. In some embodiments, it may be desirable to leave the sleeve opening end edges 454 and 456 unhemmed.

In other embodiments, cuffs 455 and 457 may be attached to the sleeve opening end edges 454 and 456, respectively, of the sleeves 449 and 451 , respectively, of the garment 410, forming cuff seams 471 and 473, respectively. The attachment of the cuffs 455 and 457 may be made non-refastenable by means as discussed above. (Sewing equipment 479 is shown in Figure 25). In the alternative, the attachment of the cuffs 455 and 457 may be made refastenable by means as discussed above. The cuff seams 471 and 473 may be constructed on a continuous or intermittent basis. The cuffs 455 and 457 may take on a variety of sizes and shapes. The cuffs 455 and 457 may be similar or dissimilar in shape, structure, material, size, and the like from each other within the ^' finished garment 410. The pattern of the cuffs 455 and 457 is restricted only by the fashion and the minimum amount of the material of the cuffs 455 and 457 that is necessary to complete the remaining steps or operations of the process of manufacture.

The cuff seams 471 and 473 of the present invention may take on a variety of structures or configurations known in the art. One embodiment of the cuff seams 471 and 473 is an out-turned configuration as illustrated in Figure 36. Such configured cuff seams 471 and 473 are formed by securing together at least a portion of the out-turned portions of the cuff edge 470 and the sleeve opening end edge 454 and the cuff edge 472 and the sleeve opening end edge 456, respectively, of the garment 410. The inner surface 411 of the cuff edges 470 and 472 of the cuffs 455 and 457, respectively, is brought into contact with the inner surface 411 of the sleeve opening edges 454 and 456 of the sleeves 449 and 451, respectively.

Another embodiment of the cuff seams 471 and 473 is an in-turned configuration as illustrated in Figure 37. Such configured cuff seams 471 and 473 are formed by securing together at least a portion of the in-turned portions of the cuff edge 470 and the sleeve opening edge 454 and the cuff edge 472 and the sleeve opening edge 456, respectively, of the garment 4 0. The outer surface 413 of the cuff edges 470 and 472 of the cuffs 455 and 457, respectively, is brought into contact with the outer surface 413 of the sleeve opening edges 454 and 456 of the sleeves 449 and 451 , respectively.

Another embodiment of the cuff seams 471 and 473 is an over-lapped configuration as illustrated in Figure 35. Such configured cuff seams 471 and 473 are formed by securing together at least a portion of the over-lapped portions of the cuff edge 470 and the sleeve opening edge 454 and the cuff edge 472 and the sleeve opening edge 456 of the sleeves 449 and 451 , respectively. The inner surface 411 of one of the cuff edge 470 or the sleeve opening edge 454 and the cuff edge 472 or the sleeve opening edge 456, is brought into contact with the outer surface 413 of the other cuff edge 470 or the sleeve opening edge 454 and the cuff edge 472 or the sleeve opening edge 456 of the sleeves 449 and 451 , respectively.

Another embodiment of the cuff seams 471 and 473 is an over-lapped configuration as illustrated in Figure 38. Such configured cuff seams 471 and 473 are formed by folding back the cuff edge 470 or the sleeve opening end edge 454 and the cuff edge 472 or the sleeve opening end edge 456 of the sleeves 449 and 451, respectively. The outer surface 413 of the folded portions and the inner surface 411 of the unfolded portions of the cuff edge 470 or the sleeve opening end edge 454 and the cuff edge 472 or the sleeve opening end edge 456 and the corresponding portions of the cuffs 455 and 457 or the sleeves 449 and 451 are brought into contact with the inner surface 411 or the outer surface 413 of the unfolded cuff edge 470 or 472 or the sleeve opening end edge 454 or 456 and the corresponding portions of the cuffs 455 and 457 or the sleeves 449 and 451. It is understood that the folding back of a cuff edge 470 or 472 or a sleeve opening end edge 454 or 456 could be performed such that the inner surface 411 would be exposed along the fold.

The materials used for the cuffs 455 and 457 may be the same as the materials used for the other portions of the garment 410. In some embodiments, it is desirable that the materials used for the cuffs 455 and 457 have an elastic element such that the cuffs 455 and 457 will conform to the portion of the wearer's arms that come into contact with the cuffs 455 and 457.

The edge 462 of the neck opening 460 can be hemmed by any method or style known in the art. In some embodiments, it may be desirable to leave the edge 462 of the neck opening 460 unhemmed.

In other embodiments, a collar 464 may be attached to the edge 462 of the neck opening 460 of the garment 410, thereby forming a collar seam 475. The attachment of the collar 464 may be made non-refastenable by means as discussed above. (Sewing equipment 478 is shown in Figure 25). In the alternative, the attachment of the collar 464 may be made refastenable by means as discussed above. The collar seam 475 may be constructed on a continuous or intermittent basis. The collar 464 may take on a variety of sizes and shapes. The pattern of the collar 464 is restricted only by fashion and the minimum amount of the material of the collar 464 that is necessary to complete the remaining steps or operations of the process of manufacture.

The collar seam 475 of the present invention may take on a variety of structures or configurations known in the art. One embodiment of the collar seam 475 is an out-turned configuration as illustrated in Figure 36. Such a configured collar seam 475 is formed by securing together at least a portion of the out-turned portions of the collar edge 474 of the collar 464 and the edge 462 of the neck opening 460 of the garment 410. The inner surface 411 of the collar edge 474 of the collar 464 is brought into contact with the inner surface 41 of the edge 462 of the neck opening 460.

Another embodiment of the collar seam 475 is an in-turned configuration as illustrated in Figure 37. Such a configured collar seam 475 is formed by securing together at least a portion of the in-turned portions of the collar edge 474 of the collar 464 and the edge 462 of the neck opening 460 of the garment 410. The outer surface 413 of the collar edge 474 of the collar 464 is brought into contact with the outer surface 413 of the edge 462 of the neck opening 460.

Another embodiment of the collar seam 475 is an over-lapped configuration as illustrated in Figure 35. Such a configured collar seam 475 is formed by securing together at least a portion of the over-lapped portions of the collar edge 474 of the collar 464 and the edge 462 of the neck opening 460 of the garment 410. The inner surface 411 of the collar edge 474 of the collar 464 or the edge 462 of the neck opening 460 is brought into contact with the outer surface 413 of the other, the collar edge 474 or the edge 462.

Another embodiment of the collar seam 475 is an over-lapped configuration as illustrated in Figure 38. Such a configured collar seam 475 is formed by folding back the collar edge 474 of the collar 464 or the edge 462 of the neck opening 460. The outer surface 413 of the folded portions and the inner surface 411 of the unfolded portions of the collar edge 474 of the collar 464 or the edge 462 of the neck opening 460 and the corresponding portions of the collar 464 or the front and back panels 418 and 423 are brought into contact with the inner surface 411 or the outer surface 413 of the unfolded collar edge 474 of the collar 464 or the edge 462 of the neck opening 460 and the corresponding portions of the collar 464 or the front and back panels 418 and 423. It is understood that the folding back of the collar edge 474 of the collar 464 or the edge 462 of the neck opening 460 could be performed such that the inner surface 411 would be exposed along the fold.

Another embodiment of the collar seam 475 is an over-lapped configuration as illustrated in Figure 39. Such a configured collar seam 475 is formed by folding the collar 464 about or over the edge 462 of the neck opening 460. The collar edges 474 of the collar 464 may be folded under bringing the outer surface 413 of the collar 464 into contact with the edge 462 of the neck opening and any portion of the adjacent material of the front panel 418, the back panel 423, or both as desired. The collar edges 474 may be left exposed by not being folding under.

Another embodiment of the collar seam 475 is an over-lapped configuration as illustrated in Figure 40. Such a configured collar seam 475 is formed by folding the collar edge 474 such that the inner surface 411 of the collar 464 is brought into contact with itself. The edge 462 of the neck opening 460 is folded such that the outer surface 413 of the front panel 418, the back panel 423, or both are brought into contact with itself. The collar edge 474 is inserted into the fold of the edge 462 of the neck opening 460. The edge 462 of the neck opening 460 is inserted into the fold of the collar edge 474. In another embodiment, the collar edge 474 is folded such that the outer surface 413 of the collar 464 is brought into contact with itself. The edge 462 of the neck opening 460 is folded such that the inner surface 411 of the front panel 418, the back panel 423, or both are brought into contact with itself. This configured collar seam 475 may be used with any seam describe herein.

The materials used for the collar 464 may be the same as the materials used for the other portions of the garment 410. In some embodiments, it is desirable that the materials used for the collar 464 have an elastic element such that the collar 464 will conform to the portion of the wearer's neck that comes into contact with the collar 464.

In various embodiments of the present invention, the front panel 418, the back panel 423, or both panels 418 and 423 may be cut or otherwise opened to form a slit 433 or 440 (shown in Figure 27) such as a placket. The slit 433 has two edges 436 and 437. The slit 440 has two edges 441 and 442. The slits 433 and 440 of the front and back panels 418 and 423, respectively, may extend from the edge 462 of the neck opening 460 to the garment bottom edges 421 and 427, respectively. In the alternative, the slits 433 and 440 may extend over only a portion of the panels 418 and 423 between the edge 462 of the neck opening 460 to the garment bottom edges 421 and 427, respectively. When the garment 410 comprises both a slit 433 in the front panel 418 and a slit 440 in the back panel 423, the slits 433 and 440 may be similar or dissimilar in size, structure, shape, and the like.

In some embodiments, the edges 436 and 437 of the slit 433 and the edges 441 and 442 of the slit 440 may be refastenably attached or secured to each other. The edges 436 and 437 may be secured together to form the front seam 476. The edges 441 and 442 may be secured together to form the back seam 477. Various fastening means, such as adhesive and mechanical type fasteners 465, see the discussion above, may be used to refastenably attach or secure the edges 436 and 437 or the edges 441 and 442 together of the slits 433 and 440, respectively.

Another embodiment of the present invention is a continuous process for the manufacture of a garment 482 (see Figures 26 and 28) for wearing about the upper body comprising a garment 482 having at least a front panel 518, a back panel 528, a neck opening 559 defined about its perimeter by edge 561 , arm openings 540 and 542 defined about their perimeters by arm opening edges 541 and 543, respectively, and a lower body opening 512 defined about its perimeter by garment bottom edges 527 and 536. The garment 482 comprises an inner surface 483 and an outer surface 484. The garment 482 may comprise single layer webs of fabric 486 and 487, multi-layer laminate webs of fabric 486 and 487, or a combination of a single layer web of fabric and a multi-layer laminate web of fabric 486 and 487. In some embodiments, the garment 482 may comprise multiple layers of the webs of fabric 486 and 487 or various combinations of fabric.

In one embodiment of the present invention (See Figure 26), two webs of fabric 486 and 487 of sufficient width of fabric to make the garment 482 is provided to produce the garments 482. The desired webs of fabric 486 and 487 are nonwoven although any disposable or washable fabric can be used. (See the discussion below). The webs of fabric 486 and 487 are typically unwound from rolls or other sources (not shown).

The webs of fabric 486 and 487 are desirably compliant and soft feeling to the wearer. The following description of materials from which the webs of fabric 486 and 487 may be formed would also be used for the materials to form the inner surface 483 and the outer surface 484 of multi-layer laminate webs of fabric 486 or 487.

The webs of fabric 486 and 487 may be any suitable material as earlier described for the webs of fabric 215 and 216.

The webs of fabric 486 and 487 may be constructed of a single spunbonded polypropylene nonwoven web having a basis weight of about 0.5 oz/yd² (17 gsm) to about 1.5 oz/yd² (51 gsm). In the structure of the garment 482, the webs of fabric 486 and 487 desirably comprise a material having a basis weight of from about 0.5 oz/yd² (17 gsm) to about 1.5 oz/yd² (51 gsm). Lesser or greater basis weights may be used in the other regions of the garment 482, such as the sleeves 544 and 547, the cuffs 554 and 556, and the collar 563. Since the garment 482 is typically intended for active wear, the webs of fabric 486 and 487 or portions thereof, can be made of materials having a basis weight that is abrasion resistant.

For embodiments wherein the webs of fabric 486 and 487 are a multi-layer laminate, both the outer surface 484 and the inner surface 483 are desirably compliant and soft feeling to the wearer. The following description of materials from which the outer surface 484 may be formed may also be used to form the material of the inner surface 483.

The outer surface 484 may be any suitable gatherable material as earlier described for the outer surface 213.

Alternatively, the outer surface 484 may be derived from a spunbonded web. In a desired embodiment, the outer surface 484 is spunbonded polypropylene nonwoven, meltblown polypropylene nonwoven and spunbonded polypropylene nonwoven laminate (SMS). The total basis weight is from about 0.4 to about 1.0 osy (more desirably 0.6 osy) and is made with about 86% spunbonded nonwoven and 14% meltblown nonwoven. A pigment such as titanium dioxide may be incorporated into the outer surface 484 and the inner surface 483. Such spunbonded meltblown nonwoven laminate material is available from Kimberly-Clark Corporation, Roswell, GA. The basis weight of the SMS material may vary from about 0.4 to about 1.0 osy. The inner surface 483 may be any soft and flexible sheet as earlier described for the inner surface 21 .

The outer surface 484 and the inner surface 483 may be further dyed, pigmented, or imprinted with any suitable color. Desirably, the inner surface 483 is either dyed, pigmented, or printed with a material which does not irritate or bleed the color onto the skin of the wearer.

One type of embodiments of the present invention is a continuous process for the manufacture of a garment 482 (see Figures 26 and 28) for wearing about the upper body comprising at least a front panel 518, a back panel 528, a neck opening 559 defined about its perimeter by edge 561 , sleeve flaps 566 and 567, and a lower body opening 512 defined about its perimeter by garment end portions 534 and 535. The garment 482 comprises an inner surface 483 and an outer surface 484. The garment 482 may comprise single layer webs of fabric 486 and 487 or may comprise multi-layer laminate webs of fabric 486 and 487. The materials comprising the webs of fabric 486 and 487 have been discussed above. In some embodiments, the garment 482 may comprise multiple layers of webs of fabric 486 and 487.

The webs of fabric 486 and 487 of sufficient width of fabric to make the garment

482 are provided to produce the garments 482. The desired webs of fabric 486 and 487 are nonwoven although any disposable or washable fabric can be used. (See the discussion above). The webs of fabric 486 and 487 are typically unwound from rolls or other sources. (Not shown).

The web of fabric 486 includes a pair of opposing web side edges 514 and 515. A repeating series of opposing indentations 537 and 539 is cut by the die cutter 485 into the web side edge 514 of the web of fabric 486. (See Figure 26). The location of the opposing indentations 537 and 539 corresponds to the garment side edges 492 and 502, respectively, of the finished garment 482. The opposing indentations 537 and 539 may be produced by a die cut operation, an ultrasonic operation, or any other suitable method of operation. The material to be removed from the opposing indentations 537 and 539 may be removed by any method known in the art, desirably a vacuum source (not shown). The web of fabric 487 includes a pair of opposing web side edges 516 and 517. A repeating series of opposing indentations 537 and 539 is cut by the die cutter 485 into the web side edge 517 of the web of fabric 487. (See Figure 26). The location of the opposing indentations 537 and 539 corresponds to the garment side edges 495 and 505 of the finished garment 482. The opposing indentations 537 and 539 may be produced by a die cut operation, an ultrasonic operation, or any other suitable method of operation. It is understood that while Figure 26 shows the die cutter 485 cutting the opposing indentations 537 and 539 into the webs of fabric 486 and 487 (or, alternatively, the web of fabric 486), these operations could be performed by separate devices and at different stages within the manufacturing process.

The opposing indentations 537 and 539 may take on a variety of sizes and shapes, such as a slit, circular, oval, triangular, square, rectangular, multi-faceted, asymmetric or irregular, or the like. The pattern of the opposing indentations 537 and 539 is restricted only by fashion and the minimum amount of the webs of fabric 486 and 487 that must remain having a sufficient integrity to withstand the remaining steps or operations of the process of manufacture. The indentations 539 may be similar or dissimilar in shape, structure, size, and the like from each other or from the indentations 537 within the finished garment 482. Alternatively, the garment side edges 492 and 502 and the garment side edges 495 and 505 may be similar or dissimilar from each other.

In one embodiment of the present invention (see Figure 26), the two webs of fabric 486 and 487 of sufficient width of fabric to make the garment 482 are combined to produce the garments 482. The desired fabric is nonwoven although any disposable or washable fabric can be used. The two webs of fabric 486 and 487 are unwound from rolls (not shown) and brought together in a side by side orientation (see Figure 43) and fastened together at the web side edge 515 of the web of fabric 486 and the web side edge 516 of the web of fabric 487, defining a center seam 519 on the composite web of fabric 521. In some embodiments, portions of the center seam 519 may be left unfastened by intermittently fastening the web side edges 515 and 516 of the webs of fabric 486 and 487, respectively. In other embodiments, the center seam 519 may be constructed on a continuous basis. The desired method of fastening is ultrasonic sealing, although other methods of fastening, such as heat sealing, adhesives, tape, sewing, or any other method of fastening known in the art can be used. In another type of embodiment, the two webs of fabric 486 and 487 to make the garment 482 are combined to produce the garments 482. The two webs of fabric 486 and 487 are unwound from rolls and brought together in a face to face (or, alternatively, back to back) orientation and fastened together at the web side edge 515 of the web of fabric 486 and the web side edge 516 of the web of fabric 487, defining the center seam 519 of the composite web of fabric 521. (See Figure 42).

The center seam 519, or portions thereof, can be constructed as a non-refastenable seam, as a refastenable seam, or as a combination of a non-refastenable seam and a refastenable seam. Any excess material from the webs of fabric 486 and 487 may be removed from the web side edges 515 and 516 (or, alternatively, the side edges 493, 494, 503, and 504) of the center seam 519 to reduce and smooth out the center seam 519. The non-refastenable center seam 519 may be formed by any suitable means such as ultrasonic sealing, adhesive bonding, tape, heat sealing, sewing, or the like known in the art. The non-refastenable center seam 519 may be constructed on a continuous or intermittent basis. One suitable method of forming such a center seam 519 is disclosed in U.S. Patent No. 4,938,753 issued July 3, 1990, to Van Gompel et al., which is incorporated herein by reference. The center seam 519 may be bonded together to form a non- refastenable center seam 519. See the discussion above for center seams 520 and 524.

In other embodiments of the present invention, the web side edges 515 and 516 (or, alternatively, the side edges 493 and 494 and the side edges 503 and 504) of the webs of fabric 486 and 487, respectively, may be held together in the finished garment 482 to form the refastenable center seam 519. The refastenable means for securing the web side edges 515 and 516 of the webs of fabric 486 and 487 include refastenable adhesive and mechanical type fasteners 564. The adhesive and mechanical type fasteners 564 include buttons and button holes, snaps, buckles, clasps, hooks and loops, end extensions, tabs, tape, and the like which are designed or adapted to interlock or engage some type of a complementary device or the outer surface 484 or the inner surface 483 of the garment 482. The refastenable center seams 519 may be constructed on a continuous or intermittent basis.

In addition, elasticized fasteners 564 may also be used in assuring better fit of the garment 482. If the garment 482 includes a refastenable center seam 519, the refastenable means is desirably strategically placed on the webs of fabric 486 and 487 before the webs of fabric 486 and 487 are cut into garment-sized pieces 488 and 489. The folding and redirection operations may be eliminated when a refastenable center seam 519 is included in the garment 482. However, there may be packaging reasons for which one would still carry out these two steps.

The center seam 519 of the present invention may take on a variety of structures or configurations known in the art. One embodiment of the center seam 519 is an out- turned configuration as illustrated in Figure 45. Such a configured center seam 519 is formed by securing together at least a portion of the out-turned portions of the web side edges 515 and 516. The inner surface 483 of the web side edges 515 and 516 of the webs of fabric 486 and 487, respectively, are brought into contact with each other.

Another embodiment of the center seam 519 is an in-turned configuration as illustrated in Figure 46. Such a configured center seam 519 is formed by securing together at least a portion of the in-turned portions of the web side edges 515 and 516. The outer surfaces 484 of the web side edges 515 and 516 of the webs of fabric 486 and 487, respectively, are brought into contact with each other.

Another embodiment of the center seam 519 is an over-lapped configuration as illustrated in Figure 44. Such a configured center seam 519 is formed by securing together at least a portion of the over-lapped portions of the web side edges 515 and 516. The inner surface 483 of one of the web side edges 515 and 516 of the webs of fabric 486 and 487, respectively, is brought into contact with the outer surface 484 of the other web side edge 515 or 516, respectively.

Another embodiment of the center seam 519 is an over-lapped configuration as illustrated in Figure 47. Such a configured center seam 519 is formed by folding back the web side edge 515 (or, alternatively, the web side edge 516). The outer surface 484 of the folded portion and the inner surface of the unfolded portion of the web side edge 515 and the corresponding portions of the web of fabric 486 (or, alternatively, of the web side edge 516 and the corresponding portions of the web of fabric 487) are brought into contact with the inner surface 483 or the outer surface 484 of the web side edge 516 and the corresponding portions of the web of fabric 487 (or, alternatively, of the web side edge 515 and the corresponding portions of the web of fabric 486). It is understood that the folding back of a web side edge 515 or 516 could be performed such that the inner surface 483 would be exposed along the fold.

The opposing indentations 537 and 539 of the web side edges 514 and 517 of the webs of fabric 486 and 487, respectively, may be cut by the die cutter 485 into the web side edges 514 and 517 before or after the two webs of fabric 486 and 487 are fastened together to form the composite web of fabric 521. The material to be removed from the opposing indentations 537 and 539 may be removed by any method known in the art, desirably a vacuum source (not shown). As the pattern of the garment 482 is restricted only by fashion and the minimum amount of the webs of fabric 486 and 487 (or, alternatively, the composite web of fabric 521) that must remain having a sufficient integrity to withstand the operations or steps of the process of manufacture, one can simply design the garment 482 such that this operation of cutting the opposing indentations 537 and 539 into the webs of fabric 486 and 487 (or, alternatively, the composite web of fabric 521) is not required. In some embodiments, the operation of cutting the opposing indentations 537 and 539 into the web side edges 514 and 517 of the webs of fabric 486 and 487, respectively, may be eliminated. The arm openings 540 and 542 may be created by leaving a portion of the garment side edges 492 and 502 and a portion of the garment side edges 495 and 505, respectively, unattached.

When the webs of fabric 486 and 487 are combined to form the composite web of fabric 521 , the opposing indentations 537 and 539 are typically positioned or arranged such that the opposing indentations 537 and 539 form a repeating series of pairs of opposing indentations 537 and 539 in the web side edges 514 and 517. However, such a placement or arrangement is not required in the present invention. The placement of the opposing indentations 537 and 539 in relation to each other, while in a typical garment 482, the opposing indentations 537 and 539 are located to be directly opposing, is restricted only by fashion and the minimum amount of the webs of fabric 486 and 487 (or, alternatively, the composite web of fabric 521) that must remain having sufficient integrity to withstand the remaining steps or operations of the process of manufacture. The opposing indentations 537 and 539 may be similar or dissimilar in shape, structure, size, and the like from each other within the finished garment 482.

A repeating series of openings 558 are cut by the die cutter 485 into at least one of the webs of fabric 486 and 487 (or, alternatively, the composite web of fabric 521). It is understood that while Figure 26 shows the die cutter 485 cutting the opening 558 and the opposing indentations 537 and 539, these cutting operations could be performed by separate devices and at different stages within the manufacturing process. The location of the opening 558 corresponds to the neck opening 559 in the finished garment 482. The openings 558 may be produced by a die cut operation, an ultrasonic operation, or any other suitable method of operation. The openings 558 may be cut into at least one of the webs of fabric 486 and 487 before or after the webs of fabric 486 and 487 are combined to form the composite web of fabric 521.

The opening 558 may take on a variety of sizes and shapes, such as slit, circular, oval, triangular, square, rectangular, multi-faceted, asymmetric or irregular, or the like. The material to be removed from the openings 558 may be removed by any method known in the art, desirably a vacuum source. The pattern of the opening 558 is restricted only by fashion and the minimum amount of the webs of fabric 486 and 487 (or, alternatively, the composite web of fabric 521) that must remain having a sufficient integrity to withstand the remaining steps or operations of the process of manufacture.

In alternative embodiments of the present invention, the openings 558 may be comprised of the indentations 571 cut into the web side edge 515 of the web of fabric 486 and the indentations 572 cut into the web side edge 516 of the web of fabric 487 prior to the combining of the webs of fabric 486 and 487 to form the composite web of fabric 521. (See Figure 41). An indentation 571 and an indentation 572 are combined to form the opening 558.

The placement of the opening 558 in relation to two pairs of opposing indentations

537 and 539, while in a typical garment 482, the opening 558 is centrally located between the two pairs of opposing indentations 537 and 539, is restricted only by fashion and the minimum amount of the webs of fabric 486 and 487 (or, alternatively, the composite web of fabric 521) that must remain having sufficient integrity to withstand the remaining steps or operations of the process of manufacture. For example, the placement of the opening 558 between the two pairs of opposing indentations 537 and 539 may be symmetrically or asymmetrically located.

The composite web fabric 521 is cut by the die cutter 417a into discrete garment- sized pieces 523 wherein each discrete garment-sized piece 523 contains at least one opening 558, two pairs of opposing indentations 537 and 539, one pair of opposing web side edges 514 and 517, one pair of opposing garment bottom edges 527 and 536, and opposing garment end portions 534 and 535. The location of the opposing web side edges 514 and 517 of the composite web of fabric 521 corresponds to a sleeve opening end edge 553 of a sleeve flap 566 proximate the garment side edge 492 of the right front panel 490 (or, alternatively, the front panel 518) and the garment side edge 502 of the right back panel 500 (or, alternatively, the back panel 528), and a sleeve opening end edge 555 of a sleeve flap 567 proximate the garment side edge 495 of the left front panel 491 (or, alternatively, the front panel 518) and the garment side edge 505 of the left back panel 501 (or, alternatively, the back panel 528), respectively, in the finished garment 482. It is understood that while the opposing web side edges 514 and 515 of the web of fabric 486 (or, alternatively, the composite web of fabric 521 or the discrete garment-sized piece 523) may typically become the sleeve opening end edges 553 and 555 in the finished garment 482, fabric may be removed from or added to the web side edges 514 and 515 to create the sleeve opening end edges 553 and 555 in the finished garment 482.

The opposing garment end portions 534 and 535 are adjacent to the garment bottom edge 527 of the front panel 518 and the garment bottom edge 536 of the back panel 528, respectively, in the finished garment 482. The location of the opposing piece side edges 548 and 549 of the discrete garment-sized piece 523 corresponds to the garment bottom edge 527 of the front panel 518 and the garment bottom edge 536 of the back panel 528, respectively, in the finished garment 482. It is understood that while the opposing piece side edges 548 and 549 of the discrete garment-sized piece 523 may typically become the garment bottom edges 527 and 536 in the finished garment 482, fabric may be removed from or added to the piece side edges 548 and 549 to create the garment bottom edges 527 and 536 in the finished garment 482.

Each discrete garment-sized piece 523 of the composite web of fabric 521 is transported typically by vacuum screens, belts, or conveyors, through hemming, folding, and fastening operations (not shown). The folding operations are desirably carried out by tuckers and folders, as well as any other known means. The discrete garment-sized piece 523 of the composite web of fabric 521 is folded by a folder 546 so as to bring together the opposing garment end portions 534 and 535 such that the web side edge 514 of the composite web of fabric 521 is folded onto itself, bringing the garment side edge 492 of the front panel 518 and the garment side edge 502 of the back panel 528 together. The web side edge 517 of the composite web of fabric 521 is folded onto itself, bringing the garment side edge 495 of the front panel 518 and the garment side edge 505 of the back panel 528 together.

In other embodiments, the webs of fabric 486 and 487 may be cut into garment- sized pieces 488 and 489, respectively, before the webs of fabric 486 and 487 are combined to form the composite web of fabric 521. The garment-sized pieces 488 and 489 of the webs of fabric 486 and 487 are fastened together to form the discrete garment- sized piece 523 of the composite web of fabric 521. The garment-sized pieces 488 and 489 are combined to form the discrete garment-sized piece 523 such that each discrete garment-sized piece 523 contains at least an opening 558, two pairs of opposing indentations 537 and 539, one pair of opposing web side edges 514 and 517, and opposing garment end portions 534 and 535, as described above.

The garment-sized pieces 488 and 489 of the webs of fabric 486 and 487 may be folded before or after the garment-sized pieces 488 and 489 are fastened together to form the discrete garment-sized piece 523 of the composite web of fabric 521. The folding operations are desirably carried out by tuckers and folders, as well as any other known means. The garment-sized piece 488 is folded by the folder 546 so as to bring together the opposing garment end portions 530 and 532 such that the garment-sized piece 488 is folded onto itself, bringing a right front panel 490 and a right back panel 500 together. The web side edge 514 folds onto itself, bringing the garment side edge 492 of the right front panel 490 and the garment side edge 502 of the right back panel 500 together. The web side edge 515 folds onto itself, forming the side edge 494 of the right front panel 490 and the side edge 504 of the right back panel 500. The garment-sized piece 488 contains at least one pair of opposing indentations 537 and 539, the web side edge 514, and the opposing garment end portions 530 and 532.

The garment-sized piece 489 is folded by the folder 546 so as to bring together the opposing garment end portions 531 and 533 such that the garment-sized piece 489 is folded onto itself forming a left front panel 491 and a left back panel 501. The web side edge 516 folds onto itself, forming the side edge 493 of the left front panel 491 and the side edge 503 of the left back panel 501. The web side edge 517 folds onto itself, bringing the garment side edge 495 of the left front panel 491 and the garment side edge 505 of the left back panel 501 together. The garment-sized piece 489 contains at least one pair of opposing indentations 537 and 539, the web side edge 515, and the opposing garment end portions 531 and 533. It is understood that the folding operations on the garment-sized pieces 488 and 489, while shown in Figure 26 to be carried out simultaneously by one folder 546, these folding operations could be performed by separate devices and at different stages within the manufacturing process.

The side edges 494 and 493 of the right and left front panels 490 and 491 , respectively, are fastened together to form a portion of the center seam 519 and the front panel 518. The side edges 504 and 503 of the right and left back panels 500 and 501, respectively, are fastened together to form a portion of the center seam 519 and the back panel 528.

The center seam 519, or portions thereof, can be constructed as a non- refastenable seam, as a refastenable seam, or as a combination of a non-refastenable seam and a refastenable seam. Any excess material from the webs of fabric 486 and 487 may be removed from the side edges 493, 494, 503, and 504 of the center seam 519 to reduce and smooth out the center seam 519. The non-refastenable center seam 519 may be formed by any suitable means such as ultrasonic sealing, adhesive bonding, tape, heat sealing, sewing, or any method known in the art. The non-refastenable center seam 519 may be constructed on a continuous or intermittent basis. See the discussion above for center seams 520 and 524.

In other embodiments of the present invention, the side edges 493, 494, 503, and 504 of the garment 482 may be held together in the finished garment 482 to form the refastenable center seam 519. The refastenable means for securing the side edges 493, 494, 503, and 504 of the garment 482 include refastenable adhesive and mechanical type fasteners 564. The adhesive and mechanical type fasteners 564 include buttons and button holes, snaps, buckles, clasps, hooks and loops, end extensions, tabs, tape, and the like which are designed or adapted to interlock or engage some type of a complementary device or the outer surface 484 or the inner surface 483 of the garment 482. A refastenable center seam 519 may be constructed on a continuous or intermittent basis.

In addition, elasticized fasteners 564 may also be used in assuring better fit of the garment 482. If the garment 482 includes a refastenable center seam 519, the refastenable means are desirably strategically placed on the webs of fabric 486 and 487 before the webs of fabric 486 and 487 are cut into garment-sized pieces 488 and 489. The folding and redirection operations may be eliminated when a refastenable center seam 519 is included in the garment 482. However, there may be packaging reasons for which one would still carry out these two steps.

The center seam 519 of the present invention may take on a variety of structures or configurations known in the art. One embodiment of the center seam 519 is an out- turned configuration as illustrated in Figure 45. Such a configured center seam 519 is formed by securing together at least a portion of the out-turned portions of the side edges 493 and 494 and the side edges 503 and 504, respectively. The inner surface 483 of the right and left front panels 490 and 491 and inner surface 483 of the right and left back panels 500 and 501, respectively, are brought into contact with each other.

Another embodiment of the center seam 519 is an in-turned configuration as illustrated in Figure 46. Such a configured center seam 519 is formed by securing together at least a portion of the in-turned portions of the side edges 493 and 503 and the side edges 494 and 504, respectively. The outer surface 484 of the right and left front panels 490 and 491 and the outer surface of the right and left back panels 500 and 501, respectively, are brought into contact with each other.

Another embodiment of the center seam 519 is an over-lapped configuration as illustrated in Figure 44. Such a configured center seam 519 is formed by securing together at least a portion of the over-lapped portions of the side edges 493 and 503 and the side edges 494 and 504, respectively. The inner surface 483 of one of the right or left front panels 490 and 491 and the inner surface 483 of the right or left back panels 500 and 501 are brought into contact with the outer surface 484 of the other panel of each pair.

Another embodiment of the center seam 519 is an over-lapped configuration as illustrated in Figure 47. Such a configured center seam 519 is formed by folding back the side edges 494 and 504 (or, alternatively, the side edges 493 and 503). The outer surface 484 of the folded portion and the inner surface 483 of the unfolded portion of the side edges 494 and 504 and the corresponding portions of the right front and right back panels 490 and 500, respectively, (or, alternatively, of the side edges 493 and 503 and the corresponding portions of the left front and left back panels 491 and 501 , respectively) are brought into contact with the inner surface 483 or the outer surface 484 of the side edges 493 and 503 and the corresponding portions of the left front and left back panels 491 and 501 , respectively (or, alternatively, of the side edges 494 and 504 and the corresponding portions of the right front and right back panels 490 and 500). It is understood that the folding back of a side edge, such as the side edges 493, 494, 503, and 504, could be performed such that the inner surface 483 would be exposed along the fold.

The locations of the garment end portion 530 of the right front panel 490 and the garment end portion 531 of the left front panel 491 correspond to the garment end portion 534 of the front panel 518 in the finished garment 482. The locations of the garment end portion 532 of the right back panel 500 and the garment end portion 533 of the left back panel 501 correspond to the garment end portion 535 of the back panel 528 in the finished garment 482.

In the embodiments where the webs of fabric 486 and 487 or the garment-sized pieces 488 and 489 are fastened together prior to the folding step, each discrete garment- sized piece 523 of the composite web of fabric 521 is transported, typically by vacuum screens, belts, or conveyors, through hemming, folding, and fastening operations. The folding operations are desirably carried out by tuckers and folders, as well as any other known means. The discrete garment-sized piece 523 of the web of fabric 521 is folded by the folder 546 so as to bring together the opposing garment end portions 534 and 535 such that the web side edge 514 of the composite web of fabric 521 is folded on to itself, bringing the garment side edge 492 of the front panel 518 and the garment side edge 502 of the back panel 528 together. The web side edge 517 of the composite web of fabric 521 is folded on to itself, bringing the garment side edge 495 of the front panel 518 and the garment side edge 505 of the back panel 528 together.

The mating of the garment side edge 492 and the garment side edge 502 as well as the mating of the garment side edge 495 and the garment side edge 505 form the garment side seams 510 and 511, respectively, of the garment 482. It may be desirable to redirect (or reorient) the discrete garment-sized piece 523 of the composite web of fabric 521 to allow easy bonding of the garment side seams 510 and 511 of the garment 482. The turning operations are desirably carried out by turn rolls and turn tables, as well as any other known means. The discrete garment-sized piece 523 of the composite web of fabric 521 may be reoriented 90 degrees (not shown).

In various embodiments of the present invention, one or both of the garment side seams 510 and 511 can be constructed as non-refastenable seams or as refastenable seams. Any excess material from the webs of fabric 486 and 487 may be removed from the edges of the garment side seams 510 and 511 to reduce and smooth out the garment side seams 510 and 511. The non-refastenable garment side seams 510 and 511 may be formed by any suitable means such as ultrasonic sealing, adhesive bonding, tape, heat sealing, sewing, or any method of fastening known in the art. (Sewing equipment 582 is shown in Figure 26). The non-refastenable garment side seams 510 and 511 may be constructed on a continuous or intermittent basis. One suitable method of forming such garment side seams 510 and 511 is disclosed in U.S. Patent No. 4,938,753 issued July 3, 1990, to Van Gompel et al., which is incorporated herein by reference. The garment side seams 510 and 511 may be bonded together to form non-refastenable garment side seams 510 and 511.

In other embodiments of the present invention, the garment side edges 492 and 502 and the garment side edges 495 and 505 of the garment 482 may be held together in the finished garment 482 to form refastenable garment side seams 510 and 511 , respectively. The refastenable means for securing the garment side edges 492 and 502 and the garment side edges 495 and 505 of the garment 482 include refastenable adhesive and mechanical type fasteners 564. The adhesive and mechanical type fasteners 564 include buttons and button holes, snaps, buckles, clasps, hooks and loops, end extensions, tabs, tape, and the like which are designed or adapted to interlock or engage some type of a complementary device or the outer surface 484 or the inner surface 483 of the garment 482.

In addition, elasticized fasteners 564 may also be used in assuring better fit of the garment 482. If the garment 482 includes refastenable garment side seams 510 and 511 , the refastenable means are desirably strategically placed on the webs of fabric 486 and 487 before the webs of fabric 486 and 487 are cut into garment-sized pieces 488 and 489. The folding and redirection operations may be eliminated when refastenable garment side seams 510 and 511 are included in the garment 482. However, there may be packaging reasons for which one would still carry out these two steps. The garment side seams 510 and 511 of the present invention may take on a variety of structures or configurations known in the art. One embodiment of the garment side seams 510 and 511 is an out-turned configuration as illustrated in Figure 45. Such configured garment side seams 510 and 511 are formed by securing together at least a portion of the out-turned portions of the garment side edges 492 and 502 and the garment side edges 495 and 505, respectively. The inner surface 483 of the garment side edges 492 and 495 of the front panel 518 and the garment side edges 502 and 505 of the back panel 528, respectively, are brought into contact with each other for each pair of side edges.

Another embodiment of the garment side seams 510 and 511 is an in-turned configuration as illustrated in Figure 46. Such configured garment side seams 510 and 511 are formed by securing together at least a portion of the in-turned portions of the garment side edges 492 and 502 and the garment side edges 495 and 505, respectively. The outer surface 484 of the garment side edges 492 and 495 of the front panel 518 and the garment side edges 502 and 505 of the back panel 528, respectively, are brought into contact with each other for each pair of side edges.

Another embodiment of the garment side seams 510 and 511 is an over-lapped configuration as illustrated in Figure 44. Such configured garment side seams 510 and 511 are formed by securing together at least a portion of the over-lapped portions of the garment side edges 492 and 502 and the garment side edges 495 and 505, respectively. The inner surface 483 of one of the garment side edges 492 and 502 and one of the garment side edges 495 and 505 are brought into contact with the outer surface 484 of the other side edges of each pair of side edges.

Another embodiment of the garment side seams 510 and 511 is an over-lapped configuration as illustrated in Figure 47. Such a configured garment side seam 510 is formed by folding back the garment side edge 492 or the garment side edge 502. The outer surface 484 of the folded portion and the inner surface 483 of the unfolded portion of the garment side edge 492 or 502 and the corresponding portion of the front panel 490 (or, alternatively, the front panel 518) or the back panel 500 (or, alternatively, the back panel 528), respectively, are brought into contact with the inner surface 483 or the outer surface 484 of the non-folded side edge and the corresponding portion of the front panel 490 (or, alternatively, the front panel 518) or the back panel 500 (or, alternatively, the back panel 528).

The garment side edge 511 is formed by folding back the garment side edge 495 or the garment side edge 505. The outer surface 484 of the folded portion and the inner surface 483 of the unfolded portion of the garment side edge 495 or 505 and the corresponding portion of the front panel 491 (or, alternatively, the front panel 518) or the back panel 501 (or, alternatively, the back panel 528), respectively, are brought into contact with the inner surface 483 or the outer surface 484 of the non-folded side edge and the corresponding portion of the front panel 491 (or, alternatively, the front panel 518) or the back panel 501 (or, alternatively, the back panel 528). It is understood that the folding back of a garment side edge 492, 502, 495, or 505 could be performed such that the inner surface 483 would be exposed along the fold.

The garment end portions 534 and 535 of the discrete garment-sized piece 523 of the composite web of fabric 521 may be hemmed in the finished garment 482. In some embodiments, it may be desirable to hem the garment end portions 530, 531, 532, and 533 of the garment-sized pieces 488 and 489 of the webs of fabric 486 and 487, respectively, before fastening the garment-sized pieces 488 and 489 together to form the discrete garment-sized piece 523 of the composite web of fabric 521. The garment end portions 534 and 535 of the discrete garment-sized piece 523 (or, alternatively, garment end portions 530, 531 , 532, and 533 of the garment-sized pieces 488 and 489) can be hemmed by any method or style known in the art. In some embodiments, it may be desirable to leave the garment end portions 534 and 535 of the discrete garment-sized piece 523 (or, alternatively, garment end portions 530, 531, 532, and 533 of the garment- sized pieces 488 and 489) unhemmed.

The garment bottom edges 527 and 536 of the discrete garment-sized piece 523 of the composite web of fabric 521 may be hemmed in the finished garment 482. In some embodiments, it may be desirable to hem the garment bottom edges 496, 497, 506, and 507 of the garment-sized pieces 488 and 489 of the webs of fabric 486 and 487, respectively, before fastening the garment-sized pieces 488 and 489 together to form the discrete garment-sized piece 523 of the composite web of fabric 521. The garment bottom edges 527 and 536 of the discrete garment-sized piece 523 (or, alternatively, garment bottom edges 496, 497, 506, and 507 of the garment-sized pieces 488 and 489) can be hemmed by any method or style known in the art. (Sewing equipment 581 is shown in Figure 26). In some embodiments, it may be desirable to leave the garment bottom edges 527 and 536 of the discrete garment-sized piece 523 (or, alternatively, garment bottom edges 496, 497, 506, and 507 of the garment-sized pieces 488 and 489) unhemmed.

In some embodiments of the present invention, the garment 482 includes sleeves 544 and 547 (see Figures 29, 30, and 34). The sleeves 544 and 547 are made from the sleeve flaps 566 and 567. The sleeve flaps 566 and 567 may take on a variety of sizes and shapes, such as a slit, circular, oval, triangular, square, rectangular, multi-faceted, asymmetric or irregular, or the like. The pattern of the sleeve flaps 566 and 567 (or, alternatively, the sleeves 544 and 547) is restricted only by fashion and the minimum amount of the material of the sleeve flaps 566 and 567 that is necessary to complete the remaining steps or operations of the process of manufacture.^" The sleeves 544 and 547, alternately the sleeve flaps 566 and 567, may be similar or dissimilar in shape, structure, material, size, and the like from each other within the finished garment 482. In some embodiments, only one sleeve 544 or 547 may be included in the finished garment 482.

The sleeve flap 566 has a pair of sleeve side edges 550 and 552, and a sleeve opening end edge 553 extending between the sleeve side edges 550 and 552. It is understood that the piece of the sleeve flap 566 could be made of multiple pieces of material or materials. The sleeve flap 566 is folded so as to bring together the opposing sleeve side edges 550 and 552 to form a sleeve seam 562 of the sleeve 544.

The sleeve flap 567 has a pair of sleeve side edges 557 and 560, and a sleeve opening end edge 555 extending between the sleeve side edges 550 and 552. It is also understood that the sleeve flap 567 could be made of multiple pieces of material or materials. The sleeve flap 567 is folded so as to bring together the opposing sleeve side edges 557 and 560 to form a sleeve seam 565 of the sleeve 547.

It may be desirable to redirect (or reorient) the garment-sized pieces 488 and 489 (or, alternatively, the discrete garment-sized piece 523) to allow easy fastening of the sleeve seams 562 and 565 of the sleeves 544 and 547, respectively, of the garment 482. The garment-sized pieces 488 and 489 (or, alternatively, the discrete garment-sized piece 523) may be reoriented 90 degrees (not shown). The sleeve seams 562 and 565 can be non-refastenable seams or refastenable seams. Any excess material of the sleeve flaps 566 and 567 can be removed from their respective edges of the sleeve seams 562 and 565 to reduce and smooth out the sleeve seams 562 and 565. The non-refastenable sleeve seams 562 and 565 may be formed by any suitable means such as ultrasonic sealing, adhesive bonding, tape, heat sealing, sewing, or any method of fastening known in the art, as discussed above. The non-refastenable sleeve seams 562 and 565 may be constructed on a continuous or intermittent basis.

In other embodiments, the opposing pair of the sleeve side edges 550 and 552 and the opposing pair of the sleeve side edges 557 and 560 of the sleeves 544 and 547, respectively, may be held together in the finished garment 482 to form refastenable sleeve seams 562 and 565. The refastenable means for securing the opposing pair of the sleeve side edges 550 and 552 and the opposing pair of the sleeve side edges 557 and 560 of the sleeves 544 and 547, respectively, include refastenable adhesive and mechanical type fasteners 564. The adhesive and mechanical type fasteners 564 include buttons and button holes, snaps, buckles, clasps, hooks and loops, end extensions, tabs, tape, and the like which are designed or adapted to interlock or engage some type of a complementary device or the inner surface 483 or the outer surface 484 of the garment 482. The refastenable sleeve seams 562 and 565 may be constructed on a continuous or intermittent basis.

In addition, elasticized fasteners 564 may also be used in assuring better fit of the sleeves 544 and 547 of the garment 482. If the garment 482 includes refastenable sleeve seams 562 and 565, the refastenable means are desirably strategically placed on the sleeve flaps 566 and 567 before the opposing indentations 537 and 539 are cut into the web side edges 514 and 517 of the composite web of fabric 521 (or, alternatively, the webs of fabric 486 and 487). The folding and redirection operations may be eliminated when refastenable sleeve seams 562 and 565 are included in the garment 482. However, there may be packaging reasons for which one would still carry out these two steps.

The sleeve seams 562 and 565 of the present invention may take on a variety of structures or configurations known in the art. One embodiment of the sleeve seams 562 and 565 is an out-turned configuration as illustrated in Figure 45. Such configured sleeve seams 562 and 565 are formed by securing together at least a portion of the out-turned portions of the sleeve side edges 550 and 552 and the sleeve side edges 557 and 560 of the sleeve flaps 566 and 567, respectively. The inner surface 483 of the sleeve side edges 550 and 552 and the sleeve side edges 557 and 560 of the sleeve flaps 566 and 567, respectively, are brought into contact with each other of the pair.

Another embodiment of the sleeve seams 562 and 565 is an in-turned configuration as illustrated in Figure 46. Such configured sleeve seams 562 and 565 are formed by securing together at least a portion of the in-turned portions of the sleeve side edges 550 and 552 and the sleeve side edges 557 and 560 of the sleeve flaps 566 and 567, respectively. The outer surface 484 of the sleeve side edges 550 and 552 and the sleeve side edges 557 and 560 of sleeve flaps 566 and 567, respectively, are brought into contact with each other of the pair.

Another embodiment of the sleeve seams 562 and 565 is an over-lapped configuration as illustrated in Figure 44. Such configured sleeve seams 562 and 565 are formed by securing together at least a portion of the over-lapped portions of the sleeve side edges 550 and 552 and the sleeve side edges 557 and 560 of the sleeve flaps 566 and 567, respectively. The inner surface 483 of one of the sleeve side edges 550 or 552 and the sleeve side edges 557 or 560 of the sleeve flaps 566 and 567 are brought into contact with the outer surface 484 of the other sleeve side edge 550 or 552 and the sleeve side edge 557 or 560 of the sleeve flap 566 and 567, respectively.

Another embodiment of the sleeve seams 562 and 565 is an over-lapped configuration as illustrated in Figure 47. Such configured sleeve seams 562 and 565 are formed by folding back the sleeve side edges 550 or 552 and the sleeve side edges 557 and 560 of the sleeve flaps 566 and 567, respectively. The outer surface 484 of the folded portions and the inner surface 483 of the unfolded portions of the sleeve side edges 550 or 552 and the sleeve side edges 557 or 560 and the corresponding portions of the sleeve flaps 566 and 567, respectively, are brought into contact with the inner surface 483 or the outer surface 484 of the non-folded sleeve side edge and the corresponding portions of the sleeve flaps 566 and 567, respectively. It is understood that the folding back of a sleeve side edge 550, 552, 557, or 560 could be performed such that the inner surface 483 would be exposed along the fold.

The sleeve opening end edges 553 and 555 of the sleeves 544 and 547, respectively, (in the alternative, the sleeve opening end edges 553 and 555 of the sleeve flaps 566 and 567) can be hemmed by any method or style known in the art. In some embodiments, it may be desirable to leave the sleeve opening end edges 553 and 555 unhemmed.

In other embodiments, cuffs 554 and 556 may be attached to the sleeve opening end edges 553 and 555, respectively, of the sleeves 544 and 547, respectively, of the garment 482, forming cuff seams 574 and 576, respectively. The attachment of the cuffs 554 and 556 may be made non-refastenable by means as discussed above. (Sewing equipment 580 is shown in Figure 26). In the alternative, the attachment of the cuffs 554 and 556 may be made refastenable by means as discussed above. The cuff seams 574 and 576 may be constructed on a continuous or intermittent basis. The cuffs 554 and 556 may take on a variety of sizes and shapes. The cuffs 554 and 556 may be similar or dissimilar in shape, structure, material, size, and the like from each other within the finished garment 482. The pattern of the cuffs 554 and 556 is restricted only by the fashion and the minimum amount of the material of the cuffs 554 and 556 that is necessary to complete the remaining steps or operations of the process of manufacture.

The cuff seams 574 and 576 of the present invention may take on a variety of structures or configurations known in the art. One embodiment of the cuff seams 574 and 576 is an out-turned configuration as illustrated in Figure 45. Such configured cuff seams 574 and 576 are formed by securing together at least a portion of the out-turned portions of the cuff edge 573 and the sleeve opening end edge 553 and the cuff edge 575 and the sleeve opening end edge 555, respectively, of the garment 482. The inner surface 483 of the cuff edges 573 and 575 of the cuffs 554 and 556, respectively, are brought into contact with the inner surface 483 of the sleeve opening edges 553 and 555 of the sleeves 544 and 547, respectively.

Another embodiment of the cuff seams 574 and 576 is an in-turned configuration as illustrated in Figure 46. Such configured cuff seams 574 and 576 are formed by securing together at least a portion of the in-turned portions of the cuff edge 573 and the sleeve opening edge 553 and the cuff edge 575 and the sleeve opening edge 555, respectively, of the garment 482. The outer surface 484 of the cuff edges 573 and 575 of the cuffs 554 and 556, respectively, are brought into contact with the outer surface 484 of the sleeve opening edges 553 and 555 of the sleeves 544 and 547, respectively. Another embodiment of the cuff seams 574 and 576 is an over-lapped configuration as illustrated in Figure 44. Such configured cuff seams 574 and 576 are formed by securing together at least a portion of the over-lapped portions of the cuff edge 573 and the sleeve opening edge 553 and the cuff edge 575 and the sleeve opening edge 555 of the sleeves 544 and 547, respectively. The inner surface 483 of one of the cuff edge 573 or the sleeve opening edge 553 and the cuff edge 575 or the sleeve opening edge 555, are brought into contact with the outer surface 484 of the other cuff edge 573 or the sleeve opening edge 553 and the cuff edge 575 or the sleeve opening edge 555 of the sleeves 544 and 547, respectively.

Another embodiment of the cuff seams 574 and 576 is an over-lapped configuration as illustrated in Figure 47. Such configured cuff seams 574 and 576 are formed by folding back the cuff edge 573 or the sleeve opening end edge 553 and the cuff edge 575 or the sleeve opening end edge 555 of the sleeves 544 and 547, respectively. The outer surface 484 of the folded portions and the inner surface 483 of the unfolded portions of the cuff edge 573 or the sleeve opening end edge 553 and the cuff edge 575 or the sleeve opening end edge 555 and the corresponding portions of the cuffs 554 and 556 or the sleeves 544 and 547 are brought into contact with the inner surface 483 or the outer surface 484 of the unfolded cuff edge 573 and 575 or the sleeve opening end edge 553 and 555 and the corresponding portions of the cuffs 554 and 556 or the sleeves 544 and 547. It is understood that the folding back of a cuff edge 573 or 575 or a sleeve opening end edge 553 or 555 could be performed such that the inner surface 483 would be exposed along the fold.

The materials used for the cuffs 554 and 556 may be the same as the materials used for the other portions of the garment 482. In some embodiments, it is desirable that the materials used for the cuffs 554 and 556 have an elastic element such that the cuffs 554 and 556 will conform to the portion of the wearer's arms that come into contact with the cuffs 554 and 556.

The edge 561 of the neck opening 559 can be hemmed by any method or style known in the art. In some embodiments, it may be desirable to leave the edge 561 of the neck opening 559 unhemmed. In other embodiments, a collar 563 may be attached to the edge 561 of the neck opening 559 of the garment 482 thereby forming a collar seam 578. The attachment of the collar 563 may be made non-refastenable by means as discussed above. (Sewing equipment 579 is shown in Figure 26). The collar seam 578 may be constructed on a continuous or intermittent basis. In the alternative, the attachment of the collar 563 may be made refastenable by means as discussed above. The collar 563 may take on a variety of sizes and shapes. The pattern of the collar 563 is restricted only by fashion and the minimum amount of the material of the collar 563 that is necessary to complete the remaining steps or operations of the process of manufacture.

The collar seam 578 of the present invention may take on a variety of structures or configurations known in the art. One embodiment of the collar seam 578 is an out-turned configuration as illustrated in Figure 45. Such a configured collar seam 578 is formed by securing together at least a portion of the out-turned portions of the collar edge 577 and the edge 561 of the neck opening 559 of the garment 482. The inner surface 483 of the collar edge 577 of the collar 563 is brought into contact with the inner surface 483 of the edge 561 of the neck opening 559.

Another embodiment of the collar seam 578 is an in-turned configuration as illustrated in Figure 46. Such a configured collar seam 578 is formed by securing together at least a portion of the in-turned portions of the collar edge 577 of the collar 563 and the edge 561 of the neck opening 559 of the garment 482. The outer surface 484 of the collar edge 577 of the collar 563 is brought into contact with the outer surface 484 of the edge 561 of the neck opening 559.

Another embodiment of the collar seam 578 is an over-lapped configuration as illustrated in Figure 44. Such a configured collar seam 578 is formed by securing together at least a portion of the over-lapped portions of the collar edge 577 of the collar 563 and the edge 561 of the neck opening 559 of the garment 482. The inner surface 483 of the collar edge 577 of the collar 563 or the edge 561 of the neck opening 559 is brought into contact with the outer surface 484 of the other, the collar edge 577 or the edge 561.

Another embodiment of the collar seam 578 is an over-lapped configuration as illustrated in Figure 47. Such a configured collar seam 578 is formed by folding back the collar edge 577 of the collar 563 or the edge 561 of the neck opening 559. The outer surface 484 of the folded portions and the inner surface 483 of the unfolded portions of the collar edge 577 of the collar 563 or the edge 561 of the neck opening 559 and the corresponding portions of the collar 563 or the front and back panels 518 and 528 are brought into contact with the inner surface 483 or the outer surface 484 of the unfolded collar edge 577 of the collar 563 or the edge 561 of the neck opening 559 and the corresponding portions of the collar 563 or the front and back panels 518 and 528. It is understood that the folding back of the collar edge 577 of the collar 563 or the edge 561 of the neck opening 559 could be performed such that the inner surface 483 would be exposed along the fold.

Another embodiment of the collar seam 578 is an over-lapped configuration as illustrated in Figure 48. Such a configured collar seam 578 is formed by folding the collar 563 about or over the edge 561 of the neck opening 559. The collar edges 577 of the collar 563 may be folded under bringing the outer surface 484 of the collar 563 into contact with the edge 561 of the neck opening and any portion of the adjacent material of the front panel 518, the back panel 528, or both as desired. The collar edges 577 may be left exposed by not being folded under.

Another embodiment of the collar seam 578 is an over-lapped configuration as illustrated in Figure 49. Such a configured collar seam 578 is formed by folding the collar edge 577 such that the inner surface 483 of the collar 563 is brought into contact with themselves. The edge 561 of the neck opening 559 is folded such that the outer surface 484 of the front panel 518, the back panel 528, or both are brought into contact with itself. The collar edge 577 is inserted into the fold of the edge 561 of the neck opening 559. The edge 561 of the neck opening 559 is inserted into the fold of the collar edge 577. In another embodiment, the collar edge 577 is folded such that the outer surface 484 of the collar 563 is brought into contact with itself. The edge 561 of the neck opening 559 is folded such that the inner surface 483 of the front panel 518, the back panel 528, or both are brought into contact with themselves. This configured collar seam 578 may be used with any seam described herein.

The materials used for the collar 563 may be the same as the materials used for the other portions of the garment 482. In some embodiments, it is desirable that the materials used for the collar 563 have an elastic element such that the collar 563 will conform to the portion of the wearer's neck that comes into contact with the collar 563.

In various embodiments of the present invention, the front panel 518, the back panel 528, or both panels 518 and 528 may be cut or otherwise opened to form a slit 513 or 568, such as a placket. The slit 513 has two edges 525 and 529. The slit 568 has two edges, 569 and 570. The slits 513 and 568 of the front and back panels 490 and 500, respectively, may extend from the edge 561 of the neck opening 559 to the garment bottom edge 527 and 536, respectively. In the alternative, the slits 513 and 568 may extend over only a portion of the panel 518 and 528 from the edge 561 of the neck opening 559 to the garment bottom edge 527 and 536, respectively. When the garment 482 comprises both a slit 513 in the front panel 518 and a slit 568 in the back panel 528, the slits 513 and 568 may be similar or dissimilar in size, structure, shape, and the like. The slits 513 and 568 may or may not coincide with the side edges 493 and 494 and the side edges 503 and 504, respectively.

In some embodiments, the edges 525 and 529 of the slit 513 and the edges 569 and 570 of the slit 568 may be refastenably attached or secured to each other. The edges 525 and 529 may be secured together to form the front seam 879a. The edges 569 and 570 may be secured together to form the back seam 680a. Various fastening means, such as adhesive and mechanical type fasteners 564, see the discussion above, may be used to refastenably attach or secure the edges 525 and 529 or the edges 569 and 570 together of the slits 513 and 568, respectively.

One embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a web of fabric including opposing web side edges; intermittently cutting the web of fabric, forming edges defining neck openings in the web of fabric; intermittently cutting the opposing web side edges of the web of fabric, defining pairs of opposing indentations in the opposing web side edges of the web of fabric; cutting the web of fabric, defining discrete garment-sized pieces wherein each of the discrete garment-sized pieces of the web of fabric includes at least one neck opening, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, a portion of two pairs of the opposing indentations in the web side edges of the web of fabric, a pair of sleeve flaps, two garment end portions, and a pair of opposing piece side edges wherein the opposing piece side edges are proximate a pair of opposing garment bottom edges of the garment; folding the discrete garment-sized piece of the web of fabric whereby one of the garment bottom edges of the pair of opposing garment bottom edges is brought into contact with the other garment bottom edge; and, fastening at least a portion of the pair of opposing garment side edges of the front panel to at least a portion of the pair of opposing garment side edges of the back panel to form a pair of garment side seams.

The neck openings may be intermediate the two pairs of the opposing indentations. The web of fabric may be folded, defining an arrangement of having the web of fabric wherein the opposing web side edges are adjacent each other. The web of fabric may be unfolded after at (east one step of intermittently cutting the web of fabric. The web of fabric may be unfolded before the step of cutting the web of fabric into the discrete garment-sized pieces of the web of fabric. At least a portion of at least one of the opposing garment bottom edges may be hemmed. The discrete garment-sized piece of the web of fabric may include at least one sleeve flap having a sleeve opening end edge and a pair of opposing sleeve side edges. The discrete garment-sized pieces of the web of fabric may include a pair of sleeve flaps wherein each sleeve flap includes a sleeve opening end edge and a pair of opposing sleeve side edges. At least a portion of at least one of the sleeve opening end edges of the sleeve flaps may be hemmed.

A collar may be provided. At least a portion of the collar may be fastened to the edge of the neck opening. The collar may be a ribbed knit collar. At least a portion of at least one of the garment side seams may be refastenable. At least a portion of at least one of the garment side seams may be non-refastenable.

The front panel may be slit at least a portion of the distance between the edge of the neck opening and the garment bottom edge, thereby defining a pair of edges of a slit. At least a portion of the edges of the slit may be fastened to form a front seam. At least a portion of the front seam may be refastenable. At least a portion of the front seam may be non-refastenable. The back panel may be slit at least a portion of the distance between the edge of the neck opening and the garment bottom edge thereby defining a pair of edges of a slit. At least a portion of the edges of the slit may be fastened to form a back seam. At least a portion of the back seam may be refastenable. At least a portion of the back seam may be non-refastenable. At least a portion of the edge of the neck opening may be hemmed. Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a web of fabric including opposing web side edges; intermittently cutting the opposing web side edges of the web of fabric, defining pairs of opposing indentations in the opposing web side edges of the web of fabric; intermittently cutting the web of fabric, forming edges defining neck openings in the web of fabric wherein the neck openings are intermediate two pairs of the opposing indentations; cutting the web of fabric, defining discrete garment-sized pieces wherein each discrete garment-sized piece of the web of fabric includes at least one neck opening, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, a portion of the two pairs of the opposing indentations in the opposing web side edges of the web of fabric, a pair of sleeve flaps, two garment end portions, and a pair of opposing piece side edges wherein the opposing piece side edges are proximate a pair of opposing garment bottom edges of the garment; folding the discrete garment-sized piece of the web of fabric whereby one of the garment bottom edges of the pair of opposing garment bottom edges is brought into contact with the other garment bottom edge; and, fastening at least a portion of the pair of opposing garment side edges of the front panel to at least a portion of the pair of opposing garment side edges of the back panel to form a pair of garment side seams.

The web of fabric may be folded, defining an arrangement of having the web of fabric wherein the opposing web side edges are adjacent each other. The web of fabric may be unfolded after at least one step of intermittently cutting the web of fabric. The web of fabric may be unfolded before the step of cutting the web of fabric into the discrete garment-sized pieces of the web of fabric. At least a portion of at least one of the opposing garment bottom edges may be hemmed. The discrete garment-sized piece of the web of fabric may include at least one sleeve flap having a sleeve opening end edge and a pair of opposing sleeve side edges. The discrete garment-sized pieces of the web of fabric may include a pair of sleeve flaps wherein each sleeve flap includes a sleeve opening end edge and a pair of opposing sleeve side edges. At least a portion of at least one of the sleeve opening end edges of the sleeve flaps may be hemmed.

A collar may be provided. At least a portion of the collar may be fastened to the edge of the neck opening. The collar may be a ribbed knit collar. At least a portion of at least one of the garment side seams may be refastenable. At least a portion of at least one of the garment side seams may be non-refastenable. The front panel may be slit at least a portion of the distance between the edge of the neck opening and the garment bottom edge, thereby defining a pair of edges of a slit. At least a portion of the edges of the slit may be fastened to form a front seam. At least a portion of the front seam may be refastenable. At least a portion of the front seam may be non-refastenable. The back panel may be slit at least a portion of the distance between the edge of the neck opening and the garment bottom edge, thereby defining a pair of edges of a slit. At least a portion of the edges of the slit may be fastened to form a back seam. At least a portion of the back seam may be refastenable. At least a portion of the back seam may be non-refastenable. At least a portion of the edge of the neck opening may be hemmed.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a web of fabric including an inner surface, an outer surface, and opposing web side edges; intermittently cutting the opposing web side edges of the web of fabric, defining pairs of opposing indentations in the opposing web side edges of the web of fabric; intermittently cutting the web of fabric, forming edges defining neck openings in the web of fabric wherein the neck openings are intermediate two pairs of the opposing indentations; cutting the web of fabric, defining discrete garment-sized pieces wherein each discrete garment-sized piece of the web of fabric includes at least one the neck opening, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, a portion of the two pairs of the opposing indentations in the opposing web side edges of the web of fabric, pair of sleeve flaps, two garment end portions, and a pair of opposing piece side edges wherein the opposing piece side edges are proximate a pair of opposing garment bottom edges of the garment; hemming at least a portion of at least one of the opposing garment bottom edges; folding the discrete garment-sized pieces of the web of fabric whereby one of the garment bottom edges of the pair of opposing garment bottom edges is brought into contact with the other garment bottom edge; and, fastening at least a portion of the pair of opposing garment side edges of the front panel to at least a portion of the pair of opposing garment side edges of the back panel to form a pair of garment side seams.

The web of fabric may be folded, defining an arrangement of having the web of fabric wherein the opposing web side edges are adjacent each other. The web of fabric may be unfolded after at least one step of intermittently cutting the web of fabric. The web of fabric may be unfolded before the step of cutting the web of fabric into the discrete garment-sized pieces of the web of fabric. Each of the sleeve flaps may include an inner surface, an outer surface, a sleeve opening end edge, and a pair of opposing sleeve side edges. At least a portion of at least one of the sleeve opening end edges of the sleeve flaps may be hemmed.

A collar may be provided. At least a portion of the collar may be fastened at the edge of the neck opening. The collar may be a ribbed knit collar. At least a portion of at least one of the garment side seams may be refastenable. At least a portion of at least one of the garment side seams may be non-refastenable.

The front panel may be slit at least a portion of the distance between the edge of the neck opening and the garment bottom edge thereby defining a pair of edges of a slit. At least a portion of the edges of the slit may be fastened to form a front seam. At least a portion of the front seam may be refastenable. At least a portion of the front seam may be non-refastenable. The back panel may be slit at least a portion of the distance between the edge of the neck opening and the garment bottom edge thereby defining a pair of edges of a slit. At least a portion of the edges of the slit may be fastened to form a back seam. At least a portion of the back seam may be refastenable. At least a portion of the back seam may be non-refastenable. At least a portion of the edge of the neck opening may be hemmed.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a web of fabric including opposing web side edges; cutting the web of fabric, defining discrete garment- sized pieces wherein each of the discrete garment-sized pieces of the web of fabric include at least a front panel, a back panel, two garment end portions, a portion of each of the web side edges of the web of fabric and the pair of opposing piece side edges wherein the opposing piece side edges are proximate a pair of opposing garment bottom edges of the garment; cutting the discrete garment-sized pieces, forming edges defining at least one neck opening in each of the discrete garment-sized pieces; cutting the opposing garment bottom edges of the discrete garment-sized pieces, defining two pairs of opposing indentations in the opposing garment bottom edges of the discrete garment- sized pieces, thereby forming a pair of opposing garment side edges of the front panel, a pair of opposing garment side edges of the back panel, and a pair of sleeve flaps; folding each of the discrete garment-sized pieces whereby one of the garment bottom edges of the pair of opposing garment bottom edges is brought into contact with the other garment bottom edge; and, fastening at least a portion of the pair of opposing garment side edges of the front panel to at least a portion of the pair of opposing garment side edges of the back panel to form a pair of garment side seams.

The neck openings may be intermediate the two pairs of the opposing indentations. The web of fabric may be folded, defining an arrangement of having the web of fabric wherein the opposing web side edges are adjacent each other. The web of fabric may be unfolded after at least one step of intermittently cutting the web of fabric. The web of fabric may be unfolded before the step of cutting the web of fabric into the discrete garment-sized pieces of the web of fabric. Each of the sleeve flaps may include an inner surface, an outer surface, a sleeve opening end edge, and a pair of opposing sleeve side edges. At least a portion of at least one of the sleeve opening end edges of the sleeve flaps may be hemmed.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a first web of fabric including opposing web side edges; providing a second web of fabric including opposing web side edges; aligning the first and second webs of fabric together in a side by side orientation defining an arrangement wherein one of the web side edges of the first web of fabric is adjacent one of the web side edges of the second web of fabric; fastening at least a portion of the adjacent web side edge of the first web of fabric to at least a portion of the adjacent web side edge of the second web of fabric in the side by side orientation, defining at least a portion of a center seam and a composite web of fabric having a pair of opposing web side edges; intermittently cutting the composite web of fabric, forming edges defining neck openings in the composite web of fabric; intermittently cutting the opposing web side edges of the composite web of fabric, defining pairs of opposing indentations in the opposing web side edges of the composite web of fabric; cutting the composite web of fabric, defining discrete garment-sized pieces wherein each discrete garment-sized piece of the composite web of fabric includes at least one neck opening, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, a portion of two pairs of the opposing indentations in the opposing web side edges of the composite web of fabric, two garment end portions, and a pair of opposing piece side edges wherein the opposing piece side edges of the discrete garment-sized piece are proximate a pair of opposing garment bottom edges of the garment; folding the discrete garment-sized piece of the composite web of fabric whereby one of the garment bottom edges of the pair of opposing garment bottom edges is brought into contact with the other garment bottom edge; and, fastening at least a portion of the pair of opposing garment side edges of the front panel to at least a portion of the pair of opposing garment side edges of the back panel to form a pair of garment side seams.

The neck openings are intermediate the two pairs of the opposing indentations. At least a portion of at least one of the opposing garment bottom edges may be hemmed. The garment-sized piece of the web of fabric may comprise at least one sleeve flap having a sleeve opening end edge and a pair of opposing side edges. At least a portion of at least one of the sleeve opening end edges of the sleeve flaps may be hemmed. The openings in the composite web of fabric may be intermediate the opposing indentations.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a first web of fabric including opposing web side edges; providing a second web of fabric including opposing web side edges; aligning the first and second webs of fabric together in a side by side orientation defining an arrangement wherein one of the web side edges of the first web of fabric is adjacent one of the web side edges of the second web of fabric; fastening at least a portion of the adjacent web side edge of the first web of fabric to at least a portion of the adjacent web side edge of the second web of fabric in the side by side orientation, defining at least a portion of a center seam and a composite web of fabric having a pair of opposing web side edges; intermittently cutting the opposing web side edges of the composite web of fabric, defining pairs of opposing indentations in the opposing web side edges of the composite web of fabric; intermittently cutting the composite web of fabric, forming edges defining neck openings in the composite web of fabric wherein the neck openings are intermediate two pairs of the opposing indentations; cutting the composite web of fabric, defining discrete garment-sized pieces wherein each discrete garment- sized piece of the composite web of fabric includes at least one neck opening, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, a portion of the two pairs of the opposing indentations in the opposing web side edges of the composite web of fabric, a pair of sleeve flaps, two garment end portions, and a pair of opposing piece side edges wherein the opposing piece side edges of the discrete garment-sized piece are proximate a pair of opposing garment bottom edges of the garment; folding the discrete garment-sized piece of the composite web of fabric whereby one of the garment bottom edges of the pair of opposing garment bottom edges is brought into contact with the other garment bottom edge; and, fastening at least a portion of the pair of opposing garment side edges of the front panel to at least a portion of the pair of opposing garment side edges of the back panel to form a pair of garment side seams. At least a portion of at least one of the oμpdsing garment bottom edges may be hemmed. Each sleeve flap may include a sleeve opening end edge and a pair of opposing sleeve side edges. At least a portion of at least one of the sleeve opening end edges of the sleeve flaps may be hemmed.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising: providing a first web of fabric including an inner surface, an outer surface, and opposing web side edges; providing a second web of fabric including an inner surface, an outer surface, and opposing web side edges; aligning the first and second webs of fabric together in a side by side orientation defining an arrangement wherein one of the web side edges of the first web of fabric is adjacent one of the web side edges of the second web of fabric; fastening at least a portion of the adjacent web side edge of the first web of fabric to at least a portion of the adjacent web side edge of the second web of fabric in the side by side orientation, defining at least a portion of a center seam and a composite web of fabric having a pair of opposing web side edges; intermittently cutting the opposing web side edges of the composite web of fabric, defining pairs of opposing indentations in the opposing web side edges of the composite web of fabric; intermittently cutting the composite web of fabric, forming edges defining neck openings in the composite web of fabric wherein the neck openings are intermediate two pairs of the opposing indentations; cutting the composite web of fabric, defining discrete garment-sized pieces wherein each discrete garment-sized piece of the composite web of fabric includes at least one neck opening, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, a portion of the two pairs of the opposing indentations in the opposing web side edges of the composite web of fabric, a pair of sleeve flaps, two garment end portions, and a pair of opposing piece side edges wherein the opposing piece side edges of the discrete garment-sized piece are proximate a pair of opposing garment bottom edges of the garment; hemming at least a portion of at least one of the opposing garment bottom edges; folding the discrete garment-sized piece of the composite web of fabric whereby one of the garment bottom edges of the pair of opposing garment bottom edges is brought into contact with the other garment bottom edge; and, fastening at least a portion of the pair of opposing garment side edges of the front panel to at least a portion of the pair of opposing garment side edges of the back panel to form a pair of garment side seams.

Each sleeve flap may include a sleeve opening end edge and a pair of opposing sleeve side edges. At least a portion of at least one of the sleeve opening end edges of the sleeve flaps may be hemmed. A collar may be provided. At least a portion of the collar may be fastened at the neck opening. The collar may be a ribbed knit collar. At least a portion of at least one of the garment side seams may be refastenable. At least a portion of at least one of the garment side seams may be non-refastenable.

The front panel may be slit at least a portion of the distance between the edge of the neck opening and the garment bottom edge thereby defining a pair of edges of a slit. At least a portion of the edges of the slit may be fastened to form a front seam. At least a portion of the front seam may be refastenable. At least a portion of the front seam may be non-refastenable. The back panel may be slit at least a portion of the distance between the edge of the neck opening and the garment bottom edge thereby, defining a pair of edges of a slit. At least a portion of the edges of the slit may be fastened to form a back seam. At least a portion of the back seam may be refastenable. At least a portion of the back seam may be non-refastenable. At least a portion of the edge of the neck opening may be hemmed.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a first web of fabric including a first web side edge and a second web side edge; providing a second web of fabric including a first web side edge and a second web side edge; intermittently cutting the second web side edge of the first web of fabric, forming indentations; intermittently cutting the second web side edge of the second web of fabric, forming indentations; aligning the first and second webs of fabric together in a side by side orientation defining an arrangement wherein the second web side edge of the first web of fabric is adjacent the second web side edge of the second web of fabric and the indentations of the second web side edge of the first web of fabric are adjacent the indentations of the second web side edge of the second web of fabric, thereby forming edges defining neck openings; fastening at least a portion of the second web side edge of the first web of fabric to at least a portion of the second web side edge of the second web of fabric in the side by side orientation, defining at least a portion of a center seam and a composite web of fabric having a pair of opposing web side edges; intermittently cutting the opposing web side edges of the composite web of fabric, defining pairs of opposing indentations in the opposing web side edges of the composite web of fabric; cutting the composite web of fabric, defining discrete garment-sized pieces wherein each discrete garment-sized piece of the composite web of fabric includes at least one neck opening, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, a portion of two pairs of the opposing indentations in the opposing web side edges of the composite web of fabric, two garment end portions, and a pair of opposing piece side edges wherein the opposing piece side edges of the discrete garment-sized piece are proximate a pair of opposing garment bottom edges of the garment; folding the discrete garment-sized piece of the composite web of fabric whereby one of the garment bottom edges of the pair of opposing garment bottom edges is brought into contact with the other garment bottom edge; and, fastening at least a portion of the pair of opposing garment side edges of the front panel to at least a portion of the pair of opposing garment side edges of the back panel to form a pair of garment side seams.

Each sleeve flap may include a sleeve opening end edge and a pair of opposing sleeve side edges. At least a portion of at least one of the sleeve opening end edges of the sleeve flaps may be hemmed. A collar may be provided. At least a portion of the collar may be fastened at the neck opening. The collar may be a ribbed knit collar. At least a portion of at least one of the garment side seams may be refastenable. At least a portion of at least one of the garment side seams may be non-refastenable. At least a portion of at least one of the opposing garment bottom edges may be hemmed. The front panel may be slit at least a portion of the distance between the edge of the neck opening and the garment bottom edge thereby defining a pair of edges of a slit. At least a portion of the edges of the slit may be fastened to form a front seam. At least a portion of the front seam may be refastenable. At least a portion of the front seam may be non-refastenable. The back panel may be slit at least a portion of the distance between the edge of the neck opening and the garment bottom edge thereby defining a pair of edges of a slit. At least a portion of the edges of the slit may be fastened to form a back seam. At least a portion of the back seam may be refastenable. At least a portion of the back seam may be non-refastenable. At least a portion of the edge of the neck opening may be hemmed.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a first web of fabric including opposing web side edges; providing a second web of fabric including opposing web side edges; aligning the first and second webs of fabric together in a face to face orientation, defining an arrangement wherein the web side edges of the first web of fabric are adjacent the web side edges of the second web of fabric, thereby defining a first pair of adjacent web side edges comprising one web side edge of the first web of fabric and one web side edge of the second web of fabric and a second pair of adjacent web side edges comprising the other web side edge of the first web of fabric and the other web side edge of the second web of fabric; fastening at least a portion of the first pair of adjacent web side edges together in the face to face orientation, defining at least a portion of a center seam and a composite web of fabric having a pair of opposing web side edges formed from the second pair of adjacent web side edges; intermittently cutting the composite web of fabric, forming edges defining neck openings in the composite web of fabric; intermittently cutting the opposing web side edges of the composite web of fabric, defining pairs of opposing indentations in the opposing web side edges of the composite web of fabric; cutting the composite web of fabric, defining discrete garment-sized pieces wherein each of the discrete garment-sized pieces of the composite web of fabric includes at least one neck opening, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, a portion of the two pairs of the opposing indentations in the opposing web side edges of the composite web of fabric, a pair of sleeve flaps, two garment end portions, and a pair of opposing piece side edges wherein the opposing piece side edges of the discrete garment-sized piece are proximate a pair of opposing garment bottom edges of the garment; folding the discrete garment- sized piece of the composite web of fabric whereby one of the garment bottom edges of the pair of opposing garment bottom edges is brought into contact with the other garment bottom edge; and, fastening at least a portion of the pair of opposing garment side edges of the front panel to at least a portion of the pair of opposing garment side edges of the back panel to form a pair of garment side seams.

The neck openings may be intermediate the two pairs of the opposing indentations. The discrete garment-sized piece of the composite web of fabric may include at least one sleeve flap having a sleeve opening end edge and a pair of opposing sleeve side edges. The discrete garment-sized piece of the composite web of fabric may include a pair of sleeve flaps wherein each sleeve flap includes a sleeve opening end edge and a pair of opposing sleeve side edges. The composite web of fabric may be unfolded. The discrete garment-sized piece of the composite web of fabric may be unfolded. At least a portion of at least one of the opposing garment bottom edges may be hemmed. At least a portion of at least one of the sleeve opening end edges of the sleeve flaps may be hemmed.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a first web of fabric including opposing web side edges; providing a second web of fabric including opposing web side edges; aligning the first and second webs of fabric together in a face to face orientation, defining an arrangement wherein the web side edges of the first web of fabric are adjacent the web side edges of the second web of fabric, thereby defining a first pair of adjacent web side edges comprising one web side edge of the first web of fabric and one web side edge of the second web of fabric and a second pair of adjacent web side edges comprising the other web side edge of the first web of fabric and the other web side edge of the second web of fabric; fastening at least a portion of the first pair of adjacent web side edges together in the face to face orientation, defining at least a portion of a center seam and a composite web of fabric having a pair of opposing web side edges formed from the second pair of adjacent web side edges; intermittently cutting the opposing web side edges of the composite web of fabric, defining pairs of opposing indentations in the opposing web side edges of the composite web of fabric; intermittently cutting the composite web of fabric, forming edges defining neck openings in the composite web of fabric wherein the neck openings are intermediate two pairs of the opposing indentations; cutting the composite web of fabric, defining discrete garment- sized pieces wherein each of the discrete garment-sized pieces of the composite web of fabric includes at least one neck opening, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, a portion of the two pairs of the opposing indentations in the opposing web side edges of the composite web of fabric, a pair of sleeve flaps, two garment end portions, and a pair of opposing piece side edges wherein the opposing piece side edges of the discrete garment-sized piece are proximate a pair of opposing garment bottom edges of the garment; folding the discrete garment-sized piece of the composite web of fabric whereby one of the garment bottom edges of the pair of opposing garment bottom edges is brought into contact with the other garment bottom edge; and, fastening at least a portion of the pair of opposing garment side edges of the front panel to at least a portion of the pair of opposing garment side edges of the back panel to form a pair of garment side seams.

The composite web of fabric may be unfolded. The discrete garment-sized piece of the composite web of fabric may be unfolded. At least a portion of at least one of the opposing garment bottom edges may be hemmed. At least a portion of at least one of the sleeve opening end edges of the sleeve flaps may be hemmed. A collar may be provided. At least a portion of the collar may be fastened at the edge of the neck opening. The collar may be a ribbed knit collar. At least a portion of at least one of the garment side seams may be refastenable. At least a portion of at least one of the garment side seams may be non-refastenable. The front panel may be slit at least a portion of the distance between the edge of the neck opening and the garment bottom edge, thereby defining a pair of edges of a slit. At least a portion of the edges of the slit may be fastened to form a front seam. At least a portion of the front seam may be refastenable. At least a portion of the front seam may be non-refastenable. The back panel may be slit at least a portion of the distance between the edge of the neck opening and the garment bottom edge, thereby defining a pair of edges of a slit. At least a portion of the edges of the slit may be fastened to form a back seam. At least a portion of the back seam may be refastenable. At least a portion of the back seam may be non-refastenable. At least a portion of the edge of the neck opening may be hemmed.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a first web of fabric including an inner surface, an outer surface, and opposing web side edges; providing a second web of fabric including an inner surface, an outer surface, and opposing web side edges; aligning the first and second webs of fabric together in a face to face orientation defining an arrangement wherein the web side edges of the first web of fabric are adjacent the web side edges of the second web of fabric, thereby defining a first pair of adjacent web side edges and a second pair of adjacent web side edges; fastening at least a portion of the first pair of adjacent web side edges together in the face to face orientation, defining at least a portion of a center seam and a composite web of fabric having a pair of opposing web side edges formed from the second pair of adjacent web side edges; intermittently cutting the opposing web side edges of the composite web of fabric, defining pairs of opposing indentations in the opposing web side edges of the composite web of fabric; intermittently cutting the composite web of fabric, forming edges defining neck openings in the composite web of fabric wherein the neck openings are intermediate two pairs of the opposing indentations; cutting the composite web of fabric, defining discrete garment-sized pieces wherein each of the discrete garment-sized pieces of the composite web of fabric includes at least one neck opening, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, a portion of each of the two pairs of the opposing indentations in the opposing web side edges of the composite web of fabric, a pair of sleeve flaps, two garment end portions, and a pair of opposing piece side edges wherein the opposing piece side edges of the discrete garment-sized piece are proximate a pair of opposing garment bottom edges of the garment; hemming at least a portion of at least one of the opposing garment bottom edges; folding the discrete garment-sized piece of the composite web of fabric whereby one of the garment bottom edges of the pair of opposing garment bottom edges is brought into contact with the other garment bottom edge; and, fastening at least a portion of the pair of opposing garment side edges of the front panel to at least a portion of the pair of opposing garment side edges of the back panel to form a pair of garment side seams.

The composite web of fabric may be unfolded. The discrete garment-sized piece of the composite web of fabric may be unfolded. The discrete garment-sized piece of the composite web of fabric may include at least one sleeve flap having an inner surface, an outer surface, a sleeve opening end edge, and a pair of opposing sleeve side edges. The discrete garment-sized piece of the composite web of fabric may include a pair of sleeve flaps wherein each sleeve flap includes an inner surface, an outer surface, a sleeve opening end edge, and a pair of opposing sleeve side edges. At least a portion of at least one of the sleeve opening end edges of the sleeve flaps may be hemmed.

A collar may be provided. At least a portion of the collar may be fastened at the edge of the opening. The collar may be a ribbed knit collar. At least a portion of at least one of the garment side seams may be refastenable. At least a portion of at least one of the garment side seams may be non-refastenable.

The front panel may be slit at least a portion of the distance between the edge of the neck opening and the garment bottom edge, thereby defining a pair of edges of a slit. At least a portion of the edges of the slit may be fastened to form a front seam. At least a portion of the front seam may be refastenable. At least a portion of the front seam may be non-refastenable. The back panel may be slit at least a portion of the distance between the edge of the neck opening and the garment bottom edge thereby defining a pair of edges of a slit. At least a portion of the edges of the slit may be fastened to form a back seam. At least a portion of the back seam may be refastenable. At least a portion of the back seam may be non-refastenable. At least a portion of the edge of the neck opening may be hemmed.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a first web of fabric including a first web side edge and a second web side edge; providing a second web of fabric including a first web side edge and a second web side edge; intermittently cutting the second web side edge of the first web of fabric, forming indentations; intermittently cutting the second web side edge of the second web of fabric, forming indentations; aligning the first and second webs of fabric together in a face to face orientation, defining an arrangement wherein the first web side edge of the first web of fabric is adjacent the first web side edge of the second web of fabric and the second web side edge of the first web of fabric is adjacent the second web side edge of the second web of fabric wherein the indentations of the second web side edge of the first web of fabric are adjacent the indentations of the second web side edge of the second web of fabric thereby forming edges defining neck openings; fastening at least a portion of the second web side edge of the first web of fabric to at least a portion of the second web side edge of the second web of fabric in the face to face orientation, defining at least a portion of a center seam and a composite web of fabric having a pair of opposing web side edges formed from the first web side edges of the first web of fabric and the first web side edges; intermittently cutting the composite web of fabric, forming edges defining neck openings in the composite web of fabric; intermittently cutting the opposing web side edges of the composite web of fabric, defining pairs of opposing indentations in the opposing web side edges of the composite web of fabric; cutting the composite web of fabric, defining discrete garment-sized pieces wherein each of the discrete garment-sized pieces of the composite web of fabric includes at least one neck opening, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, a portion of the two pairs of the opposing indentations in the opposing web side edges of the composite web of fabric, a pair of sleeve flaps, two garment end portions, and a pair of opposing piece side edges wherein the opposing piece side edges of the discrete garment-sized piece are proximate a pair of opposing garment bottom edges of the garment; folding the discrete garment-sized piece of the composite web of fabric whereby one of the garment bottom edges of the pair of opposing garment bottom edges is brought into contact with the other garment bottom edge; and, fastening at least a portion of the pair of opposing garment side edges of the front panel to at least a portion of the pair of opposing garment side edges of the back panel to form a pair of garment side seams.

A collar may be provided. At least a portion of the collar may be fastened at the edge of the opening. The collar may be a ribbed knit collar. At least a portion of at least one of the garment side seams may be refastenable. At least a portion of at least one of the garment side seams may be non-refastenable. At least a portion of at least one of the opposing garment bottom edges may be hemmed.

The garment 610 is illustrated in Figures 50 and 53. The garment 610 includes opposing inner and outer surfaces 611 and 612, respectively. Within this application, the term "garment" is understood to mean shirt, tee-shirt, wrap, robe, gown, jacket, coat, or any type of upper body covering garment having variable lengths of the garment 610 itself and the sleeves (if any) as well as a variety of neck openings and garment openings, such as plackets. According to the preferred embodiment, see Figures 54 and 55, the garment 610 desirably comprises a front panel 618 and a back panel 624. The front panel 618 has a pair of garment side edges 620 and 621 , a garment bottom edge 622, and a shoulder region 623 opposing the garment bottom edge 622 positioned between the garment side edges 620 and 621. The back panel 624 has a pair of garment side edges 625 and 626, a garment bottom edge 628, and a shoulder region 630 opposing the garment bottom edge 628 positioned between the garment side edges 625 and 626.

The garment side edge 620 is joined to the garment side edge 625 to form the garment side seam 631. The garment side edge 621 is joined to the garment side edge 626 to form the garment side seam 632. A portion of the garment side seams 631 and 632 are left unbonded or not joined, preferably in the shoulder regions 623 and 630, defining two opposing arm openings 647 and 649.

Arm coverings or sleeves 651 and 653 may be attached at the garment end edges

655 and 657 of the sleeves 651 and 653, respectively, so as to surround, at least partially, the arm openings 647 and 649 at the arm opening edges 648 and 650, respectively, of the garment 610. In some embodiments, only one sleeve 651 or 653 may be included in the finished garment 610. The attachment of the sleeves 651 and 653 may be made non- refastenable by means as discussed below. In the alternative, the attachment of the sleeves 651 and 653 may be made refastenable by means as discussed below. The length of the sleeves 651 and 653 may vary from a length intended to at least cover the entire arm of the wearer to a caplet length or shorter. The sleeve opening end edges 659 and 661 of the sleeves 651 and 653, respectively, may be hemmed. For easier manufacture, the sleeve opening end edges 659 and 661 may be left unhemmed, facilitating easy machine cutoff.

In embodiments of the garments 610 that do not include the sleeves 651 and 653, the unattached portion of the garment side edges 620 and 625 and the garment side edges 621 and 626, more specifically the arm opening edges 648 and 650, defining the arm openings 647 and 649, can be hemmed. For easier manufacture, the arm opening edges 648 and 650, defining the arm openings 647 and 649, may be left unhemmed, facilitating easy machine cutoff.

A neck opening 665, defined about its perimeter by edge 667, is located in at least one of the shoulder regions 623 and 630. The neck opening 665 is typically centered between the garment bottom edges 622 and 628 and the garment side edges 620, 621, 625, and 626, although such placement of the neck opening 665 is not required. The neck opening 665 may take on a variety of sizes and shapes, such as circular, oval, triangular, square, rectangular, multi-faceted, asymmetric or irregular, or the like. While the placement of the neck opening 665 may be symmetrical between the shoulder regions 623 and 630, as well as between the arm openings 647 and 649, typically the placement of the neck opening 665 is configured so that a larger portion of the neck opening 665 is located in the front shoulder region 623. Additionally, while the shape of the neck opening 665 can be symmetrical, typically the shape of the neck opening 665 is asymmetrical as dictated by fashion and comfort. In some embodiments of the garment 610, the edge 667 of the neck opening 665 can be hemmed. For easier manufacture, the edge 667 of the neck opening 665 may be left unhemmed, facilitating easy machine cutoff.

Various styles of a collar 669 can also be attached to the edge 667 of the neck opening 665. The attachment of the collar 669 may be made non-refastenable by means as discussed below. In the alternative, the attachment of the collar 669 may be made refastenable by means as discussed below. The collars 669 include, but are not limited to, turtlenecks, mock turtlenecks, cowls, shirt collars, tee-shirt shirt ribbed edging, decorative edging, and the like known in the garment industry.

The garment bottom edges 622 and 628 of the garment 610 may also be hemmed. (Sewing equipment 883 is shown in Figure 50). For easier manufacture, the garment bottom edges 622 and 628 of the garment 610 may be left unhemmed, facilitating easy machine cutoff.

The front panel 618, the back panel 624, or both may be cut or otherwise opened to form a slit 634 or 641 (shown in Figure 53) such as a placket. The garments 610, including one or both slits 634 and 641 , can be used as a wrap, gown, robe, or the like. The slit 634 has two edges 637 and 638. The slit 641 has two edges 642 and 643. Various fastening means, such as adhesive and mechanical type fasteners 670, see the discussion below, may be used to refastenably attach or secure the edges 637 and 638 or the edges 642 and 643 together to form reclosable or refastenable garments 610. The slits 634 and 641 of the front and back panels 618 and 624, respectively, may extend from the edge 667 of the neck opening 665 to the garment bottom edges 622 and 628, respectively. In the alternative, the slits 634 and 641 may extend over only a portion of the panels 618 and 624 between the edge 667 of the neck opening 665 to the garment bottom edges 622 and 628, respectively. When the garment 610 comprises both a slit 634 in the front panel 618 and a slit 641 in the back panel 624, the slits 634 and 641 may be similar or dissimilar in size, structure, shape, and the like. It is understood that the term 'similar' as used herein is interpreted to include identical and varying levels of similarity. It is also understood that the term 'dissimilar' as used herein is interpreted to include different and varying levels of dissimilarity. An alternate embodiment of the invention is illustrated in Figure 52. The garment 682 includes opposing inner and outer surfaces 683 and 685. According to this embodiment, the garment 682 desirably comprises a front panel 692 and a back panel 697. The front panel 692 has a pair of garment side edges 693 and 694, a garment bottom edge 695, and a shoulder region 696 opposing the garment bottom edge 695 positioned between the garment side edges 693 and 694. The back panel 697 has a pair of garment side edges 698 and 699, a garment bottom edge 701 , and a shoulder region 703 opposing the garment bottom edge 701 positioned between the garment side edges 698 and 699.

The garment side edge 693 is joined to the garment side edge 698 to form the garment side seam 704. The garment side edge 694 is joined to the garment side edge 699 to form the garment side seam 705. A portion of the garment side seams 704 and 705 are left unbonded or not joined, preferably in the shoulder regions 696 and 703, defining two opposing arm openings 729 and 731. At least a portion of the shoulder edge 712 of the front panel 692 is joined to at least a portion of the shoulder edge 713 of the back panel 697 to form the shoulder seam 714.

Arm coverings or sleeves 733 and 735 may be attached at the garment end edges

737 and 739 of the sleeves 733 and 735, respectively, so as to surround, at least partially, the arm openings 729 and 731 at the arm opening edges 730 and 732, respectively, of the garment 682. In some embodiments, only one sleeve 733 or 735 may be included in the finished garment 682. The attachment of the sleeves 733 and 735 may be made non- refastenable by means as discussed below. In the alternative, the attachment of the sleeves 733 and 735 may be made refastenable by means as discussed below. The length of the sleeves 733 and 735 may vary from a length intended to cover at least the entire arm of the wearer to a caplet length or shorter. The sleeve opening end edges 741 and 743 of the sleeves 733 and 735, respectively, may be hemmed. For easier manufacture, the sleeve opening end edges 741 and 743 may be left unhemmed, facilitating easy machine cutoff.

In the embodiments of the garments 682 that do not include the sleeves 733 and 735, the unattached portions of the garment side edges 693 and 694 and the garment side edges 698 and 699, more specifically the arm opening edges 730 and 732, defining the arm openings 729 and 731, can be hemmed. For easier manufacture, the arm opening edges 730 and 732, defining the arm openings 729 and 731 , may be left unhemmed, facilitating easy machine cutoff.

A neck opening 747, defined about its perimeter by edge 749, is located in at least one of the shoulder regions 696 and 703. The neck opening 747 is typically centered between the garment bottom edges 695 and 701 and the garment side edges 693 and 694 and the garment side edges 698 and 699, although such placement of the neck opening 747 is not required. The neck opening 747 may take on a variety of sizes and shapes, such as circular, oval, triangular, square, rectangular, multi-faceted, asymmetric or irregular, or the like. While the placement of the neck opening 747 may be symmetrical between the shoulder regions 696 and 703, as well as between the arm openings 729 and 731 , typically, the placement of the neck opening 747 is configured so that a larger portion of the neck opening 747 is located in the front shoulder region 696.

Additionally, while the shape of the neck opening 747 can be symmetrical, typically, the shape of the neck opening 747 is asymmetrical as dictated by fashion and comfort. In some embodiments of the garment 682, the edge 749 of the neck opening 747 can be hemmed. For easier manufacture, the edge 749 of the neck opening 747 may be left unhemmed, facilitating easy machine cutoff.

Various styles of a collar 751 can also be attached to the edge 749 of the neck opening 747. The attachment of the collar 751 may be made non-refastenable by means as discussed below. In the alternative, the attachment of the collar 751 may be made refastenable by means as discussed below. The collars 751 include, but are not limited to, turtlenecks, mock turtlenecks, cowls, shirt collars, tee-shirt shirt ribbed edging, decorative edging, and the like known in the garment industry.

The garment bottom edges 695 and 701 of the garment 682 may also be hemmed. For easier manufacture, the garment bottom edges 695 and 701 of the garment 682 may be left unhemmed, facilitating easy machine cutoff.

The front panel 692, the back panel 697, or both may be cut or otherwise opened to form a slit 707 or 754 (shown in Figure 52) such as a placket. The garment 682 including one or both slits 707 and 754 can be used as a wrap, gown, robe, or the like. The slit 707 has two edges 718 and 719. The slit 754 has two edges 755 and 757. Various fastening means, such as adhesive and mechanical type fasteners 752, see the discussion below, may be used to refastenably attach or secure the edges 718 and 719 or the edges 755 and 757 together to form reclosable or refastenable garments 682. The slits 707 and 754 of the front and back panels 692 and 697, respectively, may extend from the edge 749 of the neck opening 747 to the garment bottom edges 695 and 701 , respectively. In the alternative, the slits 707 and 754 may extend over only a portion of the panels 692 and 697 between the edge 749 of the neck opening 747 to the garment bottom edges 695 and 701, respectively. When the garment 682 comprises both a slit 707 in the front panel 692 and a slit 754 in the back panel 697, the slits 707 and 754 may be similar or dissimilar in size, structure, shape, and the like. It is understood that the term 'similar' as used herein is interpreted to include identical and varying levels of similarity. It is also understood that the term 'dissimilar' as used herein is interpreted to include different and varying levels of dissimilarity.

Another embodiment of the present invention is a continuous process for the manufacture of a garment 610 (see Figure 50) for wearing about the upper body comprising a garment 610 having at least a front panel 618, a back panel 624, a neck opening 665 defined about its perimeter by edge 667, arm openings 647 and 649 defined about their perimeters by arm opening edges 648 and 650, respectively, a lower body opening 633 defined about its perimeter by garment bottom edges 622 and 628. The garment 610 comprises an inner surface 611 and an outer surface 612. The garment 610 may comprise a single layer web of fabric 614 or may comprise a multi-layer laminate web of fabric 614. In some embodiments, the garment 610 may comprise multiple layers of the web of fabric 614. The present invention requires at least one web of fabric 614 in a single continuous process to create garments 610.

In one embodiment of the present invention (see Figure 50), one web of fabric 614 of sufficient width of fabric to make the garment 610 is provided to produce the garments 610. The desired web of fabric 614 is nonwoven although any disposable or washable fabric can be used. (See the discussion below). The web of fabric 614 is typically unwound from a roll or other source (not shown).

The web of fabric 614 is desirably compliant and soft feeling to the wearer. The following description of materials from which the web of fabric 614 may be formed would also be used for the materials to form the inner surface 611 and the outer surface 612 of a multi-layer laminate web of fabric 614.

The web of fabric 614 may be any suitable material as earlier described for the web of fabric 15.

The web of fabric 614 may be constructed of a single spunbonded polypropylene nonwoven web having a basis weight of about 0.5 oz/yd² (17 gsm) to about 1.5 oz/yd² (51 gsm). In the structure of the garment 610, the web of fabric 614 desirably comprises a material having a basis weight of from about 0.5 oz/yd² (17 gsm) to about 1.5 oz/yd² (51 gsm). Lesser or greater basis weights may be used in the other regions of the garment 610, such as the sleeves 651 and 653, the cuffs 660 and 662, and the collar 669. Since the garment 610 is typically intended for active wear, the web of fabric 614, or portions thereof, can be made of materials having a basis weight that is abrasion resistant.

For embodiments wherein the web of fabric 614 is a multi-layer laminate, both the outer surface 612 and the inner surface 611 are desirably compliant and soft feeling to the wearer. The following description of materials from which the outer surface 612 may be formed may also be used to form the material of the inner surface 611.

The outer surface 612 may be any suitable gatherable material as earlier described for the outer surface 13.

Alternatively, the outer surface 612 may be derived from a spunbonded web. In a desired embodiment, the outer surface 612 is spunbonded polypropylene nonwoven, meltblown polypropylene nonwoven and spunbonded polypropylene nonwoven laminate (SMS). The total basis weight is from about 0.4 to about 1.0 osy (more desirably 0.6 osy) and is made with about 86% spunbonded nonwoven and 14% meltblown nonwoven. A pigment such as titanium dioxide may be incorporated into the outer surface 612 and the inner surface 611. Such spunbonded meltblown nonwoven laminate material is available from Kimberly-Clark Corporation, Roswell, GA. The basis weight of the SMS material may vary from about 0.4 to about 1.0 osy.

The inner surface 611 may be any soft and flexible sheet as earlier described for the inner surface 11. The outer surface 612 and the inner surface 611 may be further dyed, pigmented, or imprinted with any suitable color. Desirably, the inner surface 611 is either dyed, pigmented, or printed with a material which does not irritate or bleed the color onto the skin of the wearer.

The web of fabric 614 includes a pair of opposing web side edges 635 and 636. A repeating series of openings 645 is cut by a die cutter 613 into the web of fabric 614. (See Figure 50). The location of the openings 645 in the web of fabric 614 corresponds to the arm openings 647 and 649 of the finished garment 610. The openings 645 may be produced by a die cut operation, an ultrasonic operation, or any other suitable method of operation. The material to be removed from the openings 645 may be removed by any method known in the art, desirably a vacuum source (not shown).

The openings 645 may take on a variety of sizes and shapes, such as slit, circular, oval, triangular, square, rectangular, multi-faceted, asymmetric or irregular, or the like. The pattern of the openings 645 is restricted only by fashion and the minimum amount of the web of fabric 614 that must remain having a sufficient integrity to withstand the remaining steps or operations of the process of manufacture. It is also understood that the arm openings 647 and 649 may take on a variety of sizes and shapes, such as slit, circular, oval, triangular, square, rectangular, multi-faceted, asymmetric or irregular, or the like. The pattern of the arm openings 647 and 649 is restricted only by fashion and the minimum amount of the web of fabric 614 that must remain having a sufficient integrity to withstand the remaining steps or operations of the process of manufacture.

The web of fabric 614 is cut into discrete garment-sized pieces 615 by the die cutter 613. The web side edges 635 and 636 of the web of fabric 614 become the garment bottom edges 622 and 628, respectively, of the discrete garment-sized pieces 615. It is understood that while the web side edges 635 and 636 may typically become the garment bottom edges 622 and 628, respectively, in the finished garment 610, fabric may be removed from or added to the web side edges 635 and 636 to create the garment bottom edges 622 and 628, respectively, in the finished garment 610. The piece side edges 627 and 629 of the discrete garment-sized pieces 615 become the garment side edges 620 and 625 and the garment side edges 621 and 626, respectively, in the finished garments 610. The garment side edges 620 and 625 and the garment side edges 621 and 626 created by the cutting operation are located such that the openings 645 are cut, producing the arm opening edges 648 and 650 in the garment side edges 620 and 625 and the garment side edges 621 and 626, respectively. It is understood that while Figure 50 shows the die cutter 613 cutting the web of fabric 614 into discrete garment-sized pieces 615 and the openings 645, these operations could be performed by separate devices and at different stages within the manufacturing process.

In some embodiments of the present invention, the web of fabric 614 is cut into discrete garment-sized pieces 615 prior to the performance of an operation to create arm openings 647 and 649. (See Figures 60, 63, and 64). A pair of opposing indentations 644 and 646 are cut into the garment side edges 620 and 625 and the garment side edges 621 and 626, respectively, of the discrete garment-sized pieces 615. The location of the opposing indentations 644 and 646 corresponds to the arm openings 647 and 649, defined by the arm opening edges 648 and 650, respectively, of the finished garments 610. The opposing indentations 644 and 646 may be produced by a die cut operation, an ultrasonic operation, or any other suitable method of operation. The material to be removed from the opposing indentations 644 and 646 may be removed by any method known in the art, desirably a vacuum source.

The opposing indentations 644 and 646 may take on a variety of sizes and shapes, such as slit, circular, oval, triangular, square, rectangular, multi-faceted, asymmetric or irregular, or the like. The pattern of the opposing indentations 644 and 646 is restricted only by fashion and the minimum amount of the web of fabric 614 that must remain having a sufficient integrity to withstand the remaining steps or operations of the process of manufacture. The arm openings 647 and 649, alternatively, the opposing indentations 644 and 646, may be similar or dissimilar in shape, structure, size, and the like from each other within the finished garment 610.

In some embodiments, the operation of cutting the opposing indentations 644 and 646 (or, alternatively, the openings 645) into the discrete garment-sized pieces 615 (or, the web of fabric 614) may be eliminated. As the pattern of the garment 610 is restricted only by fashion and the minimum amount of the discrete garment-sized pieces 615 (or, the web of fabric 614) that must remain having a sufficient integrity to withstand the remaining operations or steps of the process of manufacture, one can simply design the garment 610 such that the operation of cutting the opposing indentations 644 and 646 (or, the openings 645) into the garment side edges 620 and 625 and the garment side edges 621 and 626 (or, the web of fabric 614) is not required. As discussed above, the arm openings 647 and 649 may be created by leaving a portion of the garment side edges 620 and 625 and the garment side edges 621 and 626, respectively, unattached.

A repeating series of openings 664 are cut by the die cutter 613 into the web of fabric 614. The location of the opening 664 corresponds to the neck opening 665 in the finished garment 610. The openings 664 may be produced by a die cut operation, an ultrasonic operation, or any other suitable method of operation. It is understood that while Figure 50 shows the die cutter 613 cutting the opening 664 and the opening 645, these cutting operations (also, the operation for cutting the opposing indentations 644 and 646) could be performed by separate devices and at different stages within the manufacturing process. The material to be removed from the openings 664 may be removed by any method known in the art, desirably a vacuum source (not shown). The opening 664 may take on a variety of sizes and shapes, such as slit, circular, oval, triangular, square, rectangular, multi-faceted, asymmetric or irregular, or the like. The pattern of the openings 664 is restricted only by fashion and the minimum amount of the web of fabric 614 that must remain having a sufficient integrity to withstand the remaining steps or operations of the process of manufacture.

The placement of the opening 664 in relation to a pair of opposing arm openings 647 and 649 (or, alternatively, a pair of opposing indentations 644 and 646), while in a typical garment 610, the opening 664 is located between the pair of opposing arm openings 647 and 649 (or, alternatively, the pair of opposing indentations 644 and 646), is restricted only by fashion and the minimum amount of the web of fabric 614 (or, alternatively, the discrete garment-sized pieces 615) that must remain having sufficient integrity to withstand the remaining steps or operations of the process of manufacture. For example, the placement of the opening 664 between the pair of opposing arm openings 647 and 649 may be symmetrically or asymmetrically located.

The web of fabric 614 is cut by the die cutter 613 into discrete garment-sized pieces 615 wherein each discrete garment-sized piece 615 contains at least one opening 664, one pair of arm openings 647 and 649, one pair of opposing web side edges 635 and 636, and opposing garment end portions 639 and 640. The location of the opposing web side edges 635 and 636 of the web of fabric 614 (or, alternatively, the discrete garment- sized piece 615) corresponds to the garment bottom edge 622 of the front panel 618 and the garment bottom edge 628 of the back panel 624, respectively, in the finished garment 610. It is understood that while the web side edges 635 and 636 of the web of fabric 614 (or, alternatively, the discrete garment-sized piece 615) may typically become the garment bottom edges 622 and 628 in the flnished garment 610, fabric may be removed from or added to the web side edges 635 and 636 of the web of fabric 614 (or, alternatively, the discrete garment-sized piece 615) to create the garment bottom edges 622 and 628 in the finished garment 610. The opposing garment end portions 639 and 640 are adjacent to the garment bottom edge 622 of the front panel 618 and the garment bottom edge 628 of the back panel 624, respectively, in the finished garment 610.

Each discrete garment-sized piece 615 of the web of fabric 614 is transported, typically by vacuum screens, belts, or conveyors, through hemming, folding, and fastening operations (not shown). The folding operations are desirably carried out by tuckers and folders, as well as any other known means. The discrete garment-sized piece 615 of the web of fabric 614 is folded by a folder 619 so as to bring together the opposing garment end portions 639 and 640 such that the garment side edge 620 of the front panel 618 is folded or otherwise brought into contact with the garment side edge 625 of the back panel 624. The garment side edge 621 of the front panel 618 is folded or otherwise brought into contact with the garment side edge 626 of the back panel 624.

The mating of the garment side edge 620 and the garment side edge 625 as well as the garment side edge 621 and the garment side edge 626 form the garment side seams 631 and 632, respectively, of the garment 610. It may be desirable to redirect (or reorient) the discrete garment-sized piece 615 of the web of fabric 614 to allow easy bonding of the garment side seams 631 and 632 of the garment 610. The turning operations are desirably carried out by turn rolls and turn tables, as well as any other known means. The discrete garment-sized piece 615 of the web of fabric 614 may be reoriented 90 degrees (not shown).

In various embodiments of the present invention, one or both of the garment side seams 631 and 632 can be constructed as non-refastenable seams or as refastenable seams. Any excess material of the web of fabric 614 may be removed from the edges of the garment side seams 631 and 632 to reduce and smooth out the garment side seams 631 and 632. The non-refastenable garment side seams 631 and 632 may be formed by any suitable means such as ultrasonic sealing, adhesive bonding, tape, heat sealing, sewing, or any method of fastening known in the art. (Sewing equipment 884 is shown in Figure 50). The non-refastenable garment side seams 631 and 632 may be constructed on a continuous or intermittent basis. One suitable method of forming such garment side seams 631 and 632 is disclosed in U.S. Patent No. 4,938,753 issued July 3, 1990, to Van Gompel et al., which is incorporated herein by reference. The garment side seams 631 and 632 may be bonded together to form non-refastenable garment side seams 631 and 632.

In other embodiments of the present invention, the garment side edges 620 and 625 and the garment side edges 621 and 626 of the garment 610 may be held together in the finished garment 610 to form refastenable garment side seams 631 and 632, respectively. The refastenable means for securing the garment side edges 620 and 625 and the garment side edges 621 and 626 of the garment 610 include refastenable adhesive and mechanical type fasteners 670. The adhesive and mechanical type fasteners 670 include buttons and button holes, snaps, buckles, clasps, hooks and loops, end extensions, tabs, tape, and the like which are designed or adapted to interlock or engage some type of a complimentary device or the outer surface 612 or the inner surface 611 of the garment 610.

In addition, elasticized fasteners 670 may also be used in assuring better fit of the garment 610. If the garment 610 includes refastenable garment side seams 631 and 632, the refastenable means are desirably strategically placed on the web of fabric 614 before the web of fabric 614 is cut into discrete garment-sized pieces 615. The folding and redirection operations may be eliminated when refastenable garment side seams 631 and 632 are included in the garment 610. However, there may be packaging reasons for which one would still carry out these two steps.

The garment side seams 631 and 632 of the present invention may take on a variety of structures or configurations known in the art. One embodiment of the garment side seams 631 and 632 is an out-turned configuration as illustrated in Figure 68. Such configured garment side seams 631 and 632 are formed by securing together at least a portion of the out-turned portions of the garment side edges 620 and 625 and the garment side edges 621 and 626, respectively. The inner surface 611 of the garment side edges 620 and 621 of the front panel 618 and the garment side edges 625 and 626 of the back panel 624, respectively, are brought into contact with each other, respectively. Another embodiment of the garment side seams 631 and 632 is an in-turned configuration as illustrated in Figure 69. Such configured garment side seams 631 and 632 are formed by securing together at least a portion of the in-turned portions of the garment side edges 620 and 625 and the garment side edges 621 and 626, respectively. The outer surface 612 of the garment side edges 620 and 621 of the front panel 618 and the garment side edges 625 and 626 of the back panel 624 are brought into contact with each other, respectively.

Another embodiment of the garment side seams 631 and 632 is an over-lapped configuration as illustrated in Figure 67. Such configured garment side seams 631 and 632 are formed by securing together at least a portion of the over-lapped portions of the garment side edges 620 and 625 and the garment side edges 621 and 626, respectively. The inner surface 611 of one of the garment side edges 620 and 625 and one of the garment side edges 621 and 626 are brought into contact with the outer surface 612 of the other garment side edge of each pair of garment side edges.

Another embodiment of the garment side seams 631 and 632 is an over-lapped configuration as illustrated in Figure 70. Such a configured garment side seam 631 is formed by folding the garment side edge 620 or the garment side edge 625. The outer surface 612 of the folded portion and the inner surface 611 of the unfolded portion of the garment side edge 620 or the garment side edge 625 and the corresponding portion of the front panel 618 or the back panel 624, respectively, are brought into contact with the inner surface 611 or the outer surface 612 of the non-folded garment side edge 625 or the garment side edge 620 and the corresponding portion of the back panel 624 or the front panel 618.

The garment side seam 632 is formed by folding back the garment side edge 621 or the garment side edge 626. The outer surface 612 of the folded portion and the inner surface 611 of the unfolded portion of the garment side edges 621 or the garment side edge 626 and the corresponding portion of the front panel 618 or the back panel 624, respectively, is brought into contact with the inner surface 611 or the outer surface 612 of the non-folded garment side edge 626 or the garment side edge 621 and^'the corresponding portion of the back panel 624 or the front panel 618. It is understood that the folding back of a garment side edge 620, 621, 625, or 626 could be performed such that the inner surface 611 would be exposed along the fold.

The garment end portions 639 and 640 of the discrete garment-sized pieces 615 of the web of fabric 614 may be hemmed in the finished garment 610. The garment end portions 639 and 640 can be hemmed by any method or style known in the art. In some embodiments, it may be desirable to leave the garment end portions 639 and 640 unhemmed. The garment bottom edges 622 and 628 of the discrete garment-sized pieces 615 of the web of fabric 614 may be hemmed in the finished garment 610. The garment bottom edges 622 and 628 can be hemmed by any method or style known in the art. In some embodiments, it may be desirable to leave the garment bottom edges 622 and 628 unhemmed.

As shown in Figures 54 and 55, the garment 610 may include sleeves 651 and 653. In some embodiments, only one sleeve 651 or 653 may be included in the finished garment 610. The sleeves 651 and 653 are made of pieces of the sleeve web fabric 652 and 654, the same or different from the material of the web of fabric 614. The pieces of the sleeve web fabric 652 and 654 are provided as sleeve-sized pieces 617 cut from a sleeve web of fabric 616. The pieces of the sleeve web fabric 652 and 654 may take on a variety of sizes and shapes, such as circular, oval, triangular, square, rectangular, multi- faceted, asymmetric or irregular, or the like. The pattern of the sleeve web fabric 652 and 654 is restricted only by fashion and the minimum amount of the material of the pieces of the sleeve web fabric 652 and 654 that is necessary to complete the remaining steps or operations of the process of manufacture. The sleeves 651 and 653, alternately the pieces of sleeve web fabric 652 and 654, may be similar or dissimilar in shape, structure, material, size, and the like from each other within the finished garment 610. In some embodiments, only one sleeve 651 or 653 may be included in the finished garment 610.

The piece of a sleeve web fabric 652 has a pair of sleeve side edges 656 and 658, a garment end edge 655, and a sleeve opening end edge 659 opposite the garment end edge 655. It is understood that the piece of the sleeve web fabric 652 could be provided as a tube having a garment end edge 655 and a sleeve opening end edge 659 opposite the garment end edge 655. It is also understood that the piece of the sleeve web fabric 652 could be made of multiple pieces of material or materials. The piece of the sleeve web fabric 652 is folded so as to bring together the opposing sleeve side edges 656 and 658 to form a sleeve seam 668 of the sleeve 651.

The piece of a sleeve web fabric 654 has a pair of sleeve side edges 663 and 666, a garment end edge 657, and a sleeve opening end edge 661 opposite the garment end edge 657. It is understood that the piece of the sleeve web fabric 654 could be provided as a tube having a garment end edge 657 and a sleeve opening end edge 661 opposite the garment end edge 657. It is also understood that the piece of the sleeve web fabric 654 could be made of multiple pieces of material or materials. The piece of the sleeve web fabric 654 is folded so as to bring together the opposing sleeve side edges 663 and 666 to form a sleeve seam 671 of the sleeve 653.

It may be desirable to redirect (or reorient) the sleeve-sized pieces 617 of the sleeve web of fabric 616 to allow easy fastening of the sleeve seams 668 and 671 of the sleeves 651 and 653, respectively, of the garment 610. The turning operations are desirably carried out by turn rolls and turn tables, as well as any other known means. The sleeve-sized pieces 617 of the sleeve web of fabric 616 (pieces of the sleeve web fabric 652 and 654) may be reoriented 90 degrees (not shown). The sleeve seams 668 and 671 can be non-refastenable seams or refastenable seams. Any excess material of the pieces of the sleeve web fabric 652 and 654 can be removed from their respective edges of the sleeve seams 668 and 671 to reduce and smooth out the sleeve seams 668 and 671. The non-refastenable sleeve seams 668 and 671 may be formed by any suitable means such as ultrasonic sealing, adhesive bonding, tape, heat sealing, sewing, or any method of fastening known in the art, as discussed above. The non-refastenable sleeve seams 668 and 671 may be constructed on a continuous or intermittent basis.

In other embodiments, the opposing pair of the sleeve side edges 656 and 658 and the opposing pair of the sleeve side edges 663 and 666 of the sleeves 651 and 653, respectively, may be held together in the finished garment 610 to form refastenable sleeve seams 668 and 671. The refastenable means for securing the opposing pair of the sleeve side edges 656 and 658 and the opposing pair of the sleeve side edges 663 and 666 of the sleeves 651 and 653, respectively, include refastenable adhesive and mechanical type fasteners 670. The adhesive and mechanical type fasteners 670 include buttons and button holes, snaps, buckles, clasps, hooks and loops, end extensions, tabs, tape, and the like which are designed or adapted to interlock or engage some type of a complimentary device or the inner surface 611 or the outer surface 612 of the garment 610. The refastenable sleeve seams 668 and 671 may be constructed on a continuous or intermittent basis.

In addition, elasticized fasteners 670 may also be used in assuring better fit of the sleeves 651 and 653 of the garment 610. If the garment 610 includes refastenable sleeve seams 668 and 671 , the refastenable means are desirably strategically placed on the pieces of the sleeve web fabric 652 and 654 before the sleeve web of fabric 616 is cut into discrete sleeve-sized pieces 617. The folding and redirection operations may be eliminated when refastenable sleeve seams 668 and 671 are included in the garment 610. However, there may be packaging reasons for which one would still carry out these two steps.

The sleeve seams 668 and 671 of the present invention may take on a variety of structures or configurations known in the art. One embodiment of the sleeve seams 668 and 671 is an out-turned configuration as illustrated in Figure 68. Such configured sleeve seams 668 and 671 are formed by securing together at least a portion of the out-turned portions of the sleeve side edges 656 and 658 and the sleeve side edges 663 and 666 of the sleeves 651 and 653, respectively. The inner surface 611 of the sleeve side edges 656 and 658 and the sleeve side edges 663 and 666 of the sleeves 651 and 653, respectively, are brought into contact with each other of the pair.

Another embodiment of the sleeve seams 668 and 671 is an in-turned configuration as illustrated in Figure 69. Such configured sleeve seams 668 and 671 are formed by securing together at least a portion of the in-turned portions of the sleeve side edges 656 and 658 and the sleeve side edges 663 and 666 of the sleeves 651 and 653, respectively. The outer surface 612 of the sleeve side edges 656 and 658 and the sleeve side edges 663 and 666 of sleeves 651 and 653, respectively, are brought into contact with each other of the pair.

Another embodiment of the sleeve seams 668 and 671 is an over-lapped configuration as illustrated in Figure 67. Such configured sleeve seams 668 and 671 are formed by securing together at least a portion of the over-lapped portions of the sleeve side edges 656 and 658 and the sleeve side edges 663 and 666 of the sleeves 651 and 653, respectively. The inner surface 611 of one of the sleeve side edges 656 or 658 and the sleeve side edges 663 or 666 of the sleeves 651 and 653, respectively, is brought into contact with the outer surface 612 of the other sleeve side edge 656 or 658 and the sleeve side edge 663 or 666 of the sleeve 651 and 653, respectively.

Another embodiment of the sleeve seams 668 and 671 is an over-lapped configuration as illustrated in Figure 70. Such configured sleeve seams 668 and 671 are formed by folding back the sleeve side edge 656 or 658 and the sleeve side edge 663 or 666 of the sleeves 651 and 653, respectively. The outer surface 612 of the folded portions and the inner surface of the unfolded portions of the sleeve side edge 656 or 658 and the sleeve side edge 663 or 666 and the corresponding portions of the sleeves 651 and 653, respectively, are brought into contact with the inner surface 611 or the outer surface 612 of the non-folded sleeve side edge 656 or 658 and the sleeve side edge 663 or 666 and the corresponding portions of the sleeves 651 and 653, respectively. It is understood that the folding back of the sleeve side edge 656, 658, 663, or 666 could be performed such that the inner surface 611 would be exposed along the fold.

The garment end edges 655 and 657 of the pieces of the sleeve web fabric 652 and 654, respectively, may be attached to the arm opening edges 648 and 650 of the arm openings 647 and 649, respectively, of the garment 610. The attachment of the pieces of the sleeve web fabric 652 and 654 may be made non-refastenable by means as discussed above. In the alternative, the attachment of the pieces of the sleeve web fabric 652 and 654 may be made refastenable by means as discussed above.

The sleeves 651 and 653 may be constructed before attachment to the garment 610. The garment end edges 655 and 657 of the sleeves 651 and 653, respectively, may be attached to the arm opening edges 648 and 650 of the arm openings 647 and 649, respectively, of the garment 610, forming arm opening seams 672 and 673, respectively. The attachment of the sleeves 651 and 653 may be made non-refastenable by means as discussed above. (Sewing equipment 882 is shown in Figure 50). In the alternative, the attachment of the sleeves 651 and 653 may be made refastenable by means as discussed above.

The arm opening seams 672 and 673 of the present invention may take on a variety of structures or configurations. One embodiment of the arm opening seams 672 and 673 is an out-turned configuration as illustrated in Figure 68. Such configured arm opening seams 672 and 673 are formed by securing together at least a portion of the out- turned portions of the garment end edge 655 and the arm opening edge 648 and the garment end edge 657 and the arm opening edge 650, respectively, of the garment 610. The inner surface 611 of the garment end edges 655 and 657 of the sleeves 651 and 653, respectively, are brought into contact with the inner surface 611 of the arm opening edges 648 and 650, respectively.

Another embodiment of the arm opening seams 672 and 673 is an in-turned configuration as illustrated in Figure 69. Such configured arm opening seams 672 and 673 are formed by securing together at least a portion of the in-turned portions of the garment end edge 655 and the arm opening edge 648 and the garment end edge 657 and the arm opening edge 650, respectively, of the garment 610. The outer surface 612 of the garment end edges 655 and 657 of the sleeves 651 and 653, respectively, are brought into contact with the outer surface 612 of the arm opening edges 648 and 650, respectively.

Another embodiment of the arm opening seams 672 and 673 is an over-lapped configuration as illustrated in Figure 68. Such configured arm opening seams 672 and 673 are formed by securing together at least a portion of the over-lapped portions of the garment end edges 655 and the arm opening edge 648 and the garment end edge 657 and the arm opening edge 650, respectively, of the sleeves 651 and 653, respectively. The inner surface 611 of one of the garment end edge 655 or the arm opening edge 648 and the garment end edge 657 or the arm opening edge 650, is brought into contact with the outer surface 612 of the other garment end edge 655 or the arm opening edge 648 and the garment end edge 657 or the arm opening edge 650 of the sleeves 651 and 653, respectively.

Another embodiment of the arm opening seams 672 and 673 is an over-lapped configuration as illustrated in Figure 70. Such configured arm opening seams 672 and 673 are formed by folding back the garment end edge 655 or the arm opening edge 648 and the garment end edge 657 or the arm opening edge 650. The outer surface 612 of the folded portions and the inner surface 611 of the unfolded portions of the garment end edge 655 or the arm opening edge 648 and the garment end edge 657 or the arm opening edge 650 and the corresponding portions of the sleeves 651 and 653 or the front and back panels 618 and 624 are brought into contact with the inner surface 611 or the outer surface 612 of the unfolded garment end edge or arm opening edge and the corresponding portions of the sleeves 651 and 653 or the front and back panels 618 and 624. It is understood that the folding back of a garment end edge 655 or 657 or an arm opening edge 648 or 650 could be performed such that the inner surface 611 would be exposed along the fold.

The sleeve opening end edges 659 and 661 of the sleeves 651 and 653, respectively, (in the alternative, the sleeve opening end edges 659 and 661 of the pieces of the sleeve web fabric 652 and 654) can be hemmed by any method or style known in the art. In some embodiments, it may be desirable to leave the sleeve opening end edges

659 and 661 unhemmed.

In other embodiments, cuffs 660 and 662 may be attached to the sleeve opening end edges 659 and 661 , respectively, of the sleeves 651 and 653, respectively, of the garment 610, forming cuff seams 675 and 677, respectively. The attachment of the cuffs

660 and 662 may be made non-refastenable by means as discussed above. In the alternative, the attachment of the cuffs 660 and 662 may be made refastenable by means as discussed above. The cuff seams 675 and 677 may be constructed on a continuous or intermittent basis. The cuffs 660 and 662 may take on a variety of sizes and shapes. The cuffs 660 and 662 may be similar or dissimilar in shape, structure, material, size, and the like from each other within the finished garment 610. The pattern of the cuffs 660 and 662 is restricted only by the fashion and the minimum amount of the material of the cuffs 660 and 662 that is necessary to complete the remaining steps or operations of the process of manufacture.

The cuff seams 675 and 677 of the present invention may take on a variety of structures or configurations known in the art. One embodiment of the cuff seams 675 and 677 is an out-turned configuration as illustrated in Figure 68. Such configured cuff seams 675 and 677 are formed by securing together at least a portion of the out-turned portions of the cuff edge 674 and the sleeve opening end edge 659 and the cuff edge 676 and the sleeve opening end edge 661 , respectively, of the garment 610. The inner surface 611 of the cuff edges 674 and 676 of the cuffs 660 and 662, respectively, are brought into contact with the inner surface 611 of the sleeve opening edges 659 and 661, of the sleeves 651 and 653, respectively. Another embodiment of the cuff seams 675 and 677 is an in-turned configuration as illustrated in Figure 69. Such configured cuff seams 675 and 677 are formed by securing together at least a portion of the in-turned portions of the cuff edge 674 and the sleeve opening edge 659 and the cuff edge 676 and the sleeve opening edge 661 , respectively, of the garment 610. The outer surface 612 of the cuff edges 674 and 676 of the cuffs 660 and 662, respectively, are brought into contact with the outer surface 612 of the sleeve opening edges 659 and 661 of the sleeves 651 and 653, respectively.

Another embodiment of the cuff seams 675 and 677 is an over-lapped configuration as illustrated in Figure 67. Such configured cuff seams 675 and 677 are formed by securing together at least a portion of the over-lapped portions of the cuff edge 674 and the sleeve opening edge 659 and the cuff edge 676 and the sleeve opening edge 661 of the sleeves 651 and 653, respectively. The inner surface 611 of one of the cuff edge 674 or the sleeve opening edge 659 and the cuff edge 676 or the sleeve opening edge 661 , is brought into contact with the outer surface 612 of the other cuff edge 674 or the sleeve opening edge 659 and the cuff edge 676 or the sleeve opening edge 661 of the sleeves 651 and 653, respectively.

Another embodiment of the cuff seams 675 and 677 is an over-lapped configuration as illustrated in Figure 70. Such configured cuff seams 675 and 677 are formed by folding back the cuff edge 674 or the sleeve opening end edge 659 and the cuff edge 676 or the sleeve opening end edge 661 of the sleeves 651 and 653, respectively. The outer surface 612 of the folded portions and the inner surface 611 of the unfolded portions of the cuff edge 674 or the sleeve opening end edge 659 and the cuff edge 676 or the sleeve opening end edge 661 and the corresponding portions of the cuffs 660 and 662 or the sleeves 651 and 653 are brought into contact with the inner surface 611 or the outer surface 612 of the unfolded cuff edge 674 or 676 or the sleeve opening end edge 659 or 661 and the corresponding portions of the cuffs 660 and 662 or the sleeves 651 and 653. It is understood that the folding back of a cuff edge 674 or 676 or a sleeve opening end edge 659 or 661 could be performed such that the inner surface 611 would be exposed along the fold.

The materials used for the cuffs 660 and 662 may be the same as the materials used for the other portions of the garment 610. In some embodiments, it is desirable that the materials used for the cuffs 660 and 662 have an elastic element such that the cuffs 660 and 662 will conform to the portion of the wearer's arms that come into contact with the cuffs 660 and 662.

The edge 667 of the neck opening 665 can be hemmed by any method or style known in the art. In some embodiments, it may be desirable to leave the edge 667 of the neck opening 665 unhemmed.

In other embodiments, a collar 669 may be attached to the edge 667 of the neck opening 665 of the garment 610, thereby forming a collar seam 679. The attachment of the collar 669 may be made non-refastenable by means as discussed above. (Sewing equipment 681 is shown in Figure 50). In the alternative, the attachment of the collar 669 may be made refastenable by means as discussed above. The collar seam 679 may be constructed on a continuous or intermittent basis. The collar 669 may take on a variety of sizes and shapes. The pattern of the collar 669 is restricted only by the fashion and the minimum amount of the material of the collar 669 that is necessary to complete the remaining steps or operations of the process of manufacture.

The collar seam 679 of the present invention may take on a variety of structures or configurations known in the art. One embodiment of the collar seam 679 is an out-turned configuration as illustrated in Figure 68. Such a configured collar seam 679 is formed by securing together at least a portion of the out-turned portions of the collar edge 678 of the collar 669 and the edge 667 of the neck opening 665 of the garment 610. The inner surface 611 of the collar edge 678 of the collar 669 is brought into contact with the inner surface 611 of the edge 667 of the neck opening 665.

Another embodiment of the collar seam 679 is an in-turned configuration as illustrated in Figure 69. Such a configured collar seam 679 is formed by securing together at least a portion of the in-turned portions of the collar edge 678 of the collar 669 and the edge 667 of the neck opening 665 of the garment 610. The outer surface 612 of the collar edge 678 of the collar 669 is brought into contact with the outer surface 612 of the edge 667 of the neck opening 665.

Another embodiment of the collar seam 679 is an over-lapped configuration as illustrated in Figure 67. Such a configured collar seam 679 is formed by securing together at least a portion of the over-lapped portions of the collar edge 678 of the collar 669 and the edge 667 of the neck opening 665 of the garment 610. The inner surface 611 of the collar edge 678 of the collar 669 or the edge 667 of the neck opening 665 is brought into contact with the outer surface 612 of the other, the collar edge 678 or the edge 667.

Another embodiment of the collar seam 679 is an over-lapped configuration as illustrated in Figure 70. Such a configured collar seam 679 is formed by folding back the collar edge 678 of the collar 669 or the edge 667 of the neck opening 665. The outer surface 612 of the folded portions and the inner surface 611 of the unfolded portions of the collar edge 678 of the collar 669 or the edge 667 of the neck opening 665 and the corresponding portions of the collar 669 or the front and back panels 618 and 624 are brought into contact with the inner surface 611 or the outer surface 612 of the unfolded collar edge 678 of the collar 669 or the edge 667 of the neck opening 665 and the corresponding portions of the collar 669 or the front and back panels 618 and 624. It is understood that the folding back of the collar edge 678 of the collar 669 or the edge 667 of the neck opening 665 could be performed such that the inner surface 611 would be exposed along the fold.

Another embodiment of the collar seam 679 is an over-lapped configuration as illustrated in Figure 71. Such a configured collar seam 679 is formed by folding the collar 669 about or over the edge 667 of the neck opening 665. The collar edges 678 of the collar 669 may be folded under bringing the outer surface 612 of the collar 669 into contact with the edge 667 of the neck opening and any portion of the adjacent material of the front panel 618, the back panel 624, or both as desired. The collar edges 678 may be left exposed by not being folding under.

Another embodiment of the collar seam 679 is an over-lapped configuration as illustrated in Figure 72. Such a configured collar seam 679 is formed by folding the collar edge 678 such that the inner surface 611 of the collar 669 is brought into contact with itself. The edge 667 of the neck opening 665 is folded such that the outer surface 612 of the front panel 618, the back panel 624, or both are brought into contact with itself. The collar edge 678 is inserted into the fold of the edge 667 of the neck opening 665. The edge 667 of the neck opening 665 is inserted into the fold of the collar edge 678. In another embodiment, the collar edge 678 is folded such that the outer surface 612 of the collar 669 is brought into contact with itself. The edge 667 of the neck opening 665 is folded such that the inner surface 6 1 of the front panel 618, the back panel 624, or both are brought into contact with itself. This configured collar seam 679 may be used with any seam describe herein.

The materials used for the collar 669 may be the same as the materials used for the other portions of the garment 610. In some embodiments, it is desirable that the materials used for the collar 669 have an elastic element such that the collar 669 will conform to the portion of the wearer's neck that comes into contact with the collar 669.

In various embodiments of the present invention, the front panel 618, the back panel 624, or both panels 618 and 624 may be cut or otherwise opened to form a slit 634 or 641 (shown in Figure 53) such as a placket. The slit 634 has two edges 637 and 61. The slit 641 has two edges 642 and 643. The slits 634 and 641 of the front and back panels 618 and 624, respectively, may extend from the edge 667 of the neck opening 665 to the garment bottom edges 622 and 628, respectively. In the alternative, the slits 634 and 641 may extend over only a portion of the panels 618 and 624 between the edge 667 of the neck opening 665 to the garment bottom edges 622 and 628, respectively. When the garment 610 comprises both a slit 634 in the front panel 618 and a slit 641 in the back panel 624, the slits 634 and 641 may be similar or dissimilar in size, structure, shape, and the like.

In some embodiments, the edges 637 and 61 of the slit 634 and the edges 642 and 643 of the slit 641 may be refastenably attached or secured to each other. The edges 637 and 61 may be secured together to form the front seam 879. The edges 642 and 643 may be secured together to form the back seam 680. Various fastening means, such as adhesive and mechanical type fasteners 670, see the discussion above, may be used to refastenably attach or secure the edges 637 and 61 or the edges 642 and 643 together of the slits 634 and 641 , respectively.

Another embodiment of the present invention is a continuous process for the manufacture of a garment 682 (see Figure 51) for wearing about the upper body comprising a garment 682 having at least a front panel 692, a back panel 697, a neck opening 747 defined about its perimeter by edge 749, arm openings 729 and 731 defined about their perimeters by arm opening edges 730 and 732, respectively, and a lower body opening 706 defined about its perimeter by garment bottom edges 695 and 701. The garment 682 comprises an inner surface 683 and an outer surface 685. The garment 682 may comprise a single layer webs of fabric 687 and 688, multi-layer laminate webs of fabric 687 and 688, or a combination of a single layer web of fabric and a multi-layer laminate webs of fabric 687 and 688. In some embodiments, the garment 682 may comprise multiple layers of the webs of fabric 687 and 688 or various combinations of fabric.

In one embodiment of the present invention (See Figure 51), two webs of fabric 687 and 688 of sufficient width of fabric to make the garment 682 are provided to produce the garment 682. The desired webs of fabric 687 and 688 are nonwoven although any disposable or washable fabric can be used. (See the discussion below). The web of fabric 687 and 688 is typically unwound from rolls or other source (not shown).

The webs of fabric 687 and 688 are desirably compliant and soft feeling to the wearer. The following description of materials from which the webs of fabric 687 and 688 may be formed would also be used for the materials to form the inner surface 683 and the outer surface 685 of multi-layer laminate webs of fabric 687 or 688.

The webs of fabric 687 and 688 may be any suitable material as earlier described for the webs of fabric 215 and 216.

The webs of fabric 687 and 688 may be constructed of a single spunbonded polypropylene nonwoven web having a basis weight of about 0.5 oz/yd² (17 gsm) to about 1.5 oz/yd² (51 gsm). In the structure of the garment 682, the webs of fabric 687 and 688 desirably comprise a material having a basis weight of from about 0.5 oz/yd² (17 gsm) to about 1.5 oz/yd² (51 gsm). Lesser or greater basis weights may be used in the other regions of the garment 682, such as the sleeves 733 and 735, the cuffs 742 and 744, and the collar 751. Since the garment 682 is typically intended for active wear, the webs of fabric 687 and 688 or portions thereof, can be made of materials having a basis weight that is abrasion resistant.

For embodiments wherein the webs of fabric 687 and 688 are a multi-layer laminate, both the outer surface 685 and the inner surface 683 are desirably compliant and soft feeling to the wearer. The following description of materials from which the outer surface 685 may be formed may also be used to form the material of the inner surface 683. The outer surface 685 may be any suitable gatherable material as earlier described for the outer surface 213.

Alternatively, the outer surface 685 may be derived from a spunbonded web. In a desired embodiment, the outer surface 685 is spunbonded polypropylene nonwoven, meltblown polypropylene nonwoven and spunbonded polypropylene nonwoven laminate (SMS). The total basis weight is from about 0.4 to about 1.0 osy (more desirably 0.6 osy) and is made with about 86% spunbonded nonwoven and 14% meltblown nonwoven. A pigment such as titanium dioxide may be incorporated into the outer surface 685 and the inner surface 683. Such spunbonded meltblown nonwoven laminate material is available from Kimberly-Clark Corporation, Roswell, GA. The basis weight of the SMS material may vary from about 0.4 to about 1.0 osy.

The inner surface 683 may be any soft and flexible sheet as earlier described for the inner surface 211.

The outer surface 685 and the inner surface 683 may be further dyed, pigmented, or imprinted with any suitable color. Desirably, the inner surface 683 is either dyed, pigmented, or printed with a material which does not irritate or bleed the color onto the skin of the wearer.

The web of fabric 687 includes a pair of opposing web side edges 708 and 709. The web of fabric 688 includes a pair of opposing web side edges 710 and 711. The two webs of fabric 687 and 688 of sufficient width of fabric to make the garment 682 are combined to produce garment 682. The desired fabric is nonwoven, although any disposable or washable fabric can be used. In one type of embodiment of the present invention, the two webs of fabric 687 and 688 are unwound from rolls and brought together in a side by side orientation (see Figure 62) and fastened together at the web side edge 709 of the web of fabric 687 and the web side edge 710 of the web of fabric 688, defining a center seam 716 of a composite web of fabric 715.

In some embodiments, portions of the center seam 716 may be left unfastened by intermittently fastening the web side edges 709 and 710 of the webs of fabric 687 and 688, respectively. The location of the center seam 716 of the composite web of fabric 715 corresponds to the shoulder seam 714 of the finished garment 682. The desired method of fastening is ultrasonic sealing, although other methods of fastening known in the art such as heat sealing, adhesives, tape, or sewing can be used.

In another type of embodiment, the two webs of fabric 687 and 688 to make the garment 682 are combined to produce the garment 682. The two webs of fabric 687 and 688 are unwound from rolls and brought together in a face to face (or, alternatively, back to back) orientation (see Figure 61) and fastened together at the web side edge 709 of the web of fabric 687 and the web side edge 710 of the web of fabric 688, defining the center seam 716 of the composite web of fabric 715.

A repeating series of openings 725 are cut by a die cutter 686 into the composite web of fabric 715. (See Figure 51). The location of the openings 725 of the composite web of fabric 715 corresponds to the arm openings 729 and 731 , respectively, of the finished garment 682. The openings 725 may be produced by a die cut operation, an ultrasonic operation, or any other suitable method of operation. The material removed from the openings 725 may be removed by any method known in the art, desirably a vacuum source (not shown).

The openings 725 may take on a variety of shapes, such as slit, circular, oval, triangular, square, rectangular, multi-faceted, asymmetric or irregular, or the like. The pattern of the opening 725 is restricted only by fashion and the minimum amount of the composite web of fabric 715 that must remain having a sufficient integrity to withstand the remaining steps or operations of the process of manufacture. The composite web of fabric 715 is cut into the discrete garment-sized pieces 717 by the die cutter 686. (See Figure 51). The web side edges 708 and 711 of the composite web of fabric 715 (or, alternatively, of the webs of fabric 687 and 688) become the garment bottom edges 695 and 701 , respectively, of the discrete garment-sized pieces 717. It is understood that the arm openings 729 and 731 may take on a variety of shapes, such as slit, circular, oval, triangular, square, rectangular, multi-faceted, asymmetric or irregular, or the like. The pattern of the arm openings 729 and 731 is restricted only by fashion and the minimum amount of the composite web of fabric 715 that must remain having a sufficient integrity to withstand the remaining steps or operations of the process of manufacture. It is understood that while Figure 51 shows the die cutter 686 cutting the web of fabric 687 (or, alternatively, the composite web of fabric 715) into discrete garment-sized pieces 717 and the openings 725, these operations could be performed by separate devices and at different stages within the manufacturing process.

It is understood that while web side edges 708 and 711 may typically become the garment bottom side edges 695 and 701, respectively, in the finished garment 682, fabric may be removed from or added to the web side edges 708 and 711 to create the garment bottom edges 695 and 701 , respectively, in the finished garment 682. The garment side edges 693 and 698 and the garment side edges 694 and 699 created by the cutting operation are located such that the openings 725 are cut, producing the arm opening edges 730 and 732 in the garment side edges 693 and 698 and the garment side edges 694 and 699, respectively.

In some embodiments of the present invention, the webs of fabric 687 and 688 may not be joined before cuts corresponding to the openings 725 are made into the webs of fabric 687 and 688. The web of fabric 687 includes a pair of opposing web side edges 708 and 709. The web of fabric 688 includes a pair of opposing web side edges 710 and 711. A repeating series of indentations 723 are cut into the web side edge 709 of the web of fabric 687. (See Figures 58, 65, and 66). The location of the indentations 723 corresponds to a portion of the arm openings 729 and a portion of the arm openings 731 of the finished garment 682. Additionally, the indentations 723 correspond to a portion of the arm opening edges 730 and a portion of the arm opening edges 732 of the finished garment 682. The indentations 723 may be produced by a die cut operation, an ultrasonic operation, or any other suitable method of operation. The material to be removed from the indentations 723 may be removed by any method known in the art, desirably a vacuum source (not shown).

The indentations 723 may take on a variety of sizes and shapes, such as slit, circular, oval, triangular, square, rectangular, multi-faceted, asymmetric or irregular, or the like. The pattern of the indentations 723 is restricted only by fashion and the minimum amount of the web of fabric 687 that must remain having a sufficient integrity to withstand the remaining steps or operations of the process of manufacture. The indentations 723 may be similar or dissimilar in shape, structure, size, and the like from each other or from the indentations 724 within the finished garment 682. The indentations 723 may be similar or dissimilar in shape, structure, size, and the like from the opposing indentations 727 and 728 (discussed below) within the finished garment 682.

A repeating series of indentations 724 are cut into the web side edge 710 of the web of fabric 688. (See Figures 58, 65, and 66). The location of the indentations 723 corresponds to a portion of the arm openings 729 and a portion of the arm openings 731 of the finished garment 682. Additionally, the indentations 724 correspond to a portion of the arm opening edges 730 and a portion of the arm opening edges 732 of the finished garment 682. The indentations 724 may be produced by a die cut operation, an ultrasonic operation, or any other suitable method of operation. The material to be removed from the indentations 724 may be removed by any method known in the art, desirably a vacuum source (not shown).

The indentations 724 may take on a variety of sizes and shapes, such as slit, circular, oval, triangular, square, rectangular, multi-faceted, asymmetric or irregular, or the like. The pattern of the indentations 724 is restricted only by fashion and the minimum amount of the web of fabric 687 that must remain having a sufficient integrity to withstand the remaining steps or operations of the process of manufacture. The indentations 724 may be similar or dissimilar in shape, structure, size, and the like from each other or from the indentations 723 within the finished garment 682. The indentations 724 may be similar or dissimilar in shape, structure, size, and the like from the opposing indentations 727 and 728 (discussed below) within the finished garment 682.

In some embodiments of the present invention, the composite web of fabric 715 may be cut into discrete garment-sized pieces 717 prior to the performance of an operation to create the openings 725 (or, alternatively, the arm openings 729 and 731) are made into the composite web of fabric 715. (See Figures 59, 65, and 66). A pair of opposing of indentations 727 and 728 are cut into the garment side edges 693 and 698 and the garment side edges 694 and 699, respectively, of the discrete garment-sized pieces 717. The location of the opposing indentations 727 and 728 correspond to the arm openings 729 and 731, defined by the arm opening edges 730 and 732, respectively, of the finished garment 682. In other embodiments, the arm openings 729 and 731 may be created in the discrete garment-sized pieces 717 by cutting or otherwise creating indentations 722 and 726 in the piece side edges 700 and 702, respectively, of the discrete garment-sized pieces 717. The opposing indentations 727 and 728 may be produced by a die cut operation, an ultrasonic operation, or any other suitable method of operation. The material to be removed from the opposing indentations 727 and 728 may be removed by any method known in the art, desirably a vacuum source.

The opposing indentations 727 and 728 may take on a variety of sizes and shapes, such as slit, circular, oval, triangular, square, rectangular, multi-faceted, asymmetric or irregular, or the like. The pattern of the opposing indentations 727 and 728 is restricted only by fashion and the minimum amount of the composite web of fabric 715 that must remain having a sufficient integrity to withstand the remaining steps or operations of the process of manufacture. The arm openings 729, or alternatively, the indentations 727 may be similar or dissimilar in shape, structure, size, or the like from each other or from the arm openings 731 , or alternatively, the indentations 728 within the finished garment 682. The arm openings 731 , or alternatively, the indentations 728 may be similar or dissimilar in shape, structure, size, or the like from each other or from the arm openings 729, or alternatively, the indentations 727 within the finished garment 682. The opposing indentations 727 and 728 may be similar or dissimilar in shape, structure, size, and the like from the opposing indentations 723 and 724 within the finished garment 682.

In some embodiments, the operation of cutting the opposing indentations 723 and 724 or the opposing indentations 727 and 728 (or, alternatively, the openings 725) into the discrete garment-sized pieces 717 or the garment-sized pieces 689 and 690 of the webs of fabric 687 and 688, respectively (or, the composite web of fabric 715) may be eliminated. As the pattern of the garment 682 is restricted only by fashion and the minimum amount of the discrete garment-sized pieces 717 or the garment-sized pieces 689 and 690 of the webs of fabric 687 and 688, respectively (or, the composite web of fabric 715) that must remain having a sufficient integrity to withstand the remaining operations or steps of the process of manufacture, one can simply design the garment 682 such that the operation of cutting the opposing indentations 723 and 724 or the opposing indentations 727 and 728 (or, alternatively, the openings 725) into the web side edges 709 and 710 or the garment side edges 693 and 698 and the garment side edges 694 and 699 (or, the composite web of fabric 715) is not required. The piece side edges 700 and 702 of the discrete garment-sized pieces 717 (or, alternatively, of the garment- sized pieces 689 and 690 of the webs of fabric 687 and 688, respectively) become the garment side edges 693 and 698 and the garment side edges 694 and 699, respectively, in the finished garments 682. As discussed above, the arm openings 729 and 731 may be created by leaving a portion of the garment side edges 693 and 698 and the garment side edges 694 and 699, respectively, unattached.

In the other type of the embodiments of the present invention (see Figure 65), the two webs of fabric 687 and 688 of sufficient width of fabric to make the garment 682 are combined to produce garments 682. The desired fabric is nonwoven, although any disposable or washable fabric can be used. The two webs of fabric 687 and 688 are unwound from rolls and brought together in a side by side orientation and fastened together at the web side edge 709 of the web of fabric 687 and the web side edge 710 of the web of fabric 688, defining a center seam 716 on the composite web of fabric 715.

In some embodiments, portions of the center seam 716 may be left unfastened by intermittently fastening the web side edges 709 and 710 of the webs of fabric 687 and 688, respectively. The location of the center seam 716 of the composite web of fabric 715 corresponds to the shoulder seam 714 of the flnished garment 682. The desired method of fastening is ultrasonics, although other methods of fastening known in the art, such as heat sealing, adhesives, tape, or sewing can be used.

The discussion of the openings 725, the opposing indentations 723 and 724, or the opposing indentations 727 and 728 in relation to the webs of fabric 687 and 688 and the composite web of fabric 715 apply as well when the webs of fabric 687 and 688 are brought together in a side by side configuration. The material to be removed from the openings 725, the opposing indentations 723 and 724, or the opposing indentations 727 and 728 may be removed by any method known in the art, desirably a vacuum source. As the pattern of the garment 682 is restricted only by fashion and the minimum amount of the webs of fabric 687 and 688 (or, alternatively, the composite web of fabric 715) that must remain having a sufficient integrity to withstand the operations or steps of the process of manufacture, one can simply design the garment 682 such that this operation of cutting the openings 725, the opposing indentations 723 and 724, or the opposing indentations 727 and 728 into the webs of fabric 687 and 688 (or, alternatively, the composite web of fabric 715) is not required as discussed above.

A repeating series of openings 746 are cut by the die cutter 686 into at least one the webs of fabric 687 and 688 (or, alternatively, the composite web of fabric 715). The location of the opening 746 corresponds to the neck opening 747 in the finished garment 682. The openings 746 may be produced by a die cut operation, an ultrasonic operation, or any other suitable method of operation. It is understood that while Figure 2 shows the die cutter 686 cutting the opening 746 and the opening 725, these cutting operations (also, the operation for cutting the opposing indentations 723 and 724 and the opposing indentations 727 and 728) could be performed by separate devices and at different stages within the manufacturing process. The openings 746 may be cut into at least one of the webs of fabric 687 and 688 before or after the webs of fabric 687 and 688 are combined to form the composite web of fabric 715.

The opening 746 may take on a variety of sizes and shapes, such as slit, circular, oval, triangular, square, rectangular, multi-faceted, asymmetric or irregular, or the like. The material to be removed from the openings 746 may be removed by any method known in the art, desirably a vacuum source (not shown). The pattern of the opening 746 is restricted only by fashion and the minimum amount of the webs of fabric 687 and 688 (or, alternatively, the composite web of fabric 715) that must remain having a sufficient integrity to withstand the remaining steps or operations of the process of manufacture.

In alternative embodiments of the present invention, the openings 746 may be comprised of the indentations 758 cut into the web side edge 709 of the web of fabric 687 and 759 cut into the web side edge 710 of the web of fabric 688 prior to the combining of the webs of fabric 687 and 688 to form the composite web of fabric 715. An indentation 758 and an indentation 759 are combined to form the opening 746.

The placement of the opening 746 in relation to a pair of opposing arm openings 729 and 731 (or, alternatively, the opposing indentations 723 and 724 or the opposing indentations 727 and 728), while in a typical garment 682, the opening 746 is located between the pair of opposing arm openings 729 and 731 (or, alternatively, the opposing indentations 723 and 724 or the opposing indentations 727 and 728), is restricted only by fashion and the minimum amount of the webs of fabric 687 and 688 (or, alternatively, the composite web of fabric 715 or the discrete garment-sized pieces 717) that must remain having sufficient integrity to withstand the remaining steps or operations of the process of manufacture. For example, the placement of the opening 746 between the pair of opposing arm openings 729 and 731 may be symmetrically or asymmetrically located. The composite web fabric 715 is cut by the die cutter 686 into discrete garment- sized pieces 717 wherein each discrete garment-sized piece 717 contains at least one opening 746, one pair of arm openings 729 and 731, one pair of opposing web side edges 708 and 711, and opposing garment end portions 720 and 721. The location of the opposing web side edges 708 and 711 of the composite web of fabric 715 (or, alternatively, the discrete garment-sized pieces 717) corresponds to the garment bottom edge 695 of the front panel 692 and the garment bottom edge 701 of the back panel 697, respectively, in the finished garment 682. The opposing garment end portions 720 and 721 are adjacent the garment bottom edge 695 of the front panel 692 and the garment bottom edge 701 of the back panel 697, respectively, in the finished garment 682.

The location of the opposing web side edges 708 and 711 of the composite web of fabric 715 (or, alternatively, the discrete garment-sized piece 717) correspond to the garment bottom edge 695 of the front panel 692 and the garment bottom edge 701 of the back panel 697, respectively, in the finished garment 682. It is understood that while the web side edges 708 and 709 of the composite web of fabric 715 (or, alternatively, the discrete garment-sized piece 717) may typically become the garment bottom edges 695 and 701 of the front and back panels 692 and 697, respectively, in the finished garment 682, fabric may be removed from or added to the web side edges 708 and 709 of the composite web of fabric 715 (or, alternatively, the discrete garment-sized piece 717) to create the garment bottom edges 695 and 701 in the finished garment 682.

The webs of fabric 687 and 688 may be cut into garment-sized pieces 689 and 690, respectively, before the webs of fabric 687 and 688 are combined to form the composite web of fabric 715. The garment-sized pieces 689 and 690 of the webs of fabric 687 and 688 are fastened together at the web side edges 709 and 710 to form the discrete garment-sized piece 717 of the composite web of fabric 715. The garment-sized pieces 689 and 690 are combined to form the discrete garment-sized piece 717 such that each discrete garment-sized piece 717 contains at least an opening 746, one pair of arm openings 729 and 731, one pair of opposing web side edges 708 and 711, and opposing garment end portions 720 and 721, as described above.

The garment-sized pieces 689 and 690 of the webs of fabric 687 and 688 are positioned before the garment-sized pieces 689 and 690 are fastened together to form the discrete garment-sized piece 717 of the composite web of fabric 715. The garment-sized piece 689 may be positioned by a turn roll or turn table so as to place the garment end portion 720 of the garment-sized piece 689 adjacent the garment end portion 721 of the garment-sized piece 690. The turning operations are desirably carried out by turn rolls and turn tables, as well as any other known means. The web side edge 709 of the garment-sized piece 689 is attached at the web side edge 710 of the garment-sized piece 690, thereby forming the center seam 716.

The center seam 716, or portions thereof, can be constructed as a non- refastenable seam, as a refastenable seam, or as a combination of a non-refastenable seam and a refastenable seam. Any excess material from the webs of fabric 687 and 688 may be removed from the web side edges 709 and 710 of the center seam 716 to reduce and smooth out the center seam 716. The non-refastenable center seam 716 may be formed by any suitable means such as ultrasonic sealing, adhesive bonding, tape, heat sealing, sewing, or any method of fastening known in the art. The non-refastenable center seam 716 may be constructed on a continuous or intermittent basis. One suitable method of forming such a center seam 716 is disclosed in U.S. Patent No. 4,938,753 issued July 3, 1990, to Van Gompel et al., which is incorporated herein by reference. The center seam 716 may be bonded together to form a non-refastenable center seam 716.

In other embodiments of the present invention, the web side edges 709 and 710 of the garment 682 may be held together in the finished garment 682 to form refastenable center seam 716. The refastenable means for securing the web side edges 709 and 710 of the garment 682 include refastenable adhesive and mechanical type fasteners 752. The adhesive and mechanical type fasteners 752 include buttons and button holes, snaps, buckles, clasps, hooks and loops, end extensions, tabs, tape, and the like which are designed or adapted to interlock or engage some type of a complimentary device or the outer surface 685 or the inner surface 683 of the garment 682. A refastenable center seam 716 may be constructed on a continuous or intermittent basis.

In addition, elasticized fasteners 752 may also be used in assuring better fit of the garment 682. If the garment 682 includes a refastenable center seam 716, the refastenable means are desirably strategically placed on the webs of fabric 687 and 688 before the webs of fabric 687 and 688 are cut into discrete garment-sized pieces 689 and 690 (or, before the composite web of fabric 715 is cut into the discrete garment-sized pieces 717). The folding and redirection operations may be eliminated when a refastenable center seam 716 is included in the garment 682. However, there may be packaging reasons for which one would still carry out these two steps.

The center seam 716 of the present invention may take on a variety of structures or configurations known in the art. One embodiment of the center seam 716 is an out- turned configuration as illustrated in Figure 74. Such a configured center seam 716 is formed by securing together at least a portion of the out-turned portions of the web side edges 709 and 710. The inner surfaces 683 of the front and back panels 692 and 697 at the web side edges 709 and 710, respectively, are brought into contact with each other.

Another embodiment of the center seam 716 is an in-turned configuration as illustrated in Figure 75. Such a configured center seam 716 is formed by securing together at least a portion of the in-turned portions of the web side edges 709 and 710. The outer surfaces 685 of the front and back panels 692 and 697 at the web side edges 709 and 710, respectively, are brought into contact with each other.

Another embodiment of the center seam 716 is an over-lapped configuration as illustrated in Figure 73. Such a configured center seam 716 is formed by securing together at least a portion of the over-lapped portions of the web side edges 709 and 710. The inner surface 683 of one of the front and back panels 692 and 697 at the web side edges 709 and 710 is brought into contact with the outer surface 685 of the other panel 692 or 697 at the web side edges 709 and 710, respectively.

Another embodiment of the center seams 716 is an over-lapped configuration as illustrated in Figure 76. Such a configured center seam 716 is formed by folding back the web side edge 709 (or, alternatively, the web side edge 710). The outer surface 685 of the folded portion and the inner surface 683 of the unfolded portion of the web side edge 709 and the corresponding portion of the front panel 692 (or, alternatively, the web side edge 710 and the corresponding portion of the back panel 697) is brought into contact with the inner surface 683 or the outer surface 685 of the web side edge 710 and the corresponding portions of the back panel 697 (or, alternatively, the web side edge 709 and the corresponding portion of the front panel 692). It is understood that the folding back of the web side edges 709 or 710 could be performed such that the inner surface 683 would be exposed along the fold. In the embodiments where the webs of fabric 687 and 688 or the garment-sized pieces 689 and 690 are fastened together prior to the folding step, each discrete garment- sized piece 717 of the composite web of fabric 715 is transported, typically by vacuum screens, belts, or conveyors, through hemming, folding, and fastening operations. The folding operations are desirably carried out by tuckers and folders, as well as any other known means. The discrete garment-sized piece 717 of the composite web of fabric 715 is folded by a folder 619a so as to bring together the opposing garment end portions 720 and 721 such that the garment side edge 693 of the front panel 692 of the composite web of fabric 715 is folded or otherwise brought into contact with the garment side edge 698 of the back panel 697. The garment side edge 694 of the front panel 692 is folded or otherwise brought into contact with the garment side edge 699 of the back panel 697.

The mating of the garment side edge 693 and the garment side edge 698, as well as the mating of the garment side edge 694 and the garment side edge 699, form the garment side seams 704 and 705, respectively, of the garment 682. It may be desirable to redirect (or reorient) the discrete garment-sized piece 717 of the composite web of fabric 715 to allow easy bonding of the garment side seams 704 and 705 of the garment 682. The turning operations are desirably carried out by turn rolls and turn tables, as well as any other known means. The discrete garment-sized piece 717 of the composite web of fabric 715 may be reoriented 90 degrees (not shown).

In various embodiments of the present invention, one or both of the garment side seams 704 and 705 can be constructed as non-refastenable seams or as refastenable seams. Any excess material from the webs of fabric 687 and 688 may be removed from the edges of the garment side seams 704 and 705 to reduce and smooth out the garment side seams 704 and 705. The non-refastenable garment side seams 704 and 705 may be formed by any suitable means such as ultrasonic sealing, adhesive bonding, tape, heat sealing, sewing, or any method of fastening known in the art. (Sewing equipment 772 is shown in Figure 51). The non-refastenable garment side seams 704 and 705 may be constructed on a continuous or intermittent basis. One suitable method of forming such garment side seams 704 and 705 is disclosed in U.S. Patent No. 4,938,753 issued July 3, 1990, to Van Gompel et al., which is incorporated herein by reference. The garment side seams 704 and 705 may be bonded together to form non-refastenable garment side seams 704 and 705. In other embodiments of the present invention, the garment side edges 693 and 698 and the garment side edges 694 and 699 of the garment 682 may be held together in the finished garment 682 to form refastenable garment side seams 704 and 705, respectively. The refastenable means for securing the garment side edges 693 and 698 and the garment side edges 694 and 699 of the garment 682 include refastenable adhesive and mechanical type fasteners 752. The adhesive and mechanical type fasteners 752 include buttons and button holes, snaps, buckles, clasps, hooks and loops, end extensions, tabs, tape, and the like which are designed or adapted to interlock or engage some type of a complementary device or the outer surface 685 or the inner surface 683 of the garment 682.

In addition, elasticized fasteners 752 may also be used in assuring better fit of the garment 682. If the garment 682 includes refastenable garment side seams 704 and 705, the refastenable means are desirably strategically placed on the webs of fabric 687 and 688 before the webs of fabric 687 and 688 are cut into garment-sized pieces 689 and 690 (or, alternatively, the composite web of fabric 715 or the discrete garment-sized pieces 717). The folding and redirection operations may be eliminated when refastenable garment side seams 704 and 705 are included in the garment 682. However, there may be packaging reasons for which one would still carry out these two steps.

The garment side seams 704 and 705 of the present invention may take on a variety of structures or configurations known in the art. One embodiment of the garment side seams 704 and 705 is an out-turned configuration as illustrated in Figure 74. Such configured garment side seams 704 and 705 are formed by securing together at least a portion of the out-turned portions of the garment side edges 693 and 698 and the garment side edges 694 and 699, respectively. The inner surface 683 of the garment side edges 693 and 694 of the front panel 692 and the garment side edges 698 and 699 of the back panel 697, respectively, are brought into contact with each other for each pair of garment side edges.

Another embodiment of the garment side seams 704 and 705 is an in-turned configuration as illustrated in Figure 75. Such configured garment side seams 704 and 705 are formed by securing together at least a portion of the in-turned portions of the garment side edges 693 and 698 and the garment side edges 694 and 699, respectively. The outer surface 685 of the garment side edges 693 and 694 of the front panel 692 and the garment side edges 698 and 699 of the back panel 697, respectively, are brought into contact with each other for each pair of garment side edges.

Another embodiment of the garment side seams 704 and 705 is an over-lapped configuration as illustrated in Figure 73. Such configured garment side seams 704 and 705 are formed by securing together at least a portion of the over-lapped portions of the garment side edges 693 and 698 and the garment side edges 694 and 699, respectively. The inner surface 683 of one of the garment side edges 693 and 698 and one of the garment side edges 694 and 699 are brought into contact with the outer surface 685 of the other garment side edges of each pair of garment side edges.

Another embodiment of the garment side seams 704 and 705 is an over-lapped configuration as illustrated in Figure 76. Such a configured garment side seam 704 is formed by folding back the garment side edge 693 or the garment side edge 698. The outer surface 685 of the folded portion and the inner surface 683 of the unfolded portion of the garment side edge 693 or the garment side edge 698 and the corresponding portion of the front panel 692 or the back panel 697, respectively, is brought into contact with the inner surface 683 or the outer surface 685 of the non-folded garment side edge 698 or 693 and the corresponding portion of the back panel 697 or the front panel 692.

The garment side seam 705 is formed by folding back the garment side edge 694 or the garment side edge 699. The outer surface 685 of the folded portion and the inner surface 683 of the unfolded portion of the garment side edge 694 or the garment side edge 699 and the corresponding portion of the front panel 692 or the back panel 697, respectively, are brought into contact with the inner surface 683 or the outer surface 685 of the non-folded garment side edge 699 or 694 and the corresponding portion of the back panel 697 or the front panel 692. It is understood that the folding back of a garment side edge 693, 698, 694, or 699, could be performed such that the inner surface 683 would be exposed along the fold.

The garment end portions 720 and 721 of the discrete garment-sized piece 717 of the composite web of fabric 715 may be hemmed in the finished garment 682. In some embodiments, it may be desirable to hem the garment end portions 720 and 721 of the garment-sized pieces 689 and 690 of the webs of fabric 687 and 688, respectively, before fastening the garment-sized pieces 689 and 690 together to form the discrete garment- sized piece 717 of the composite web of fabric 715. The garment end portions 720 and 721 of the discrete garment-sized piece 717 (or, alternatively, garment end portions 720 and 721 of the garment-sized pieces 689 and 690, respectively) can be hemmed by any method or style known in the art. In some embodiments, it may be desirable to leave the garment end portions 720 and 721 of the discrete garment-sized piece 717 (or, alternatively, garment end portions 720 and 721 of the garment-sized pieces 689 and 690, respectively) unhemmed.

The garment bottom edges 695 and 701 of the discrete garment-sized piece 717 of the composite web of fabric 715 may be hemmed in the finished garment 682. (Sewing equipment 771 is shown in Figure 51). In some embodiments, it may be desirable to hem the garment bottom edges 695 and 701 of the garment-sized pieces 689 and 690 of the webs of fabric 687 and 688, respectively, before fastening the garment-sized pieces 689 and 690 together to form the discrete garment-sized piece 717 of the composite web of fabric 715. The garment bottom edges 695 and 701 of the discrete garment-sized piece 717 (or, alternatively, garment bottom edges 695 and 701 of the garment-sized pieces 689 and 690, respectively) can be hemmed by any method or style known in the art. In some embodiments, it may be desirable to leave the garment bottom edges 695 and 701 of the discrete garment-sized piece 717 (or, alternatively, garment bottom edges 695 and 701 of the garment-sized pieces 689 and 690, respectively) unhemmed.

In some embodiments of the present invention, the garment 682 includes sleeves 733 and 735. (See Figures 56 and 57). The sleeves 733 and 735 are made of pieces of the sleeve web fabric 734 and 736, the same or different from the material of the webs of fabric 687 and 688. In some embodiments, only one sleeve 733 or 735 may be included in the finished garment 682. The pieces of the sleeve web fabric 734 and 736 are provided as sleeve-sized pieces 691 cut from a sleeve web of fabric 684. The pieces of the sleeve web fabric 734 and 736 may take on a variety of sizes and shapes, such as circular, oval, triangular, square, rectangular, multi-faceted, asymmetric or irregular, or the like. The pattern of the sleeve web fabric 734 and 736 is restricted only by fashion and the minimum amount of the material of the pieces of the sleeve web fabric 734 and 736 that is necessary to complete the remaining steps or operations of the process of manufacture. The sleeves 733 and 735, alternately the pieces of sleeve web fabric 734 and 736, may be similar or dissimilar in shape, structure, material, size, and the like from each other within the finished garment 682. The piece of a sleeve web fabric 734 has a pair of sleeve side edges 738 and 740, a garment end edge 737, and a sleeve opening end edge 741 opposite the garment end edge 737. It is understood that the piece of the sleeve web fabric 734 could be provided as a tube having a garment end edge 737 and a sleeve opening end edge 741 opposite the garment end edge 737. It is also understood that the piece of the sleeve web fabric 734 could be made of multiple pieces of material or materials. The piece of the sleeve web fabric 734 is folded so as to bring together the opposing sleeve side edges 738 and 740 to form a sleeve seam 750 of the sleeve 733.

The piece of a sleeve web fabric 736 has a pair of sleeve side edges 745 and 748, a garment end edge 739, and a sleeve opening end edge 743 opposite the garment end edge 739. It is understood that the piece of the sleeve web fabric 736 could be provided as a tube having a garment end edge 739 and a sleeve opening end edge 743 opposite the garment end edge 739. It is also understood that the piece of the sleeve web fabric 736 could be made of multiple pieces of material or materials. The piece of the sleeve web fabric 736 is folded so as to bring together the opposing sleeve side edges 745 and 748 to form a sleeve seam 753 of the sleeve 735.

It may be desirable to redirect (or reorient) the sleeve-sized pieces 691 of the sleeve web of fabric 684 to allow easy fastening of the sleeve seams 750 and 753 of the sleeves 733 and 735, respectively, of the garment 682. The turning operations are desirably carried out by turn rolls and turn tables, as well as any other known means. The sleeve-sized pieces 691 of the sleeve web of fabric 684 (pieces of the sleeve web fabric 734 and 736) may be reoriented 90 degrees (not shown). The sleeve seams 750 and 753 can be non-refastenable seams or refastenable seams. Any excess material of the pieces of the sleeve web fabric 734 and 736 can be removed from their respective edges of the sleeve seams 750 and 753 to reduce and smooth out the sleeve seams 750 and 753. The non-refastenable sleeve seams 750 and 753 may be formed by any suitable means such as ultrasonic sealing, adhesive bonding, tape, heat sealing, sewing, or any method of fastening known in the art. The non-refastenable sleeve seams 750 and 753 may be constructed on a continuous or intermittent basis.

In other embodiments, the opposing pair of the sleeve side edges 738 and 740 and the opposing pair of the sleeve side edges 745 and 748 of the sleeves 733 and 735, respectively, may be held together in the finished garment 682 to form refastenable sleeve seams 750 and 753. The refastenable means for securing the opposing pair of the sleeve side edges 738 and 740 and the opposing pair of the sleeve side edges 745 and 748 of the sleeves 733 and 735, respectively, include refastenable adhesive and mechanical type fasteners 752. The adhesive and mechanical type fasteners 752 include buttons and button holes, snaps, buckles, clasps, hooks and loops, end extensions, tabs, tape, and the like which are designed or adapted to interlock or engage some type of a complementary device or the inner surface 683 or the outer surface 685 of the garment 682. The refastenable sleeve seams 750 and 753 may be constructed on a continuous or intermittent basis.

In addition, elasticized fasteners 752 may also be used in assuring better fit of the sleeves 733 and 735 of the garment 682. If the garment 682 includes refastenable sleeve seams 750 and 753, the refastenable means are desirably strategically placed on the pieces of the sleeve web fabric 734 and 736 before the sleeve web of fabric 684 is cut into discrete sleeve-sized pieces 691. The folding and redirection operations may be eliminated when refastenable sleeve seams 750 and 753 are included in the garment 682. However, there may be packaging reasons for which one would still carry out these two steps.

The sleeve seams 750 and 753 of the present invention may take on a variety of structures or configurations known in the art. One embodiment of the sleeve seams 750 and 753 is an out-turned configuration as illustrated in Figure 74. Such configured sleeve seams 750 and 753 are formed by securing together at least a portion of the out-turned portions of the sleeve side edges 738 and 740 and the sleeve side edges 745 and 748 of the sleeves 733 and 735, respectively. The inner surface 683 of the sleeve side edges 738 and 740 and the sleeve side edges 745 and 748 of the sleeves 733 and 735, respectively, are brought into contact with each other of the pair.

Another embodiment of the sleeve seams 750 and 753 is an in-turned configuration as illustrated in Figure 75. Such configured sleeve seams 750 and 753 are formed by securing together at least a portion of the in-turned portions of the sleeve side edges 738 and 740 and the sleeve side edges 745 and 748 of the sleeves 733 and 735, respectively. The outer surface 685 of the sleeve side edges 738 and 740 and the sleeve side edges 745 and 748 of sleeves 733 and 735, respectively, are brought into contact with each other of the pair.

Another embodiment of the sleeve seams 750 and 753 is an over-lapped configuration as illustrated in Figure 73. Such configured sleeve seams 750 and 753 are formed by securing together at least a portion of the over-lapped portions of the sleeve side edges 738 and 740 and the sleeve side edges 745 and 748 of the sleeves 733 and 735, respectively. The inner surface 683 of one of the sleeve side edges 738 or 740 and the sleeve side edges 745 or 748 of the sleeves 733 and 735, respectively, are brought into contact with the outer surface 685 of the other sleeve side edge 738 or 740 and the sleeve side edge 745 or 748 of the sleeve 733 and 735, respectively.

Another embodiment of the sleeve seams 750 and 753 is an over-lapped configuration as illustrated in Figure 76. Such configured sleeve seams 750 and 753 are formed by folding back the sleeve side edges 738 or 740 and the sleeve side edges 745 and 748 of the sleeves 733 and 735, respectively. The outer surface 685 of the folded portions and the inner surface 683 of the unfolded portions of the sleeve side edges 738 or 740 and the sleeve side edges 745 or 748 and the corresponding portions of the sleeves 733 and 735, respectively, are brought into contact with the inner surface 683 or the outer surface 685 of the non-folded sleeve side edge 740 or 738 and the sleeve side edge 748 or 745 and the corresponding portions of the sleeves 733 and 735, respectively. It is understood that the folding back of a sleeve side edge 738, 740, 745, or 748 could be performed such that the inner surface 683 would be exposed along the fold.

The garment end edges 737 and 739 of the pieces of the sleeve web fabric 734 and 736, respectively, may be attached to the arm opening edges 730 and 732 of the arm openings 729 and 731 , respectively, of the garment 682. The attachment of the pieces of the sleeve web fabric 734 and 736 may be made non-refastenable by means as discussed above. (Sewing equipment 770 is shown in Figure 51). In the alternative, the attachment of the pieces of the sleeve web fabric 734 and 736 may be made refastenable by means as discussed above.

The sleeves 733 and 735 may be constructed before attachment to the garment 682. The garment end edges 737 and 739 of the sleeves 733 and 735, respectively, may be attached to the arm opening edges 730 and 732 of the arm openings 729 and 731 , respectively, of the garment 682, forming arm opening seams 756 and 760, respectively. The attachment of the sleeves 733 and 735 may be made non-refastenable by means as discussed above. In the alternative, the attachment of the sleeves 733 and 735 may be made refastenable by means as discussed above. The arm opening seams 756 and 760 may be constructed on a continuous or intermittent basis.

The arm opening seams 756 and 760 of the present invention may take on a variety of structures or configurations. One embodiment of the arm opening seams 756 and 760 is an out-turned configuration as illustrated in Figure 74. Such configured arm opening seams 756 and 760 are formed by securing together at least a portion of the out- turned portions of the garment end edge 737 and the arm opening edge 730 and the garment end edge 739 and the arm opening edge 732, respectively, of the garment 682. The inner surface 683 of the garment end edges 737 and 739 of the sleeves 733 and 735, respectively, are brought into contact with the inner surface 683 of the arm opening edges 730 and 732, respectively.

Another embodiment of the arm opening seams 756 and 760 is an in-turned configuration as illustrated in Figure 75. Such configured arm opening seams 756 and 760 are formed by securing together at least a portion of the in-turned portions of the garment end edge 737 and the arm opening edge 730 and the garment end edge 739 and the arm opening edge 732, respectively, of the garment 682. The outer surface 685 of the garment end edges 737 and 739 of the sleeves 733 and 735 are brought into contact with the outer surface 685 of the arm opening edges 730 and 732, respectively.

Another embodiment of the arm opening seams 756 and 760 is an over-lapped configuration as illustrated in Figure 73. Such configured arm opening seams 756 and 760 are formed by securing together at least a portion of the over-lapped portions of the garment end edges 737 and the arm opening edge 730 and the garment end edge 739 and the arm opening edge 732, respectively, of the sleeves 733 and 735, respectively. The inner surface 683 of one of the garment end edge 737 or the arm opening edge 730 and the garment end edge 739 or the arm opening edge 732, is brought into contact with the outer surface 685 of the other garment end edge 737 or the arm opening edge 730 and the garment end edge 739 or the arm opening edge 732 of the sleeves 733 and 735, respectively. Another embodiment of the arm opening seams 756 and 760 is an over-lapped configuration as illustrated in Figure 76. Such configured arm opening seams 756 and 760 are formed by folding back the garment end edge 737 or the arm opening edge 730 and the garment end edge 739 or the arm opening edge 732. The outer surface 685 of the folded portions and the inner surface 683 of the unfolded portions of the garment end edge 737 or the arm opening edge 730 and the garment end edge 739 or the arm opening edge 732 and the corresponding portions of the sleeves 733 and 735 or the front and back panels 692 and 697 are brought into contact with the inner surface 683 or the outer surface 685 of the unfolded garment end edge 739 or 737 or arm opening edge 732 or 730 and the corresponding portions of the sleeves 733 and 735 or the front and back panels 692 and 697. It is understood that the folding back of a garment end edge 737 or 739 or an arm opening edge 730 or 732 could be performed such that the inner surface 683 would be exposed along the fold.

The sleeve opening end edges 741 and 743 of the sleeves 733 and 735, respectively, (in the alternative, the sleeve opening end edges 741 and 743 of the pieces of the sleeve web fabric 734 and 736) can be hemmed by any method or style known in the art. In some embodiments, it may be desirable to leave the sleeve opening end edges

741 and 743 unhemmed.

In other embodiments, cuffs 742 and 744 may be attached to the sleeve opening end edges 741 and 743, respectively, of the sleeves 733 and 735, respectively, of the garment 682, forming cuff seams 762 and 764, respectively. The attachment of the cuffs

742 and 744 may be made non-refastenable by means as discussed above. In the alternative, the attachment of the cuffs 742 and 744 may be made refastenable by means as discussed above. The cuff seams 762 and 764 may be constructed on a continuous or intermittent basis. The cuffs 742 and 744 may take on a variety of sizes and shapes. The cuffs 742 and 744 may be similar or dissimilar in shape, structure, material, size, and the like from each other within the finished garment 682. The pattern of the cuffs 742 and 744 is restricted only by the fashion and the minimum amount of the material of the cuffs 742 and 744 that is necessary to complete the remaining steps or operations of the process of manufacture.

The cuff seams 762 and 764 of the present invention may take on a variety of structures or configurations known in the art. One embodiment of the cuff seams 762 and 764 is an out-turned configuration as illustrated in Figure 74. Such configured cuff seams 762 and 764 are formed by securing together at least a portion of the out-turned portions of the cuff edge 761 and the sleeve opening end edge 741 and the cuff edge 763 and the sleeve opening end edge 743, respectively, of the garment 682. The inner surface 683 of the cuff edges 761 and 763 of the cuffs 742 and 744, respectively, are brought into contact with the inner surface 683 of the sleeve opening edges 741 and 743 of the sleeves 733 and 735, respectively.

Another embodiment of the cuff seams 762 and 764 is an in-turned configuration as illustrated in Figure 75. Such configured cuff seams 762 and 764 are formed by securing together at least a portion of the in-turned portions of the cuff edge 761 and the sleeve opening edge 741 and the cuff edge 763 and the sleeve opening edge 743, respectively, of the garment 682. The outer surface 685 of the cuff edges 761 and 763 of the cuffs 742 and 744, respectively, are brought into contact with the outer surface 685 of the sleeve opening edges 741 and 743 of the sleeves 733 and 735, respectively.

Another embodiment of the cuff seams 762 and 764 is an over-lapped configuration as illustrated in Figure 73. Such configured cuff seams 762 and 764 are formed by securing together at least a portion of the over-lapped portions of the cuff edge 761 and the sleeve opening edge 741 and the cuff edge 763 and the sleeve opening edge 743 of the sleeves 733 and 735, respectively. The inner surface 683 of one of the cuff edge 761 or the sleeve opening edge 741 and the cuff edge 763 or the sleeve opening edge 743, is brought into contact with the outer surface 685 of the other cuff edge 761 or the sleeve opening edge 741 and the cuff edge 763 or the sleeve opening edge 743 of the sleeves 733 and 735, respectively.

Another embodiment of the cuff seams 762 and 764 is an over-lapped configuration as illustrated in Figure 76. Such configured cuff seams 762 and 764 are formed by folding back the cuff edge 761 or the sleeve opening end edge 741 and the cuff edge 763 or the sleeve opening end edge 743 of the sleeves 733 and 735, respectively. The outer surface 685 of the folded portions and the inner surface 683 of the unfolded portions of the cuff edge 761 or the sleeve opening end edge 741 and the cuff edge 763 or the sleeve opening end edge 743 and the corresponding portions of the cuffs 742 and 744 or the sleeves 733 and 735 are brought into contact with the inner surface 683 or the outer surface 685 of the unfolded cuff edge 761 and 763 or the sleeve opening end edge 741 and 743 and the corresponding portions of the cuffs 742 and 744 or the sleeves 733 and 735. It is understood that the folding back of a cuff edge 761 or 763 or a sleeve opening end edge 741 or 743 could be performed such that the inner surface 683 would be exposed along the fold.

The materials used for the cuffs 742 and 744 may be the same as the materials used for the other portions of the garment 682. In some embodiments, it is desirable that the materials used for the cuffs 742 and 744 have an elastic element such that the cuffs 742 and 744 will conform to the portion of the wearer's arms that come into contact with the cuffs 742 and 744.

The edge 749 of the neck opening 747 can be hemmed by any method or style known in the art. In some embodiments, it may be desirable to leave the edge 749 of the neck opening 747 unhemmed.

In other embodiments, a collar 751 may be attached to the edge 749 of the neck opening 747 of the garment 682, thereby forming a collar seam 766. The attachment of the collar 751 may be made non-refastenable by means as discussed above. (Sewing equipment 769 is shown in Figure 51). In the alternative, the attachment of the collar 751 may be made refastenable by means as discussed above. The collar seam 766 may be constructed on a continuous or intermittent basis. The collar 751 may take on a variety of sizes and shapes. The pattern of the collar 751 is restricted only by the fashion and the minimum amount of the material of the collar 751 that is necessary to complete the remaining steps or operations of the process of manufacture.

The collar seam 766 of the present invention may take on a variety of structures or configurations known in the art. One embodiment of the collar seam 766 is an out-turned configuration as illustrated in Figure 74. Such a configured collar seam 766 is formed by securing together at least a portion of the out-turned portions of the collar edge 765 and the edge 749 of the neck opening 747 of the garment 682. The inner surface 683 of the collar edge 765 of the collar 751 is brought into contact with the inner surface 683 of the edge 749 of the neck opening 747.

Another embodiment of the collar seam 766 is an in-turned configuration as illustrated in Figure 75. Such a configured collar seam 766 is formed by securing together at least a portion of the in-turned portions of the collar edge 765 of the collar 751 and the edge 749 of the neck opening 747 of the garment 682. The outer surface 685 of the collar edge 765 of the collar 751 is brought into contact with the outer surface 685 of the edge 749 of the neck opening 747.

Another embodiment of the collar seam 766 is an over-lapped configuration as illustrated in Figure 75. Such a conflgured collar seam 766 is formed by securing together at least a portion of the over-lapped portions of the collar edge 765 of the collar 751 and the edge 749 of the neck opening 747 of the garment 682. The inner surface 683 of the collar edge 765 of the collar 751 or the edge 749 of the neck opening 747 is brought into contact with the outer surface 685 of the other, the collar edge 765 of the collar 751 or the edge 749 of the neck opening 747.

Another embodiment of the collar seam 766 is an over-lapped configuration as illustrated in Figure 76. Such a configured collar seam 766 is formed by folding back the collar edge 765 of the collar 751 or the edge 749 of the neck opening 747. The outer surface 685 of the folded portions and the inner surface 683 of the unfolded portions of the collar edge 765 of the collar 751 or the edge 749 of the neck opening 747 and the corresponding portions of the collar 751 or the front and back panels 692 and 697 are brought into contact with the inner surface 683 or the outer surface 685 of the unfolded collar edge 765 of the collar 751 or the edge 749 of the neck opening 747 and the corresponding portions of the collar 751 or the front and back panels 692 and 697. It is understood that the folding back of the collar edge 765 of the collar 751 or the edge 749 of the neck opening 747 could be performed such that the inner surface 683 would be exposed along the fold.

Another embodiment of the collar seam 766 is an over-lapped configuration as illustrated in Figure 77. Such a configured collar seam 766 is formed by folding the collar 751 about or over the edge 749 of the neck opening 747. The collar edges 765 of the collar 751 may be folded under bringing the outer surface 685 of the collar 751 into contact with the edge 749 of the neck opening and any portion of the adjacent material of the front panel 692, the back panel 697, or both as desired. The collar edges 765 may be left exposed by not being folding under. Another embodiment of the collar seam 766 is an over-lapped configuration as illustrated in Figure 78. Such a configured collar seam 766 is formed by folding the collar edge 765 such that the inner surface 683 of the collar 751 is brought into contact with itself. The edge 749 of the neck opening 747 is folded such that the outer surface 685 of the front panel 692, the back panel 697, or both are brought into contact with itself. The collar edge 765 is inserted into the fold of the edge 749 of the neck opening 747. The edge 749 of the neck opening 747 is inserted into the fold of the collar edge 765. In another embodiment, the collar edge 765 is folded such that the outer surface 685 of the collar 751 is brought into contact with itself. The edge 749 of the neck opening 747 is folded such that the inner surface 683 of the front panel 692, the back panel 697, or both are brought into contact with itself. This configured collar seam 766 may be used with any seam describe herein.

The materials used for the collar 751 may be the same as the materials used for the other portions of the garment 682. In some embodiments, it is desirable that the materials used for the collar 751 have an elastic element such that the collar 751 will conform to the portion of the wearer's neck that comes into contact with the collar 751.

In various embodiments of the present invention, the front panel 692, the back panel 697, or both panels 692 and 697 may be cut or otherwise opened to form a slit 707 or 754 (shown in Figure 52) such as a placket. The slit 707 has two edges 718 and 719. The slit 754 has two edges 755 and 757. The slits 707 and 754 of the front and back panels 692 and 697, respectively, may extend from the edge 749 of the neck opening 747 to the garment bottom edges 695 and 701, respectively. In the alternative, the slits 707 and 754 may extend over only a portion of the panels 692 and 697 between the edge 749 of the neck opening 747 to the garment bottom edges 695 and 701 , respectively. When the garment 682 comprises both a slit 707 in the front panel 692 and a slit 754 in the back panel 697, the slits 707 and 754 may be similar or dissimilar in size, structure, shape, and the like.

In some embodiments, the edges 718 and 719 of the slit 707 and the edges 755 and 757 of the slit 754 may be refastenably attached or secured to each other. The edges 718 and 719 may be secured together to form the front seam 767. The edges 755 and 757 may be secured together to form the back seam 768. Various fastening means, such as adhesive and mechanical type fasteners 752, see the discussion above, may be used to refastenably attach or secure the edges 718 and 719 or the edges 755 and 757 together of the slits 707 and 754, respectively.

One embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a web of fabric including opposing web side edges wherein said opposing web side edges are proximate a pair of opposing garment bottom edges of said garment; intermittently cutting said web of fabric, forming edges defining neck openings in said web fabric; cutting said web of fabric, defining discrete garment-sized pieces wherein each of said discrete garment- sized piece of said web of fabric includes at least one said neck opening, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, two opposing garment end portions, and said pair of opposing bottom end edges; folding said discrete garment-sized piece of said web of fabric whereby one of said garment bottom edges of said pair of opposing garment bottom edges is brought into contact with the other said garment bottom edge; and, fastening at least a portion of said pair of opposing garment side edges of said front panel to at least a portion of said pair of opposing garment side edges of said back panel to form a pair of garment side seams.

The web of fabric may be intermittently cut, forming arm opening edges defining pairs of opposing arm openings in said web of fabric. At least a portion of at least one of said opposing garment bottom edges may be hemmed. The discrete garment-sized pieces of said web of fabric may include at least one pair of said arm opening edges. Pieces of sleeve web fabric may be provided wherein each of said pieces of said sleeve web fabric includes at least a pair of opposing sleeve side edges, a garment end edge having a shape complementary to at least a portion of the shape of at least one of said arm opening edges of said arm openings and an opposing sleeve opening end edge. At least a portion of said garment end edge of each of said piece of said sleeve web fabric may be applied and fastened to at least a portion of one of said arm opening edges of said arm openings. At least a portion of at least one of said sleeve opening end edges of said pieces of said sleeve web fabric may be hemmed.

The neck opening in said discrete garment-sized piece may be intermediate at least one of said pairs of opposing arm opening edges. A collar may be provided. At least a portion of said collar may be fastened to at least a portion of said edge of said neck opening. The collar may be a ribbed knit collar. At least a portion of at least one of said garment side seams may be refastenable. At least a portion of at least one of said garment side seams may be non-refastenable. At least a portion of said edge of said neck opening may be hemmed. At least a portion of at least one of said arm opening edges of said arm openings may be hemmed.

Pieces of sleeve web fabric may be provided wherein each of said pieces of said sleeve web fabric includes at least a garment end edge having at least a portion of a shape complementary to at least a portion of the shape of a portion of said opposing garment side edges of said front panel, or said back panel, or of both said front and back panels, and an opposing sleeve opening end edge. At least a portion of said garment end edge of each of said pieces of said sleeve web fabric may be applied and fastened to at ' least a portion of one of said garment side edges defining said arm opening. At least a portion of at least one of said sleeve opening end edges of said pieces of said sleeve web fabric may be hemmed.

The front panel may be slit at least a portion of the distance between said edge of said neck opening and said garment bottom edge, thereby defining a pair of edges of a slit. At least a portion of said edges of said slit may be fastened to form a front seam. At least a portion of said front seam may be refastenable. At least a portion of said front seam may be non-refastenable. The back panel may be slit at least a portion of the distance between said edge of said neck opening and said garment bottom edge, thereby defining a pair of edges of a slit. At least a portion of said edges of said slit may be fastened to form a back seam. At least a portion of said back seam may be refastenable. At least a portion of said back seam may be non-refastenable.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a web of fabric including opposing web side edges wherein said opposing web side edges are proximate a pair of opposing garment bottom edges of said garment; intermittently cutting said web of fabric, forming arm opening edges defining arm openings and edges defining neck openings in said web fabric; cutting said web of fabric, defining discrete garment-sized pieces wherein each of said discrete garment-sized piece of said web of fabric includes at least one said neck opening, one pair of opposing arm opening edges, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, two opposing garment end portions, and said pair of opposing bottom end edges; folding said discrete garment-sized pieces of said web of fabric whereby one of said garment bottom edges of said pair of opposing garment bottom edges is brought into contact with the other said garment bottom edge; and, fastening at least a portion of said pair of opposing garment side edges of said front panel to at least a portion of said pair of opposing garment side edges of said back panel to form a pair of garment side seams.

At least a portion of at least one of said opposing garment bottom edges may be hemmed. Pieces of sleeve web fabric may be provided wherein each of said pieces of said sleeve web fabric includes at least a pair of opposing sleeve side edges, a garment end edge having at least a portion of a shape complimentary to at least a portion of the shape of at least one of said arm opening edges of said arm openings and an opposing sleeve opening end edge. At least a portion of said garment end edge of each of said pieces of said sleeve web fabric may be applied and fastened to at least a portion of one of said arm opening edges of said arm openings. At least a portion of at least one of said sleeve opening end edges of said pieces of said sleeve web fabric may be hemmed.

The neck opening in said discrete garment-sized piece may be intermediate at least one of said pairs of opposing arm opening edges. A collar may be provided. At least a portion of said collar may be fastened to at least a portion of said edge of said neck opening. At least a portion of said collar may be a ribbed knit collar. At least a portion of at least one of said garment side seams may be refastenable. At least a portion of at least one of said garment side seams may be non-refastenable. At least a portion of said edge of said neck opening may be hemmed. At least a portion of at least one of said arm opening edges of said arm openings may be hemmed.

The front panel may be slit at least a portion of the distance between said edge of said neck opening and said garment bottom edge, thereby defining a pair of edges of a slit. At least a portion of said edges of said slit may be fastened to form a front seam. At least a portion of said front seam may be refastenable. At least a portion of said front seam may be non-refastenable. The back panel may be slit at least a portion of the distance between said edge of said neck opening and said garment bottom edge, thereby defining a pair of edges of a slit. At least a portion of said edges of said slit may be fastened to form a back seam. At least a portion of said back seam may be refastenable. At least a portion of said back seam may be non-refastenable. Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a web of fabric including opposing web side edges wherein said web side edges are proximate a pair of opposing garment bottom edges of said garment; intermittently cutting said web of fabric, forming arm opening edges defining pairs of opposing arm openings in said web of fabric; intermittently cutting said web of fabric, forming edges defining neck openings in said web of fabric; providing pieces of sleeve web fabric, wherein each of said pieces of sleeve web fabric includes at least a garment end edge having at least a portion of a shape complementary to at least a portion of the shape of at least one of said arm opening edges of said arm openings, a pair of opposing sleeve side edges, and an opposing sleeve opening end edge; applying and fastening at least a portion of said garment end edge of each of said piece of said sleeve web fabric to at least a portion of said arm opening edge of one of said arm openings; hemming at least a portion of at least one of said sleeve opening end edges of said pieces of said sleeve web fabric; cutting said web of fabric, defining discrete garment-sized pieces wherein each of said discrete garment- sized pieces of said web of fabric includes at least a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, a pair of said arm opening edges of said arm openings, one of said neck opening, two opposing garment end portions, and said pair of opposing garment bottom edges; hemming at least a portion of at least one of said opposing garment bottom edges; folding said discrete garment-sized piece of said web of fabric whereby one of said garment bottom edges of said pair of opposing garment bottom edges is brought into contact with other said garment bottom edge; and, fastening at least a portion of said pair of opposing garment side edges of said front panel to at least a portion of said pair of opposing garment side edges of said back panel to form a pair of garment side seams.

The web of fabric may be folded, defining an arrangement of having said web of fabric wherein said opposing web side edges are adjacent each other. The web of fabric may be unfolded after at least one of said steps of intermittently cutting said web of fabric. The discrete garment-sized piece of said web of fabric may be unfolded before the step of folding said discrete garment-sized piece of said web of fabric whereby said pair of opposing garment side edges of said front panel are brought into contact with said pair of opposing garment side edges of said back panel.

A collar may be provided. At least a portion of said collar may be fastened to at least a portion of said edge of said neck opening. At least a portion of said collar may be a ribbed knit collar. At least a portion of at least one of said garment side seams may be refastenable. At least a portion of at least one of said garment side seams may be non- refastenable. The neck opening in said discrete garment-sized piece may be intermediate at least one of said pairs of opposing arm opening edges. At least a portion of said edge of said neck opening may be hemmed. At least a portion of at least one of said arm opening edges of said opposing arm openings may be hemmed.

The front panel may be slit at least a portion of the distance between said edge of said neck opening and said garment bottom edge thereby defining a pair of edges of a slit. At least a portion of said edges of said slit may be fastened to form a front seam. At least a portion of said front seam may be refastenable. At least a portion of said front seam may be non-refastenable. The back panel may be slit at least a portion of the distance between said edge of said neck opening and said garment bottom edge, thereby defining a pair of edges of a slit. At least a portion of said edges of said slit may be fastened to form a back seam. At least a portion of said back seam may be refastenable. At least a portion of said back seam may be non-refastenable.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a web of fabric including an inner surface, an outer surface, and opposing side edges wherein said opposing web side edges are proximate a pair of opposing garment bottom edges of said garment; intermittently cutting said web of fabric, forming arm opening edges defining pairs of opposing arm openings in said web of fabric; intermittently cutting said web of fabric, forming edges defining neck openings in said web of fabric; cutting said web of fabric, defining discrete garment-sized pieces wherein each of said discrete garment- sized piece of said web of fabric includes at least a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, a pair of said arm opening edges of said arm openings, one said neck opening, two opposing garment end portions, and said pair of opposing garment bottom edges; hemming at least a portion of at least one of said opposing garment bottom edges; folding said discrete garment-sized piece of said web of fabric whereby one of said garment bottom edges of said pair of opposing garment side edges is brought into contact with the other said garment bottom edge; and, fastening at least a portion of said pair of opposing garment side edges of said front panel to at least a portion of said pair of opposing garment side edges of said back panel to form a pair of garment side seams. The web of fabric may be folded, defining an arrangement of having said web of fabric wherein said opposing web side edges are adjacent each other. The web of fabric may be unfolded after at least one of said steps of intermittently cutting said web of fabric. The discrete garment-sized piece of said web of fabric may be unfolded before the step of folding said discrete garment-sized piece of said web of fabric whereby said pair of opposing garment side edges of said front panel are brought into contact with said pair of opposing garment side edges of said back panel.

Pieces of sleeve web fabric may be provided wherein each of said pieces of said sleeve web fabric includes at least an inner surface, an outer surface, a garment end edge having at least a portion of a shape complementary to at least a portion of the shape of at least one of said arm opening edge of at least one of said arm openings, and an opposing sleeve opening end edge wherein said garment end edge is aligned with one of said arm opening edges of said arm opening and said outer surface of said piece of said sleeve web fabric is in contact with said outer surface of said web of fabric at least at said arm opening edge of said arm opening. At least a portion of said garment end edge of said piece of said sleeve web fabric may be applied and fastened to at least a portion of said arm opening edge of said arm opening. At least a portion of said sleeve opening end edge of said piece of said sleeve web fabric may be hemmed.

The neck opening in said discrete garment-sized piece may be intermediate at least one of said pairs of said opposing arm opening edges. A collar may be provided. The collar may be fastened to at least a portion of said edge of said neck opening. The collar may be a ribbed knit collar. At least a portion of at least one of said garment side seams may be refastenable. At least a portion of at least one of said garment side seams may be non-refastenable. At least a portion of said edge of said neck opening may be hemmed. At least a portion of at least one of said arm opening edges of said arm openings may be hemmed.

The front panel may be slit at least a portion of the distance between said edge of said neck opening and said garment bottom edge thereby defining a pair of edges of a slit. At least a portion of said edges of said slit may be fastened to form a front seam. At least a portion of said front seam may be refastenable. At least a portion of said front seam may be non-refastenable. The back panel may be slit at least a portion of the distance between said edge of said neck opening and said garment bottom edge thereby defining a pair of edges of a slit. At least a portion of said edges of said slit may be fastened to form a back seam. At least a portion of said back seam may be refastenable. At least a portion of said back seam may be non-refastenable.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a first web of fabric including opposing web side edges; providing a second web of fabric including opposing web side edges; aligning said first and second webs of fabric together in a side by side orientation defining an arrangement fabric wherein one of said opposing web side edges of said first web of fabric is adjacent one of said opposing web side edges of said second web of fabric; fastening at least a portion of said adjacent web side edge of said first web of fabric to at least a portion of said adjacent web side edge of said second web of fabric in said side by side orientation, defining at least a portion of a center seam and a composite web of fabric having a pair of opposing web side edges wherein said opposing web side edges of said composite web of fabric are proximate a pair of opposing garment bottom edges of said garment; intermittently cutting said composite web of fabric, forming edges defining neck openings in said composite web of fabric; cutting said composite web of fabric, defining discrete garment-sized pieces wherein each of said discrete garment-sized pieces of said composite web of fabric includes at least one said neck opening, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, two opposing garment end portions, and said pair of opposing garment bottom edges; folding said discrete garment-sized piece of said composite web of fabric whereby one of said garment bottom edges of said pair of opposing garment bottom edges is brought into contact with the other said garment bottom edge; and, fastening at least a portion of said pair of opposing garment side edges of said front panel to at least a portion of said pair of opposing garment side edges of said back panel to form a pair of garment side seams.

The composite web of fabric may be intermittently cut, forming arm opening edges defining pairs of opposing arm openings in said composite web of fabric. At least a portion of at least one of said opposing garment bottom edges may be hemmed. The discrete garment-sized pieces may include at least one pair of said arm opening edges. Pieces of sleeve web fabric may be provided, wherein each of said pieces of said sleeve web fabric includes at least a garment end edge having at least a portion of a shape complementary to at least a portion of the shape of at least one of said arm opening edges of said arm openings and an opposing sleeve opening end edge. The garment end edge of each piece of said sleeve web fabric may be applied and fastened to one of said arm opening edges of said arm openings. At least a portion of at least one of said sleeve opening end edges of said pieces of said sleeve web fabric may be hemmed.

At least one of said neck openings in said composite web of fabric may be intermediate a pair of said opposing arm opening edges. A collar may be provided. At least a portion of said collar may be fastened to at least a portion of said edge of said neck opening. At least a portion of said collar may be a ribbed knit collar. At least a portion of at least one of said garment side seams may be refastenable. At least a portion of at least one of said garment side seams may be non-refastenable. At least a portion of said edge of said neck opening may be hemmed. At least a portion of at least one of said arm opening edges of said arm openings may be hemmed.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a first web of fabric including opposing web side edges; providing a second web of fabric including opposing web side edges; aligning said first and second webs of fabric together in a side by side orientation defining an arrangement wherein one of said opposing web side edges of said first web of fabric is adjacent one of said opposing web side edges of said second web of fabric; fastening at least a portion of said adjacent web side edge of said first web of fabric to at least a portion of said adjacent web side edge of said second web of fabric in said side by side orientation, defining at least a portion of a center seam and a composite web of fabric having a pair of opposing web side edges wherein said opposing web side edges of said composite web of fabric are proximate a pair of opposing garment bottom edges of said garment; intermittently cutting said composite web of fabric, forming arm opening edges defining pairs of opposing arm openings in said composite web of fabric; intermittently cutting said composite web of fabric, forming edges defining neck openings in said composite web of fabric wherein said neck openings are intermediate said pairs of opposing arm opening edges; cutting said composite web of fabric, defining discrete garment-sized pieces wherein each of said discrete garment-sized piece of said composite web of fabric includes at least a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, one of said neck openings, at least one pair of said arm opening edges, two opposing garment end portions, and said pair of opposing garment bottom edges; folding said discrete garment- sized piece of said composite web of fabric whereby one of said garment bottom edges of said pair of opposing garment bottom edges is brought into contact with the other said garment bottom edge; and, fastening at least a portion of said pair of opposing garment side edges of said front panel to at least a portion of said pair of opposing garment side edges of said back panel to form a pair of garment side seams.

At least a portion of at least one of said opposing garment bottom edges may be hemmed. Pieces of sleeve web fabric may be provided, wherein each of said pieces of said sleeve web fabric includes at least a garment end edge having at least a portion of a shape complementary to at least a portion of the shape of at least a portion of said arm opening edge of said arm opening and an opposing sleeve opening end edge. At least a portion of said garment end edge of each of said pieces of said sleeve web fabric may be applied and fastened to at least a portion of one of said arm opening edges of said arm openings. At least a portion of at least one of said sleeve opening end edges of said pieces of said sleeve web fabric may be hemmed. At least one of said neck openings in said composite web of fabric may be intermediate a pair of said opposing arm opening edges.

A collar may be provided. At least a portion of said collar may be fastened to at least a portion of said edge of said neck opening. At least a portion of said collar may be a ribbed knit collar. At least a portion of at least one of said garment side seams may be refastenable. At least a portion of at least one of said garment side seams may be non- refastenable. At least a portion of said edge of said neck opening may be hemmed. At least a portion of at least one of said arm opening edges of said arm openings may be hemmed.

The front panel may be slit at least a portion of the distance between said edge of said neck opening and said garment bottom edge, thereby defining a pair of edges of a slit. At least a portion of said edges of said slit may be fastened to form a front seam. At least a portion of said front seam may be refastenable. At least a portion of said front seam may be non-refastenable. The back panel may be slit at least a portion of the distance between said edge of said neck opening and said garment bottom edge thereby defining a pair of edges of a slit. At least a portion of said edges of said slit may be fastened to form a back seam. At least a portion of said back seam may be refastenable. At least a portion of said back seam may be non-refastenable.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a first web of fabric including opposing web side edges; providing a second web of fabric including opposing web side edges; aligning said first and second webs of fabric together in a side by side orientation defining an arrangement wherein one of said opposing web side edges of said first web of fabric is adjacent one of said opposing web side edges of said second web of fabric; fastening at least a portion of said adjacent web side edge of said first web of fabric to at least a portion of said adjacent web side edge of said second web of fabric in said side by side orientation, defining at least a portion of a center seam and a composite web of fabric having a pair of opposing web side edges wherein said opposing web side edges of said composite web of fabric are proximate a pair of opposing garment bottom edges of said garment; intermittently cutting said composite web of fabric, forming arm opening edges defining pairs of opposing arm openings in said composite web of fabric; intermittently cutting said composite web of fabric, forming edges defining neck openings in said composite web of fabric wherein said neck openings are intermediate said pairs of said opposing arm opening edges; providing pieces of sleeve web fabric, wherein each of said pieces of sleeve web fabric includes at least a garment end edge having at least a portion of a shape complementary to at least a portion of the shape of at least a portion of said arm opening edges of said arm openings and an opposing sleeve opening end edge; applying and fastening at least a portion of said garment end edge of each of said pieces of said sleeve web fabric to at least a portion of one of said edges of said arm openings; hemming at least a portion of at least one of said sleeve opening end edges of said pieces of said sleeve web fabric; cutting said composite web of fabric, defining discrete garment-sized pieces wherein each of said discrete garment-sized piece of said composite web of fabric includes at least a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing side edges, one of said neck openings, one pair of said arm opening edges, two opposing garment end portions, and said pair of opposing garment bottom edges; hemming at least a portion of at least one of said opposing garment bottom edges; folding said discrete garment-sized piece of said composite web of fabric whereby one of said garment bottom edges of said pair of opposing garment side edges is brought into contact with other said garment bottom edge; and, fastening at least a portion of said pair of opposing garment side edges of said front panel to at least a portion of said pair of opposing garment side edges of said back panel to form a pair of garment side seams.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a first web of fabric including opposing web side edges, an inner surface, and an outer surface; providing a second web of fabric including opposing web side edges, an inner surface, and an outer surface; aligning said first and second webs of fabric together in a side by side orientation defining an arrangement wherein one of said opposing web side edges of said first web of fabric is adjacent one of said opposing web side edges of said second web of fabric; fastening at least a portion of said adjacent web side edge of said first web of fabric to at least a portion of said adjacent web side edge of said second web of fabric in said side by side orientation, defining at least a portion of a center seam and a composite web of fabric having a pair of opposing web side edges wherein said opposing web side edges of said composite web of fabric are proximate a pair of opposing garment bottom edges of said garment; intermittently cutting said composite web of fabric, forming arm opening edges defining pairs of opposing arm openings in said composite web of fabric; intermittently cutting said composite web of fabric, forming edges defining neck openings in said composite web of fabric wherein each said neck opening is intermediate a pair of said opposing arm opening edges; cutting said composite web of fabric, defining discrete garment-sized pieces wherein each of said discrete garment-sized pieces of said composite web of fabric includes at least a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, one of said neck openings, one pair of said arm opening edges, two opposing garment end portions, and said pair of opposing garment bottom edges; hemming at least a portion of at least one of said opposing garment bottom edges; folding said discrete garment-sized piece of said composite web of fabric whereby one of said garment bottom edges of said pair of opposing garment bottom edges is brought into contact with the other said garment bottom edge; and, fastening at least a portion of said pair of opposing garment side edges of said front panel to at least a portion of said pair of opposing garment side edges of said back panel to form a pair of garment side seams.

Pieces of sleeve web fabric may be provided wherein each of said pieces of said sleeve web fabric includes at least an inner surface, an outer surface, a garment end edge having at least a portion of a shape complementary to at least a portion of the shape of at least a portion of said arm opening edge of at least one of said arm openings, and an opposing sleeve opening end edge wherein said garment end edge is aligned with one of said arm opening edges of said arm openings in said composite web of fabric and said outer surface of said piece of said sleeve web fabric is in contact with said outer surface of said composite web of fabric at least at at least a portion of said arm opening edge of said arm openings. At least a portion of said garment end edge of said piece of said sleeve web fabric may be applied and fastened to at least a portion of said arm opening edge of said arm opening. At least a portion of said sleeve opening end edge of said piece of said sleeve web fabric may be hemmed.

At least one of said neck openings in said composite web of fabric may be intermediate at least one of said pairs of said opposing arm openings. A collar may be hemmed. At least a portion of said collar may be fastened to at least a portion_. of said edge of said neck opening. At least a portion of said collar may be a ribbed knit collar. At least a portion of at least one of said garment side seams may be refastenable. At least a portion of at least one of said garment side seams may be non-refastenable. At least a portion of said edge of said neck opening may be hemmed. At least a portion of at least one of said arm opening edges of said arm openings may be hemmed.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a first web of fabric including a first web side edge and a second web side edge; providing a second web of fabric including a first web side edge and a second web side edge; intermittently cutting said second web side edge of said first web of fabric, forming indentations; intermittently cutting said second web side edge of said second web of fabric, forming indentations; aligning said first and second webs of fabric together in a side by side orientation defining an arrangement wherein said second web side edge of said first web of fabric is adjacent said second web side edge of said second web of fabric and said indentations of said second web side edge of said first web of fabric are adjacent said indentations of said second web side edge of said second web of fabric, thereby forming edges defining neck openings; fastening at least a portion of said second web side edge of said first web of fabric to at least a portion of said second web side edge of said second web of fabric in said side by side orientation, defining at least a portion of a center seam and a composite web of fabric having a pair of opposing web side edges wherein said opposing web side edges of said composite web of fabric are proximate a pair of opposing garment bottom edges of said garment; intermittently cutting said composite web of fabric, forming arm opening edges defining pairs of opposing arm openings in said composite web of fabric; cutting said composite web of fabric, defining discrete garment-sized pieces wherein each of said discrete garment-sized pieces of said composite web of fabric includes at least one said neck opening, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, one pair of said arm opening edges, two garment end portions, and said pair of opposing garment bottom edges; folding said discrete garment-sized piece of said composite web of fabric whereby one of said garment bottom edges of said pair of opposing garment bottom edges is brought into contact with the other said garment bottom edge; and fastening at least a portion of said pair of opposing garment side edges of said front panel to at least a portion of said pair of opposing garment side edges of said back panel to form a pair of garment side seams.

Pieces of sleeve web fabric may be provided wherein each of said pieces of said sleeve web fabric includes at least an inner surface, an outer surface, a garment end edge having at least a portion of a shape complementary to at least a portion of the shape of at least a portion of said arm opening edge of at least one of said arm openings, and an opposing sleeve opening end edge wherein said garment end edge is aligned with one of said arm opening edges of said arm openings in said composite web of fabric and said outer surface of said piece of said sleeve web fabric is in contact with said outer surface of said composite web of fabric at least at at least a portion of said arm opening edge of said arm openings. At least a portion of said garment end edge of said piece of said sleeve web fabric may be applied and fastened to at least a portion of said arm opening edge of said arm opening. At least a portion of said sleeve opening end edge of said piece of said sleeve web fabric may be hemmed. At least a portion of at least one of said opposing garment bottom edges may be hemmed.

At least one of said neck openings in said composite web of fabric may be intermediate at least one of said pairs of said opposing arm openings. A collar may be hemmed. At least a portion of said collar may be fastened to at least a portion of said edge of said neck opening. At least a portion of said collar may be a ribbed knit collar. At least a portion of at least one of said garment side seams may be refastenable. At least a portion of at least one of said garment side seams may be non-refastenable. At least a portion of said edge of said neck opening may be hemmed. At least a portion of at least one of said arm opening edges of said arm openings may be hemmed.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a first web of fabric including opposing web side edges; providing a second web of fabric including opposing web side edges; aligning said first and second webs of fabric together in a face to face orientation defining an arrangement wherein said opposing web side edges of said first web of fabric are adjacent said opposing web side edges of said second web of fabric, thereby defining a first pair of adjacent web side edges and a second pair of adjacent web side edges; fastening at least a portion of said first pair of adjacent web side edges together in said face to face orientation, defining at least a portion of a center seam and a composite web of fabric having a pair of opposing web side edges formed from said second pair of adjacent web side edges wherein said opposing web side edges of said composite web of fabric are proximate a pair of opposing garment bottom edges of said garment; intermittently cutting said composite web of fabric, forming edges defining neck openings in said composite web of fabric; cutting said composite web of fabric, defining discrete garment-sized pieces wherein each of said discrete garment-sized pieces of said composite web of fabric includes at least one of said neck openings, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, two opposing garment end portions, and said pair of opposing garment bottom edges; folding said discrete garment-sized piece of said composite web of fabric whereby one of said garment bottom edges of said pair of opposing garment side edges is brought into contact with the other said garment bottom edge; and, fastening at least a portion of said pair of opposing garment side edges of said front panel to at least a portion of said pair of opposing garment side edges of said back panel to form a pair of garment side seams.

The composite web of fabric may be unfolded. The discrete garment-sized piece of said composite web of fabric may be unfolded. The composite web of fabric may be intermittently cut, forming arm opening edges defining pairs of opposing arm openings in said composite web of fabric. At least a portion of at least one of said opposing garment bottom edges may be hemmed. The discrete garment-sized pieces may include at least one pair of said arm opening edges. Pieces of sleeve web fabric may be provided, wherein each of said pieces of said sleeve web fabric includes at least a garment end edge having at least a portion of a shape complementary to at least a portion of the shape of a portion of said opposing garment side edges of said front panel, or said back panel, or of both said front and back panels, and an opposing sleeve opening end edge. At least a portion of said garment end edge of each piece of said sleeve web fabric may be applied and fastened to at least a portion of one of said garment side edges defining said arm opening. At least a portion of at least one of said sleeve opening end edges of said pieces of said sleeve web fabric may be hemmed. At least one of said neck openings in said composite web of fabric may be intermediate one of said pairs of said opposing arm opening edges.

A collar may be provided. At least a portion of said collar may be fastened to at least a portion of said edge of said neck opening. At least a portion of said collar may be a ribbed knit collar. At least a portion of at least one of said garment side seams may be refastenable. At least a portion of at least one of said garment side seams may be non- refastenable. Pieces of sleeve web fabric may be provided, wherein each of said pieces of said sleeve web fabric includes at least a garment end edge having at least a portion of a shape complementary to at least a portion of the shape of at least a portion of said arm opening edges of said opposing arm openings and an opposing sleeve opening end edge. At least a portion of said garment end edge of one piece of said sleeve web fabric may be applied and fastened to at least a portion of one of said arm opening edges of said arm openings. At least a portion of at least one of said sleeve opening end edges of said pieces of said sleeve web fabric may be hemmed. At least a portion of said edge of said neck opening may be hemmed. At least a portion of at least one of said arm opening edges of said arm openings may be hemmed.

The front panel may be slit at least a portion of the distance between said edge of said neck opening and said garment bottom edge, thereby defining a pair of edges of a slit. At least a portion of said edges of said slit may be fastened to form a front seam. At least a portion of said front seam may be refastenable. At least a portion of said front seam may be non-refastenable. The back panel may be slit at least a portion of the distance between said edge of said neck opening and said garment bottom edge thereby defining a pair of edges of a slit. At least a portion of said edges of said slit may be fastened to form a back seam. At least a portion of said back seam may be refastenable. At least a portion of said back seam may be non-refastenable. Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a first web of fabric including opposing web side edges; providing a second web of fabric including opposing web side edges; aligning said first and second webs of fabric together in a face to face orientation, defining an arrangement wherein said opposing web side edges of said first web of fabric are adjacent said opposing web side edges of said second web of fabric, thereby defining a first pair of adjacent web side edges comprising one said web side edge of said first web of fabric and one said web side edge of said second web of fabric and a second pair of adjacent web side edges comprising one said web side edge of said first web of .fabric and one said web side edge of said second web of fabric; fastening at least a portion of said first pair of adjacent web side edges together in a face to face orientation, defining at least a portion of a center seam and a composite web of fabric having a pair of opposing web side edges formed from said second pair of adjacent web side edges wherein said opposing web side edges of said composite web of fabric are proximate a pair of opposing garment bottom edges of said garment; intermittently cutting said composite web of fabric, forming arm opening edges defining pairs of opposing arm openings in said composite web of fabric; intermittently cutting said composite web of fabric, forming edges defining neck openings in said composite web of fabric wherein said neck openings are intermediate said pairs of said opposing arm opening edges; cutting said composite web of fabric, defining discrete garment-sized pieces wherein each of said discrete garment-sized piece of said composite web of fabric includes at least a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, said neck opening, at least one pair of said arm opening edges, two opposing garment end portions, and said pair of opposing garment bottom edges; folding said discrete garment-sized piece of said composite web of fabric whereby one of said garment bottom edges of said pair of opposing garment side edges is brought into contact with the other said garment bottom edge; and, fastening at least a portion of said pair of opposing garment side edges of said front panel to at least a portion of said pair of opposing garment side edges of said back panel to form a pair of garment side seams.

The composite web of fabric may be unfolded. The discrete garment-sized piece of said composite web of fabric may be unfolded. At least a portion of at least one of said opposing garment bottom edges may be hemmed. Pieces of sleeve web fabric may be provided wherein each of said pieces of said sleeve web fabric includes at least a garment end edge having at least a portion of a shape complementary to at least a portion of the shape of at least one of said arm opening edges of one of said arm openings and an opposing sleeve opening end edge. At least a portion of said garment end edge of each piece of said sleeve web fabric may be applied and fastened to at least a portion of one of said arm opening edges of said arm openings. At least a portion of at least one of said sleeve opening end edges of said pieces of said sleeve web fabric may be hemmed.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a first web of fabric including opposing web side edges; providing a second web of fabric including opposing web side edges; aligning said first and second webs of fabric together in a face to face orientation defining an arrangement wherein said opposing web side edges of said first web of fabric are adjacent said opposing web side edges of said second web of fabric, thereby defining a first pair of adjacent web side edges and a second pair of adjacent web side edges; fastening at least a portion of said first pair of adjacent web side edges together in said face to face orientation, defining at least a portion of a center seam and a composite web of fabric having a pair of opposing web side edges formed from said second pair of adjacent web side edges, wherein said opposing web side edges of said composite web of fabric are proximate a pair of opposing garment bottom edges of said garment; intermittently cutting said composite web of fabric, forming arm opening edges defining pairs of opposing arm openings in said composite web of fabric; intermittently cutting said composite web of fabric, forming edges defining neck openings in said composite web of fabric wherein said neck openings are intermediate said pairs of said opposing arm opening edges; providing pieces of sleeve web fabric, wherein each of said pieces of sleeve web fabric includes at least a garment end edge having at least a portion of a shape complementary to at least a portion of the shape of said arm opening edges of said arm openings and an opposing sleeve opening end edge; applying and fastening at least a portion of said garment end edge of each piece of said sleeve web fabric to at least a portion of one of said arm openings; hemming at least a portion of at least one of said sleeve opening end edges of said pieces of said sleeve web fabric; cutting said composite web of fabric, defining discrete garment-sized pieces wherein each of said discrete garment-sized pieces of said composite web of fabric includes at least a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing side edges, one of said neck openings, at least one pair of said arm opening edges, two opposing garment end portions, and said pair of opposing garment bottom edges; hemming at least a portion of at least one of said opposing garment bottom edges; folding said discrete garment-sized piece of said composite web of fabric whereby one of said garment bottom edges of said pair of opposing garment bottom edges is brought into contact with the other said garment bottom edge; and, fastening at least a portion of said pair of opposing garment side edges of said front panel to at least a portion of said pair of opposing garment side edges of said back panel to form a pair of garment side seams.

The composite web of fabric may be unfolded. The discrete garment-sized piece of said composite web of fabric may be unfolded. A collar may be provided. At least a portion of said collar may be fastened to at least a portion of said edge of said neck opening. At least a portion of said collar may be a ribbed knit collar. At least a portion of at least one of said garment side seams may be refastenable. At least a portion of at least one of said garment side seams may be non-refastenable. At least a portion of said edge of said neck opening may be hemmed. At least a portion of at least one of said arm opening edges of said arm openings may be hemmed.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a first web of fabric including opposing web side edges, an inner surface, and an outer surface; providing a second web of fabric including opposing web side edges, an inner surface, and an outer surface; aligning said first and second webs of fabric together in a face to face orientation, defining an arrangement wherein said opposing web side edges of said first web of fabric are adjacent said opposing web side edges of said second web of fabric, thereby defining a first pair of adjacent web side edges and a second pair of adjacent web side edges; fastening at least a portion of said first pair of web adjacent side edges together in said face to face orientation, defining at least a portion of a center seam and a composite web of fabric having a pair of opposing web side edges formed from said second pair of adjacent web side edges, wherein said opposing web side edges of said composite web of fabric are proximate a pair of opposing garment bottom edges of said garment; intermittently cutting said composite web of fabric, forming arm opening edges defining pairs of opposing arm openings in said composite web of fabric; intermittently cutting said composite web of fabric, forming edges defining neck openings in said composite web of fabric, wherein said neck openings are intermediate said pairs of said opposing arm opening edges; cutting said composite web of fabric, defining discrete garment-sized pieces wherein each of said discrete garment-sized pieces of said composite web of fabric includes at least a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, one of said neck openings, one pair of said arm opening edges, two opposing garment end portions, and said pair of opposing garment bottom edges; hemming at least a portion of at least one of said opposing garment bottom edges; folding said discrete garment-sized piece of said composite web of fabric whereby one of said garment bottom edges of said pair of opposing garment bottom edges is brought into contact with the other said garment bottom edge; and, fastening at least a portion of said pair of opposing garment side edges of said front panel to at least a portion of said pair of opposing garment side edges of said back panel to form a pair of garment side seams. The composite web of fabric may be unfolded. The discrete garment-sized piece of said composite web of fabric may be unfolded. Pieces of sleeve web fabric may be provided, wherein each of said pieces of said sleeve web fabric includes at least an inner surface, an outer surface, a garment end edge having at least a portion of a shape complimentary to at least a portion of the shape of said arm opening edges of said arm openings, and an opposing sleeve opening end edge, wherein said garment end edge is aligned with one of said arm opening edge of said arm openings in said composite web of fabric and said outer surface of said piece of said sleeve web fabric is in contact with said outer surface of said composite web of fabric at least at at least a portion of said arm opening edge of said arm openings. At least a portion of said garment end edge of said piece of said sleeve web fabric may be applied and fastened to at least a portion of said arm opening edge of said arm opening. At least a portion of at least one of said sleeve opening end edges of said pieces of said sleeve web fabric may be hemmed.

A collar may be provided. At least a portion of said collar may be fastened to at least a portion of said edge of said neck opening. At least a portion of said collar may be a ribbed knit collar. At least a portion of at least one of said garment side seams may be refastenable. At least a portion of at least one of said garment side seams may be non- refastenable. At least a portion of said edge of said opening may be hemmed. At least a portion of at least one of said arm opening edges of said openings may be hemmed.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a first web of fabric including a first web side edge and a second web side edge; providing a second web of fabric including a first web side edge and a second web side edge; intermittently cutting said second web side edge of said first web of fabric, forming indentations; intermittently cutting said second web side edge of said second web of fabric, forming indentations; aligning said first and second webs of fabric together in a face to face orientation, defining an arrangement wherein said first web side edge of said first web of fabric is adjacent said first web side edge of said second web of fabric and said second web side edge of said first web of fabric is adjacent said second web side edge of said second web of fabric, wherein said indentations of said second web side edge of said first web of fabric are adjacent said indentations of said second web side edge of said second web of fabric, thereby forming edges defining neck openings; fastening at least a portion of said second web side edge of said first web of fabric to at least a portion of said second web side edge of said second web of fabric in said face to face orientation, defining at least a portion of a center seam and a composite web of fabric having a pair of opposing web side edges formed from said first web side edges of said first web of fabric and said first web side edges, wherein said opposing web side edges of said composite web of fabric are proximate a pair of opposing garment bottom edges of said garment; intermittently cutting said composite web of fabric, forming arm opening edges defining pairs of opposing arm openings in said composite web of fabric; cutting said composite web of fabric, defining discrete garment-sized pieces wherein each of said discrete garment-sized pieces of said composite web of fabric includes at least one said neck opening, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, one pair of said arm opening edges, two garment end portions, and said pair of opposing garment bottom edges; folding said discrete garment-sized piece of said composite web of fabric whereby one of said garment bottom edges of said pair of opposing garment bottom edges is brought into contact with the other said garment bottom edge; and, fastening at least a portion of said pair of opposing garment side edges of said front panel to at least a portion of said pair of opposing garment side edges of said back panel to form a pair of garment side seams.

The composite web of fabric may be unfolded. The discrete garment-sized piece of said composite web of fabric may be unfolded. Pieces of sleeve web fabric may be provided, wherein each of said pieces of said sleeve web fabric includes at least an inner surface, an outer surface, a garment end edge having at least a portion of a shape complementary to at least a portion of the shape of said arm opening edges of said arm openings, and an opposing sleeve opening end edge wherein said garment end edge is aligned with one of said arm opening edge of said arm openings in said composite web of fabric and said outer surface of said piece of said sleeve web fabric is in contact with said outer surface of said composite web of fabric at least at at least a portion of said arm opening edge of said arm openings. At least a portion of said garment end edge of said piece of said sleeve web fabric may be applied and fastened to at least a portion of said arm opening edge of said arm opening. At least a portion of at least one of said sleeve opening end edges of said pieces of said sleeve web fabric may be hemmed. At least a portion of at least one of said opposing garment bottom edges may be hemmed.

The garment 810 is illustrated in Figures 79 and 88. The garment 810 includes opposing inner and outer surfaces 811 and 812, respectively. Within this application, the term "garment" is understood to mean shirt, tee-shirt, wrap, robe, gown, jacket, coat, or any type of upper body covering garment having variable lengths of the garment 810 itself and the sleeves (if any) as well as a variety of neck openings and garment openings, such as plackets. According to the preferred embodiment, see Figure 81 , the garment 810 desirably comprises a front panel 815 and a back panel 820. The front panel 815 has a pair of garment side edges 816 and 817, a garment bottom edge 818 and a shoulder region 819 positioned between the garment side edges 816 and 817. The back panel 820 has a pair of garment side edges 821 and 822, a garment bottom edge 824 and a shoulder region 826 positioned between the garment side edges 821 and 822. The garment side edge 816 is joined to the garment side edge 821 to form the garment side seam 827. The garment side edge 817 is joined to the garment side edge 822 to form the garment side seam 828. A portion of the garment side seams 827 and 828 is left unbonded or not joined, preferably in the shoulder regions 819 and 826, defining two opposing arm openings 846 and 848.

The finished garment 810 may include sleeves 850 and 852 so as to surround, at least partially, the arm openings 846 and 848, respectively, of the garment 810. In some embodiments, only one sleeve 850 or 852 may be included in the finished garment 810. The length of the sleeves 850 and 852 may vary from a length intended to at least cover the entire arm of the wearer to a caplet length or shorter. The sleeve opening end edges 858 and 860 of the sleeves 850 and 852, respectively, may be hemmed. For easier manufacture, the sleeve opening end edges 858 and 860 may be left unhemmed, facilitating easy machine cutoff.

In the embodiments of the garments 810 that do not include the sleeves 850 and 852, the unattached portions of the garment side edges 816 and 821 and the garment side edges 817 and 822, more specifically the arm opening edges 847 and 849 defining the arm openings 846 and 848, can be hemmed. For easier manufacture, the arm opening edges 847 and 849, defining the arm openings 846 and 848, may be left unhemmed, facilitating easy machine cutoff.

A neck opening 864, defined about its perimeter by edge 866, is located in at least one of the shoulder regions 819 and 826. The neck opening 864 is typically centered between the garment side edges 816, 817, 821 , and 822, although such placement of the neck opening 864 is not required. The neck opening 864 may take on a variety of sizes and shapes, such as circular, oval, triangular, square, rectangular, multi-faceted, asymmetric or irregular, or the like. While the placement of the neck opening 864 may be symmetrical between the shoulder regions 819 and 826, as well as between the garment side edges 816 and 817 and the garment side edges 821 and 822, typically the placement of the neck opening 864 is configured so that a larger portion of the neck opening 864 is located within the front shoulder region 819. Additionally, while the shape of the neck opening 864 can be symmetrical, typically the shape of the neck opening 864 is asymmetrical as dictated by fashion and comfort. In some embodiments of the garment 810, the edge 866 of the neck opening 864 can be hemmed. For easier manufacture, the edge 866 of the neck opening 864 may be left unhemmed, facilitating easy machine cutoff.

Various styles of a collar 868 can also be attached to the edge 866 of the neck opening 864. The attachment of the collar 868 may be made non-refastenable by means as discussed below. In the alternative, the attachment of the collar 868 may be made refastenable by means as discussed below. The collars 868 include, but are not limited to, turtlenecks, mock turtlenecks, cowls, shirt collars, tee-shirt shirt ribbed edging, decorative edging, and the like known in the garment industry.

The garment bottom edges 818 and 824 of the garment 810 may also be hemmed. (Sewing equipment 883 is shown in Figure 79). For easier manufacture, the garment bottom edges 818 and 824 of the garment 810 may be left unhemmed, facilitating easy machine cutoff.

The front panel 815, the back panel 820, or both may be cut or otherwise opened to form a slit 830 or 839 (shown in Figure 88) such as a placket. The garment 810, including one or both slits 830 and 839, can be used as a wrap, gown, robe, or the like. The slit 830 has two edges 834 and 836. The slit 839 has two edges 840 and 841. Various fastening means, such as adhesive and mechanical type fasteners 869, see the discussion below, may be used to refastenably attach or secure the edges 834 and 836 or the edges 840 and 841 together to form reclosable or refastenable garments 810. The slits 830 and 839 of the front and back panels 815 and 820, respectively, may extend from the edge 866 of the neck opening 864 to the garment bottom edges 818 and 824, respectively. In the alternative, the slits 8570 and 8579 may extend over only a portion of the front and back panels 815 and 820 between the edge 866 of the neck opening 864 to the garment bottom edges 818 and 824, respectively. When the garment 810 comprises both a slit 830 in the front panel 815 and a slit 839 in the back panel 820, the slits 830 and 839 may be similar or dissimilar in size, structure, shape, and the like. It is understood that the term 'similar' as used herein is interpreted to include identical and varying levels of similarity. It is also understood that the term 'dissimilar' as used herein is interpreted to include different and varying levels of dissimilarity. An alternate embodiment of the invention is illustrated in Figure 82. The garment 885 includes opposing inner and outer surfaces 886 and 887. According to this embodiment, the garment 885 desirably comprises a front panel 892 and a back panel 897. The front panel 892 has a pair of garment side edges 893 and 894, a garment bottom edge 895, and a shoulder region 896 opposing the garment bottom edge 895 and positioned between the garment side edges 893 and 894. The back panel 897 has a pair of garment side edges 898 and 899, a garment bottom edge 903, and a shoulder region 906(b) opposing the garment bottom edge 903 and positioned between the garment side edges 898 and 899.

The garment side edge 893 is joined to the garment side edge 898 to form the garment side seam 907. The garment side edge 894 is joined to the garment side edge 899 to form the garment side seam 908. A portion of the garment side seams 907 and 908 is left unbonded or not joined, preferably in the shoulder regions 896 and 907, defining two opposing arm openings 932 and 934. At least a portion of the shoulder edge 915 of the front panel 892 is joined to at least a portion of the shoulder edge 916 of the back panel 897 to form the center seam 917.

The finished garment 885 may include arm coverings or sleeves 936 and 938 so as to surround, at least partially, the arm openings 932 and 934, respectively, of the garment 885. In some embodiments, only one sleeve 936 or 938 may be included in the finished garment 885. The length of the sleeves 936 and 938 may vary from a length intended to cover at least the entire arm of the wearer to a caplet length or shorter. The sleeve opening end edges 942 and 944 of the sleeves 936 and 938, respectively, may be hemmed. For easier manufacture, the sleeve opening end edges 942 and 944 are left unhemmed, facilitating easy machine cutoff.

In the embodiments of the garments 885 that do not include the sleeves 936 and 938, the unattached portion of the garment side edges 893 and 898 and the garment side edges 894 and 899, more specifically the arm opening edges 933 and 935 defining the arm openings 932 and 934, can be hemmed. For easier manufacture, the arm opening edges 933 and 935, defining the arm openings 932 and 934, may be left unhemmed, facilitating easy machine cutoff. A neck opening 948, defined about its perimeter by edge 950, is located in at least one of the shoulder regions 896 and 906(b). The neck opening 948 is typically centered between the garment bottom edges 895 and 903 and the garment side edges 893 and 894 and the garment side edges 898 and 899, although such placement of the neck opening 948 is not required. The neck opening 948 may take on a variety of sizes and shapes, such as circular, oval, triangular, square, rectangular, multi-faceted, asymmetric or irregular, or the like. While the placement of the neck opening 948 may be symmetrical between the shoulder regions 896 and 906(b), as well as between the garment side edges 893 and 894 and the garment side edges 898 and 899, typically the placement of the neck opening 948 is configured so that a larger portion of the neck opening 948 is located within the front shoulder region 896.

Additionally, while the shape of the neck opening 948 can be symmetrical, typically the shape of the neck opening 948 is asymmetrical as dictated by fashion and comfort. In some embodiments of the garment 885, the edge 950 of the neck opening 948 can be hemmed. For easier manufacture, the edge 950 of the neck opening 948 may be left unhemmed, facilitating easy machine cutoff.

Various styles of a collar 952 can also be attached to the edge 950 of the neck opening 948. The attachment of the collar 952 may be made non-refastenable by means as discussed below. In the alternative, the attachment of the collar 952 may be made refastenable by means as discussed below. The collars 952 include, but are not limited to, turtlenecks, mock turtlenecks, cowls, shirt collars, tee-shirt shirt ribbed edging, decorative edging, and the like known in the garment industry.

The garment bottom edges 895 and 903 of the garment 885 may also be hemmed. For easier manufacture, the garment bottom edges 895 and 903 of the garment 885 may be left unhemmed, facilitating easy machine cutoff.

The front panel 892, the back panel 897, or both may be cut or otherwise opened to form a slit 910 or 925 (shown in Figure 89) such as plackets. The garment 885, including one or both slits 910 and 925, can be used as a wrap, gown, robe, or the like. The slit 910 has two edges 920 and 921. The slit 925 has two edges 926 and 927. Various fastening means, such as fasteners 953 discussed above, may be used to refastenably attach or secure the edges 920 and 921 or 926 and 927 together to form a reclosable or refastenable garment 885. The slits 910 and 925 of the front and back panels 892 and 897, respectively, may extend from the edge 950 of the neck opening 948 to the garment bottom edges 895 and 903, respectively. In the alternative, the slits 910 and 925 may extend over only a portion of the front and back panels 892 and 897 between the edge 950 of the neck opening 948 to the garment bottom edges 895 and 903, respectively. When the garment 885 comprises both a slit 910 in the front panel 892 and a slit 925 in the back panel 897, the slits 910 and 925 may be similar or dissimilar in size, structure, shape, and the like. It is understood that the term 'similar' as used herein is interpreted to include identical and varying levels of similarity. It is also understood that the term 'dissimilar' as used herein is interpreted to include different and varying levels of dissimilarity.

Another embodiment of the present invention is a continuous process for the manufacture of a garment 810 (see Figure 79) for wearing about the upper body comprising at least a front panel 815, a back panel 820, a neck opening 864 defined about its perimeter by edge 866, arm openings 846 and 848 defined about their perimeters by arm opening edges 847 and 849, respectively, and a lower body opening 829 defined about its perimeter by garment bottom edges 818 and 824. The garment 810 comprises an inner surface 811 and an outer surface 812. The garment 810 may comprise a single layer web of fabric 813 or may comprise a multi-layer laminate web of fabric 813. In some embodiments, the garment 810 may comprise multiple layers of the web of fabric 813. The present invention requires at least one web of fabric 813 in a single continuous process to create the garments 810.

In one embodiment of the present invention (see Figure 79), one web of fabric

813 of sufficient width of fabric to make the garment 810 is provided to produce the garments 810. The desired web of fabric 813 is nonwoven although any disposable or washable fabric can be used. (See the discussion below). The web of fabric 813 is typically unwound from a roll or other source (not shown).

The web of fabric 813 is desirably compliant and soft feeling to the wearer. The following description of materials from which the web of fabric 813 may be formed would also be used for the materials to form the inner surface 811 and the outer surface 812 of a multi-layer laminate web of fabric 813. The web of fabric 813 may be any suitable material as earlier described for the web of fabric 15.

The web of fabric 813 may be constructed of a single spunbonded polypropylene nonwoven web having a basis weight of about 0.5 oz/yd² (17 gsm) to about 1.5 oz/yd² (51 gsm). In the structure of the garment 810, the web of fabric 813 desirably comprises a material having a basis weight of from about 0.5 oz/yd² (17 gsm) to about 1.5 oz yd² (51 gsm). Lesser or greater basis weights may be used in the other regions of the garment 810, such as the sleeves 850 and 852, the cuffs 859 and 861, and the collar 868. Since the garment 810 is typically intended for active wear, the web of fabric 813 or portions thereof, can be made of materials having a basis weight that is abrasion resistant.

For embodiments wherein the web of fabric 813 is a multi-layer laminate, both the outer surface 812 and the inner surface 811 are desirably compliant and soft feeling to the wearer. The following description of materials from which the outer surface 812 may be formed may also be used to form the material of the inner surface 811.

The outer surface 812 may be any suitable gatherable material as earlier described for the outer surface 13.

Alternatively, the outer surface 812 may be derived from a spunbonded web. In a desired embodiment, the outer surface 812 is spunbonded polypropylene nonwoven, meltblown polypropylene nonwoven and spunbonded polypropylene nonwoven laminate (SMS). The total basis weight is from about 0.4 to about 1.0 osy (more desirably 0.6 osy) and is made with about 86% spunbonded nonwoven and 14% meltblown nonwoven. A pigment such as titanium dioxide may be incorporated into the outer surface 812 and the inner surface 811. Such spunbonded meltblown nonwoven laminate material is available from Kimberly-Clark Corporation, Roswell, GA. The basis weight of the SMS material may vary from about 0.4 to about 1.0 osy.

The inner surface 811 may be any soft and flexible sheet as earlier described for the inner surface 11. The outer surface 812 and the inner surface 811 may be further dyed, pigmented, or imprinted with any suitable color. Desirably, the inner surface 811 is either dyed, pigmented, or printed with a material which does not irritate or bleed the color onto the skin of the wearer.

Another embodiment of the present invention is a continuous process for the manufacture of a garment 810 (see Figures 79, 81 , and 83) for wearing about the upper body comprising at least a front panel 815, a back panel 820, a neck opening 864 defined about its perimeter by edge 866, sleeve flaps 871 and 872, a lower body opening 829 defined about its perimeter by the garment bottom edges 818 and 824. The garment 810 comprises an inner surface 811 and an outer surface 812. The garment 810 may comprise a single layer web of fabric 813 or may comprise a multi-layer laminate web of fabric 813. In some embodiments, the garment 810 may comprise multiple layers of the web of fabric 813. The materials comprising the web of fabric 813 have been discussed above.

The web of fabric 813 of sufficient width of fabric to make the garment 810 is provided to produce the garments 810. The desired web of fabric 813 is nonwoven although any disposable or washable fabric can be used. (See the discussion above). The web of fabric 813 is typically unwound from a roll or other source (not shown).

The web of fabric 813 includes a pair of opposing web side edges 831 and 832. A repeating series of pairs of opposing indentations 842 and 844 is cut into the web side edges 831 and 832, respectively, of the web of fabric 813 by a die cutter 851. (See Figure 79). The location of the opposing indentations 842 and 844 corresponds to the garment side edges 816 and 817, and the garment side edges 821 and 822, respectively, of the finished garment 810. The opposing indentations 842 and 844 may be produced by a die cut operation, an ultrasonic operafion, or any other suitable method of operation. The material to be removed from the opposing indentations 842 and 844 may be removed by any method known in the art, desirably a vacuum source (not shown).

The opposing indentations 842 and 844 may take on a variety of sizes and shapes, such as oval, triangular, square, rectangular, multi-faceted, asymmetric or irregular, or the like. The pattern of the opposing indentations 842 and 844 is restricted only by fashion and the minimum amount of web of fabric 813 that must remain having a sufficient integrity to withstand the remaining steps or operations of the process of manufacture. The opposing indentations 842 and 844 may be similar or dissimilar in shape, structure, size, and the like from each other within the finished garment 810.

The web of fabric 813 is cut into discrete garment-sized pieces 814 by the die cutter

851. The web side edges 831 and 832 of the web of fabric 813 become the garment bottom edges 818 and 824, respectively of the discrete garment-sized pieces 814. It is understood that while the web side edges 831 and 832 may typically become the garment bottom edges 818 and 824, respectively, in the finished garment 810, fabric may be removed from or added to the web side edges 831 and 832 to create the garment bottom edges 818 and 824, respectively, in the finished garment 810. The piece side edges 823 and 825 of the discrete garment-sized pieces 814 created by cutting operation are located such that the opposing indentations 842 and 844 are cut, producing the garment side edges 816 and 817 and the garment side edges 821 and 822, respectively, in the finished garments 810. It is understood that while Figure 79 shows the die cutter 851 cutting the web of fabric 813 into discrete garment-sized pieces 814 and the opposing indentations 842 and 844, these operations could be performed by separate devices and at different stages within the manufacturing process.

In some embodiments of the present invention, the web of fabric 813 is cut into the discrete garment-sized pieces 814 prior to the performance of an operation to create the opposing indentations 842 and 844 (see Figure 83). A repeating series of pairs of opposing indentations 843 and 845 is cut into the piece side edges 823 and 825, respectively, of the discrete garment-sized pieces 814. The location of the opposing indentations 843 and 845 corresponds to the garment side edges 816 and 817 and the garment side edges 821 and 822, respectively, of the finished garments 810. The opposing indentations 843 and 845 may be produced by a die cut operation, an ultrasonic operation, or any other suitable method of operation. The material to be removed from the opposing indentations 843 and 845 may be removed by any method known in the art, desirably a vacuum source.

The opposing indentations 843 and 845 may take on a variety of sizes and shapes, such as a slit, circular, oval, triangular, square, rectangular, multi-faceted, asymmetric or irregular, or the like. The pattern of the opposing indentations 843 and 845 is restricted only by fashion and the minimum amount of the discrete garment-sized piece 814 (or, alternatively, the web of fabric 813) that must remain having sufficient integrity to withstand the remaining steps or operations of the process of manufacture. The opposing indentations 843 and 845, alternatively, the garment side edges 816 and 817 and the garment-side edges 821 and 822, respectively, may be similar or dissimilar in shape, structure, size, and the like from each other within the finished garment 810.

In some embodiments, the operation of cutting the opposing indentations 843 and 845 (or, alternatively, the opposing indentations 842 and 844) into the discrete garment- sized pieces 814 (or, alternatively, the web of fabric 813) may be eliminated. As the pattern of the garment 810 is restricted only by fashion and the minimum amount of the discrete garment-sized pieces 814 (or, alternatively, the web of fabric 813) that must remain having a sufficient integrity to withstand the operations or steps of the process of manufacture, one can simply design the garment 810 such that this operation of cutting the opposing indentations 843 and 845 (or, alternatively, the opposing indentations 842 and 844) into the discrete garment-sized pieces 814 (or, alternatively, the web of fabric 813) is not required. As discussed above, the arm openings 846 and 848 may be created by leaving a portion of the garment side edges 816 and 821 and the garment side edges 817 and 822, respectively, unattached.

A repeating series of openings 863 is cut by the die cutter 851 into the web of fabric

813. The location of the opening 863 corresponds to the neck opening 864 in the finished garment 810. The openings 863 may be produced by a die cut operation, an ultrasonic operation, or any other suitable method of operation. It is understood that while Figure 79 shows the die cutter 851 cutting the opening 863 and the opposing indentations 842 and 844, these cutting operations (also, the operation for cutting the opposing indentations 843 and 845) could be performed by separate devices and at different stages within the manufacturing process. The material to be removed from the openings 863 may be removed by any method known in the art, desirably a vacuum source (not shown). The opening 863 may take on a variety of sizes and shapes, such as slit, circular, oval, triangular, square, rectangular, multi-faceted, asymmetric or irregular, or the like. The pattern of the opening 863 is restricted only by fashion and the minimum amount of web of fabric 813 that must remain having a sufficient integrity to withstand the remaining steps or operations of the process of manufacture. The placement of the opening 863 in relation to a repeating series of opposing indentations 842 and 844, while in a typical garment 810, the opening 863 is centrally located between the repeating series of pairs of the opposing indentations 842 and 844, is restricted only by fashion and the minimum amount of web of fabric 813 that must remain having sufficient integrity to withstand the remaining steps or operations of the process of manufacture. For example, the placement of the opening 863 between the repeating series of opposing indentations 842 and 844 may be symmetrically or asymmetrically located. The placement of the opening 863 in relation to the two pairs of the opposing indentations 843 and 845, while in a typical garment 810, the opening 863 is centrally located between the two pairs of opposing indentations 843 and 845, is restricted only by fashion and the minimum amount of the discrete garment-sized piece 814 that must remain having sufficient integrity to withstand the remaining steps or operations of the process of manufacture. For example, the placement of the opening 863 between two pairs of opposing indentations 843 and 845 may be symmetrically or asymmetrically located.

The web of fabric 813 is cut by the die cutter 851 into discrete garment-sized pieces 814 wherein each discrete garment-sized piece 814 contains at least one opening 863, two pairs of opposing indentations 843 and 845, one pair of opposing piece side edges 823 and 825, one pair of opposing garment bottom edges 818 and 824, and opposing garment end portions 8577 and 8578. The location of the opposing piece side edges 823 and 825 of the discrete garment-sized piece 814 of the web of fabric 813 corresponds to a sleeve opening end edge 84 of a sleeve flap 871 proximate the garment side edge 816 of the front panel 815 and the garment side edge 821 of the back panel 820, and a sleeve opening end edge 860 of a sleeve flap 872 proximate the garment side edge 817 of the front panel 815 and the garment side edge 822 of the back panel 820, respectively, in the finished garment 810. It is understood that while the piece side edges 823 and 825 of the discrete garment-sized piece 814 may typically become the sleeve opening end edges 84 and 860 in the finished garment 810, fabric may be removed from or added to the piece side edges 823 and 825 to create the sleeve opening end edges 858 and 860 in the finished garment 810.

The opposing garment end portions 837 and 838 are adjacent to the garment bottom edge 818 of the front panel 815 and the garment bottom edge 824 of the back panel 820, respectively, in the finished garment 810. The location of the opposing web side edges 831 and 832 of the web of fabric 813 (or, alternatively, the discrete garment- sized piece 814) corresponds to the garment bottom edge 818 of the front panel 815 and the garment bottom edge 824 of the back panel 820, respectively, in the finished garment 810. It is understood that while the web side edges 831 and 832 of the web of fabric 813 (or, alternatively, the discrete garment-sized piece 814) may typically become the garment bottom edges 818 and 824 in the finished garment 810, fabric may be removed from or added to the web side edges 831 and 832 of the web of fabric 813 (or, alternatively, the discrete garment-sized piece 814) to create the garment bottom edges 818 and 824 in the finished garment 810.

Each discrete garment-sized piece 814 of the web of fabric 813 is transported, typically by vacuum screens, belts, or conveyors, through hemming, folding, and fastening operations (not shown). The folding operations are desirably carried out by tuckers and folders, as well as any other known means. The discrete garment-sized piece 814 of the web of fabric 813 is folded by a folder 853 so as to bring together the opposing garment end portions 837 and 838 such that piece side edge 823 of the discrete garment-sized piece 814 of the web of fabric 813 is folded on to itself, bringing the garment side edge 816 of the front panel 815 and the garment side edge 821 of the back panel 820 together. The piece side edge 825 of the discrete garment-sized piece 814 of the web of fabric 813 is folded on to itself, bringing the garment side edge 817 of the front panel 815 and the garment side edge 822 of the back panel 820 together.

The mating of the garment side edge 816 and the garment side edge 821 as well as the mating of the garment side edge 817 and the garment side edge 822 form the garment side seams 827 and 828, respectively, of the garment 810. It may be desirable to redirect (or reorient) the discrete garment-sized piece 814 of the web of fabric 813 to allow easy bonding of the garment side seams 827 and 828 of the garment 810. The turning operations are desirably carried out by turn rolls and turn tables, as well as any other known means. The discrete garment-sized piece 814 of the web of fabric 813 may be reoriented 90 degrees (not shown).

In various embodiments of the present invention, one or both of the garment side seams 827 and 828 can be constructed as non-refastenable seams or as refastenable seams. Any excess material of the web of fabric 813 may be removed from the edges of the garment side seams 827 and 828 to reduce and smooth out the garment side seams 827 and 828. The non-refastenable garment side seams 827 and 828 may be formed by any suitable means such as ultrasonic sealing, adhesive bonding, tape, heat sealing, sewing, or any method of fastening known in the art. (Sewing equipment 884 is shown in Figure 79). The garment side edges 827 and 828 may be constructed on a continuous or intermittent basis. One suitable method of forming such garment side seams 827 and 828 is disclosed in U.S. Patent No. 4,938,753 issued July 3, 1990, to Van Gompel et al., which is incorporated herein by reference. The garment side seams 827 and 828 may be bonded together to form non-refastenable garment side seams 827 and 828.

In other embodiments of the present invention, the garment side edges 816 and

821 and the garment side edges 817 and 822 of the garment 810 may be held together in the finished garment 810 to form refastenable garment side seams 827 and 828, respectively. The refastenable means for securing the garment side edges 816 and 821 and the garment side edges 817 and 822 of the garment 810 include refastenable adhesive and mechanical type fasteners 869. The adhesive and mechanical type fasteners 869 include buttons and button holes, snaps, buckles, clasps, hooks and loops, end extensions, tabs, tape, and the like which are designed or adapted to interlock or engage some type of a complementary device or the outer surface 812 or the inner surface 811 of the garment 810.

In addition, elasticized fasteners 869 may also be used in assuring better fit of the garment 810. If the garment 810 includes refastenable garment side seams 827 and 828, the refastenable means are desirably strategically placed on the web of fabric 813 before the web of fabric 813 is cut into discrete garment-sized pieces 814. The folding and redirection operations may be eliminated when refastenable garment side seams 827 and

828 are included in the garment 810. However, there may be packaging reasons for which one would still carry out these two steps.

The garment side seams 827 and 828 of the present invention may take on a variety of structures or configurations known in the art. One embodiment of the garment side seams 827 and 828 is an out-turned configuration as illustrated in Figure 95. Such configured garment side seams 827 and 828 are formed by securing together at least a portion of the out-turned portions of the garment side edges 816 and 821 and the garment side edges 817 and 822, respectively. The inner surface 811 of the garment side edges 816 and 817 of the front panel 815 and the garment side edges 821 and 822 of the back panel 820, respectively, are brought into contact with each other, respectively.

Another embodiment of the garment side seams 827 and 828 is an in-turned configuration as illustrated in Figure 96. Such configured garment side seams 827 and 828 are formed by securing together at least a portion of the in-turned portions of the garment side edges 816 and 821 and the garment side edges 817 and 822, respectively. The outer surface 812 of the garment side edges 816 and 817 of the front panel 815 and • the garment side edges 821 and 822 of the back panel 820 are brought into contact with each other, respectively.

Another embodiment of the garment side seams 827 and 828 is an over-lapped configuration as illustrated in Figure 94. Such configured garment side seams 827 and 828 are formed by securing together at least a portion of the over-lapped portions of the garment side edges 816 and 821 and the garment side edges 817 and 822, respectively. The inner surface 811 of one of the garment side edges 816 and 821 and one of the garment side edges 817 and 822 are brought into contact with the outer surface 812 of the other garment side edge of each pair of garment side edges.

Another embodiment of the garment side seams 827 and 828 is an over-lapped configuration as illustrated in Figure 97. Such a configured garment side seam 827 is formed by folding the garment side edge 816 or the garment side edge 821. The outer surface 812 of the folded portion and the inner surface 811 of the unfolded portion of the garment side edge 816 or the garment side edge 821 and the corresponding portion of the front panel 815 or the back panel 820, respectively, are brought into contact with the inner surface 11 or the outer surface 812 of the non-folded garment side edge 821 or the garment side edge 816 and the corresponding portion of the back panel 820 or the front panel 815.

The garment side seam 828 is formed by folding back the garment side edge 817 or the garment side edge 822. The outer surface 812 of the folded portion and the inner surface 11 of the unfolded portion of the garment side edges 817 or the garment side edge 822 and the corresponding portion of the front panel 815 or the back panel 820, respectively, are brought into contact with the inner surface 811 or the outer surface 812 of the non-folded garment side edge 822 or the garment side edge 817 and the corresponding portion of the back panel 820 or the front panel 815. It is understood that the folding back of a garment side edge 816, 817, 821 , or 822 could be performed such that the inner surface 811 would be exposed along the fold.

The garment end portions 837 and 838 of the discrete garment-sized pieces 814 of the web of fabric 813 may be hemmed in the finished garment 810. The garment end portions 837 and 838 can be hemmed by any method or style known in the art. In some embodiments, it may be desirable to leave the garment end portions 837 and 838 unhemmed. The garment bottom edges 818 and 824 of the discrete garment-sized pieces 814 of the web of fabric 813 may be hemmed in the finished garment 810. The garment bottom edges 818 and 824 can be hemmed by any method or style known in the art. (Sewing equipment 883 is shown in Figure 79). In some embodiments, it may be desirable to leave the garment bottom edges 818 and 824 unhemmed

As shown in Figures 90 and 91, the garment 810 includes sleeve flaps 871 and

872. The sleeve flaps 871 and 872 may take on a variety of sizes and shapes, such as circular, oval, triangular, square, rectangular, multi-faceted, asymmetric or irregular, or the like. The pattern of the sleeve flaps 871 and 872 is restricted only by fashion and the minimum amount of the material of the sleeve flaps 871 and 872 that is necessary to complete the remaining steps or operations of the process of manufacture. The sleeves 850 and 852, alternately the sleeve flaps 871 and 872, may be similar or dissimilar in shape, structure, material, size, and the like from each other within the flnished garment 810. In some embodiments, only one sleeve 850 or 852 may be included in the finished garment 810.

The sleeve flap 871 has a pair of sleeve side edges 855 and 857, and a sleeve opening end edge 858 extending between the sleeve side edges 855 and 857. It is understood that the sleeve flap 871 could be made of multiple pieces of material or materials. The sleeve flap 871 is folded so as to bring together the opposing sleeve side edges 81 and 857 to form a sleeve seam 867 of the sleeve 850. It is understood that while the piece side edge 823 of the discrete garment-sized piece 814 may typically become the sleeve opening end edge 858 in the flnished garment 810, fabric may be removed from or added to the piece side edge 823 to create the sleeve opening end edge 858 in the flnished garment 810. The sleeve flap 872 has a pair of sleeve side edges 862 and 865, and a sleeve opening end edge 860 extending between the sleeve side edges 862 and 865. It is understood that the sleeve flap 872 could be made of multiple pieces of material or materials. The sleeve flap 872 is folded so as to bring together the opposing sleeve side edges 862 and 865 to form a sleeve seam 870 of the sleeve 852. It is understood that while the piece side edge 825 of the discrete garment-sized piece 814 may typically become the sleeve opening end edge 860 in the finished garment 810, fabric may be removed from or added to the piece side edge 825 to create the sleeve opening end edge 860 in the flnished garment 810.

It may be desirable to redirect (or reorient) the discrete garment-sized pieces 814 to allow easy fastening of the sleeve seams 867 and 870 of the sleeves 850 and 852, respectively, of the garment 810. The turning operations are desirably carried out by turn rolls and turn tables, as well as any other known means. The discrete garment-sized pieces 814 may be reoriented 90 degrees (not shown). The sleeve seams 867 and 870 can be non-refastenable seams or refastenable seams. Any excess material of the fabric pieces 871 and 872 can be removed from the edges of the sleeve seams 867 and 870 to reduce and smooth out the sleeve seams 867 and 870. The non-refastenable sleeve seams 867 and 870 may be formed by any suitable means such as ultrasonic sealing, adhesive bonding, tape, heat sealing, sewing, or other methods of fastening as known in the art, as discussed above. The non-refastenable sleeve seams 867 and 870 may be constructed on a continuous or intermittent basis.

In other embodiments, the opposing pair of the sleeve side edges 855 and 857 and the opposing pair of the sleeve side edges 862 and 865 of the sleeves 850 and 852, respectively, may be held together in the finished garment 810 to form refastenable sleeve seams 867 and 870. The refastenable means for securing the opposing pair of the sleeve side edges 855 and 857 and the opposing pair of the sleeve side edges 862 and 865 of the sleeves 850 and 852, respectively, include refastenable adhesive and mechanical type fasteners 869. The adhesive and mechanical type fasteners 869 include buttons and button holes, snaps, buckles, clasps, hooks and loops, end extensions, tabs, tape, and the like which are designed or adapted to interlock or engage some type of a complementary device or the inner surface 811 or the outer surface 812 of the garment 810. The refastenable sleeve seams 867 and 870 may be constructed on a continuous or intermittent basis. In addition, elasticized fasteners may also be used in assuring better fit of the sleeves 850 and 852 of the garment 810. If the garment 810 includes refastenable sleeve seams 867 and 870, the refastenable means are desirably strategically placed on the sleeve flaps 871 and 872 before or after the web of fabric 813 is cut into discrete garment- sized pieces 814 of the web of fabric 813. The folding and redirection operations may be eliminated when refastenable sleeve seams 867 and 870 are included in the garment 810. However, there may be packaging reasons for which one would still carry out these two steps.

The sleeve seams 867 and 870 of the present invention may take on a variety of structures or configurations known in the art. One embodiment of the sleeve seams 867 and 870 is an out-turned configuration as illustrated in Figure 95. Such configured sleeve seams 867 and 870 are formed by securing together at least a portion of the out-turned portions of the sleeve side edges 81 and 857 and the sleeve side edges 862 and 865 of the sleeves 850 and 852, respectively. The inner surface 811 of the sleeve side edges 855 and 857 and the sleeve side edges 862 and 865 of the sleeves 850 and 852, respectively, are brought into contact with each other of the pair.

Another embodiment of the sleeve seams 867 and 870 is an in-turned configuration as illustrated in Figure 96. Such configured sleeve seams 867 and 870 are formed by securing together at least a portion of the in-turned portions of the sleeve side edges 855 and 857 and the sleeve side edges 862 and 865 of the sleeves 850 and 852, respectively. The outer surface 812 of the sleeve side edges 855 and 857 and the sleeve side edges 862 and 865 of sleeves 850 and 852, respectively, are brought into contact with each other of the pair.

Another embodiment of the sleeve seams 867 and 870 is an over-lapped configuration as illustrated in Figure 94. Such configured sleeve seams 867 and 870 are formed by securing together at least a portion of the over-lapped portions of the sleeve side edges 855 and 857 and the sleeve side edges 862 and 865 of the sleeves 850 and 852, respectively. The inner surface 811 of one of the sleeve side edges 855 or 857 and the sleeve side edges 862 or 865 of the sleeves 850 and 852, respectively, are brought into contact with the outer surface 812 of the other sleeve side edge 81 or 857 and the sleeve side edge 862 or 865 of the sleeve 850 and 852, respectively. Another embodiment of the sleeve seams 867 and 870 is an over-lapped configuration as illustrated in Figure 97. Such configured sleeve seams 867 and 870 are formed by folding back the sleeve side edge 855 or 857 and the sleeve side edge 862 or 865 of the sleeves 850 and 852, respectively. The outer surface 812 of the folded portions and the inner surface of the unfolded portions of the sleeve side edge 855 or 857 and the sleeve side edge 862 or 865 and the corresponding portions of the sleeves 850 and 852, respectively, are brought into contact with the inner surface 811 or the outer surface 812 of the non-folded sleeve side edge 855 or 857 and the sleeve side edge 862 or 865 and the corresponding portions of the sleeves 850 and 852, respectively. It is understood that the folding back of the sleeve side edge 855, 857, 862, or 865 could be performed such that the inner surface 811 would be exposed along the fold.

The sleeve opening end edges 858 and 860 of the sleeves 850 and 852, respectively, (in the alternative, the sleeve opening end edges 858 and 860 of the sleeve flaps 871 and 872, respectively) can be hemmed by any method or style known in the art. In some embodiments, it may be desirable to leave the sleeve opening end edges 858 and 860 unhemmed.

In other embodiments, cuffs 859 and 861 may be attached to the sleeve opening end edges 858 and 860, respectively of the sleeves 850 and 852, respectively, of the garment 810, forming cuff seams 874 and 876, respectively. The attachment of the cuffs 859 and 861 may be made non-refastenable by means as discussed above. (Sewing equipment 882 is shown in Figure 79). The cuff seams 874 and 876 may be constructed on a continuous or intermittent basis. In the alternative, the attachment of the cuffs 859 and 861 may be made refastenable by means as discussed above. The cuffs 859 and 861 may take on a variety of sizes and shapes. The cuffs 859 and 861 may be similar or dissimilar in shape, structure, material, size, and the like from each other within the finished garment 810. The pattern of the cuffs 859 and 861 is restricted only by the fashion and the minimum amount of the material of the cuffs 859 and 861 that is necessary to complete the remaining steps or operations of the process of manufacture.

The cuff seams 874 and 876 of the present invention may take on a variety of structures or configurations known in the art. One embodiment of the cuff seams 874 and 876 is an out-turned configuration as illustrated in Figure 95. Such configured cuff seams 874 and 876 are formed by securing together at least a portion of the out-turned portions of the cuff edge 873 and the sleeve opening end edge 858 and the cuff edge 875 and the sleeve opening end edge 860, respectively, of the garment 810. The inner surface 811 of the cuff edges 873 and 875 of the cuffs 859 and 861 , respectively, is brought into contact with the inner surface 811 of the sleeve opening edges 858 and 860 of the sleeves 850 and 852, respectively.

Another embodiment of the cuff seams 874 and 876 is an in-turned configuration as illustrated in Figure 96. Such configured cuff seams 874 and 876 are formed by securing together at least a portion of the in-turned portions of the cuff edge 873 and the sleeve opening edge 858 and the cuff edge 875 and the sleeve opening edge 860, respectively, of the garment 810. The outer surface 812 of the cuff edges 873 and 875 of the cuffs 859 and 861, respectively, are brought into contact with the outer surface 812 of the sleeve opening edges 858 and 860 of the sleeves 850 and 852, respectively.

Another embodiment of the cuff seams 874 and 876 is an over-lapped configuration as illustrated in Figure 94. Such configured cuff seams 874 and 876 are formed by securing together at least a portion of the over-lapped portions of the cuff edge 873 and the sleeve opening edge 858 and the cuff edge 875 and the sleeve opening edge 860 of the sleeves 850 and 852, respectively. The inner surface 811 of one of the cuff edge 873 or the sleeve opening edge 858 and the cuff edge 875 or the sleeve opening edge 860, are brought into contact with the outer surface 812 of the other cuff edge 873 or the sleeve opening edge 858 and the cuff edge 875 or the sleeve opening edge 860 of the sleeves 850 and 852, respectively.

Another embodiment of the cuff seams 874 and 876 is an over-lapped configuration as illustrated in Figure 97. Such configured cuff seams 874 and 876 are formed by folding back the cuff edge 873 or the sleeve opening end edge 858 and the cuff edge 875 or the sleeve opening end edge 860 of the sleeves 850 and 852, respectively. The outer surface 812 of the folded portions and the inner surface 811 of the unfolded portions of the cuff edge 873 or the sleeve opening end edge 858 and the cuff edge 875 or the sleeve opening end edge 860 and the corresponding portions of the cuffs 859 and 861 or the sleeves 850 and 852 are brought into contact with the inner surface 811 or the outer surface 812 of the unfolded cuff edge 873 or 875 or the sleeve opening end edge 858 or 860 and the corresponding portions of the cuffs 859 and 861 or the sleeves 850 and 852. It is understood that the folding back of a cuff edge 873 or 875 or a sleeve opening end edge 858 or 860 could be performed such that the inner surface 811 would be exposed along the fold.

The materials used for the cuffs 859 and 861 may be the same as the materials used for the other portions of the garment 810. In some embodiments, it is desirable that the materials used for the cuffs 859 and 861 have an elastic element such that the cuffs 859 and 861 will conform to the portion of the wearer's arms that come into contact with the cuffs 859 and 861.

The edge 866 of the neck opening 864 can be hemmed by any method or style known in the art. In some embodiments, it may be desirable to leave the edge 866 of the neck opening 864 unhemmed.

In other embodiments, a collar 868 may be attached to the edge 866 of the neck opening 864 of the garment 810, thereby forming a collar seam 878. The attachment of the collar 868 may be made non-refastenable by means as discussed above. (Sewing equipment 881 is shown in Figure 79). In the alternative, the attachment of the collar 868 may be made refastenable by means as discussed above. The collar seam 878 may be constructed on a continuous or intermittent basis. The collar 868 may take on a variety of sizes and shapes. The pattern of the collar 868 is restricted only by the fashion and the minimum amount of the material of the collar 868 that is necessary to complete the remaining steps or operations of the process of manufacture.

The collar seam 878 of the present invention may take on a variety of structures or configurations known in the art. One embodiment of the collar seam 878 is an out-turned configuration as illustrated in Figure 95. Such a configured collar seam 878 is formed by securing together at least a portion of the out-turned portions of the collar edge 877 of the collar 868 and the edge 866 of the neck opening 864 of the garment 810. The inner surface 811 of the collar edge 877 of the collar 868 is brought into contact with the inner surface 811 of the edge 866 of the neck opening 864.

Another embodiment of the collar seam 878 is an in-turned configuration as illustrated in Figure 96. Such a configured collar seam 878 is formed by securing together at least a portion of the in-turned portions of the collar edge 877 of the collar 868 and the edge 866 of the neck opening 864 of the garment 810. The outer surface 812 of the collar edge 877 of the collar 868 is brought into contact with the outer surface 812 of the edge 866 of the neck opening 864.

Another embodiment of the collar seam 878 is an over-lapped configuration as illustrated in Figure 94. Such a configured collar seam 878 is formed by securing together at least a portion of the over-lapped portions of the collar edge 877 of the collar 868 and the edge 866 of the neck opening 864 of the garment 810. The inner surface 811 of the collar edge 877 of the collar 868 or the edge 866 of the neck opening 864 is brought into contact with the outer surface 812 of the other, the collar edge 877 or the edge 866.

Another embodiment of the collar seam 878 is an over-lapped configuration as illustrated in Figure 97. Such a configured collar seam 878 is formed by folding back the collar edge 877 of the collar 868 or the edge 866 of the neck opening 864. The outer surface 812 of the folded portions and the inner surface 811 of the unfolded portions of the collar edge 877 of the collar 868 or the edge 866 of the neck opening 864 and the corresponding portions of the collar 868 or the front and back panels 815 and 820 are brought into contact with the inner surface 811 or the outer surface 812 of the unfolded collar edge 877 of the collar 868 or the edge 866 of the neck opening 864 and the corresponding portions of the collar 868 or the front and back panels 815 and 820. It is understood that the folding back of the collar edge 877 of the collar 868 or the edge 866 of the neck opening 864 could be performed such that the inner surface 811 would be exposed along the fold.

Another embodiment of the collar seam 878 is an over-lapped configuration as illustrated in Figure 98. Such a configured collar seam 878 is formed by folding the collar 868 about or over the edge 866 of the neck opening 864. The collar edges 877 of the collar 868 may be folded under, bringing the outer surface 812 of the collar 868 into contact with the edge 866 of the neck opening and any portion of the adjacent material of the front panel 815, the back panel 820, or both as desired. The collar edges 877 may be left exposed by not being folding under.

Another embodiment of the collar seam 878 is an over-lapped configuration as illustrated in Figure 99. Such a configured collar seam 878 is formed by folding the collar edge 877 such that the inner surface 811 of the collar 868 is brought into contact with itself. The edge 866 of the neck opening 864 is folded such that the outer surface 812 of the front panel 815, the back panel 820, or both are brought into contact with itself. The collar edge 877 is inserted into the fold of the edge 866 of the neck opening 864. The edge 866 of the neck opening 864 is inserted into the fold of the collar edge 877. In another embodiment, the collar edge 877 is folded such that the outer surface 812 of the collar 868 is brought into contact with itself. The edge 866 of the neck opening 864 is folded such that the inner surface 811 of the front panel 815, the back panel 820, or both, is brought into contact with itself. This configured collar seam 878 may be used with any seam described herein.

The materials used for the collar 868 may be the same as the materials used for the other portions of the garment 810. In some embodiments, it is desirable that the materials used for the collar 868 have an elastic element such that the collar 868 will conform to the portion of the wearer's neck that comes into contact with the collar 868.

In various embodiments of the present invention, the front panel 815, the back panel 820, or both panels 815 and 820 may be cut or otherwise opened to form a slit 830 or 831 (shown in Figure 88) such as a placket. The slit 830 has two edges 834 and 836. The slit 831 has two edges 840 and 841. The slits 830 and 831 of the front and back panels 815 and 820, respectively, may extend from the edge 866 of the neck opening 864 to the garment bottom edges 818 and 824, respectively. In the alternative, the slits 830 and 831 may extend over only a portion of the panels 815 and 820 between the edge 866 of the neck opening 864 to the garment bottom edges 818 and 824, respectively. When the garment 810 comprises both a slit 8570 in the front panel 815 and a slit 8579 in the back panel 820, the slits 830 and 831 may be similar or dissimilar in size, structure, shape, and the like.

In some embodiments, the edges 834 and 836 of the slit 830 and the edges 840 and 841 of the slit 831 may be refastenably attached or secured to each other. The edges 834 and 836 may be secured together to form the front seam 879. The edges 840 and 841 may be secured together to form the back seam 880. Various fastening means, such as adhesive and mechanical type fasteners 869, see the discussion above, may be used to refastenably attach or secure the edges 834 and 836 or the edges 840 and 841 together of the slits 830 and 831 , respectively. Another embodiment of the present invention is a continuous process for the manufacture of a garment 885 (see Figure 80) for wearing about the upper body comprising at least a front panel 892, a back panel 897, a neck opening 948 defined about its perimeter by edge 950, arm openings 932 and 934 defined about their perimeters by arm opening edges 933 and 935, respectively, and a lower body opening 909 defined about its perimeter by garment bottom edges 895 and 903. The garment 885 comprises an inner surface 886 and an outer surface 887. The garment 885 may comprise a single layer of webs of fabric 888 and 889, multi-layer laminate webs of fabric 888 and 889, or a combination of a single layer web of fabric and a multi-layer laminate web of the webs of fabric 888 and 889. In some embodiments, the garment 885 may comprise multiple layers of the webs of fabric 888 and 889 or various combinations thereof.

In one embodiment of the present invention (See Figure 80), the two webs of fabric 888 and 889 of sufficient width of fabric to make the garment 885 are provided to produce the garments 885. The desired webs of fabric 888 and 889 are nonwoven although any disposable or washable fabric can be used. (See the discussion below). The webs of fabric 888 and 889 are typically unwound from rolls or other sources (not shown).

The webs of fabric 888 and 889 are desirably compliant and soft feeling to the wearer. The following description of materials from which the webs of fabric 888 and 889 may be formed would also be used for the materials to form the inner surface 886 and the outer surface 887 of multi-layer laminate webs of fabric 888 or 889.

The webs of fabric 888 and 889 may be any suitable material as earlier described for the webs of fabric 215 and 216.

The webs of fabric 888 and 889 may be constructed of a single spunbonded polypropylene nonwoven web having a basis weight of about 0.5 oz/yd² (17 gsm) to about 1.5 oz/yd² (51 gsm). In the structure of the garment 885, the webs of fabric 888 and 889 desirably comprise a material having a basis weight of from about 0.5 oz/yd² (17 gsm) to about 1.5 oz/yd² (51 gsm). Lesser or greater basis weights may be used in the other regions of the garment 885, such as the sleeves 936 and 938, the cuffs 943 and 945, and the collar 952. Since the garment 885 is typically intended for active wear, the webs of fabric 888 and 889, or portions thereof, can be made of materials having a basis weight that is abrasion resistant.

The webs of fabric 888 and 889 may be made of the same material or may be made of different materials. In addition, the webs of fabric 888 and 889 may be both made of single layered materials, both multi-layered materials, or one of single layered materials and the other of multi-layered materials.

For embodiments wherein the webs of fabric 888 and 889 are a multi-layer laminate, both the outer surface 887 and the inner surface 886 are desirably compliant and soft feeling to the wearer. The following description of materials from which the outer surface 887 may be formed may also be used to form the material of the inner surface 886.

The outer surface 887 may be any suitable gatherable material as earlier described for the outer surface 213.

Alternatively, the outer surface 887 may be derived from a spunbonded web. In a desired embodiment, the outer surface 887 is spunbonded polypropylene nonwoven, meltblown polypropylene nonwoven and spunbonded polypropylene nonwoven laminate (SMS). The total basis weight is from about 0.4 to about 1.0 osy (more desirably 0.6 osy) and is made with about 86% spunbonded nonwoven and 14% meltblown nonwoven. A pigment such as titanium dioxide may be incorporated into the outer surface 887 and the inner surface 886. Such spunbonded meltblown nonwoven laminate material is available from Kimberly-Clark Corporation, Roswell, GA. The basis weight of the SMS material may vary from about 0.4 to about 1.0 osy.

The inner surface 886 may be any soft and flexible sheet as earlier described for the inner surface 211.

The outer surface 887 and the inner surface 886 may be further dyed, pigmented, or imprinted with any suitable color. Desirably, the inner surface 886 is either dyed, pigmented, or printed with a material which does not irritate or bleed the color onto the skin of the wearer. One type of embodiment of the present invention is a continuous process for the manufacture of a garment 885 (see Figures 80 and 89) for wearing about the upper body comprising at least a front panel 892, a back panel 897, a neck opening 948 defined about its perimeter by edge 950, sleeve flaps 956 and 957, and a lower body opening 909 defined about its perimeter by garment bottom edges 895 and 903. The garment 885 comprises an inner surface 886 and an outer surface 887. The garment 885 may comprise single layer webs of fabric 888 and 889 or may comprise multi-layer laminate webs of the webs of fabric 888 and 889. The materials comprising the webs of fabric 888 and 889 have been discussed above.

The webs of fabric 888 and 889 of sufficient width of fabric to make the garment 885 are provided to produce the garments 885. The desired webs of fabric 888 and 889 are nonwoven although any disposable or washable fabric can be used. (See the discussion above). The webs of fabric 888 and 889 are typically unwound from rolls or other sources (not shown).

The web of fabric 888 includes a pair of opposing web side edges 911 and 912. The web of fabric 889 includes a pair of opposing web side edges 913 and 914. The two webs of fabric 888 and 889 are unwound from rolls and brought together in a side by side orientation (see Figure 87) and fastened together at the web side edge 912 of the web of fabric 888 and the web side edge 913 of the web of fabric 889, defining a center seam 917 of the composite web of fabric 918.

In some embodiments, portions of the center seam 917 may be left unfastened by intermittently fastening the web side edges 912 and 913 of the webs of fabric 888 and 889, respectively. The location of the center seam 917 corresponds to the seam formed by the mating of the shoulder edge 915 of the front panel 892 and the shoulder edge 916 of the back panel 897 of the finished garment 885. The desired method of fastening is ultrasonic sealing, although other methods of fastening known in the art such as heat sealing, adhesives, tape, or sewing can be used.

In another type of embodiment of the present invention, the two webs of fabric 888 and 889 to make the garments 885 are combined to produce the garments 885. The two webs of fabric 888 and 889 are unwound from rolls and brought together in a face to face (or, alternatively, back to back) orientation (see Figure 86) and fastened together at the web side edge 912 of the web of fabric 888 and the web side edge 913 of the web of fabric 889, defining the center seam 917 of the composite web of fabric 918.

A repeating series of indentations 928 is cut into the web side edge 911 of the web of fabric 888 by a die cutter 937. (See Figure 80). The location of the indentations 928 corresponds to the garment side edges 893 and 894 of the finished garment 885. The indentations 928 may be produced by a die cut operation, an ultrasonic operation, or any other suitable method of operation. The material to be removed from the indentations 928 may be removed by any method known in the art, desirably a vacuum source (not shown).

The indentations 928 may take on a variety of sizes and shapes, such as a slit, circular, oval, triangular, square, rectangular, multi-faceted, asymmetric or irregular, or the like. The pattern of the indentations 928 is restricted only by fashion and the minimum amount of the web of fabric 888 that must remain having a sufficient integrity to withstand the remaining steps or operations of the process of manufacture. The indentations 928 may be similar or dissimilar in shape, structure, size, and the like from each other or the indentations 930 within the finished garment 885.

A repeating series of indentations 930 is cut into the web side edge 914 of the web of fabric 889 by the die cutter 937. (See Figure 80). The location of the indentations 930 corresponds to the garment side edges 898 and 899 of the finished garment 885. The indentations 930 may be produced by a die cut operation, an ultrasonic operation, or any other suitable method of operation. The material to be removed from the indentations 930 may be removed by any method known in the art, desirably a vacuum source (not shown).

The indentations 930 may take on a variety of sizes and shapes, such as a slit, circular, oval, triangular, square, rectangular, multi-faceted, asymmetric or irregular, or the like. The pattern of the indentations 930 is restricted only by fashion and the minimum amount of the web of fabric 889 that must remain having a sufficient integrity to withstand the remaining steps or operations of the process of manufacture. The indentations 930 may be similar or dissimilar in shape, structure, size, and the like from each other or from the indentations 928 within the finished garment 885.

The web of fabric 888 is cut into garment-sized pieces 890 by the die cutter 937. The web side edge 911 of the web of fabric 888 becomes the garment bottom edge 895 of the garment-sized piece 890. It is understood that while the web side edges 911 may typically become the garment bottom edge 895 in the finished garment 885, fabric, may be removed from or added to the web side edge 911 to create the garment bottom edge 895 in the finished garment 885. The piece side edges 901 and 905 of the garment-sized pieces 890 created by the cutting operation are located such that the indentations 928 are cut, producing the garment side edges 893 and 894 in the finished garments 885. It is understood that while Figure 80 shows the die cutter 937 cutting the web of fabric 888 (or, alternatively, the composite web of fabric 918) into discrete garment-sized pieces 890 and the opposing indentafions 928 and 930, these operations could be performed by separate devices and at different stages within the manufacturing process.

The web of fabric 889 is cut into garment-sized pieces 891 by the die cutter 937. The web side edge 914 of the web of fabric 889 becomes the garment bottom edge 903 of the garment-sized piece 891. It is understood that while the web side edges 912 may typically become the garment bottom edge 903 in the finished garment 885, fabric may be removed from or added to the web side edge 914 to create the garment bottom edge 903 in the finished garment 885. The piece side edges 902 and 906 of the garment-sized pieces 891 created by the cutting operation are located such that the indentations 930 are cut, producing the garment side edges 898 and 899 in the finished garments 885.

In some embodiments, the webs of fabric 888 and 889 are combined (as described above), forming the composite web of fabric 918 prior to being cut by the die cutter 937 into discrete garment-sized pieces 919. The web side edges 911 and 914 of the composite web of fabric become the garment bottom edges 895 and 903, respectively, of the discrete garment-sized pieces 919. It is understood that while the web side edges 911 and 914 may typically become the garment bottom edges 895 and 903, respectively, in the finished garments 885, fabric may be removed from or added to the web side edges 911 and 914 to create the garment bottom edges 895 and 903, respectively, in the finished garments 885. The piece side edges 900 and 904 of the discrete garment-sized pieces 919 created by the cutting operation are located such that the opposing indentations 928 and 930 are cut, producing the garment side edges 893 and 894 and the garment side edges 898 and 899, respectively, in the finished garments 885.

In some embodiments of the present invention, the webs of fabric 888 and 889 (or, alternatively, the composite web of fabric 918) are cut into the garment-sized pieces 890 and 891 (or, alternatively, the discrete garment-sized pieces 919) prior to the performance of an operation to create the opposing indentations 928 and 930 (see Figures 84 and 85). A repeating series of pairs of opposing indentations 929 and 931 is cut into the piece side edges 901 and 905 and the piece side edges 902 and 906, respectively, (or, alternatively, the piece side edges 900 and 904, respectively) of the garment-sized pieces 890 and 891 (or, alternatively, the discrete garment-sized pieces 919). The location of the opposing indentations 929 and 931 corresponds to the garment side edges 893 and 894 and the garment side edges 898 and 899, respectively, of the finished garments 885. The opposing indentations 929 and 931 may be produced by a die cut operation, an ultrasonic operation, or any other suitable method of operation. The material to be removed from the indentations 929 and 931 may be removed by any method known in the art, desirably a vacuum source (not shown).

The opposing indentations 929 and 931 may take on a variety of sizes and shapes, such as a lit, circular, oval, triangular, square, rectangular, multi-faceted, asymmetric or irregular, or the like. The pattern of the opposing indentations 929 and 931 is restricted only by fashion and the minimum amount of the garment-sized pieces 890 and 891 (or, alternatively, the discrete garment-sized pieces 919) that must remain having sufficient integrity to withstand the remaining steps or operations of the process of manufacture. The opposing indentations 929 and 931 , alternatively, the garment side edges 893 and 894 and the garment side edges 898 and 899, respectively, may be similar or dissimilar in shape, structure, size, and the like from each other within the finished garment 885.

In some embodiments, the operation of cutting the opposing indentations 929 and 931 (or, alternatively, the opposing indentations 928 and 930) into the discrete garment- sized pieces 919 or the garment-sized pieces 890 and 891 (or, alternatively, the composite web of fabric 918 or the webs of fabric 888 and 889) may be eliminated. As the pattern of the garment 885 is restricted only by fashion and the minimum amount of the discrete garment-sized pieces 919 or the garment-sized pieces 890 and 891 (or, alternatively, the composite web of fabric 918 or the webs of fabric 888 and 889) that must remain having sufficient integrity to withstand the operations or steps of the process of manufacture, one can simply design the garment 885 such that this operation of cutting the opposing indentations 929 and 931 (or, alternatively, the opposing indentations 928 and 930) into the discrete garment-sized pieces 919 or the garment-sized pieces 890 and 891 (or, alternatively, the composite web of fabric 918 or the webs of fabric 888 and 889) is not required. As discussed above, the arm openings 932 and 934 may be created by leaving a portion of the garment side edges 893 and 898 and the garment side edges 894 and 899, respectively, unattached.

A repeating series of openings 947 is cut by the die cutter 937 into at least one of the webs of fabric 888 and 889 (or the composite web of fabric 918). The location of the opening 947 corresponds to the neck opening 948 in the finished garment 885. The openings 947 may be produced by a die cut operation, an ultrasonic operation, or any other suitable method of operation. It is understood that while Figure 80 shows the die cutter 937 cutting the openings 947 and the opposing indentations 928 and 930, these cutting operations (also, the operation for cutting the opposing indentations 929 and 931) could be performed by separate devices and at different stages within the manufacturing process. The openings 947 may be cut into at least one of the webs of fabric 888 and 889 before or after the webs of fabric 888 and 889 are combined to form the composite web of fabric 918.

The opening 947 may take on a variety of sizes and shapes, such as slit, circular, oval, triangular, square, rectangular, multi-faceted, asymmetric or irregular, or the like. The material to be removed from the openings 947 may be removed by any method known in the art, desirably a vacuum source (not shown). The pattern of the opening 947 is restricted only by fashion and the minimum amount of the webs of fabric 888 and 889 (or the composite web of fabric 918) that must remain having a sufficient integrity to withstand the remaining steps or operations of the process of manufacture.

In alternative embodiments of the present invention, the opening 947 may be comprised of the indentations 958a cut into the web side edge 912 of the web of fabric 888 and the indentations 958b cut into the web side edges 913 of the web of fabric 889 prior to the combining of the webs of fabric 888 and 889 to form the composite web of fabric 918. An indentation 958a and an indentation 958b are combined to form the opening 947.

The placement of the opening 947 in relation to the repeating series of opposing indentations 928 and 930, while in a typical garment 885, the opening 947 is centrally located between the repeating series of opposing indentations 928 and 930, is restricted only by fashion and the minimum amount of the webs of fabric 888 and 889 (or, alternatively, the composite web of fabric 918) that must remain having sufficient integrity to withstand the remaining steps or operations of the process of manufacture. For example, the placement of the opening 947 between the repeating series of opposing indentations 928 and 930 may be symmetrically or asymmetrically located.

The placement of the opening 947 in the relation to the two pairs of the opposing indentations 929 and 931 , while in a typical garment 885, the opening 947 is centrally located between the two pairs of opposing indentations 929 and 931 , is restricted only by fashion and the minimum amount of the discrete garment-sized pieces 919 (or, alternatively, the garment-sized pieces 890 and 891) that must remain having sufficient integrity to withstand the remaining steps or operations of the process of manufacture. For example, the placement of the opening 947 between the two pairs of opposing indentations 929 and 931 may be symmetrically or asymmetrically located.

The composite web fabric 918 is cut by the die cutter 937 into discrete garment- sized pieces 919 wherein each discrete garment-sized piece 919 contains at least one opening 947, two pairs of opposing indentations 929 and 931, one pair of opposing piece side edges 900 and 904, one pair of opposing garment bottom edges 895 and 903, and opposing garment end portions 922 and 924. The location of the opposing piece side edges 900 and 904 of the discrete garment-sized piece 919 corresponds to a sleeve opening end edge 942 of a sleeve flap 956 proximate to the garment side edge 893 of the front panel 892 and the garment side edge 898 of the back panel 897, and a sleeve opening end edge 944 of a sleeve flap 957 proximate to the garment side edge 894 of the front panel 892 and the garment side edge 899 of the back panel 897, respectively, in the finished garment 885. It is understood that while the piece side edges 900 and 904 of the discrete garment-sized piece 919 may typically become the sleeve opening end edges 942 and 944 in the finished garment 885, fabric may be removed from or added to the piece side edges 900 and 904 to create the sleeve opening end edges 942 and 944 in the finished garment 885.

The opposing garment end portions 922 and 924 are adjacent to the garment bottom edge 895 of the front panel 892 and the garment bottom edge 903 of the back panel 897, respectively, in the finished garment 885. The location of the opposing web side edges 911 and 914 of the composite web of fabric 918 (or, alternatively, the discrete garment-sized piece 919) correspond to the garment bottom edge 895 of the front panel 892 and the garment bottom edge 903 of the back panel 897, respectively, in the finished garment 885. It is understood that while the web side edges 911 and 912 of the composite web of fabric 918 (or, alternatively, the discrete garment-sized piece 919) may typically become the garment bottom edges 895 and 903 of the front and back panels 892 and 897, respectively, in the finished garment 885, fabric may be removed from or added to the web side edges 911 and 912 of the composite web of fabric 918 (or, alternatively, the discrete garment-sized piece 919) to create the garment bottom edges 895 and 903 in the finished garment 885.

The webs of fabric 888 and 889 may be cut into discrete garment-sized pieces 890 and 891 , respectively, before the webs of fabric 888 and 889 are combined to form the composite web of fabric 918. The garment-sized pieces 890 and 891 of the webs of fabric 888 and 889 are fastened together at the web side edges 912 and 913 to form the discrete garment-sized piece 919 of the composite web of fabric 918. The garment-sized pieces 890 and 891 are combined to form the discrete garment-sized piece 919 such that each discrete garment-sized piece 919 contains at least an opening 947, two pairs of opposing indentations 929 and 931 , one pair of opposing piece side edges 900 and 904, one pair of opposing web side edges 911 and 914, and opposing garment end portions 922 and 924, as described above.

The garment-sized pieces 890 and 891 of the webs of fabric 888 and 889 are positioned before the garment-sized pieces 890 and 891 are fastened together to form the discrete garment-sized piece 919 of the composite web of fabric 918. The garment-sized piece 890 may be positioned by a turn roll or turn table (not shown) so as to place the garment end portion 922 of the garment-sized piece 890 adjacent the garment end portion 924 of the garment-sized piece 891. The web side edge 912 of the garment-sized piece 890 is attached at the web side edge 913 of the garment-sized piece 891 , thereby forming the center seam 917.

The center seam 917, or portions thereof, can be constructed as a non- refastenable seam, as a refastenable seam, or as a combination of a non-refastenable seam and a refastenable seam. Any excess material from the webs of fabric 888 and 889 may be removed from the web side edges 912 and 913 of the center seam 917 to reduce and smooth out the center seam 917. The non-refastenable center seam 917 may be formed by any suitable means such as ultrasonic sealing, adhesive bonding, tape, heat sealing, sewing, or any method of fastening known in the art. The center seam 917 may be constructed on a continuous or intermittent basis. One suitable method of forming such center seam 917 is disclosed in U.S. Patent No. 4,938,753 issued July 3, 1990, to Van Gompel et al., which is incorporated herein by reference. The center seam 917 may be bonded together to form a non-refastenable center seam 917.

In other embodiments of the present invention, the web side edges 912 and 913 of the webs of fabric 888 and 889, respectively, may be held together in the finished garment 885 to form refastenable center seam 917. The refastenable means for securing the web side edges 912 and 913 of the garment 885 include refastenable adhesive and mechanical type fasteners 953. The adhesive and mechanical type fasteners 953 include buttons and button holes, snaps, buckles, clasps, hooks and loops, end extensions, tabs, tape, and the like which are designed or adapted to interlock or engage some type of a complementary device or the outer surface 887 or inner surface 886 of the garment 885. A refastenable center seam 917 may be constructed on a continuous or intermittent basis.

In addition, elasticized fasteners 953 may also be used in assuring better fit of the garment 885. If the garment 885 includes a refastenable center seam 917, the refastenable means are desirably strategically placed on the webs of fabric 888 and 889 before the webs of fabric 888 and 889 are cut into discrete garment-sized pieces 890 and 891 (or, alternatively, before the composite web of fabric 918 is cut into the discrete garment-sized pieces 919). The folding and redirection operations may be eliminated when a refastenable center seam 917 is included in the garment 885. However, there may be packaging reasons for which one would still carry out these two steps.

The center seam 917 of the present invention may take on a variety of structures or configurations known in the art. One embodiment of the center seam 917 is an out- turned configuration as illustrated in Figure 101. Such a configured center seam 917 is formed by securing together at least a portion of the out-turned portions of the web side edges 912 and 913. The inner surfaces 886 of the front and back panels 892 and 897 at the web side edges 912 and 913, respectively, are brought into contact with each other.

Another embodiment of the center seam 917 is an in-turned configuration as illustrated in Figure 101. Such a configured center seam 917 is formed by securing together at least a portion of the in-turned portions of the web side edges 912 and 913. The outer surfaces 887 of the front and back panels 892 and 897 at the web side edges 912 and 913, respectively, are brought into contact with each other.

Another embodiment of the center seam 917 is an over-lapped configuration as illustrated in Figure 100. Such a conflgured center seam 917 is formed by securing together at least a portion of the over-lapped portions of the web side edges 912 and 913. The inner surface 886 of one of the front and back panels 892 and 897 at the web side edges 912 and 913 is brought into contact with the outer surface 887 of the other panel 892 or 897 at the web side edges 912 and 913, respectively.

Another embodiment of the center seams 917 is an over-lapped configuration as illustrated in Figure 103. Such a configured center seam 917 is formed by folding back the web side edge 912 (or, alternatively, the web side edge 913). The outer surface 887 of the folded portion and the inner surface 886 of the unfolded portion of the web side edge 912 and the corresponding portion of the front panel 892 (or, alternatively, the web side edge 913 and the corresponding portion of the back panel 897) are brought into contact with the inner surface 886 or the outer surface 887 of the web side edge 913 and the corresponding portions of the back panel 897 (or, alternatively, the web side edge 912 and the corresponding portion of the front panel 892). It is understood that the folding back of the web side edges 912 or 913 could be performed such that the inner surface 886 would be exposed along the fold.

In the embodiments where the webs of fabric 888 and 889 or the garment-sized pieces 890 and 891 are fastened together prior to the folding step,, each discrete garment- sized piece 919 of the composite web of fabric 918 is transported, typically by vacuum screens, belts, or conveyors, through hemming, folding, and fastening operations. The folding operations are desirably carried out by tuckers and folders, as well as any other known means. The discrete garment-sized piece 919 of the composite web of fabric 918 is folded by a folder 939 so as to bring together the opposing garment end portions 922 and 924 such that the garment side edge 893 of the front panel 892 of the composite web of fabric 918 is folded or otherwise brought into contact with the garment side edge 898 of the back panel 897. The garment side edge 894 of the front panel 892 is folded or otherwise brought into contact with the garment side edge 899 of the back panel 897. The mating of the garment side edge 893 and the garment side edge 898, as well as the mating of the garment side edge 894 and the garment side edge 899, form the garment side seams 907 and 908, respectively, of the garment 885. It may be desirable to redirect (or reorient) the discrete garment-sized piece 919 of the composite web of fabric 918 to allow easy bonding of the garment side seams 907 and 908 of the garment 885. The turning operations are desirably carried out by turn rolls and turn tables, as well as any other known means. The discrete garment-sized piece 919 of the composite web of fabric 918 may be reoriented 90 degrees (not shown).

In various embodiments of the present invention, one or both of the garment side seams 907 and 908 can be constructed as non-refastenable seams or as refastenable seams. Any excess material from the webs of fabric 888 and 889 may be removed from the edges of the garment side seams 907 and 908 to reduce and smooth out the garment side seams 907 and 908. The non-refastenable garment side seams 907 and 908 may be formed by any suitable means such as ultrasonic sealing, adhesive bonding, tape, heat sealing, sewing, or any method of fastening known in the art. (Sewing equipment 971 is shown in Figure 80). The garment side seams 907 and 908 may be constructed on a continuous or intermittent basis. One suitable method of forming such garment side seams 908 and 907 is disclosed in U.S. Patent No. 4,938,753 issued July 3, 1990, to Van Gompel et al., which is incorporated herein by reference. The garment side seams 907 and 908 may be bonded together to form non-refastenable garment side seams 907 and 908.

In other embodiments of the present invention, the garment side edges 893 and 898 and the garment side edges 894 and 899 of the garment 885 may be held together in the finished garment 885 to form refastenable garment side seams 907 and 908, respectively. The refastenable means for securing the garment side edges 893 and 898 and the garment side edges 894 and 899 of the garment 885 include refastenable adhesive and mechanical type fasteners 953. The adhesive and mechanical type fasteners 953 include buttons and button holes, snaps, buckles, clasps, hooks and loops, end extensions, tabs, tape, and the like which are designed or adapted to interlock or engage some type of a complementary device or the outer surface 887 or the inner surface 886 of the garment 885.

In addition, elasticized fasteners 953 may also be used in assuring better fit of the garment 885. If the garment 885 includes refastenable garment side seams 907 and 908, the refastenable means are desirably strategically placed on the webs of fabric 888 and 889 before the webs of fabric 888 and 889 are cut into discrete garment-sized pieces 890 and 891 (or, alternatively, the composite web of fabric 918 or the discrete garment-sized pieces 919). The folding and redirection operations may be eliminated when a refastenable garment side seams 907 and 908 are included in the garment 885.

However, there may be packaging reasons for which one would still carry out these two steps.

The garment side seams 907 and 908 of the present invention may take on a variety of structures or configurations known in the art. One embodiment of the garment side seams 907 and 908 is an out-turned configuration as illustrated in Figure 101. Such configured garment side seams 907 and 908 are formed by securing together at least a portion of the out-turned portions of the garment side edges 893 and 898 and the garment side edges 894 and 899, respectively. The inner surface 886 of the garment side edges 893 and 894 of the front panel 892 and the garment side edges 898 and 899 of the back panel 897, respectively, are brought into contact with each other for each pair of garment side edges.

Another embodiment of the garment side seams 907 and 908 is an in-turned configuration as illustrated in Figure 102. Such configured garment side seams 907 and 908 are formed by securing together at least a portion of the in-turned portions of the garment side edges 893 and 898 and the garment side edges 894 and 899, respectively. The outer surface 887 of the garment side edges 893 and 894 of the front panel 892 and the garment side edges 898 and 899 of the back panel 897, respectively, are brought into contact with each other for each pair of garment side edges.

Another embodiment of the garment side seams 907 and 908 is an over-lapped configuration as illustrated in Figure 100. Such configured garment side seams 907 and 908 are formed by securing together at least a portion of the over-lapped portions of the garment side edges 893 and 898 and the garment side edges 894 and 899, respectively. The inner surface 886 of one of the garment side edges 893 and 898 and one of the garment side edges 894 and 899 are brought into contact with the outer surface 887 of the other garment side edges of each pair of garment side edges. Another embodiment of the garment side seams 907 and 908 is an over-lapped configuration as illustrated in Figure 103. Such a configured garment side seam 907 is formed by folding back the garment side edge 893 or the garment side edge 898. The outer surface 887 of the folded portion and the inner surface 886 of the unfolded portion of the garment side edge 893 or the garment side edge 898 and the corresponding portion of the front panel 892 or the back panel 897, respectively, are brought into contact with the inner surface 886 or the outer surface 887 of the non-folded garment side edge 898 or 893 and the corresponding portion of the back panel 897 or the front panel 892.

The garment side seam 908 is formed by folding back the garment side edge 894 or the garment side edge 899. The outer surface 887 of the folded portion and the inner surface 886 of the unfolded portion of the garment side edge 894 or the garment side edge 899 and the corresponding portion of the front panel 892 or the back panel 897, respectively, are brought into contact with the inner surface 886 or the outer surface 887 of the non-folded garment side edge 899 or 894 and the corresponding portion of the back panel 897 or the front panel 892. It is understood that the folding back of a garment side edge 893, 898, 894, or 899, could be performed such that the inner surface 886 would be exposed along the fold.

The garment end portions 922 and 924 of the discrete garment-sized piece 919 of the composite web of fabric 918 may be hemmed in the finished garment 885. In some embodiments, it may be desirable to hem the garment end portions 922 and 924 of the garment-sized pieces 890 and 891 of the webs of fabric 888 and 889, respectively, before fastening the garment-sized pieces 890 and 891 together to form the discrete garment- sized piece 919 of the composite web of fabric 918. The garment end portions 922 and 924 of the discrete garment-sized piece 919 (or garment end portions 922 and 924 of the garment-sized pieces 890 and 891 , respectively) can be hemmed by any method or style known in the art. In some embodiments, it may be desirable to leave the garment end portions 922 and 924 of the discrete garment-sized piece 919 (or garment end portions 922 and 924 of the garment-sized pieces 890 and 891 , respectively) unhemmed.

The garment bottom edges 895 and 903 of the discrete garment-sized piece 919 of the composite web of fabric 918 may be hemmed in the finished garment 885. (Sewing equipment 970 is shown in Figure 80). In some embodiments, it may be desirable to hem the garment bottom edges 895 and 903 of the garment-sized pieces 890 and 891 of the webs of fabric 888 and 889, respectively, before fastening the garment-sized pieces 890 and 891 together to form the discrete garment-sized piece 919 of the composite web of fabric 918. The garment bottom edges 895 and 903 of the discrete garment-sized piece 919 (or garment bottom edges 895 and 903 of the garment-sized pieces 890 and 891, respectively) can be hemmed by any method or style known in the art. In some embodiments, it may be desirable to leave the garment bottom edges 895 and 903 of the discrete garment-sized piece 919 (or garment bottom edges 895 and 903 of the garment- sized pieces 890 and 891 , respectively) unhemmed.

In some embodiments of the present invention, the garment 885 includes sleeve flaps 956 and 957. (See Figures 92 and 93). The sleeve flaps 956 and 957 may take on a variety of sizes and shapes, such as a slit, circular, oval, triangular, square, rectangular, multi-faceted, asymmetric or irregular, or the like. The pattern of the sleeve flaps 956 and 957 is restricted only by fashion and the minimum amount of the material of the sleeve flaps 956 and 957 that is necessary to complete the remaining steps or operations of the process of manufacture. The sleeves 936 and 938, alternately the sleeve flaps 956 and 957, may be similar or dissimilar in shape, structure, material, size, and the like from each other within the finished garment 885. In some embodiments, only one sleeve 936 or 938 may be included in the finished garment 885.

The sleeve flap 956 has a pair of sleeve side edges 940 and 941 , and a sleeve opening end edge 942 extending between the sleeve side edges 940 and 941. It is understood that the piece of the sleeve flap 956 could be made of multiple pieces of material or materials. The sleeve flap 956 is folded so as to bring together the opposing sleeve side edges 940 and 941 to form a sleeve seam 951 of the sleeve 936. It is understood that while the piece side edge 900 (or, alternatively, the piece side edges 901 and 902) of the discrete garment-sized piece 919 may typically become the sleeve opening end edge 942 in the finished garment 885, fabric may be removed from or added to the piece side edge 900 (or, alternatively, the piece side edges 901 and 902) to create the sleeve opening end edge 942 in the finished garment 885.

The sleeve flap 957 has a pair of sleeve side edges 946 and 949, and a sleeve opening end edge 944 extending between the sleeve side edges 940 and 941. It is also understood that the sleeve flap 957 could be made of multiple pieces of material or materials. The sleeve flap 957 is folded so as to bring together the opposing sleeve side edges 946 and 949 to form a sleeve seam 955 of the sleeve 938. It is understood that while the piece side edge 904 (or, alternatively, the piece side edges 905 and 906) of the discrete garment-sized piece 919 may typically become the sleeve opening end edge 944 in the finished garment 885, fabric may be removed from or added to the piece side edge 904 (or, alternatively, the piece side edges 905 and 906) to create the sleeve opening end edge 944 in the finished garment 885.

It may be desirable to redirect (or reorient) the garment-sized pieces 890 and 891 (or the discrete garment-sized piece 919) to allow easy fastening of the sleeve seams 951 and 955 of the sleeves 936 and 938, respectively, of the garment 885. The turning operations are desirably carried out by turn rolls and turn tables, as well as any other known means. The garment-sized pieces 890 and 891 (or the discrete garment-sized piece 919) may be reoriented 90 degrees (not shown). The sleeve seams 951 and 955 can be non-refastenable seams or refastenable seams. Any excess material of the sleeve flaps 956 and 957 can be removed from their respective edges of the sleeve seams 951 and 955 to reduce and smooth out the sleeve seams 951 and 955. The non- refastenable sleeve seams 951 and 955 may be formed by any suitable means such as ultrasonic sealing, adhesive bonding, tape, heat sealing, sewing, or any method of fastening known in the art, as discussed above. The non-refastenable sleeve seams 951 and 955 may be constructed on a continuous or intermittent basis.

In other embodiments, the opposing pair of the sleeve side edges 940 and 941 and the opposing pair of the sleeve side edges 946 and 949 of the sleeves 936 and 938, respectively, may be held together in the finished garment 885 to form refastenable sleeve seams 951 and 955. The refastenable means for securing the pair of opposing sleeve side edges 940 and 2857 and the pair of opposing the sleeve side edges 946 and 949 of the sleeves 936 and 938, respectively, include refastenable adhesive and mechanical type fasteners 953. The adhesive and mechanical type fasteners 953 include buttons and button holes, snaps, buckles, clasps, hooks and loops, end extensions, tabs, tape, and the like which are designed or adapted to interlock or engage some type of a complementary device or the inner surface 886 or the outer surface 887 of the garment 885. The refastenable sleeve seams 951 and 955 may be constructed on a continuous or intermittent basis. In addition, elasticized fasteners 953 may also be used in assuring better fit of the sleeves 936 and 938 of the garment 885. If the garment 885 includes refastenable sleeve seams 951 and 955, the refastenable means are desirably strategically placed on the sleeve flaps 956 and 957 before the indentations 929 and 931 are cut into the web side edges 911 and 914 of the composite web of fabric 918 (or the webs of fabric 888 and 889). The folding and redirection operations may be eliminated when refastenable sleeve seams 951 and 955 are included in the garment 885. However, there may be packaging reasons for which one would still carry out these two steps.

The sleeve seams 951 and 955 of the present invention may take on a variety of structures or configurations known in the art. One embodiment of the sleeve seams 951 and 955 is an out-turned configuration as illustrated in Figure 101. Such configured sleeve seams 951 and 955 are formed by securing together at least a portion of the out- turned portions of the sleeve side edges 940 and 941 and the sleeve side edges 946 and 949 of the sleeves 936 and 938, respectively. The inner surface 886 of the sleeve side edges 940 and 941 and the sleeve side edges 946 and 949 of the sleeves 936 and 938, respectively, are brought into contact with each other of the pair.

Another embodiment of the sleeve seams 951 and 955 is an in-turned configuration as illustrated in Figure 101. Such configured sleeve seams 951 and 955 are formed by securing together at least a portion of the in-turned portions of the sleeve side edges 940 and 941 and the sleeve side edges 946 and 949 of the sleeves 936 and 938, respectively. The outer surface 887 of the sleeve side edges 940 and 2857 and the sleeve side edges 946 and 949 of sleeves 936 and 938, respectively, are brought into contact with each other of the pair.

Another embodiment of the sleeve seams 951 and 955 is an over-lapped configuration as illustrated in Figure 100. Such configured sleeve seams 951 and 955 are formed by securing together at least a portion of the over-lapped portions of the sleeve side edges 940 and 2857 and the sleeve side edges 946 and 949 of the sleeves 936 and 938, respectively. The inner surface 886 of one of the sleeve side edges 940 or 2857 and the sleeve side edges 946 or 949 of the sleeves 936 and 938, respectively, are brought into contact with the outer surface 887 of the other sleeve side edge 940 or 2857 and the sleeve side edge 946 or 949 of the sleeve 936 and 938, respectively. Another embodiment of the sleeve seams 951 and 955 is an over-lapped configuration as illustrated in Figure 103. Such configured sleeve seams 951 and 955 are formed by folding back the sleeve side edges 940 or 941 and the sleeve side edges 946 and 949 of the sleeves 936 and 938, respectively. The outer surface 887 of the folded portions and the inner surface 886 of the unfolded portions of the sleeve side edges 940 or 2857 and the sleeve side edges 946 or 949 and the corresponding portions of the sleeves 936 and 938, respectively, are brought into contact with the inner surface 886 or the outer surface 887 of the non-folded sleeve side edge 941 or 940 and the sleeve side edge 949 or 946 and the corresponding portions of the sleeves 936 and 938, respectively. It is understood that the folding back of a sleeve side edge 940, 941, 946, or 949 could be performed such that the inner surface 886 would be exposed along the fold.

The sleeve opening end edges 942 and 944 of the sleeves 936 and 938, respectively, (in the alternative, the sleeve opening end edges 942 and 944 of the sleeve flaps 956 and 957) can be hemmed by any method or style known in the art. In some embodiments, it may be desirable to leave the sleeve opening end edges 942 and 944 unhemmed.

In other embodiments, cuffs 943 and 945 may be attached to the sleeve opening end edges 942 and 944, respectively, of the sleeves 936 and 938, respectively, of the garment 885, forming cuff seams 960 and 962, respectively. The attachment of the cuffs 943 and 945 may be made non-refastenable by means as discussed above. (Sewing equipment 969 is shown in Figure 80). In the alternative, the attachment of the cuffs 943 and 945 may be made refastenable by means as discussed above. The cuff seams 960 and 962 may be constructed on a continuous or intermittent basis. The cuffs 943 and 945 may take on a variety of sizes and shapes. The cuffs 943 and 945 may be similar or dissimilar in shape, structure, material, size, and the like from each other within the flnished garment 885. The pattern of the cuffs 943 and 945 is restricted only by fashion and the minimum amount of the material of the cuffs 943 and 945 that is necessary to complete the remaining steps or operations of the process of manufacture.

The cuff seams 960 and 962 of the present invention may take on a variety of structures or configurations known in the art. One embodiment of the cuff seams 960 and 962 is an out-turned configuration as illustrated in Figure 101. Such configured cuff seams 960 and 962 are formed by securing together at least a portion of the out-turned portions of the cuff edge 959 and the sleeve opening end edge 942 and the cuff edge 961 and the sleeve opening end edge 944, respectively, of the garment 885. The inner surface 886 of the cuff edges 959 and 961 of the cuffs 943 and 945, respectively, is brought into contact with the inner surface 886 of the sleeve opening edges 942 and 944 of the sleeves 936 and 938, respectively.

Another embodiment of the cuff seams 960 and 962 is an in-turned configuration as illustrated in Figure 101. Such configured cuff seams 960 and 962 are formed by securing together at least a portion of the in-turned portions of the cuff edge 959 and the sleeve opening edge 942 and the cuff edge 961 and the sleeve opening edge 944, respectively, of the garment 885. The outer surface 887 of the cuff edges 959 and 961 of the cuffs 943 and 945, respectively, is brought into contact with the outer surface 887 of the sleeve opening edges 942 and 944 of the sleeves 936 and 938, respectively.

Another embodiment of the cuff seams 960 and 962 is an over-lapped configuration as illustrated in Figure 100. Such configured cuff seams 960 and 962 are formed by securing together at least a portion of the over-lapped portions of the cuff edge 959 and the sleeve opening edge 942 and the cuff edge 961 and the sleeve opening edge 944 of the sleeves 936 and 938, respectively. The inner surface 886 of one of the cuff edge 959 or the sleeve opening edge 942 and the cuff edge 961 or the sleeve opening edge 944, are brought into contact with the outer surface 887 of the other cuff edge 959 or the sleeve opening edge 942 and the cuff edge 961 or the sleeve opening edge 944 of the sleeves 936 and 938, respectively.

Another embodiment of the cuff seams 960 and 962 is an over-lapped configuration as illustrated in Figure 103. Such configured cuff seams 960 and 962 are formed by folding back the cuff edge 959 or the sleeve opening end edge 942 and the cuff edge 961 or the sleeve opening end edge 944 of the sleeves 936 and 938, respectively. The outer surface 887 of the folded portions and the inner surface 886 of the unfolded portions of the cuff edge 959 or the sleeve opening end edge 942 and the cuff edge 961 or the sleeve opening end edge 944 and the corresponding portions of the cuffs 943 and 945 or the sleeves 936 and 938 are brought into contact with the inner surface 886 or the outer surface 887 of the unfolded cuff edge 959 and 961 or the sleeve opening end edge 942 and 944 and the corresponding portions of the cuffs 943 and 945 or the sleeves 936 and 938. It is understood that the folding back of a cuff edge 959 or 961 or a sleeve opening end edge 942 or 944 could be performed such that the inner surface 886 would be exposed along the fold.

The materials used for the cuffs 943 and 945 may be the same as the materials used for the other portions of the garment 885. In some embodiments, it is desirable that the materials used for the cuffs 943 and 945 have an elastic element such that the cuffs 943 and 945 will conform to the portion of the wearer's arms that come into contact with the cuffs 943 and 945.

The edge 950 of the neck opening 948 can be hemmed by any method or style known in the art. In some embodiments, it may be desirable to leave the edge 950 of the neck opening 948 unhemmed.

In other embodiments, a collar 952 may be attached to the edge 950 of the neck opening 948 of the garment 885, thereby forming a collar seam 964. The attachment of the collar 952 may be made non-refastenable by means as discussed above. (Sewing equipment 968 is shown in Figure 80). In the alternative, the attachment of the collar 952 may be made refastenable by means as discussed above. The collar seam 964 may be constructed on a continuous or intermittent basis. The collar 952 may take on a variety of sizes and shapes. The pattern of the collar 952 is restricted only by the fashion and the minimum amount of the material of the collar 952 that is necessary to complete the remaining steps or operations of the process of manufacture.

The collar seam 964 of the present invention may take on a variety of structures or configurations known in the art. One embodiment of the collar seam 964 is an out-turned configuration as illustrated in Figure 101. Such a configured collar seam 964 is formed by securing together at least a portion of the out-turned portions of the collar edge 963 of the collar 952 and the edge 950 of the neck opening 948 of the garment 885. The inner surface 886 of the collar edge 963 of the collar 952 is brought into contact with the inner surface 886 of the edge 950 of the neck opening 948.

Another embodiment of the collar seam 964 is an in-turned configuration as illustrated in Figure 101. Such a configured collar seam 964 is formed by securing together at least a portion of the in-turned portions of the collar edge 963 of the collar 952 and the edge 950 of the neck opening 948 of the garment 885. The outer surface 887 of the collar edge 963 of the collar 952 is brought into. contact with the outer surface 887 of the edge 950 of the neck opening 948.

Another embodiment of the collar seam 964 is an over-lapped configuration as illustrated in Figure 100. Such a configured collar seam 964 is formed by securing together at least a portion of the over-lapped portions of the collar edge 963 of the collar 952 and the edge 950 of the neck opening 948 of the garment 885. The inner surface 886 of the collar edge 963 of the collar 952 or the edge 950 of the neck opening 948 is brought into contact with the outer surface 887 of the other, the collar edge 963 of the collar 952 or the edge 950 of the neck opening 948.

Another embodiment of the collar seam 964 is an over-lapped configuration as illustrated in Figure 103. Such a configured collar seam 964 is formed by folding back the collar edge 963 of the collar 952 or the edge 950 of the neck opening 948. The outer surface 887 of the folded portions and the inner surface 886 of the unfolded portions of the collar edge 963 of the collar 952 or the edge 950 of the neck opening 948 and the corresponding portions of the collar 952 or the front and back panels 892 and 897 are brought into contact with the inner surface 886 or the outer surface 887 of the unfolded collar edge 963 of the collar 952 or the edge 950 of the neck opening 948 and the corresponding portions of the collar 952 or the front and back panels 892 and 897. It is understood that the folding back of the collar edge 963 of the collar 952 or the edge 950 of the neck opening 948 could be performed such that the inner surface 886 would be exposed along the fold.

Another embodiment of the collar seam 964 is an over-lapped configuration as illustrated in Figure 104. Such a configured collar seam 964 is formed by folding the collar 952 about or over the edge 950 of the neck opening 948. The collar edges 963 of the collar 952 may be folded under, bringing the outer surface 887 of the collar 952 into contact with the edge 950 of the neck opening and any portion of the adjacent material of the front panel 892, the back panel 897, or both as desired. The collar edges 963 may be left exposed by not being folding under.

Another embodiment of the collar seam 964 is an over-lapped configuration as illustrated in Figure 105. Such a configured collar seam 964 is formed by folding the collar edge 963 such that the inner surface 886 of the collar 952 is brought into contact with itself. The edge 950 of the neck opening 948 is folded such that the outer surface 887 of the front panel 892, the back panel 897, or both are brought into contact with itself. The collar edge 963 is inserted into the fold of the edge 950 of the neck opening 948. The edge 950 of the neck opening 948 is inserted into the fold of the collar edge 963. In another embodiment, the collar edge 963 is folded such that the outer surface 887 of the collar 952 is brought into contact with itself. The edge 950 of the neck opening 948 is folded such that the inner surface 886 of the front panel 892, the back panel 897, or both, is brought into contact with itself. This configured collar seam 964 may be used with any seam describe herein.

The materials used for the collar 952 may be the same as the materials used for the other portions of the garment 885. In some embodiments, it is desirable that the materials used for the collar 952 have an elastic element such that the collar 952 will conform to the portion of the wearer's neck that comes into contact with the collar 952.

In various embodiments of the present invention, the front panel 892, the back panel 897, or both panels 892 and 897 may be cut or otherwise opened to form a slit 910 or 925 (shown in Figure 89) such as a placket. The garments 885, including one or both slits 910 and 925, can be used as a wrap, gown, robe, or the like. The slit 910 has two edges 920 and 921. The slit 925 has two edges 926 and 927. Various fastening means, such as adhesive and mechanical type fasteners 953, see the discussion below, may be used to refastenably attach or secure the edges 920 and 921 or the edges 926 and 927 together to form reclosable or refastenable garments 885. The slits 910 and 925 of the front and back panels 892 and 897, respectively, may extend from the edge 950 of the neck opening 948 to the garment bottom edges 895 and 903, respectively. In the alternative, the slits 910 and 925 may extend over only a portion of the panels 892 and 897 between the edge 950 of the neck opening 948 to the garment bottom edges 895 and 903, respectively. When the garment 885 comprises both a slit 910 in the front panel 892 and a slit 925 in the back panel 897, the slits 910 and 925 may be similar or dissimilar in size, structure, shape, and the like.

In some embodiments of the present invention, the edges 920 and 921 of the slit 910 and the edges 926 and 927 of the slit 925 may be refastenably attached or secured to each other. The edges 920 and 921 may be secured together to form the front seam 965. The edges 926 and 927 may be secured together to form the back seam 966. Various fastening means, such as adhesive and mechanical type fasteners 953, see the discussion above, may be used to refastenably attach or secure the edges 920 and 921 or the edges 926 and 927 together of the slits 910 and 925, respectively.

One embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a web of fabric including opposing web side edges wherein the opposing web side edges are proximate a pair of opposing garment bottom edges of the garment; intermittently cutting the web of fabric, forming edges defining neck openings in the web of fabric; intermittently cutting the opposing web side edges of the web of fabric, defining pairs of opposing indentations in the opposing web side edges of the web of fabric; cutting the web of fabric, defining discrete garment-sized pieces wherein each of the discrete garment-sized pieces of the web of fabric includes at least one neck opening, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, a portion of two pairs of the opposing indentations in the web side edges of the web of fabric, two garment end portions, and the pair of opposing garment bottom edges; folding the discrete garment-sized piece of the web of fabric whereby one of the garment bottom edges of the pair of opposing garment bottom edges is brought into contact with the other garment bottom edge; and, fastening at least a portion of the pair of opposing garment side edges of the front panel to at least a portion of the pair of opposing garment side edges of the back panel to form a pair of garment side seams.

The openings may be intermediate the two pairs of the opposing indentations. The web of fabric may be folded, defining an arrangement of having the web of fabric wherein the opposing web side edges are adjacent each other. The web of fabric may be unfolded after at least one step of intermittently cutting the web of fabric. The web of fabric may be unfolded before the step of cutting the web of fabric into the discrete garment-sized pieces of the web of fabric. At least a portion of at least one of the opposing garment bottom edges may be hemmed. The discrete garment-sized piece of the web of fabric may include at least one sleeve flap having at least a sleeve opening end edge and a pair of opposing sleeve side edges. The discrete garment-sized pieces of the web of fabric may include a pair of sleeve flaps wherein each sleeve flap includes at least a sleeve opening end edge and a pair of opposing sleeve side edges. At least a portion of at least one of the sleeve opening end edges of the sleeve flaps may be hemmed. A collar may be provided. At least a portion of the collar may be fastened to at least a portion of the edge of the neck opening. At least a portion of the collar may be a ribbed knit collar. At least a portion of at least one of the garment side seams may be refastenable. At least a portion of at least one of the garment side seams may be non- refastenable.

The front panel may be slit at least a portion of the distance between the edge of the neck opening and the garment bottom edge, thereby defining a pair of edges of a slit. At least a portion of the edges of the slit may be fastened to form a front seam. At least a portion of the front seam may be refastenable. At least a portion of the front seam may be non-refastenable. The back panel may be slit at least a portion of the distance between the edge of the neck opening and the garment bottom edge, thereby defining a pair of edges of a slit. At least a portion of the edges of the slit may be fastened to form a back seam. At least a portion of the back seam may be refastenable. At least a portion of the back seam may be non-refastenable. At least a portion of the edge of the neck opening may be hemmed.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a web of fabric including opposing web side edges wherein the opposing web side edges are proximate a pair of opposing garment bottom edges of the garment; intermittently cutting the opposing web side edges of the web of fabric, defining pairs of opposing indentations in the opposing web side edges of the web of fabric; intermittently cutting the web of fabric, forming edges defining neck openings in the web of fabric wherein the neck openings are intermediate two pairs of the opposing indentations; cutting the web of fabric, defining discrete garment-sized pieces wherein each of the discrete garment-sized piece of the web of fabric includes at least one neck opening, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, a portion of the two pairs of the opposing indentations in the opposing web side edges of the web of fabric, two garment end portions, and the pair of opposing garment bottom edges; folding the discrete garment-sized piece of the web of fabric whereby one of the garment bottom edges of the pair of opposing garment bottom edges is brought into contact with the other garment bottom edge; and, fastening at least a portion of the pair of opposing garment side edges of the front panel to at least a portion of the pair of opposing garment side edges of the back panel to form a pair of garment side seams. The web of fabric may be folded, defining an arrangement of having the web of fabric wherein the opposing web side edges are adjacent each other. The web of fabric may be unfolded after at least one step of intermittently cutting the web of fabric. The web of fabric may be unfolded before the step of cutting the web of fabric into the discrete garment-sized pieces of the web of fabric. At least a portion of at least one of the opposing garment bottom edges may be hemmed. The discrete garment-sized piece of the web of fabric may include at least one sleeve flap having at least a sleeve opening end edge and a pair of opposing sleeve side edges. The discrete garment-sized pieces of the web of fabric may include a pair of sleeve flaps wherein each sleeve flap includes at least a sleeve opening end edge and a pair of opposing sleeve side edges. At least a portion of at least one of the sleeve opening end edges of the sleeve flaps may be hemmed.

A collar may be provided. At least a portion of the collar may be fastened to at least a portion of the edge of the neck opening. At least a portion of the collar may be a ribbed knit collar. At least a portion of at least one of the garment side seams may be refastenable. At least a portion of at least one of the garment side seams may be non- refastenable.

The front panel may be slit at least a portion of the distance between, the edge of the neck opening and the garment bottom edge, thereby defining a pair of edges of a slit. At least a portion of the edges of the slit may be fastened to form a front seam. At least a portion of the front seam may be refastenable. At least a portion of the front seam may be non-refastenable. The back panel may be slit at least a portion of the distance between the edge of the neck opening and the garment bottom edge, thereby defining a pair of edges of a slit. At least a portion of the edges of the slit may be fastened to form a back seam. At least a portion of the back seam may be refastenable. At least a portion of the back seam may be non-refastenable. At least a portion of the edge of the neck opening may be hemmed.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a web of fabric including an inner surface, an outer surface, and opposing web side edges wherein the opposing web side edges are proximate a pair of opposing garment bottom edges of the garment; intermittently cutting the opposing web side edges of the web of fabric, defining pairs of opposing indentations in the opposing web side edges of the web of fabric; intermittently cutting the web of fabric, forming edges defining neck openings in the web of fabric wherein the neck openings are intermediate two pairs of the opposing indentations; cutting the web of fabric, defining discrete garment-sized pieces wherein each of the discrete garment-sized piece of the web of fabric includes at least one the neck opening, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, a portion of the two pairs of the opposing indentafions in the opposing web side edges of the web of fabric, a pair of sleeve flaps, two garment end portions, and the pair of opposing garment bottom edges; hemming at least a portion of at least one of the opposing garment bottom edges; folding the discrete garment-sized piece of the web of fabric whereby one of the garment bottom edges of the pair of opposing garment bottom edges is brought into contact with other the garment bottom edge; and, fastening at least a portion of the pair of opposing garment side edges of the front panel to at least a portion of the pair of opposing garment side edges of the back panel to form a pair of garment side seams.

The web of fabric may be folded, defining an arrangement of having the web of fabric wherein the opposing web side edges are adjacent each other. The web of fabric may be unfolded after at least one step of intermittently cutting the web of fabric. The web of fabric may be unfolded before the step of cutting the web of fabric into the discrete garment-sized pieces of the web of fabric. Each of the sleeve flaps may include at least an inner surface, an outer surface, a sleeve opening end edge, and a pair of opposing sleeve side edges. At least a portion of at least one of the sleeve opening end edges of the sleeve flaps may be hemmed.

A collar may be provided. At least a portion of the collar may be fastened at at least a portion of the edge of the neck opening. At least a portion of the collar may be a ribbed knit collar. At least a portion of at least one of the garment side seams may be refastenable. At least a portion of at least one of the garment side seams may be non- refastenable.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a web of fabric including opposing web side edges wherein the opposing web side edges are proximate a pair of opposing garment bottom edges of the garment; cutting the web of fabric, defining discrete garment-sized pieces wherein each of the discrete garment-sized pieces of the web of fabric includes at least a front panel, a back panel, two garment end portions, a portion of each the opposing web side edges of the web of fabric, and the pair of opposing garment bottom edges; cutting the discrete garment-sized pieces, forming edges defining at least one neck opening in each the discrete garment-sized pieces; cutting the opposing garment bottom edges of the discrete garment-sized pieces, defining two pairs of opposing indentations in the opposing garment bottom edges of the discrete garment-sized pieces, thereby forming a pair of opposing garment side edges of the front panel, a pair of opposing garment side edges of the back panel, and a pair of sleeve flaps; folding each the discrete garment-sized piece whereby one of the garment bottom edges of the pair of opposing garment bottom edges is brought into contact with other the garment bottom edge; and, fastening at least a portion of the pair of opposing garment side edges of the front panel to at least a portion of the pair of opposing garment side edges of the back panel to form a pair of garment side seams.

The neck openings may be intermediate the two pairs of the opposing indentations. The web of fabric may be folded, defining an arrangement of having the web of fabric wherein the opposing web side edges are adjacent each other. The web of fabric may be unfolded after at least one step of intermittently cutting the web of fabric. The web of fabric may be unfolded before the step of cutting the web of fabric into the discrete garment-sized pieces of the web of fabric. Each of the sleeve flaps may include at least an inner surface, an outer surface, a sleeve opening end edge, and a pair of opposing sleeve side edges. At least a portion of at least one of the sleeve opening end edges of the sleeve flaps may be hemmed.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a first web of fabric including opposing web side edges; providing a second web of fabric including opposing web side edges; aligning the first and second webs of fabric together in a side by side orientation, defining an arrangement wherein one of the opposing web side edges of the first web of fabric is adjacent one of the opposing web side edges of the second web of fabric; fastening at least a portion of the adjacent web side edge of the first web of fabric to at least a portion of the adjacent web side edge of the second web of fabric in the side by side orientation, defining at least a portion of a center seam and a composite web of fabric having a pair of opposing web side edges wherein the opposing web side edges of the composite web of fabric are proximate a pair of opposing garment bottom edges of the garment; intermittently cutting the composite web of fabric, forming edges defining neck openings in the composite web of fabric; intermittently cutting the opposing web side edges of the composite web of fabric, defining pairs of opposing indentations in the opposing web side edges of the composite web of fabric; cutting the composite web of fabric, defining discrete garment-sized pieces wherein each of the discrete garment-sized pieces of the composite web of fabric includes at least one neck opening, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, a portion of two pairs of the opposing indentations in the opposing web side edges of the composite web of fabric, two garment end portions, and the pair of opposing garment bottom edges; folding the discrete garment-sized piece of the composite web of fabric whereby one of the garment bottom edges of the pair of opposing garment bottom edges is brought into contact with the other garment bottom edge; and, fastening at least a portion of the pair of opposing garment side edges of the front panel to at least a portion of the pair of opposing garment side edges of the back panel to form a pair of garment side seams.

The neck openings may be intermediate the two pairs of the opposing indentations. At least a portion of at least one of the opposing garment bottom edges may be hemmed. The garment-sized piece of the web of fabric may comprise at least one sleeve flap having at least a sleeve opening end edge and a pair of opposing side edges. At least a portion of at least one of the sleeve opening end edges of the sleeve flaps may be hemmed.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a first web of fabric including opposing web side edges; providing a second web of fabric including opposing web side edges; aligning the first and second webs of fabric together in a side by side orientation, defining an arrangement wherein one of the opposing web side edges of the first web of fabric is adjacent one of the opposing web side edges of the second web of fabric; fastening at least a portion of the adjacent web side edge of the first web of fabric to at least a portion of the adjacent web side edge of the second web of fabric in the side by side orientation, defining at least a portion of a center seam and a composite web of fabric having a pair of opposing web side edges wherein the opposing web side edges of the composite web of fabric are proximate a pair of opposing garment bottom edges of the garment; intermittently cutting the opposing web side edges of the composite web of fabric, defining pairs of opposing indentations in the opposing web side edges of the composite web of fabric; intermittently cutting the composite web of fabric, forming edges defining neck openings in the composite web of fabric wherein the neck openings are intermediate two pairs of the opposing indentations; cutting the composite web of fabric, defining discrete garment-sized pieces wherein each of the discrete garment-sized pieces of the composite web of fabric includes at least one neck opening, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, a portion of the two pairs of the opposing indentations in the opposing web side edges of the composite web of fabric, a pair of sleeve flaps, two garment end portions, and the pair of opposing garment bottom edges; folding the discrete garment- sized piece of the composite web of fabric whereby one of the garment bottom edges of the pair of opposing garment bottom edges is brought into contact with other the garment bottom edge; and, fastening at least a portion of the pair of opposing garment side edges of the front panel to at least a portion of the pair of opposing garment side edges of the back panel to form a pair of garment side seams.

At least a portion of at least one of the opposing garment bottom edges may be hemmed. Each sleeve flap may include at least a sleeve opening end edge and a pair of opposing sleeve side edges. At least a portion of at least one of the sleeve opening end edges of the sleeve flaps may be hemmed.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a first web of fabric including an inner surface, an outer surface, and opposing web side edges; providing a second web of fabric including an inner surface, an outer surface, and opposing web side edges; aligning the first and second webs of fabric together in a side by side orientation, defining an arrangement wherein one of opposing the web side edges of the first web of fabric is adjacent one of the opposing web side edges of the second web of fabric; fastening at least a portion of the adjacent web side edge of the first web of fabric to at least a portion of the adjacent web side edge of the second web of fabric in the side by side orientation, defining at least a portion of a center seam and a composite web of fabric having a pair of opposing web side edges wherein the opposing web side edges of the composite web of fabric are proximate a pair of opposing garment bottom edges of the garment; intermittently cutting the opposing web side edges of the composite web of fabric, defining pairs of opposing indentations in the opposing web side edges of the composite web of fabric; intermittently cutting the composite web of fabric, forming edges defining neck openings in the composite web of fabric wherein the neck openings are intermediate two pairs of the opposing indentations; cutting the composite web of fabric, defining discrete garment-sized pieces wherein each of the discrete garment-sized pieces of the composite web of fabric includes at least one neck opening, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, a portion of the two pairs of the opposing indentations in the opposing web side edges of the composite web of fabric, a pair of sleeve flaps, two garment end portions, and the pair of opposing garment bottom edges; hemming at least a portion of at least one of the opposing garment bottom edges; folding the discrete garment-sized piece of the composite web of fabric whereby one of the garment bottom edges of the pair of opposing garment bottom edges is brought into contact with the other garment bottom edge; and, fastening at least a portion of the pair of opposing garment side edges of the front panel to at least a portion of the pair of opposing garment side edges of the back panel to form a pair of garment side seams.

Each sleeve flap may include at least a sleeve opening end edge and a pair of opposing sleeve side edges. At least a portion of at least one of the sleeve opening end edges of the sleeve flaps may be hemmed.

A collar may be provided. At least a portion of the collar may be fastened at at least a portion of the neck opening. At least a portion of the collar may be a ribbed knit collar. At least a portion of at least one of the garment side seams may be refastenable. At least a portion of at least one of the garment side seams may be non-refastenable.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a first web of fabric including a first web side edge and a second web side edge; providing a second web of fabric including a first web side edge and a second web side edge; intermittently cutting the second web side edge of the first web of fabric, forming indentations; intermittently cutting the second web side edge of the second web of fabric, forming indentations; aligning the first and second webs of fabric together in a side by side orientation, defining an arrangement wherein the second web side edge of the first web of fabric is adjacent the second web side edge of the second web of fabric and the indentations of the second web side edge of the first web of fabric are adjacent the indentations of the second web side edge of the second web of fabric, thereby forming edges defining neck openings; fastening at least a portion of the second web side edge of the first web of fabric to at least a portion of the second web side edge of the second web of fabric in the side by side orientation, defining at least a portion of a center seam and a composite web of fabric having a pair of opposing web side edges wherein the opposing web side edges of the composite web of fabric are proximate a pair of opposing garment bottom edges of the garment; intermittently cutting the opposing web side edges of the composite web of fabric, defining pairs of opposing indentations in the opposing web side edges of the composite web of fabric; cutting the composite web of fabric, defining discrete garment- sized pieces wherein each of the discrete garment-sized pieces of the composite web of fabric includes at least one neck opening, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, a portion of two pairs of the opposing indentations in the opposing web side edges of the composite web of fabric, two garment end portions, and the pair of opposing garment bottom edges; folding the discrete garment-sized piece of the composite web of fabric whereby one of the garment bottom edges of the pair of opposing garment bottom edges is brought into contact with the other garment bottom edge; and, fastening at least a portion of the pair of opposing garment side edges of the front panel to at least a portion of the pair of opposing garment side edges of the back panel to form a pair of garment side seams.

Each sleeve flap may include at least a sleeve opening end edge and a pair of opposing sleeve side edges. At least a portion of at least one of the sleeve opening end edges of the sleeve flaps may be hemmed. At least a portion of at least one of the opposing garment bottom edges may be hemmed.

The front panel may be slit at least a portion of the distance between the edge of the neck opening and the garment bottom edge thereby defining a pair of edges of a slit. At least a portion of the edges of the slit may be fastened to form a front seam. At least a portion of the front seam may be refastenable. At least a portion of the front seam may be non-refastenable. The back panel may be slit at least a portion of the distance between the edge of the neck opening and the garment bottom edge, thereby defining a pair of edges of a slit. At least a portion of the edges of the slit may be fastened to form a back seam. At least a portion of the back seam may be refastenable. At least a portion of the back seam may be non-refastenable. At least a portion of the edge of the neck opening may be hemmed.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a first web of fabric including opposing web side edges; providing a second web of fabric including opposing web side edges; aligning the first and second webs of fabric together in a face to face orientation, defining an arrangement wherein the opposing web side edges of the first web of fabric are adjacent the opposing web side edges of the second web of fabric, thereby defining a first pair of adjacent web side edges comprising one web side edge of the first web of fabric and one web side edge of the second web of fabric and a second pair of adjacent web side edges comprising the other web side edge of the first web of fabric and the other web side edge of the second web of fabric; fastening at least a portion of the first pair of adjacent web side edges together in the face to face orientation, defining at least a portion of a center seam and a composite web of fabric having a pair of opposing web side edges formed from the second pair of adjacent web side edges wherein the opposing web side edges of the composite web of fabric are proximate a pair of opposing garment bottom edges of the garment; intermittently cutting the composite web of fabric, forming edges defining neck openings in the composite web of fabric; intermittently cutting the opposing web side edges of the composite web of fabric, defining pairs of opposing indentations in the opposing web side edges of the composite web of fabric; cutting the composite web of fabric, defining discrete garment-sized pieces wherein each of the discrete garment-sized pieces of the composite web of fabric includes at least one neck opening, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, a portion of the two pairs of the opposing indentations in the opposing web side edges of the composite web of fabric, a pair of sleeve flaps, two garment end portions, and the pair of opposing garment bottom edges; folding the discrete garment-sized piece of the composite web of fabric whereby one of the garment bottom edges of the pair of opposing garment bottom edges is brought into contact with the other garment bottom edge; and, fastening at least a portion of the pair of opposing garment side edges of the front panel to at least a portion of the pair of opposing garment side edges of the back panel to form a pair of garment side seams.

The neck openings may be intermediate the two pairs of the opposing indentations. The discrete garment-sized piece of the composite web of fabric may include at least one sleeve flap having at least a sleeve opening end edge and a pair of opposing sleeve side edges. The discrete garment-sized piece of the composite web of fabric may include a pair of sleeve flaps wherein each sleeve flap includes at least a sleeve opening end edge and a pair of opposing sleeve side edges. The composite web of fabric may be unfolded. The discrete garment-sized piece of the composite web of fabric may be unfolded. At least a portion of at least one of the opposing garment bottom edges may be hemmed. At least a portion of at least one of the sleeve opening end edges of the sleeve flaps may be hemmed.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a first web of fabric including opposing web side edges; providing a second web of fabric including opposing web side edges; aligning the first and second webs of fabric together in a face to face orientation, defining an arrangement wherein the opposing web side edges of the first web of fabric are adjacent the opposing web side edges of the second web of fabric, thereby defining a first pair of adjacent web side edges comprising one web side edge of the first web of fabric and one web side edge of the second web of fabric and a second pair of adjacent web side edges comprising the other web side edge of the first web of fabric and the other web side edge of the second web of fabric; fastening at least a portion of the first pair of adjacent web side edges together in the face to face orientation, defining at least a portion of a center seam and a composite web of fabric having a pair of opposing web side edges formed from the second pair of adjacent web side edges wherein the opposing web side edges of the composite web of fabric are proximate a pair of opposing garment bottom edges of the garment; intermittently cutting the opposing web side edges of the composite web of fabric, defining pairs of opposing indentations in the opposing web side edges of the composite web of fabric; intermittently cutting the composite web of fabric, forming edges defining neck openings in the composite web of fabric wherein the neck openings are intermediate two pairs of the opposing indentations; cutting the composite web of fabric, defining discrete garment-sized pieces wherein each of the discrete garment-sized pieces of the composite web of fabric includes at least one neck opening, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, a portion of the two pairs of the opposing indentations in the opposing web side edges of the composite web of fabric, a pair of sleeve flaps, two garment end portions, and the pair of opposing garment bottom edges; folding the discrete garment-sized piece of the composite web of fabric whereby one of the garment bottom edges of the pair of opposing garment bottom edges is brought into contact with the other garment bottom edge; and, fastening at least a portion of the pair of opposing garment side edges of the front panel to at least a portion of the pair of opposing garment side edges of the back panel to form a pair of garment side seams.

The composite web of fabric may be unfolded. The discrete garment-sized piece of the composite web of fabric may be unfolded. At least a portion of at least one of the opposing garment bottom edges may be hemmed. At least a portion of at least one of the sleeve opening end edges of the sleeve flaps may be hemmed.

The front panel may be slit at least a portion of the distance between the edge of the neck opening and the garment bottom edge, thereby defining a pair of edges of a slit. At least a portion of the edges of the slit may be fastened to form a front seam. At least a portion of the front seam may be refastenable. At least a portion of the front seam may be non-refastenable. The back panel may be at least a portion of the distance between the edge of the neck opening and the garment bottom edge, thereby defining a pair of edges of a slit. At least a portion of the edges of the slit may be fastened to form a back seam. At least a portion of the back seam may be refastenable. At least a portion of the back seam may be non-refastenable. At least a portion of the edge of the neck opening may be hemmed.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a first web of fabric including an inner surface, an outer surface, and opposing web side edges; providing a second web of fabric including an inner surface, an outer surface, and opposing web side edges; aligning the first and second webs of fabric together in a face to face orientation, defining an arrangement wherein the opposing web side edges of the first web of fabric are adjacent the opposing web side edges of the second web of fabric, thereby defining a first pair of adjacent web side edges and a second pair of adjacent web side edges; fastening at least a portion of the first pair of adjacent web side edges together in the face to face orientation, defining at least a portion of a center seam and a composite web of fabric having a pair of opposing web side edges formed from the second pair of adjacent web side edges wherein the opposing web edges of the composite web of fabric are proximate a pair of opposing garment bottom edges of the garment; intermittently cutting the opposing web side edges of the composite web of fabric, defining pairs of opposing indentations in the opposing web side edges of the composite web of fabric; intermittently cutting the composite web of fabric, forming edges defining neck openings in the composite web of fabric wherein the neck openings are intermediate two pairs of the opposing indentations; cutting the composite web of fabric, defining discrete garment- sized pieces wherein each of the discrete garment-sized pieces of the composite web of fabric includes at least one neck opening, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, a portion of each of the two pairs of the opposing indentations in the opposing web side edges of the composite web of fabric, a pair of sleeve flaps, two garment end portions, and the pair of opposing garment bottom edges; hemming at least a portion of at least one of the opposing garment bottom edges; folding the discrete garment-sized piece of the composite web of fabric whereby one of the garment bottom edges of the pair of opposing garment bottom edges is brought into contact with the other garment bottom edge; and, fastening at least a portion of the pair of opposing garment side edges of the front panel to at least a portion of the pair of opposing garment side edges of the back panel to form a pair of garment side seams. The composite web of fabric may be unfolded. The discrete garment-sized piece of the composite web of fabric may be unfolded. The discrete garment-sized piece of the composite web of fabric may include at least one sleeve flap having at least an inner surface, an outer surface, a sleeve opening end edge, and a pair of opposing sleeve side edges. The discrete garment-sized piece of the composite web of fabric may include a pair of sleeve flaps wherein each sleeve flap includes at least an inner surface, an outer surface, a sleeve opening end edge, and a pair of opposing sleeve side edges. At least a portion of at least one of the sleeve opening end edges of the sleeve flaps may be hemmed.

A collar may be provided. At least a portion of the collar may be fastened at at least a portion of the edge of the opening. At least a portion of the collar may be a ribbed knit collar. At least a portion of at least one of the garment side seams may be refastenable. At least a portion of at least one of the garment side seams may be non- refastenable.

Another embodiment of the present invention is a continuous process for the manufacture of a garment comprising the following steps: providing a first web of fabric including a first web side edge and a second web side edge; providing a second web of fabric including a first web side edge and a second web side edge; intermittently cutting the second web side edge of the first web of fabric, forming indentations; intermittently cutting the second web side edge of the second web of fabric, forming indentations; aligning the first and second webs of fabric together in a face to face orientation, defining an arrangement wherein the first web side edge of the first web of fabric is adjacent the first web side edge of the second web of fabric and the second web side edge of the first web of fabric is adjacent the second web side edge of the second web of fabric wherein the indentations of the second web side edge of the first web of fabric are adjacent the indentations of the second web side edge of the second web of fabric thereby forming edges defining neck openings; fastening at least a portion of the second web side edge of the first web of fabric to at least a portion of the second web side edge of the second web of fabric in the face to face orientation, defining at least a portion of a center seam and a composite web of fabric having a pair of opposing web side edges formed from the first web side edges of the first web of fabric and the first web side edges wherein the opposing web side edges of the composite web of fabric are proximate a pair of opposing garment bottom edges of the garment; intermittently cutting the opposing web side edges of the composite web of fabric, defining pairs of opposing indentations in the opposing web side edges of the composite web of fabric; cutting the composite web of fabric, defining discrete garment-sized pieces wherein each of the discrete garment-sized pieces of the composite web of fabric includes at least one neck opening, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, a portion of the two pairs of the opposing indentations in the opposing web side edges of the composite web of fabric, a pair of sleeve flaps, two garment end portions, and the pair of opposing garment bottom edges; folding the discrete garment- sized piece of the composite web of fabric whereby one of the garment bottom edges of the pair of opposing garment bottom edges is brought into contact with the other garment bottom edge; and, fastening at least a portion of the pair of opposing garment side edges of the front panel to at least a portion of the pair of opposing garment side edges of the back panel to form a pair of garment side seams.

The composite web of fabric may be unfolded. The discrete garment-sized piece of the composite web of fabric may be unfolded. The discrete garment-sized piece of the composite web of fabric may include at least one sleeve flap having at least an inner surface, an outer surface, a sleeve opening end edge, and a pair of opposing sleeve side edges. The discrete garment-sized piece of the composite web of fabric may include a pair of sleeve flaps wherein each sleeve flap includes at least an inner surface, an outer surface, a sleeve opening end edge, and a pair of opposing sleeve side edges. At least a portion of at least one of the sleeve opening end edges of the sleeve flaps may be hemmed. At least a portion of at least one of the opposing garment bottom edges may be hemmed. A collar may be provided. At least a portion of the collar may be fastened at at least a portion of the edge of the opening. At least a portion of the collar may be a ribbed knit collar. At least a portion of at least one of the garment side seams may be refastenable. At least a portion of at least one of the garment side seams may be non- refastenable.

While the invention has been described in detail with respect to the specific aspects thereof, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing, may readily conceive of alterations to, variations of, and equivalents to these aspects. Accordingly, the scope of the present invention should be assessed as that of the appended claims and any equivalents thereto.

Claims

We claim: 13850 PCT

1 . A continuous process for the manufacture of a garment comprising: a. providing a web of fabric including opposing web side edges; b. intermittently cutting said web of fabric, forming edges defining neck openings in said web fabric; c. cutting said web of fabric, defining discrete garment-sized pieces wherein each of said discrete garment-sized piece of said web of fabric includes at least one said neck opening, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, two opposing garment end portions, and a pair of opposing piece side edges wherein said opposing piece side edges of said discrete garment-sized piece are proximate a pair of opposing garment bottom edges of said garment; d. folding said discrete garment-sized piece of said web of fabric whereby one of said garment bottom edges of said pair of opposing garment bottom edges is brought into contact with other said garment bottom edge; and, e. fastening at least a portion of said pair of opposing garment side edges of said front panel to at least a portion of said pair of opposing garment side edges of said back panel to form a pair of garment side seams.

2. The continuous process according to Claim 1 , further comprising the step of intermittently cutting said web of fabric, forming arm opening edges defining pairs of opposing arm openings in said web of fabric.

3. The continuous process according to Claim 1 , further comprising the step of hemming at least a portion of at least one of said opposing garment bottom edges.

4. The continuous process according to Claim 3, wherein said discrete garment-sized pieces of said web of fabric further include at least one pair of said arm opening edges.

5. The continuous process according to Claim 4, further comprising the step of providing pieces of sleeve web fabric, wherein each of said pieces of said sleeve web fabric includes at least a pair of opposing sleeve side edges, a garment end edge having a shape complimentary to at least a portion of the shape of at least one of said arm opening edges of said arm openings and an opposing sleeve opening end edge.

6. The continuous process according to Claim 5, further comprising the step of applying and fastening at least a portion of said garment end edge of each of said piece of said sleeve web fabric to at least a portion of one of said arm opening edges of said arm openings.

7. The continuous process according to Claim 6, further comprising the step of hemming at least a portion of at least one of said sleeve opening end edges of said pieces of said sleeve web fabric.

8. The continuous process according to Claim 1 , wherein said neck opening in said discrete garment-sized piece is intermediate at least one of said pairs of opposing arm opening edges.

9. The continuous process according to Claim 1 , further comprising the step of providing a collar.

10. The continuous process according to Claim 9, further comprising the step of fastening at least a portion of said collar to at least a portion of said edge of said neck opening.

1 1 . The continuous process according to Claim 9, wherein at least a portion of said collar is a ribbed knit collar.

12. The continuous process according to Claim 1 , wherein at least a portion of at least one of said garment side seams is refastenable.

13. The continuous process according to Claim -1 , wherein at least a portion of at least one of said garment side seams is non-refastenable.

14. The continuous process according to Claim 1 , further comprising the step of hemming at least a portion of said edge of said neck opening.

15. The continuous process according to Claim 1 , further comprising the step of hemming at least a portion of at least one of said arm opening edges of said arm openings.

16. The continuous process according to Claim 1 , further comprising the step of providing pieces of sleeve web fabric, wherein each of said piece of said sleeve web fabric includes at least a garment end edge having at least a portion of a shape complimentary to at least a portion of the shape of a portion of said opposing garment side edges of said front panel, or said back panel, or of both said front and back panels, and an opposing sleeve opening end edge.

17. The continuous process according to Claim 16, further comprising the step of applying and fastening at least a portion of said garment end edge of each of said piece of said sleeve web fabric to at least a portion of one of said garment side edges defining said arm opening.

18. The continuous process according to Claim 17, further comprising the step of hemming at least a portion at least one of said sleeve opening end edges of said pieces of said sleeve web fabric.

19. The continuous process according to Claim 1 , further comprising the step of slitting said front panel at least a portion of the distance between said edge of said neck opening and said garment bottom edge thereby defining a pair of edges of a slit.

20. The continuous process according to Claim 19, further comprising the step of fastening at least a portion of said edges of said slit to form a front seam.

21. The continuous process according to Claim 20, wherein at least a portion of said front seam is refastenable.

22. The continuous process according to Claim 20, wherein at least a portion of said front seam is non-refastenable.

23. The continuous process according to Claim 1 , further comprising the step of slitting said back panel at least a portion of the distance between said edge of said neck opening and said garment bottom edge thereby defining a pair of edges of a slit.

24. The continuous process according to Claim 23, further comprising the step of fastening at least a portion of said edges of said slit to form a back seam.

25. The continuous process according to Claim 24, wherein at least a portion of said back seam is refastenable.

26. The continuous process according to Claim 24, wherein at least a portion of said back seam is non-refastenable.

27. A continuous process for the manufacture of a garment comprising: a. providing a first web of fabric including opposing web side edges; b. providing a second web of fabric including opposing web side edges; c. aligning said first and second webs of fabric together in a side by side orientation defining an arrangement fabric wherein one of said opposing web side edges of said first web of fabric is adjacent one of said opposing web side edge of said second web of fabric; d. fastening at least a portion of said adjacent web side edge of said first web of fabric to at least a portion of said adjacent web side edge of said second web of fabric in said side by side orientation, defining at least a portion of a center seam and a composite web of fabric having a pair of opposing web side edges; e. intermittently cutting said composite web of fabric, forming edges defining neck openings in said composite web of fabric; f. cutting said composite web of fabric, defining discrete garment-sized pieces wherein each of said discrete garment-sized piece of said composite web of fabric includes at least one said neck opening, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, two opposing garment end portions, and a pair of opposing piece side edges wherein said opposing piece side edges of said discrete garment-sized piece are proximate a pair of opposing garment bottom edges of said garment; g. folding said discrete garment-sized piece of said composite web of fabric whereby one of said garment bottom edges of said pair of opposing garment bottom edges is brought into contact with other said garment bottom edge; and, h. fastening at least a portion of said pair of opposing garment side edges of said front panel to at least a portion of said pair of opposing garment side edges of said back panel to form a pair of garment side seams.

28. The continuous process according to Claim 27, further comprising the step of intermittently cutting said composite web of fabric, forming arm opening edges defining pairs of opposing arm openings in said composite web of fabric.

29. The continuous process according to Claim 27, further comprising the step of hemming at least a portion of at least one of said opposing garment bottom edges.

30. The continuous process according to Claim 28, wherein said discrete garment-sized pieces further includes at least one pair of said arm opening edges.

31 . The continuous process according to Claim 30, further comprising the step of providing pieces of sleeve web fabric, wherein each of said pieces of said sleeve web fabric includes at least a garment end edge having at least a portion of a shape complimentary to at least a portion of the shape of at least one of said arm opening edges of said arm openings and an opposing sleeve opening end edge.

32. The continuous process according to Claim 31 , further comprising the step of applying and fastening said garment end edge of each piece of said sleeve web fabric to one of said arm opening edges of said arm openings.

33. The continuous process according to Claim 32, further comprising the step of hemming at least a portion of at least one of said sleeve opening end edges of said pieces of said sleeve web fabric.

34. The continuous process according to Claim 27, wherein at least one of said neck openings in said composite web of fabric is intermediate a pair of said opposing arm opening edges.

35. The continuous process according to Claim 27, further comprising the step of providing a collar.

36. The continuous process according to Claim 35, further comprising the step of fastening at least a portion of said collar to at least a portion of said edge of said neck opening.

37. The continuous process according to Claim 35, wherein at least a portion of said collar is a ribbed knit collar.

38. The continuous process according to Claim 27, wherein at least a portion of at least one of said garment side seams is refastenable.

39. The continuous process according to Claim 27, wherein at least a portion of at least one of said garment side seams is non-refastenable.

40. The continuous process according to Claim 27, further comprising the step of hemming at least a portion of said edge of said neck opening.

41 . The continuous process according to Claim 27, further comprising the step of hemming at least a portion of at least one of said arm opening edges of said arm openings.

42. The continuous process according to Claim 27, further comprising the step of slitting said front panel at least a portion of the distance between said edge of said neck opening and said garment bottom edge thereby defining a pair of edges of a slit.

43. The continuous process according to Claim 42, further comprising the step of fastening at least a portion of said edges of said slit to form a front seam.

44. The continuous process according to Claim 43, wherein at least a portion of said front seam is refastenable.

45. The continuous process according to Claim 43, wherein at least a portion of said front seam is non-refastenable.

46. The continuous process according to Claim 27, further comprising the step of slitting said back panel at least a portion of the distance between said edge of said neck opening and said garment bottom edge thereby defining a pair of edges of a slit.

47. The continuous process according to Claim 46, further comprising the step of fastening at least a portion of said edges of said slit to form a back seam.

48. The continuous process according to Claim 47, wherein at least a portion of said back seam is refastenable.

49. The continuous process according to Claim 47, wherein at least a portion of said back seam is non-refastenable.

50. A continuous process for the manufacture of a garment comprising: a. providing a web of fabric including opposing web side edges; b. intermittently cutting said web of fabric, forming edges defining neck openings in said web of fabric; c. intermittently cutting said opposing web side edges of said web of fabric, defining pairs of opposing indentations in said opposing web side edges of said web of fabric; d. cutting said web of fabric, defining discrete garment-sized pieces wherein each of said discrete garment-sized pieces of said web of fabric includes at least one said neck opening, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, a portion of two pairs of said opposing indentations in said web side edges of said web of fabric, a pair of sleeve flaps, two garment end portions, and a pair of opposing piece side edges wherein said opposing piece side edges are proximate a pair of opposing garment bottom edges of said garment; e. folding said discrete garment-sized piece of said web of fabric whereby one of said garment bottom edges of said pair of opposing garment bottom edges is brought into contact with other said garment bottom edge; and, f. fastening at least a portion of said pair of opposing garment side edges of said front panel to at least a portion of said pair of opposing garment side edges of said back panel to form a pair of garment side seams.

51 . The continuous process according to Claim 50, wherein said neck openings are intermediate said two pairs of said opposing indentations.

52. The continuous process according to Claim 50, further comprising the step of folding said web of fabric, defining an arrangement of having said web of fabric wherein said opposing web side edges are adjacent each other.

53. The continuous process according to Claim 52, further comprising the step of unfolding said web of fabric after at least one step of intermittently cutting said web of fabric.

54. The continuous process according to Claim 52, further comprising the step of unfolding said web of fabric before step of cutting said web of fabric into said discrete garment-sized pieces of said web of fabric.

55. The continuous process according to Claim 50, further comprising the step of hemming at least a portion of at least one of said opposing garment bottom edges.

56. The confinuous process according to Claim 50, wherein said discrete garment-sized piece of said web of fabric further includes at least one sleeve flap having a sleeve opening end edge and a pair of opposing sleeve side edges.

57. The continuous process according to Claim 50, wherein said discrete garment-sized pieces of said web of fabric further includes a pair of sleeve flaps wherein each said sleeve flap includes a sleeve opening end edge and a pair of opposing sleeve side edges.

58. The continuous process according to Claim 57, further comprising the step of hemming at least a portion of at least one of said sleeve opening end edges of said sleeve flaps.

59. The continuous process according to Claim 50, further comprising the step of providing a collar.

60. The continuous process according to Claim 59, further comprising the step of fastening at least a portion of said collar to said edge of said neck opening.

61 . The continuous process according to Claim 59, wherein said collar is a ribbed knit collar.

62. The continuous process according to Claim 50, wherein at least a portion of at least one of said garment side seams is refastenable.

63. The continuous process according to Claim 50, wherein at least a portion of at least one of said garment side seams is non-refastenable.

64. The continuous process according to Claim 50, further comprising the step of slitting said front panel at least a portion of the distance between said edge of said neck opening and said garment bottom edge thereby defining a pair of edges of a slit.

65. The confinuous process according to Claim 64, further comprising the step of fastening at least a portion of said edges of said slit to form a front seam.

66. The continuous process according to Claim 65, wherein at least a portion of said front seam is refastenable.

67. The continuous process according to Claim 65, wherein at least a portion of said front seam is non-refastenable.

68. The continuous process according to Claim 50, further comprising the step of slitting said back panel at least a portion of the distance between said edge of said neck opening and said garment bottom edge thereby defining a pair of edges of a slit.

69. The continuous process according to Claim 68, further comprising the step of fastening at least a portion of said edges of said slit to form a back seam.

70. The continuous process according to Claim 69, wherein at least a portion of said back seam is refastenable.

71 . The continuous process according to Claim 69, wherein at least a portion of said back seam is non-refastenable.

72. The continuous process according to Claim 50, further comprising the step of hemming at least a portion of said edge of said neck opening.

73. A continuous process for the manufacture of a garment comprising: a. providing a first web of fabric including opposing web side edges; b. providing a second web of fabric including opposing web side edges; c. aligning said first and second webs of fabric together in a side by side orientation defining an arrangement wherein one of said web side edges of said first web of fabric is adjacent one of said web side edges of said second web of fabric; d. fastening at least a portion of said adjacent web side edge of said first web of fabric to at least a portion of said adjacent web side edge of said second web of fabric in said side by side orientation, defining at least a portion of a center seam and a composite web of fabric having a pair of opposing web side edges; e. intermittently cutting said composite web of fabric, forming edges defining neck openings in said composite web of fabric; f. intermittently cutting said opposing web side edges of said composite web of fabric, defining pairs of opposing indentations in said opposing web side edges of said composite web of fabric; g. cutting said composite web of fabric, defining discrete garment-sized pieces wherein each of discrete garment-sized piece of said composite web of fabric includes at least one said neck opening, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, a portion of two pairs of said opposing indentations in said opposing web side edges of said composite web of fabric, two garment end portions, and a pair of opposing piece side edges wherein said opposing piece side edges of said discrete garment-sized piece are proximate a pair of opposing garment bottom edges of said garment; h. folding said discrete garment-sized piece of said composite web of fabric whereby one of said garment bottom edges of said pair of opposing garment bottom edges is brought into contact with other said garment bottom edge; and, i. fastening at least a portion of said pair of opposing garment side edges of said front panel to at least a portion of said pair of opposing garment side edges of said back panel to form a pair of garment side seams.

74. The continuous process according to Claim 73, wherein said neck openings are intermediate said two pairs of said opposing indentations.

75. The continuous process according to Claim 73, further comprising the step of hemming at least a portion of at least one of said opposing garment bottom edges.

76. The confinuous process according to Claim 73, wherein said garment-sized piece of said web of fabric further comprises at least one sleeve flap having a sleeve opening end edge and a pair of opposing side edges.

77. The confinuous process according to Claim 76, further comprising the step of hemming at least a portion of at least one of said sleeve opening end edges of said sleeve flaps.

78. The continuous process according to Claim 77, wherein said openings in said composite web of fabric are intermediate said opposing indentations.

79. The continuous process according to Claim 77, further comprising the step of providing a collar.

80. The continuous process according to Claim 79, further comprising the step of fastening at least a portion of said collar at said edge of said neck opening.

81 . The continuous process according to Claim 79, wherein said collar is a ribbed knit collar.

82. The continuous process according to Claim 73, wherein at least a portion of at least one of said garment side seams is refastenable.

83. The continuous process according to Claim 73, wherein at least a portion of at least one of said garment side seams is non-refastenable.

84. The continuous process according to Claim 73, further comprising the step of slitting said front panel at least a portion of the distance between said edge of said neck opening and said garment bottom edge thereby defining a pair of edges of a slit.

85. The continuous process according to Claim 84, further comprising the step of fastening at least a portion of said edges of said slit to form a front seam.

86. The continuous process according to Claim 85, wherein at least a portion of said front seam is refastenable.

87. The continuous process according to Claim 85, wherein at least a portion of said front seam is non-refastenable.

88. The continuous process according to Claim 73, further comprising the step of slitfing said back panel at least a portion of the distance between said edge of said neck opening and said garment bottom edge thereby defining a pair of edges of a slit.

89. The continuous process according to Claim 88, further comprising the step of fastening at least a portion of said edges of said slit to form a back seam.

90. The continuous process according to Claim 89, wherein at least a portion of said back seam is refastenable.

91 . The continuous process according to Claim 89, wherein at least a portion of said back seam is non-refastenable.

92. The continuous process according to Claim 73, further comprising the step of hemming at least a portion of said edge of said neck opening.

93. A continuous process for the manufacture of a garment comprising: a. providing a web of fabric including opposing web side edges wherein said opposing web side edges are proximate a pair of opposing garment bottom edges of said garment; b. intermittently cutting said web of fabric, forming edges defining neck openings in said web fabric; c. cutting said web of fabric, defining discrete garment-sized pieces wherein each of said discrete garment-sized piece of said web of fabric includes at least one said neck opening, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, two opposing garment end portions, and said pair of opposing bottom end edges; d. folding said discrete garment-sized piece of said web of fabric whereby one of said garment bottom edges of said pair of opposing garment bottom edges is brought into contact with other said garment bottom edge; and, e. fastening at least a portion of said pair of opposing garment side edges of said front panel to at least a portion of said pair of opposing garment side edges of said back panel to form a pair of garment side seams.

94. The continuous process according to Claim 93, further comprising the step of intermittently cutting said web of fabric, forming arm opening edges defining pairs of opposing arm openings in said web of fabric.

95. The continuous process according to Claim 93, further comprising the step of hemming at least a portion of at least one of said opposing garment bottom edges.

96. The continuous process according to Claim 95, wherein said discrete garment-sized pieces of said web of fabric further include at least one pair of said arm opening edges.

97. The continuous process according to Claim 96, further comprising the step of providing pieces of sleeve web fabric, wherein each of said pieces of said sleeve web fabric includes at least a pair of opposing sleeve side edges, a garment end edge having a shape complimentary to at least a portion of the shape of at least one of said arm opening edges of said arm openings and an opposing sleeve opening end edge.

98. The continuous process according to Claim 97, further comprising the step of applying and fastening at least a portion of said garment end edge of each of said piece of said sleeve web fabric to at least a portion of one of said arm opening edges of said arm openings.

99. The continuous process according to Claim 98, further comprising the step of hemming at least a portion of at least one of said sleeve opening end edges of said pieces of said sleeve web fabric.

100. The continuous process according to Claim 93, wherein said neck opening in said discrete garment-sized piece is intermediate at least one of said pairs of opposing arm opening edges.

101 . The continuous process according to Claim 93, further comprising the step of providing a collar.

102. The confinuous process according to Claim 101, further comprising the step of fastening at least a portion of said collar to at least a portion of said edge of said neck opening.

103. The confinuous process according to Claim 101 , wherein at least a portion of said collar is a ribbed knit collar.

104. The continuous process according to Claim 93, wherein at least a portion of at least one of said garment side seams is refastenable.

105. The continuous process according to Claim 93, wherein at least a portion of at least one of said garment side seams is non-refastenable.

106. The continuous process according to Claim 93, further comprising the step of hemming at least a portion of said edge of said neck opening.

107. The continuous process according to Claim 93, further comprising the step of hemming at least a portion of at least one of said arm opening edges of said arm openings.

108. The continuous process according to Claim 93, further comprising the step of providing pieces of sleeve web fabric, wherein each of said piece of said sleeve web fabric includes at least a garment end edge having at least a portion of a shape complimentary to at least a portion of the shape of a portion of said opposing garment side edges of said front panel, or said back panel, or of both said front and back panels, and an opposing sleeve opening end edge.

109. The continuous process according to Claim 108, further comprising the step of applying and fastening at least a portion of said garment end edge of each of said piece of said sleeve web fabric to at least a portion of one of said garment side edges defining said arm opening.

1 10. The continuous process according to Claim 109, further comprising the step of hemming at least a portion at least one of said sleeve opening end edges of said pieces of said sleeve web fabric.

1 1 1 . The continuous process according to Claim 93, further comprising the step of slitting said front panel at least a portion of the distance between said edge of said neck opening and said garment bottom edge thereby defining a pair of edges of a slit.

1 12. The continuous process according to Claim 111 , further comprising the step of fastening at least a portion of said edges of said slit to form a front seam.

1 13. The continuous process according to Claim 112, wherein at least a portion of said front seam is refastenable.

1 14. The confinuous process according to Claim 112, wherein at least a portion of said front seam is non-refastenable.

1 15. The continuous process according to Claim 93, further comprising the step of slitting said back panel at least a portion of the distance between said edge of said neck opening and said garment bottom edge thereby defining a pair of edges of a slit.

1 16. The continuous process according to Claim 115, further comprising the step of fastening at least a portion of said edges of said slit to form a back seam.

1 17. The continuous process according to Claim 116, wherein at least a portion of said back seam is refastenable.

1 18. The continuous process according to Claim 116, wherein at least a portion of said back seam is non-refastenable.

1 19. A continuous process for the manufacture of a garment comprising: a. providing a first web of fabric including opposing web side edges; b. providing a second web of fabric including opposing web side edges; c. aligning said first and second webs of fabric together in a side by side orientation defining an arrangement fabric wherein one of said opposing web side edges of said first web of fabric is adjacent one of said opposing web side edge of said second web of fabric; d. fastening at least a portion of said adjacent web side edge of said first web of fabric to at least a portion of said adjacent web side edge of said second web of fabric in said side by side orientation, defining at least a portion of a center seam and a composite web of fabric having a pair of opposing web side edges wherein said opposing web side edges of said composite web of fabric are proximate a pair of opposing garment bottom edges of said garment; e. intermittently cutting said composite web of fabric, forming edges defining neck openings in said composite web of fabric; f. cutting said composite web of fabric, defining discrete garment-sized pieces wherein each of said discrete garment-sized piece of said composite web of fabric includes at least one said neck opening, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, two opposing garment end portions, and said pair of opposing garment bottom edges; g. folding said discrete garment-sized piece of said composite web of fabric whereby one of said garment bottom edges of said pair of opposing garment bottom edges is brought into contact with other said garment bottom edge; and, h. fastening at least a portion of said pair of opposing garment side edges of said front panel to at least a portion of said pair of opposing garment side edges of said back panel to form a pair of garment side seams.

120. The continuous process according to Claim 119, further comprising the step of intermittently cutting said composite web of fabric, forming arm opening edges defining pairs of opposing arm openings in said composite web of fabric.

121. The continuous process according to Claim 119, further comprising the step of hemming at least a portion of at least one of said opposing garment bottom edges.

122. The continuous process according to Claim 120, wherein said discrete garment- sized pieces further includes at least one pair of said arm opening edges.

123. The continuous process according to Claim 122, further comprising the step of providing pieces of sleeve web fabric, wherein each of said pieces of said sleeve web fabric includes at least a garment end edge having at least a portion of a shape complimentary to at least a portion of the shape of at least one of said arm opening edges of said arm openings and an opposing sleeve opening end edge.

124. The continuous process according to Claim 123, further comprising the step of applying and fastening said garment end edge of each piece of said sleeve web fabric to one of said arm opening edges of said arm openings.

125. The continuous process according to Claim 124, further comprising the step of hemming at least a portion of at least one of said sleeve opening end edges of said pieces of said sleeve web fabric.

126. The continuous process according to Claim 119, wherein at least one of said neck openings in said composite web of fabric is intermediate a pair of said opposing arm opening edges.

127. The continuous process according to Claim 119, further comprising the step of providing a collar.

128. The confinuous process according to Claim 127, further comprising the step of fastening at least a portion of said collar to at least a portion of said edge of said neck opening.

129. The continuous process according to Claim 127, wherein at least a portion of said collar is a ribbed knit collar.

130. The continuous process according to Claim 119, wherein at least a portion of at least one of said garment side seams is refastenable.

131. The continuous process according to Claim 119, wherein at least a portion of at least one of said garment side seams is non-refastenable.

132. The continuous process according to Claim 119, further comprising the step of hemming at least a portion of said edge of said neck opening.

133. The confinuous process according to Claim 119, further comprising the step of hemming at least a portion of at least one of said arm opening edges of said arm openings.

134. The continuous process according to Claim 119, further comprising the step of slitfing said front panel at least a portion of the distance between said edge of said neck opening and said garment bottom edge thereby defining a pair of edges of a slit.

135. The continuous process according to Claim 134, further comprising the step of fastening at least a portion of said edges of said slit to form a front seam.

136. The continuous process according to Claim 135, wherein at least a portion of said front seam is refastenable.

137. The confinuous process according to Claim 135, wherein at least a portion of said front seam is non-refastenable.

138. The continuous process according to Claim 119, further comprising the step of slitting said back panel at least a portion of the distance between said edge of said neck opening and said garment bottom edge thereby defining a pair of edges of a slit.

139. The confinuous process according to Claim 138, further comprising the step of fastening at least a portion of said edges of said slit to form a back seam.

140. The continuous process according to Claim 139, wherein at least a portion of said back seam is refastenable.

141 . The continuous process according to Claim 139, wherein at least a portion of said back seam is non-refastenable.

142. A confinuous process for the manufacture of a garment comprising: a. providing a web of fabric including opposing web side edges wherein said opposing web side edges are proximate a pair of opposing garment bottom edges of said garment; b. intermittently cutting said web of fabric, forming edges defining neck openings in said web of fabric; c. intermittently cutting said opposing web side edges of said web of fabric, defining pairs of opposing indentations in said opposing web side edges of said web of fabric; d. cutting said web of fabric, defining discrete garment-sized pieces wherein each of said discrete garment-sized pieces of said web of fabric includes at least one said neck opening, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, a portion of two pairs of said opposing indentations in said web side edges of said web of fabric, two garment end portions, and said pair of opposing garment bottom edges; e. folding said discrete garment-sized piece of said web of fabric whereby one of said garment bottom edges of said pair of opposing garment bottom edges is brought into contact with other said garment bottom edge; and, f. fastening at least a portion of said pair of opposing garment side edges of said front panel to at least a portion of said pair of opposing garment side edges of said back panel to form a pair of garment side seams.

143. The confinuous process according to Claim 142, wherein said neck openings are intermediate said two pairs of said opposing indentations.

144. The continuous process according to Claim 142, further comprising the step of folding said web of fabric, defining an arrangement of having said web of fabric wherein said opposing web side edges are adjacent each other.

145. The continuous process according to Claim 144, further comprising the step of unfolding said web of fabric after at least one step of intermittently cutting said web of fabric.

146. The continuous process according to Claim 144, further comprising the step of unfolding said web of fabric before step of cutting said web of fabric into said discrete garment-sized pieces of said web of fabric.

147. The continuous process according to Claim 142, further comprising the step of hemming at least a portion of at least one of said opposing garment bottom edges.

148. The confinuous process according to Claim 142, wherein said discrete garment- sized piece of said web of fabric further includes at least one sleeve flap having at least a sleeve opening end edge and a pair of opposing sleeve side edges.

149. The continuous process according to Claim 142, wherein said discrete garment- sized pieces of said web of fabric further includes a pair of sleeve flaps wherein each said sleeve flap includes at least a sleeve opening end edge and a pair of opposing sleeve side edges.

150. The confinuous process according to Claim 149, further comprising the step of hemming at least a portion of at least one of said sleeve opening end edges of said sleeve flaps.

151 . The continuous process according to Claim 142, further comprising the step of providing a collar.

152. The confinuous process according to Claim 151 , further comprising the step of fastening at least a portion of said collar to at least a portion of said edge of said neck opening.

153. The continuous process according to Claim 151 , wherein at least a portion of said collar is a ribbed knit collar.

154. The continuous process according to Claim 142, wherein at least a portion of at least one of said garment side seams is refastenable.

155. The confinuous process according to Claim 142, wherein at least a portion of at least one of said garment side seams is non-refastenable.

156. The confinuous process according to Claim 142, further comprising the step of slitting said front panel at least a portion of the distance between said edge of said neck opening and said garment bottom edge thereby defining a pair of edges of a slit.

157. The continuous process according to Claim 156, further comprising the step of fastening at least a portion of said edges of said slit to form a front seam.

158. The continuous process according to Claim 157, wherein at least a portion of said front seam is refastenable.

159. The continuous process according to Claim 157, wherein at least a portion of said front seam is non-refastenable.

160. The continuous process according to Claim 142, further comprising the step of slitting said back panel at least a portion of the distance between said edge of said neck opening and said garment bottom edge thereby defining a pair of edges of a slit.

161. The continuous process according to Claim 160, further comprising the step of fastening at least a portion of said edges of said slit to form a back seam.

162. The continuous process according to Claim 161 , wherein at least a portion of said back seam is refastenable.

163. The continuous process according to Claim 161 , wherein at least a portion of said back seam is non-refastenable.

164. The continuous process according to Claim 142, further comprising the step of hemming at least a portion of said edge of said neck opening.

165. A continuous process for the manufacture of a garment comprising: a. providing a first web of fabric including opposing web side edges; b. providing a second web of fabric including opposing web side edges; c. aligning said first and second webs of fabric together in a side by side orientation defining an arrangement wherein one of said opposing web side edges of said first web of fabric is adjacent one of said opposing web side edges of said second web of fabric; d. fastening at least a portion of said adjacent web side edge of said first web of fabric to at least a portion of said adjacent web side edge of said second web of fabric in said side by side orientation, defining at least a portion of a center seam and a composite web of fabric having a pair of opposing web side edges wherein said opposing web side edges of said composite web of fabric are proximate a pair of opposing garment bottom edges of said garment; e. intermittently cutting said composite web of fabric, forming edges defining neck openings in said composite web of fabric; f. intermittently cutting said opposing web side edges of said composite web of fabric, defining pairs of opposing indentations in said opposing web side edges of said composite web of fabric; g. cutting said composite web of fabric, defining discrete garment-sized pieces wherein each of said discrete garment-sized piece of said composite web of fabric includes at least one said neck opening, a front panel having a pair of opposing garment side edges, a back panel having a pair of opposing garment side edges, a portion of two pairs of said opposing indentations in said opposing web side edges of said composite web of fabric, two garment end portions, and said pair of opposing garment bottom edges; h. folding said discrete garment-sized piece of said composite web of fabric whereby one of said garment bottom edges of said pair of opposing garment bottom edges is brought into contact with other said garment bottom edge; and, i. fastening at least a portion of said pair of opposing garment side edges of said front panel to at least a portion of said pair of opposing garment side edges of said back panel to form a pair of garment side seams.

166. The continuous process according to Claim 165, wherein said neck openings are intermediate said two pairs of said opposing indentations.

167. The confinuous process according to Claim 165, further comprising the step of hemming at least a portion of at least one of said opposing garment bottom edges.

168. The continuous process according to Claim 165, wherein said garment-sized piece of said web of fabric further comprises at least one sleeve flap having at least a sleeve opening end edge and a pair of opposing side edges.

169. The continuous process according to Claim 168, further comprising the step of hemming at least a portion of at least one of said sleeve opening end edges of said sleeve flaps.

170. The continuous process according to Claim 165, further comprising the step of providing a collar.

171. The continuous process according to Claim 170, further comprising the step of fastening at least a portion of said collar at at least a portion of said edge of said neck opening.

172. The continuous process according to Claim 170, wherein at least a portion of said collar is a ribbed knit collar.

173. The continuous process according to Claim 165, wherein at least a portion of at least one of said garment side seams is refastenable.

174. The continuous process according to Claim 165, wherein at least a portion of at least one of said garment side seams is non-refastenable.

175. The continuous process according to Claim 165, further comprising the step of slitting said front panel at least a portion of the distance between said edge of said neck opening and said garment bottom edge thereby defining a pair of edges of a slit.

176. The continuous process according to Claim 175, further comprising the step of fastening at least a portion of said edges of said slit to form a front seam.

177. The continuous process according to Claim 176, wherein at least a portion of said front seam is refastenable.

178. The continuous process according to Claim 176, wherein at least a portion of said front seam is non-refastenable.

179. The continuous process according to Claim 165, further comprising the step of slitting said back panel at least a portion of the distance between said edge of said neck opening and said garment bottom edge thereby defining a pair of edges of a slit.

180. The confinuous process according to Claim 179, further comprising the step of fastening at least a portion of said edges of said slit to form a back seam.

181. The continuous process according to Claim 180, wherein at least a portion of said back seam is refastenable.

182. The continuous process according to Claim 180, wherein at least a portion of said back seam is non-refastenable.

183. The continuous process according to Claim 165, further comprising the step of hemming at least a portion of said edge of said neck opening.