Abstract:
An improved waistband construction for garments including a new one piece flat elastic strip having upper and lower portions of different stretchability. The elastic strip is connected to the fabric of the waistband and the shell of the garment so as to allow more expansion and comfort in fitting multiple sizes.

Description:
FIELD OF THE INVENTION 
     This invention relates to the manufacture of garments and more particularly to an improved waistband construction for garments whereby a single garment may be manufactured so as to properly fit persons varying over several standard waist sizes. 
     BACKGROUND OF THE INVENTION 
     The present invention is an improvement over the invention disclosed in my U.S. Pat. No. 4,549,317 which in turn was an improvement over the invention disclosed in my U.S. Pat. No. 3,848,268. My prior patents disclosed and claimed garments having improved waistband constructions by which a single garment usually fits persons having waist sizes in the range of three standard sizes. The waistband constructions of my prior patents both employed an elastic strip in the waistband construction with a fabric curtain depending therefrom. In my U.S. Pat. No. 3,848,268 the fabric curtain was secured to the inside surface of the elastic strip facing the wearer. In my U.S. Pat. No. 4,549,317 the fabric curtain was secured to the outside surface of the elastic strip facing away from the wearer. 
     The constructions shown in my previous patents have enjoyed substantial success but I have now discovered that I can eliminate the fabric curtain by using a new one piece flat elastic strip having upper and lower portions of different stretchability and in doing so provide an improved waistband construction by which a single garment will fit persons having waist sizes in the range of up to four standard sizes. While prior patents such as Moore U.S. Pat. No. 2,195,894, Ruby U.S. Pat. No. 3,723,993, and Muse U.S. Pat. No. 4,332,034 have disclosed the use of elastic bands of different stretchability, such waistband constructions have left something to be desired. My improved waistband construction not only allows more expansion and comfort in fitting multiple sizes but also results in savings in cost of the curtain cloth material and saving in the labor in binding and attaching the curtain to the elastic strip used in my prior patents. It also provides for easier finish pressing of the garment and is cosmetically cleaner both inside and outside. 
     OBJECTS OF THE INVENTION 
     It is an object of the invention to provide an improved waistband construction for garments which accommodate persons of varying waist sizes without causing unsightly bulges, folds, wrinkles, or the like. It is a further object of the invention to provide an improved waistband construction which eliminates the conventional fabric curtain thus providing a smoother inside and outside appearance of the waistband. By providing an improved elastic strip in the waistband assembly to make the sole contact with the wearer&#39;s waist there is provided an improved gripping on the waist without binding. The slipping is eliminated and a holding grip is maintained on the waist even when the wearer is moving. The improved waistband construction of the present invention provides a floating waistband action which automatically adjusts upwardly and downwardly to conform to the wearer waistline. Due to the simplified construction and cosmetic appearance of the improved waistband it can be used on all waistband garments for men, women and children including fine dress garments or work clothes. 
     SUMMARY OF THE INVENTION 
     In accordance with the present invention there is provided an improved waistband assembly for a garment comprising a waistband of a fabric material turned over at its upper extremity to form a U-shaped bight with a small inner flap depending therefrom. An elastic strip of one piece construction having an upper portion which is longitudinally elastic including means substantially preventing transverse bending of the upper portion thereby to exhibit no-roll characteristics. The upper portion is positioned adjacent to and sewn to the side of the inner flap facing inwardly to the wearer away from the waistband at the top of the strip. The elastic strip has a lower portion extending below the lower edge of the waistband, the lower portion of the elastic strip offering a lower resistance to elongation than the upper portion of the elastic strip. In accordance with one aspect of the invention the lower portion of the elastic strip has a stretchability of about 85% with a range of plus or minus 10% and the upper portion of the elastic strip has a stretchability of about 53% with a range of plus or minus 10%. The ratio of the width of the upper portion of the elastic strip to the lower portion of the elastic strip is about 3 to 1. 
     In accordance with another aspect of the invention there is provided a waistband construction for clothing comprising a shell portion and a waistband portion wherein the exposed fabric of the shell portion and waistband portion may be of any desired fabric material. The waistband portion of the fabric material is cut on a bias and the waistband portion being turned over at its upper extremity to form a U-shaped bight portion with a small inner flap depending therefrom. An elastic strip of one piece construction having an upper portion which is longitudinally elastic, including means substantially preventing transverse bending of the upper portion thereby to exhibit non-roll characteristics, is positioned adjacent to and sewn to the side of the inner flap facing inwardly to the wearer away from the waistband portion at the top of the strip. The elastic strip has a lower portion extending below the lower edge of the waistband portion, the lower portion of the elastic strip offering a lower resistance to elongation than the upper portion of the elastic strip to provide better gripping on the waist without binding. A shell portion of the fabric is joined to the lower edge of the waistband portion at a location above the lower edge of the elastic strip wherein the shell portion has formed therein several gathers, the gathers being concealed by the elastic strip away from the wearer so that the shell portion exhibits fullness, whereby a garment incorporating the waistband construction can accommodate persons of several waist sizes. The elastic strip is stitched at periodic intervals around the waistband portion to the juncture between the shell portion of the fabric and the lower edge of the waistband portion to prevent restriction of stretch. A fusible non-woven material is secured to the inner face of the waistband portion, the non-woven material having the characteristic of being stretchable in the longitudinal direction and substantially non-stretchable in the transverse direction. 
     For more detailed disclosure of the invention and for further objects and advantages thereof, reference is to be had to the following description taken in conjunction with the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of the waistband area of trousers embodying the improved waistband construction of the present invention. 
     FIG. 2 is a fractional side elevational view of the so-called &#34;black fly&#34; portion of the trousers as seen from the inside. 
     FIG. 3 is a fractional view of the so-called &#34;white fly&#34; portion of the trousers seen from the outside. 
     FIG. 4 is a cross-sectional view taken along the lines 4--4 in FIG. 2. 
     FIG. 5 is a cross-sectional view taken along the lines 5--5 in FIG. 3. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     As pointed out above, the present invention is an improvement on my prior waistband constructions disclosed in my aforesaid U.S. Pat. Nos. 3,848,268 and 4,549,317. The disclosures in those patents are incorporated herein by this reference thereto. Accordingly, where a specific constructional detail is not specified herein, it may in general be assumed that the construction is similar to that previously shown. 
     Referring to FIG. 1 there is shown a pair of trousers or slacks 10 having a waistband 12 attached to the garment shell 14. The fabric of the waistband 12 and the lower shell 14 are of the same material. Any material is suitable and it is not limited to what is known in the trade as stretchable material. However, as hereinafter described the waistband 12 is cut on a bias so that it will be capable of stretching. At the front of the trousers the fly portion comprises a black fly portion 18, in FIG. 2, and a mating white fly portion 20, FIG. 3, including the conventional zipper components and metal clip and mating retainer. Pockets may also be provided as shown. It will also be understood that the waistband construction of the present invention is useful for garments other than trousers, such as ladies and children&#39;s skirts, and the fly need not necessarily be provided. 
     As pointed out above the waistband 12 stretches because it is cut on a bias, i.e., the warp and woof are inclined with respect to the horizontal, preferably between about 30° to 50°. The shell 14 is not required to be cut on a bias. As hereinafter described, by providing the shell 14 with a small degree of &#34;fullness&#34; the warp and woof can be vertically aligned, while permitting the waistband to accommodate persons of several sizes in comfort, without unsightly bulging, while allowing the waistband 12 and shell 14 to be made of any desired material including such non-stretchable fabrics as corduroy. 
     As best shown in FIGS. 4 and 5 the fabric material of the waistband 12 is turned over at its upper extremity to form a U-shaped bight 22 with a small inner flap 24 depending therefrom. The inner face of the waistband 12 has adhesively secured thereto a fusible non-woven material 26 having the characteristic of being stretchable in the longitudinal direction and substantially non-stretchable in the transverse direction. Disposed within the U-shaped bight 22 is a header or strip 28 of stiffening elastic material. The strip 28 preferably has a width of about 3/8&#34; to 5/8&#34; and a stretchability in the range of about 100% to 120%. The waistband construction includes an elastic strip 30 of one piece construction having an upper portion 30a which is a longitudinally elastic webbing of width wise rigidity ribbed weave and includes a series of reinforced vertical ribs for preventing transverse bending of the upper portion thereby to exhibit non-roll characteristics. The upper portion 30a is positioned adjacent to and sewn to the side of the inner flap 24 facing inwardly to the wearer away from the waistband at the top of the strip 30. As may be seen in FIGS. 4 and 5 the stitching 32 joins the upper portion of the elastic strip 30a with the elastic strip 28 and the depending flap 24 but does not extend through the outer or exposed face of the waistband 12. It will also be noted that the upper edge of the elastic strip 30 is well below the bight 22 so as to be concealed from view when the garment is worn and assuring an attractive appearance of the waistband. The elastic strip 30 also includes a lower portion 30b extending below the lower edge of the waistband 12. The lower portion 30b of the elastic strip 30 is also longitudinally elastic in the form of flat woven elastic webbing and has the characteristic of offering a lower resistance to elongation than the upper portion 30a of the elastic strip 30. The elastomer used in the elastic strip 30 may be of Spandex or Lycra and polyester or equivalent. In general, the lower portion of the elastic strip has a degree of stretchability with respect to the upper portion of the elastic strip within the range of about 2 to 1 to about 1.3 to 1. In a preferred form of the invention the lower portion 30b of the elastic strip 30 has a width of about 1/2&#34; and a stretchability of about 85% with a range of plus or minus 10% and the upper portion 30a has a width of about 1-1/2&#34; including a 1/16&#34; bead along the upper edge and a stretchability of about 53% with a range of plus or minus 10%. It will be noted that the elastic strip 30 is the only portion of the waistband assembly to engage the wearer&#39;s waist. This is in contrast to the elastic strip used in my prior patents where the lower portion of the elastic strip was stitched to a non-stretchable fabric curtain. As pointed out above the fabric has been eliminated in the present waistband construction. 
     Referring again to FIGS. 3-5 it will be seen that the shell portion 14 of the fabric material is joined to the lower edge of the waistband 12 by the stitching 34 at a location above the lower edge of the elastic strip 30. The stitching 34 forms a seam extending around the garment and forms a juncture between the shell portion 14 of the fabric and the lower edge of the waistband portion 12. This juncture is sometimes referred to as a crack. Referring to FIG. 3 there is illustrated one of the gathers 14b formed in the shell 14 to provide it with fullness so that the shell 14 will have some &#34;give&#34;, allowing it to be sewn to the stretchable waistband 12. The gathers 14b are further described in my aforesaid U.S. Pat. No. 4,549,317 and several gathers are incorporated in the shell material 14 around the waistband 12. In view of the substantial stretch in the elastic strip 38, I have found that that extra yield or fullness in the shell 14 can range from 5/8&#34; to 3/4&#34; on each panel of the trousers and the waistband will stretch enough to take up this additional fullness. A pair of trousers has two panels on the front and two panels on the back and thus the total material gathered should be 1-1/4&#34; to 1-1/2&#34; around each half of the waistband. It will be seen that the total amount of gathers in my new waistband construction is approximately twice that employed in my prior U.S. Pat. No. 4,549,317. This permits my new waistband construction to accommodate a larger number of sizes, i.e. up to four standard sizes. 
     While the upper edge or bead of the elastic strip 30 is stitched at 32 to the waistband 12 around the entire length, the elastic strip 30 is only stitched at periodic intervals around the waistband 12 to the juncture between the shell 14 and the lower edge of the waistband 12 to prevent restriction of stretch. This periodic stitching is illustrated at 36 and is referred to as a &#34;crack&#34; stitch. 
     While a preferred embodiment of the garment waistband construction has been described and illustrated, it is to be understood that further modifications thereof may be made within the scope of the appended claims.