PATENT ABSTRACT
A method is provided for forming a garment, including providing a fabric layer having sonically weldable material, the fabric layer having an inner surface and at least one opening region, the opening region having a periphery and an outer free edge, placing an elastic edge band having sonically weldable material around the entire periphery of the opening region, the edge band having first and second free edges and an inner surface, securing the first free edge of the edge band to the outer free edge of the opening region with a subsonic or ultrasonic edge weld to form a finished seamless edge along the opening region, and activating an adhesive along more than half of the inner surface of the edge band to secure the edge band and second free edge to the inner surface of the fabric layer.

PATENT DESCRIPTION
CROSS REFERENCE TO RELATED APPLICATION  
       [0001]    This application is a continuation of pending U.S. application Ser. No. 12/944,017, filed on Nov. 11, 2010, the entirety of which is herein incorporated by reference, which is a divisional of U.S. application Ser. No. 11/032,285, filed on Jan. 10, 2005, now U.S. Pat. No. 7,854,022, issued Dec. 21, 2010. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates to garments. More particularly, the present invention relates to garments having edge bands seamlessly secured thereto and processes for making such garments. 
         [0004]    2. Description of Related Art 
         [0005]    Many types of garments require bands secured to the edge of the garment. In some instances, the bands provide elasticity to the edge of the garment to maintain the garment in a desired location when worn. For example, intimate apparel garments such as, but not limited to, briefs and panties include an elastic waistband and often include elastic leg bands. Garments such as brassieres include an elastic chest band, while garments such as socks and hosiery include elastic leg bands. In other instances, the bands may provide a decorative or aesthetic effect to the garment. 
         [0006]    Sewn seams have traditionally been used to secure bands to the garment edges; however, in applications where a band rests against the skin of the wearer, the sewn seams may be a source of physical and/or aesthetic discomfort. For example, the seams may cause chaffing and discomfort to the skin, and may be bulky so as to be seen through the outer clothing of the wearer. 
         [0007]    Adhesives have been previously used to secure bands to garments. While adhered bands can resolve some of the discomforts associated with sewn seams, the adhered bands can lead to other deleterious effects. For example, the normal washing and drying cycles that typical garments are exposed to require the use of aggressive adhesives that may diminish the elasticity of the band and/or negatively effect the hand feel of the garment. Also, the manufacture of garments having adhered bands has proven to require additional process steps that lead to increased garment costs and decreased productivity. 
         [0008]    The use of sonic energy, both subsonic and ultrasonic, to bond or weld (hereinafter “weld”) materials having thermoplastic components has also been used to secure elastic bands to garments, such as in the disposable diaper industry. The process typically involves the use of high frequency mechanical vibrations that cause friction and melting at adjoining surfaces of the thermoplastic components, fusing them together in a strong molecular bond. Typically, the process includes pressing the materials to be joined between a vibrating horn and an anvil. The horn channels mechanical vibrations into the materials to fuse the materials at the location of the horn. While sonically welded elastic bands can result in increased productivity, they have not proven durable enough for many non-disposable garment applications. 
         [0009]    Accordingly, there is a continuing need for garments having bands seamlessly secured thereto and processes for making such garments that resolve one or more deleterious effects and drawbacks of prior garments and processes. 
       BRIEF SUMMARY OF THE INVENTION  
       [0010]    It is an object of the present invention to provide garments having bands seamlessly secured thereto. 
         [0011]    It is another object to provide processes for seamlessly securing bands to garments. 
         [0012]    These and other objects and advantages of the present invention are provided by a garment having a fabric layer and an edge band. The edge band and the fabric layer each include a sonically weldable material. In one embodiment, the garment comprises a sonic edge weld securing the edge band to the fabric layer along a cut edge of the garment, and an adhesive securing the edge band to the fabric layer. 
         [0013]    Further objects and advantages are provided by a process for making a garment. One process includes: (1) placing an edge band on a fabric layer, the fabric layer and edge band each including a sonically weldable material, (2) applying sonic energy to the fabric layer and the edge band so that the fabric layer and the edge band are simultaneously trimmed along a cut edge and welded to one another along the cut edge, and (3) activating an adhesive between the fabric layer and the edge band to adhere the edge band to the fabric layer. 
         [0014]    The above-described and other features and advantages of the present invention will be appreciated and understood by those skilled in the art from the following detailed description, drawings, and appended claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS  
         [0015]      FIG. 1  is a perspective view of an exemplary embodiment of a garment according to the present invention; 
           [0016]      FIG. 2  is a view of the garment of  FIG. 1  prior to the addition of side seams; 
           [0017]      FIG. 3  is a sectional view taken along lines  3 - 3  of  FIG. 2 ; 
           [0018]      FIG. 4  is a view of a portion of an alternate exemplary embodiment of the garment of  FIG. 1 ; 
           [0019]      FIG. 5  is a sectional view taken along lines  5 - 5  of  FIG. 4 ; and 
           [0020]      FIGS. 6 through 10  schematically depict an exemplary embodiment of a manufacturing process according to the present invention for the garment of  FIG. 1 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0021]    Referring to the drawings and in particular to  FIGS. 1 and 2 , an exemplary embodiment of a garment according to the present invention, generally referred to by reference numeral  10  is shown. Garment  10  includes a fabric layer  12  having an edge band  14  secured to one or more regions of the fabric layer. In the illustrated embodiment, garment  10  includes side seams  16  for securing portions of fabric layer  12  to one another. 
         [0022]    Garment  10  is illustrated by way of example as a panty having an elastic edge band  14  secured to a waist region  18  and leg region  20 . Of course, it is contemplated by the present invention for garment  10  to be any other apparel or clothing item such as, but not limited to, a brassiere, a shirt, a pair of pants, a coat, a sock, a pair of pantyhose, a bathing suit, a camisole, a boxer short, a men&#39;s brief, and any other clothing item having an edge band secured to any desired region. 
         [0023]    In addition, garment  10  is illustrated by way of example having a single fabric layer  12 . Of course, it is contemplated by the present invention for the garment to include more than one fabric layer  12 . 
         [0024]    Edge band  14  is seamlessly secured to fabric layer  12  by an edge weld  22  and an adhesive  24 . As described in detail below, the energy input into garment  10  to define edge weld  22  may also simultaneously trim fabric layer  12  and edge band  14  to define a cut edge  26  of garment  10 . Advantageously, edge weld  22  also seals cut edge  26  so that the free outer edge of fabric layer  12  and a free edge of the edge band  14  terminate at the same point and do not fray during use of garment  10 . Further, the simultaneous cutting of fabric layer  12  and edge band  14  at cut edge  26  ensures that the fabric layer and band are co-planar at the cut edge. Thus, fabric layer  12  and edge band  14  are sonically welded to one another along cut edge  26  and are adhered to one another in the remaining portions where the band overlaps the fabric layer. In one embodiment, the adhesive  24  is applied along more than half of the inner surface of the edge band  14 . 
         [0025]    In some embodiments, edge band  14  may further be seamlessly secured to fabric layer  12  by one or more tack welds  28 . As described in detail below, edge weld  22 , and tack welds  28  if present, hold fabric layer  12  and edge band  14  in place with respect to one another during the manufacturing process prior to activation of adhesive  24 . 
         [0026]    Fabric layer  12  and/or edge band  14  may be formed of any non-woven fabric, woven fabric, or knitted fabric having between about ten percent and about one hundred percent of a sonically weldable material and all subranges therebetween. Sonically weldable materials include polypropylene, lycra spandex, tricot, polyester, nylon, acrylic, vinyl, PVC, thermoplastic urethane, or any combinations and blends thereof. Advantageously, fabric layer  12  and/or edge band  14  have up to about ninety percent natural fibers. 
         [0027]    In one embodiment, fabric layer  12  and/or edge band  14  may be a blend of about sixty percent sonically weldable material and about forty-percent natural fibers. In another embodiment, fabric layer  12  is a blend of about twelve percent sonically weldable material and about eighty-eight percent natural fibers, while edge band  14  is a one hundred percent sonically weldable material. It is believed that fabric layer  12  and/or edge band  14  may include at least about 70 percent natural fibers. 
         [0028]    The adhesive  24  may be any heat activated adhesive material. In some embodiments, adhesive  24  may impart a desired elasticity to garment  10 . In other embodiments, edge band  14  alone, or in combination with adhesive  24 , may impart a desired elasticity to garment  10 . Thus, garment  10  may be provided with elasticity at its edges by adhesive  24 , edge band  14 , or any combination thereof. 
         [0029]    Adhesive  24  is preferably a heat activated adhesive net or film. For example, adhesive  24  may be a heat activated adhesive net that provides elasticity to garment  10  such as the adhesive nets commercially available under the DELNET® tradename from Delstar Technologies of Austin, Tex. In another example, adhesive  24  may be a heat activated elastic film such as the adhesive films commercially available under the tradename SEWFREE® from Bemis Associates Incorporated of Shirley, Mass. 
         [0030]    Referring now to  FIGS. 4 and 5 , an alternate exemplary embodiment of garment  10  is shown. Here, fabric layer  12  and edge band  14  are shown having various decorative features incorporated therein. For example, cut edge  26  is provided with a decorative pattern  30  such as, but not limited to, a scallop edge. Again, edge weld  22  is defined at decorative pattern  30  to seal cut edge  26 . 
         [0031]    In addition, fabric layer  12  and edge band  14  may include multiple cut edges  26  to provide garment  10  with a decorative effect  32 , such as a lace effect. Here, an edge weld  22  is defined at each of the cut edges  26  of decorative effect  32 . 
         [0032]    In some embodiments, edge band  14  may further be seamlessly secured to fabric layer  12  by one or more tack welds  28 . However, it has also been found that provision of multiple cut edges  26  and, thus, multiple edge welds  22 , not only provides decorative effect  32 , but also can mitigate the need for additional tack welds  28 . 
         [0033]    An exemplary embodiment of a process  40  for making garment  10  is described with reference to  FIGS. 6  though  10 . During a first step of process  40  shown in  FIG. 6 , fabric layer  12  is trimmed to the approximate shape of the finished garment. For example, fabric layer  12  may be trimmed to define a selvage  42  outside a final garment shape  44  (illustrated in phantom). 
         [0034]    During a second step of process  40 , shown in  FIG. 7 , edge band  14  is secured to fabric layer  12  along a portion of waist region  18 . During the second process step, adhesive  24  and edge band  14  are placed on fabric layer  12  to cover a portion of selvage  42  and a portion of final garment shape  44 . 
         [0035]    In a preferred embodiment, adhesive  24  is laminated on edge band  14  prior to placement of the edge band on fabric layer  12 . Here, edge band  14  is placed on fabric layer  12  so that adhesive  24  is in contact with the fabric layer. 
         [0036]    As edge band  14  and adhesive  24  are placed on fabric layer  12 , the edge band, adhesive, and fabric layer are sonically cut and welded along final shape  44  to define edge weld  22  (not shown) and cut edge  26 . Selvage  42  having both fabric layer  12  and edge band  14  is removed and discarded. In some embodiments, fabric layer  12  and edge band  14  are also sonically welded to define tack welds  28  (not shown). Accordingly, the second process step applies sonic energy with sufficient intensity to simultaneously cut fabric layer  12 , adhesive  24 , and edge band  14  along cut edge  26  and weld the fabric layer and edge band to one another at edge weld  22  and, if present, at tack welds  28 . For example, it is contemplated for process  40  to expose fabric layer  12  and edge band  14  to sonic energy of between about 20 and 60 kilohertz (kHz) and a pressure of between about 20 and 40 pounds per square inch (psi). 
         [0037]    In a preferred embodiment, the second process step of process  40  is carried out using a sealing and bonding machine commercially available under the tradenames SEAMMASTER or LACEMASTER from Sonobond Ultrasonics of West Chester, Pa. 
         [0038]    At this point, fabric layer  12  and edge band  14  are held in place with respect to one another by edge weld  22  and, if present, by tack welds  28 . The sonic energy that creates cut edge  26  and welds  22 ,  28  also locally activates adhesive  24 . Thus, welds  22 ,  28  include components of fabric layer  12 , edge band  14 , and adhesive  24  in addition to a localized area of activated adhesive surrounding around the welds. However, adhesive  24  remains un-activated in the remaining portions of overlap between fabric layer  12  and edge band  14 . 
         [0039]    During a third step of process  40 , shown in  FIG. 8 , the second process step is repeated to secure edge band  14  to the remaining waist and leg regions  18 ,  20 , as desired. Again, fabric layer  12  and edge band  14  are held in place with respect to one another by the sonic welds, but adhesive  24  remains largely un-activated. 
         [0040]    Process  40  can be easily modified to provide tack welds  28 , decorative pattern  30 , and/or decorative effect  32  as desired. For example, the horn used to apply sonic energy during the second and third steps may be modified using known methods to provide the tack welds  28 , decorative pattern  30  and/or decorative effect  32 , as desired. 
         [0041]    During a fourth step of process  40 , shown in  FIG. 9 , adhesive  24  is activated. For example, fabric layer  12  and edge band  14  may be compressed between a pair of presses  46  at a pressure, temperature, and/or time sufficient to activate adhesive  24 . At the end of the fourth step, fabric layer  12  and edge band  14  are secured to one another by edge weld  22 , adhesive  24 , and tack welds  28 , if any. 
         [0042]    Finally, garment  10  may be completed by folding the garment and adding side seams  16  for securing portions of fabric layer  12  to one another, as shown in  FIG. 10 . 
         [0043]    Advantageously, process  40  uses sonic welds  22 ,  28  to hold fabric layer  12  and edge band  14  in place with respect to one another while cutting through both the edge band and fabric, so that the edges are co-planar with one another. Process  40  then activates adhesive  24  to firmly secure edge band  14  to fabric layer  12  without deleteriously effecting the elastic characteristics of the edge band or the hand feel of the edge band and fabric. It has been determined that the combination of edge weld  22  and adhesive  24 , as well as tack welds  28  if present, provide garment  10  with a desired durability, washability, hand feel, and method of manufacture not previously possible. 
         [0044]    It should also be noted that the terms “first”, “second”, “third”, “upper”, “lower”, and the like may be used herein to modify various elements. These modifiers do not imply a spatial, sequential, or hierarchical order to the modified elements unless specifically stated. 
         [0045]    While the present disclosure has been described with reference to one or more exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular embodiment(s) disclosed, but that the disclosure will include all embodiments falling within the scope of the appended claims.