Abstract:
The present invention is a method of manufacturing a fully-reversible belt generally comprising the following steps: selecting a face material and contrast material, cutting an equal length of face material and contrast material, cutting an additional piece of contrast material, sewing material pieces together to form a strap, sewing an extra piece of contrast material to form a point; sewing an extra contrast piece to face material side of strap, and anchoring a buckle on the strap in a unique manner to form a perfectly symmetrical reversible belt. This method is simple, inexpensive, and efficient.

Description:
CROSS-REFERENCE TO RELATED APPLICATION  
       [0001]     The present application derives priority from U.S. provisional application No. 60/832,029 filed 20 Jul. 2006. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1. Field of the Invention  
         [0003]     The present invention generally relates to a method of manufacturing a belt, and more particularly to a method of manufacturing a reversible belt.  
         [0004]     2. Description of the Background  
         [0005]     In its simplest form a belt is strictly utilitarian and is used for holding clothing on. However, belts have become fashion accessories with a huge variety of decorative characteristics. Various types of belts are available and they are made of many types of materials, such as fabric, leather, etc., with many types of adornments (beads, rhinestones, etc.), to suit the fashion sense of the wearer.  
         [0006]     Reversible belts are popular because they provide twice the mix-and-match opportunities with different outfits. Also, because reversible belts have two usable, decorative sides they are functional, cost-effective, and fit two belts in the same amount of space as one belt. For many years, reversible belts have been available and various mechanisms have been provided whereby the belt may be reversed to display either side, which may be of different colors and/or designs. Prior art U.S. Pat. Nos. showing various types of belt reversing mechanisms include: U.S. Pat. Nos. 2,197,665; 2,630,612; 3,369,278 and 3,855,637.  
         [0007]     One exemplary type of reversible belt that is gaining popularity is the fabric artisan belt. These are typically formed from two elongate strips each having one side of brightly colored and/or patterned fabric and another backing side. The two strips are sewn together back-to-back with seamed and fused edges, revealing opposing outer sides of decorative fabric. It is sometimes desirable to make artisan fabric belts reversible to permit two types of decorative effects, one on each side of the belt. This is accomplished with opposing outer sides of differently-decorated fabric.  
         [0008]     Unfortunately, it is difficult to commercially manufacture finished, fully reversible belts including fabric artisan belts or any other reversible belt in which two different sides are bound together with a binder yarn. This is primarily due to the fact that the belt, once sewn together lengthwise, must be attached at one end around a buckle and then sewn in a closed loop around the buckle. This is awkward with reversible belts because the loop necessarily overlaps to one side of the belt superposing an inch or two of one contrasting fabric over the other. Thus, the two sides of the belt are not truly symmetrical and prior art fabric artisan belts are not truly reversible. For example, current manufacturing methods using commercial sewing equipment result in a reversible belt as seen in FIG. 3 (Prior Art). The buckle is anchored to the strap by inserting a length of the end of the belt through the buckle, looping around, and then sewing it onto itself. This belt is obviously not perfectly reversible because the length sewn onto itself contrasts with the other side of the belt. Thus, prior art belt does not have a finished, aesthetically appealing appearance.  
         [0009]     Contrarily, FIG. 4 (Prior Art) shows a perfectly reversible belt with a symmetrical finished appearance (uniform on both sides). This is accomplished by joining and seaming the opposing strips at the very distal end proximate the buckle, so that the color/pattern transition cannot be seen when wearing the belt. The face and contrast ribbons sewn together directly above and beneath the center bar of the buckle, thereby firmly anchoring the strap around the center bar. Unfortunately, this belt must be partially manufactured by hand, as commercial sewing machines need clearance and cannot gain enough access to make the seam at the buckle. The stitching across topside of the buckle can be hand or commercially sewn, but the closely-confined side stitching needs to be by hand. As can be seen, the belt of FIG. 4 is very aesthetically appealing because it is fully reversible and finished, however the partially-manual method of manufacturing of it is laborious, time-consuming, and expensive.  
         [0010]     Therefore, there is a need for a method of manufacturing a finished, perfectly reversible double face belt using commercial sewing equipment thereby allowing for mass production, efficiency, and cost-savings.  
       SUMMARY OF THE INVENTION  
       [0011]     It is, therefore, a primary object of the present invention to provide a method of manufacturing a reversible belt that is simple and can be implemented in any location, including in the convenience of one&#39;s own home or place of business.  
         [0012]     Still another object of the present invention is to provide a method of manufacturing a reversible belt that is time and cost-effective, using existing commercial manufacturing equipment.  
         [0013]     These and other objects are accomplished by a method of manufacturing a reversible belt generally comprising the following steps:  
         [0014]     Step 1. Select a face material and contrast material, each having at least one “decorative” side (decorative herein being defined as any pattern, design, color, texture or material to be outwardly displayed).  
         [0015]     Step 2. Cut an equal length of face material and contrast material into strips with tapered ends, the taper preferably comprising pointed triangular ends.  
         [0016]     Step 3. Align the decorative sides of the face strip and contrast strip and sew just their tapered ends together (both ends).  
         [0017]     Step 4. Invert the now-joined face strip and contrast strip to hide the seamed ends and to expose the decorative sides.  
         [0018]     Step 5. Cut an additional piece of contrast material (preferably the same decorative pattern, design, color, texture or material as the original) into a shorter third strip (approximately 5½″ long) conforming to an end of the existing face and/or contrast strips, e.g., tapered at one end with an opposing generic end (may be squared or otherwise).  
         [0019]     Step 6. Sew the generic end of the shorter third strip (decorative side facing inward) approximately 5½″ inward of the tapered end of the face material strip such that the points of all three strips are now aligned and the tapered end of the shorter third strip remains free.  
         [0020]     Step 7. Sew the edges of the original face material strip and contrast material strip along all sides to make one unitary main belt strip, and also thereby securing the third strip in place.  
         [0021]     Step 8. Insert the tapered end of the unitary main belt up and around through a buckle and sew its tip onto itself (with face material side of the tip doubled back and juxtaposed over the contrast material).  
         [0022]     The foregoing method forms a fully reversible belt attached to a buckle with equal proportions of face pattern and contrast pattern appearing on both sides, and the entire process can be completed with commercial sewing equipment. The method can be used to manufacture most any reversible belt with contrasting sides. The contrasting sides may be like materials having a different decorative pattern, design, texture or color, or different materials (for example, suede on one side and patent leather on the other). 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0023]     Other objects, features, and advantages of the present invention will become more apparent from the following detailed description of the preferred embodiments and certain modifications thereof when taken together with the accompanying drawings in which:  
         [0024]      FIG. 1  is a flowchart of the general steps of the method of the present invention.  
         [0025]      FIG. 2A  illustrates equal lengths of cut face strip  10  and contrast strip  20  each cut with tapered ends on both sides.  
         [0026]      FIG. 2B  illustrates equal lengths of cut face strip  10  and contrast strip  20  with just the points attached, but the sides of the face strip  10  and contrast strip  20  are not.  
         [0027]      FIG. 2C  illustrates the generic (squared) end of the shorter third strip  30  sewn against the face strip  10  so that the tapered ends will conform.  
         [0028]      FIG. 2D  shows the face strip  10  and contrast strip  20  sewn together edgewise and the third strip  30  flipped to align the points (the decorative side of the third strip  30  facing inward against the decorative side of the face strip  10  such that three points of all three strips are exactly aligned.  
         [0029]      FIG. 2E  illustrates the joined and tapered end of the unitary belt strip (sewn face strip  10  and contrast strip  20 ) is inserted up through a buckle  40 , over the buckle central post.  
         [0030]      FIG. 3  (Prior Art) shows a reversible belt attained by current manufacturing methods using commercial sewing equipment.  
         [0031]      FIG. 4  (Prior Art) shows a perfectly reversible belt with a symmetrical finished appearance (uniform on both sides) attained by hand-sewing. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0032]      FIG. 1  shows the general steps of the method of the present invention. The present method of manufacturing reversible belts generally comprises the following steps:  
         [0033]     Step 1. Select a face material and contrast material, each having at least one decorative side (decorative herein being defined as any pattern, design, color or material to be outwardly displayed).  
         [0034]     Step 2. Cut an equal length of face material and contrast material into strips with tapered ends, the taper preferably comprising pointed triangular ends.  
         [0035]     Step 3. Align the decorative sides of the face strip and contrast strip and sew just their tapered ends together (both ends).  
         [0036]     Step 4. Invert the now-joined face strip and contrast strip to hide the seamed ends and to expose the decorative sides.  
         [0037]     Step 5. Cut an additional piece of contrast material (preferably the same decorative pattern, color, design, texture or material as the original) into a shorter third strip (approximately 5½″ long) conforming to an end of the existing face and/or contrast strips, e.g., tapered at one end with an opposing generic end (may be squared or otherwise).  
         [0038]     Step 6. Sew the generic end of the shorter third strip (decorative side facing inward) approximately 5½″ inward of the tapered end of the face material strip such that the points of all three strips are now aligned and the tapered end of the shorter third strip remains free.  
         [0039]     Step 7. Sew the edges of the original face material strip and contrast material strip along all sides to make one unitary main belt strip, and also thereby securing the third strip in place.  
         [0040]     Step 8. Insert the tapered end of the unitary main belt up and around through a buckle and sew its tip onto itself (with face material side of the tip doubled back and juxtaposed over the contrast material).  
         [0041]     One skilled in the art will understand the preceding steps need not necessarily be performed in the sequential order disclosed, but so long as all are performed the result will be a fully reversible (symmetrical on both sides) belt attached to the buckle with equal proportions of decorative face material and contrast material pattern appearing on both sides.  
         [0042]     The foregoing steps are described below in further detail.  
         [0043]     Step 1 involves selecting any type of textile fabric material for use as the pieces of face material and contrast material that serve as the decorative display surfaces of the reversible belt produced from this method. The face material and contrast material each have one side bearing any of a variety of different designs, patterns, colors, combinations of colors, or textures. The face material and contrast material preferably bear different designs, patterns, or colors from each other, or may be different types of material, to provide contrast and to take advantage of the resulting belt being reversible. However, the face material and contrast material may also be solid colors or be patterned alike as a matter of design choice.  
         [0044]     Step 2 entails cutting an equal length of face material and contrast material into strips with tapered (triangular pointed) ends.  FIG. 2A  illustrates equal lengths of cut face strip  10  and contrast strip  20  each with tapered ends on both sides. The face strip  10  and contrast strip  20  are preferably cut into pieces that are approximately 5½″ longer than the desired belt length. For example, if the desired belt length is 42″ long, then the face strip  10  and contrast strip  20  should each be cut to approximately 47½″ in length. In order to achieve accurateness in cutting, the face strip  10  and contrast strip  20  pieces should be cut individually rather than together. Accurate cutting ensures that face strip  10  and contrast strip  20  will both be the same size and shape. Scissors, a razor knife with a straight edge, or any other suitable cutting method can be used as a means for cutting.  
         [0045]     Step 3 entails aligning the face strip  10  and contrast strip  20  with decorative sides facing inward and sewing their tips together at the points (both ends), but leaving their peripheral edges unattached. This is best envisioned from  FIG. 2A  if the face strip  10  were flipped up and onto contrast strip  20  (decorative sides facing inward) and the two strips  10 ,  20  sewn together along the triangular edges of the points.  
         [0046]     Next at step 4, invert the now-joined face strip and contrast strip to hide the seamed points and to expose the decorative sides. This is seen in  FIG. 2B  where just the points are attached, but the sides of the face strip  10  and contrast strip  20  are not.  
         [0047]     At step 5, an additional piece of contrast material (with the same pattern as contrast strip  20 ) is cut into a shorter third strip conforming to one end of the joined face and contrast strips  10 ,  20 . This is likewise seen in  FIG. 2B  where the shorter third strip  30  has been cut into an approximate 5½″ length, same decorative pattern, design, color, texture or material as the contrast strip  20 , and with a pointed tip at one end and opposing generic end which may be squared or otherwise formed.  
         [0048]     Next, at step 6, the generic (here squared) end of the shorter third strip  30  is sewn inwardly against the face strip  10  so that the tapered ends conform. This can be seen in  FIG. 2C  and is best accomplished by aligning the third strip  30  along the face strip  10  and pointing opposite therefrom (as seen), and seaming across the generic end of the third strip  30  to face strip  10  approximately 5½″ inward from the pointed tips. This way, when the third strip  30  is flipped to align the points the decorative side of the third strip  30  will face inward against the decorative side of the face strip  10  and, indeed, all three points of all three strips are exactly aligned.  
         [0049]     Next, at step 7, the remaining edges of the original face strip  10  and contrast strip  20  are sewn together to yield one unitary belt strip with the tapered end of the shorter third strip  30  protruding freely.  FIG. 2D  shows the face strip  10  and contrast strip  20  be sewn together edgewise and the third strip  30  being flipped to align the points (the decorative side of the third strip  30  facing inward against the decorative side of the face strip  10  such that three points of all three strips are exactly aligned. One skilled in the art will understand that any number of stitch types may be used including cross-stitch, run stitch, bean stitch, catch stitch, blatt stitch, underlay stitch, and fill stitch.  
         [0050]     At step 8, and as seen in  FIG. 2E , the joined and tapered end of the unitary belt strip is inserted up through a buckle  40 , over the buckle central post, and then back down around through the buckle. The buckle  40  may be any conventional buckle having a center post with dimensions adapted to receive the width to the belt. Thus, for example, the buckle  40  can be approximately 2″ in diameter for a 1¾″ width belt, and can be made of plastic, metal, or any other suitable material for a belt buckle. The tip of the unitary belt strip is sewn back onto itself (so that the decorative side of the face strip  10  doubles back and is juxtaposed over the contrast material strip  20  side on the opposing side).  
         [0051]     Finally, at step 8, the pointed tip of the shorter third strip  30  (decorative side now facing outward) is passed down through the other side of buckle  40  and is sewn onto the face strip  10  (so that the decorative side of the third strip  30  doubles back and is juxtaposed over the face material  10  side). This can be seen in  FIG. 2F .  
         [0052]     As shown in  FIG. 2G , the foregoing method yields a perfectly symmetric reversible belt attached to the buckle  40  with equal proportions of decorative face pattern, color or material, and contrast pattern, color or material appearing on both sides (one side with face material overlying contrast material as seen in  FIG. 2G , and one side with contrast material (via third strip  30 ) overlying face material as seen in  FIG. 2F ). Moreover, all stitching, threading, and other sewing steps can be performed using commercial sewing equipment. For example, one may use a single needle industrial Singer straight stitch sewing machine. This method of manufacturing results in the production of a perfectly reversible, fully-finished belt. The method of manufacturing the reversible belt is simple and can be implemented in any location, including in the convenience of one&#39;s own home or place of business. Additionally, this method produces an aesthetically appealing finished perfectly reversible belt (i.e. neither side looks like the back side) that cannot be produced by any known prior art methods.  
         [0053]     Having now fully set forth the preferred embodiment and certain modifications of the concept underlying the present invention, various other embodiments as well as certain variations and modifications of the embodiments herein shown and described will obviously occur to those skilled in the art upon becoming familiar with said underlying concept. It is to be understood, therefore, that the invention may be practiced otherwise than as specifically set forth in the appended claims.