Abstract:
A clothing connector having tensile components is formed in any of the conventional ways, and a soft roughness insulating covering layer is attached to one side and then moved to the other side in an inside-out process which provides a soft finish not only to the side to which it was moved, but also the peripheral edges and a narrow portion of the side of the clothing connector to which it was originally attached. This structure and process enables quick application of a softening, object insulating covering to any clothing connector expected to face the body.

Description:
BACKGROUND OF THE INVENTION 
     This invention relates to a method and technique for attachment of a roughness insulating soft layer to a clothing connector to enable roughness insulation of a main side, and edges adjacent the side from which the roughness insulating soft layer was attached. 
     BACKGROUND OF THE INVENTION 
     Clothing having connectors, support structure, and supported components take special steps and structures for consistency with the clothing. Consistency can be measured by adequate support, adequate securement and a configuration to distributively garner and lend support. Tradeoffs are made all the time, with structures bearing significant force having to be adequately sewn in a manner that helps compensate for the strength of the supported component versus the strength of the cloth which supports it. In many cases, the provision of supported structures requires significant sewing, bolting, stapling or the addition of other structures to the cloth. Such other structures may be sharp, protrusive, rough, unsightly, extremely uncomfortable. Any supplemental structures which can reduce such sharpness, protrusion, roughness, unsightliness and discomfort, and can perform such reduction in an efficient manner are highly desired. 
     However, building in softness and wear resistant layers over any clothing connector component can be very expensive, labor intensive and time consuming. Building up layers can require fixation which can further cause sharpness, protrusion, roughness, unsightliness and discomfort. As a result, the technique of building on layers from the outside and directly onto the side which is sought to be softened, is very difficult and requires a labor intensive manual operation with a requirement for close inspection. 
     SUMMARY OF THE INVENTION 
     A clothing connector having tensile components is formed in any of the conventional ways. Most of the conventional ways involve considerable sewing, gluing, welding and other methods to achieve a component with the desired shape and connector characteristics. Then, a soft planar material is attached in a position covering the connectors or other structure which would be facing away from the user when the clothing connector would be in a position to be worn. The soft planar material is attached near the periphery of the clothing connector with some small portion remaining unconnected. 
     The soft planar material may be preferably attached somewhat inboard of the outermost edge of the connector portion, and in such a way that if the resulting clothing connector piece and soft planar material is turned inside out, that the soft planar material covers to the full extent possible the outer edges of the clothing connector piece adjacent the length of attachment. The resulting structure is covered by the soft planar material at a main extent which would otherwise contact the user, as well as the edges of the connector portion covered by the soft planar material. The result is also that the outwardly projecting edges of the hook &amp; Eye Tape is covered by the soft fabric. Original Hook &amp; Eye tape may have used ultrasonic cut/seal using stitching to attached all the layers. The edge provided by ultrasonic seal is quite sharp (and not comfortable), and if using stitching, the edge may not perfect—some little thread at edge, but the invention will cover and help overcome the shortcomings of any type of binding technique. Therefore covering the edge can provide better edge to the hook &amp; Eye Tape. 
     Where the clothing connector is a tensile connector, such as a main bra strap having multiple metal loop connectors for selectable lateral displacement connection with a metal hook connector, the main bra strap connector can be formed in a variety of ways. For example, a width of material of sufficient magnitude width to form several multiple metal loop connectors can be formed by providing several very long folds of cloth into which the multiple metal loop connectors may be sewn, typically with a spacing which will result in two metal loops or “eyes” per main bra strap connector. The very long folds will create a wide length from which multiple connectors can be formed by cutting or welding or melting, to name a few separation techniques. Once formed and stabilized by sewing, gluing, welding, or the like, the expanse of material is cut along its short length to form a multiple number of main bra strap connectors. In some instances this cutting can be by two way tricot seal-cutting, which laterally seals the multiple folded cloth members, each of which may be fitted with two or three evenly spaced apart eye loop engagement members. 
     The result of this operation is a clothing connector which may have a rough surface on the side opposite the eyes, as well as rough edges. Where the seal cutting is accompanied by heat, some of the material may melt and leave sharp edges during processing. Further, the sealing along the opposite edges where cuts were made may also have rough edges. Supplemental sewing or preparation or fixation can occur just before cutting or just after cutting and may occur independently of the attachment of the soft layer of material. In some clothing connector structures a wide variety of other structures may be left in place for further processing. Other processing may be done before or after cutting. Other processing may be done prior to attachment of the soft layer or after. 
     A soft layer of material is next attached against the access face of the clothing connector. By access face it is meant the side of the clothing connector which will need to be accessed later for connection purposes after all of the processing is complete. The soft layer of material will preferably be able to be stretched as it will be attached just inward of the outer periphery of the clothing connector, and yet the width of material between two attachment points will be required to stretch sufficiently to cover the outer edges and the complete back width of the clothing connector, in this case the clothing connector being a main bra strap eyelet or eye loop connector. 
     The attachment of the soft layer can be by welding, sewing, and particularly by zig zag sewing. The extent of sewing will depend upon the ability to turn any pocket formed by such sewing, “inside out” to reverse the formed pocket structure, enable the soft material to cover the side opposite the access face, as well as the edges along the sides adjacent the line or points of attachment of the soft layer. 
     When the main bra strap connector is in place, the soft layer will lie against the user&#39;s body or underwear, while the engagement loops or eye loops or eyelets will face away from the user. A male or hook connector will extend over the engagement loops and facing the user, but may generally have a lesser area, either vertically or by longitudinal extent and will be both held away from the body and will be prevented from touching the body by resting on the main bra strap connector made in accord with the present invention. A further advantage of the invention is the provision of a seamless back. Originally, and traditionally, Hook &amp; Eye tape structures have visible seam at the back which can be viewed through clothing and the like. The invention provides a layer which is turned inside out and covers the back, any visual stitching or other visual anomalies will be covered. 
     However, at the end of the process steps described herein, the result will be, in the case where a clothing connector is a main bra strap connector, at minimum a finished hook &amp; eye tape member which can be further sold and employed on a variety of clothing structures, including a main bra strap connector. 
     The ability to selectively use seal-cutting (ultrasonic) versus shear cutting will depend upon the materials selected. The types of fabric used is not particularly limited, and tricot fabric may be used. Further, although a hook &amp; eye tape structure is described which is formed from a series of sewn layers, the utilization of the soft protective material of this invention might make possible a molded eye tape which can be covered in a soft reversible fabric and then reversed to an inside-out position. In addition, folding with any structure is expected to occur with a combination of stretching of the soft cover layer combined with some contortion of the other layer, such as an eye-loop layer to which it is attached. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention, its configuration, construction, and operation will be best further described in the following detailed description, taken in conjunction with the accompanying drawings in which: 
         FIG. 1  is a cross sectional view of one possible starting configuration either as a single eye loop tape assembly or a very wide assembly from which eye loop tape assemblies can be cut to form a clothing connector especially for a main bra strap or other clothing structure; 
         FIG. 2  is a plan view of a eye device seen in side view in  FIG. 1 ; 
         FIG. 3  is a perspective view of a number of eye loop assemblies which may have been cut from the starting structure of  FIG. 1 ; 
         FIG. 4  is a perspective view of a single eye loop tape assembly with a reversible covering layer in position for attachment; 
         FIG. 5  is a plan view of the eye loop tape assembly with reversible covering layer in place and illustrating a stitch which may be used around three sides to form a pocket structure as a precursor to the inside-out folding; 
         FIG. 6  is a sectional view taken along line  6 - 6  of  FIG. 5  and further illustrating the points of connection of the reversible covering layer and illustrating the formation of a pre-inside-out pocket space over the eye loop side of the eye loop tape assembly; 
         FIG. 7  is a plan view of the eye loop tape assembly after inside-out folding, and with the folded reversible covering layer visible only slightly just inside the periphery of the eye loop tape assembly and covering a portion of the main facing surface in  FIG. 7 , all the edges and all of the reverse side; and 
         FIG. 8  is a sectional view taken along line  8 - 8  of  FIG. 7  illustrating the eye loop tape assembly after inside-out folding, and identifying the post-inside-out pocket space over the back side the eye loop tape assembly, and into which further softening structure may be inserted prior to attachable sewing. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to  FIG. 1 , a side sectional view of a length of a eye loop tape assembly  21  is shown. The actual resulting shape is planar, but the schematic nature of the figure causes it to appear somewhat slanted in height and uneven. There are many alternatives which can be constructed of the eye loop tape assembly  21 , and in fact the invention herein very likely opens the door to other constructions of less complicated construction. Assembly  21  includes a central strength layer  23  about which a softer finishing layer  25  extends in an a mutual support fashion. A series of eye loops  27 , seen in side view, are attached to the eye loop tape assembly  21  in such a manner that the lower (right hand from the perspective of  FIG. 1 ) portion of the eye loops  27  are covered by layers of material to both cover and protect their points of attachment. 
     The left-most eye loop  27  is attached using a first covering and fastening layer  31  and includes a first portion  33  which overlies the eye loop  27  and a second portion  35  which extends to underlie the next most adjacent eye loop  27 . The covering and fastening layer  31  is positioned over the eye loop  27  and the eye loop  27  is sewn through the openings in the eye loop (to be shown), and through both sides of the softer finishing layer  25  and through the central strength layer  23 . The point at which the covering and fastening layer  31  is sewn onto the eye loop  27  sets the lengths of the first and second portions  33  and  35 . The idea in choosing the lengths of the first and second portions  33  and  35  is to provide enough of the first portion  33  so that the sewing operation will not occur near the edge, and to provide enough of the first portion  33  to extend underneath the next most adjacent eye loop  27 . 
     The sewn attachment is schematically shown as a stitch  37  which may terminate in a rough end  39 . The rough end  39  is not necessarily a pointy end and in terms of user discomfort, such discomfort can come via the type of thread used, whether any loose threads are present, and especially where a random out of place thread is loose or terminates at a sharp point. Polymeric threads can particularly cause problems as they tend to be stiff where loose ends extend from a material from which they are bound. The stitch  37  need not even be a traditional stitch, as it can be innovative artwork, like weldinf. A weld can occur where the materials are melted together either by heat or ultrasonic input accompanied by pressure. The use of the covering and fastening layer  31  helps users try and hook the left exposed side of the eye loop  27  using a compatible hook (not shown) in order to avoid any interference or snagging on the bottom or right hand most structures of the eye loop  27 . In this way, any hook which is dragged across the second portion  35  of the first covering and fastening layer  31  would more easily “find” or slip into an opening formed the left side of eye loop  27  rather than any of the structures on the right side of the eye loop  27  or the stitch  37  if it were used to directly engage the eye loop  27 . This is especially useful where fastening is to occur when the user cannot directly see the hooks (not shown) and eye loops  27 . 
     It is understood that the eye loops  27  can number more or less than three along the length (width from the perspective of  FIG. 1 ) of any eye loop tape assembly  21  seen. Three eye loops  27  are shown in this embodiment. The middle eye loop  27  is attached using a second covering and fastening layer  41  and includes a first portion  43  which overlies the eye loop  27  and a second portion  45  which extends to underlie the next most adjacent, namely the right-most eye loop  27 . The covering and fastening layer  41  is positioned over the middle eye loop  27  and the middle eye loop  27  is sewn through the openings in the eye loop (to be shown) in the same manner as was done for the left-most eye loop  27 . A sewn attachment is schematically shown as a stitch  47  which may terminate in a rough end  49 . 
     The right-most eye loop  27  has a different covering and fastening layer. The right-most eye loop  27  is attached using a double covering and fastening and securing layer assembly which includes an outer, relatively softer covering and fastening layer  51  which sandwiches a second central strength layer  53  which may or may not be made from the same material as the central strength layer  23 . The covering and fastening and securing layer  51  is so designated because it will act with central strength layer  23  and softer finishing layer  25  to secure the eye loop tape assembly  21  to another structure. It can be seen that the double covering layer assembly, including layers  51  and  53 , has ends  55 . A stitch  57  attaches the double covering layer assembly spaced slightly apart from the ends  55  sufficient to form a good connection. Note that the main extent of the double covering layer assembly, including layers  51  and  53 , were connected in a manner to be directed toward the middle and left most eye loop  27  and then folded over toward the opposite end of the eye loop tape assembly  21 . This helps to cover the end of the stitch  57 , while the rough end  59  still appears at the bottom of the eye loop tape assembly  21 . Further, the double covering layer assembly, including layers  51  and  53 , helps to form, with the central strength layer  23  and softer finishing layer  25  a pair of lengths of material which can capture another member between them to form an evenly secured fit. 
     Also seen in phantom is a reversible roughness insulating roughness insulating covering layer  71  having an attachment point  73 . These structures are first introduced in  FIG. 1  so that the reader can know where such a layer should extend with regard to the structures seen in  FIG. 1 . The end of the reversible roughness insulating covering layer  71  can extend to a point short of the end of eye loop tape assembly  21  or fall short of it. The attachment point  73  can be of any type, such as ultrasonic welded, stitched, melted or any other manner of attachment. Further details will be shown from a perspective in which the extent of attachment of the reversible roughness insulating covering layer  71  will be shown. Further, it is preferable that the reversible roughness insulating covering layer  71  be made of material which can soften the presence of underlying structures such as the rough ends  39 ,  49 , and  59 . Further, reversible roughness insulating covering layer  71  should have the ability to stretch. As can be seen in  FIG. 1 , any movement of the reversible roughness insulating covering layer  71  to the other side of the eye loop tape assembly  21  will have to either stretch or have additional material to both cover a terminal edge  75  of the eye loop tape assembly  21 . 
     Referring to  FIG. 2 , a plan view of an eye loop connector  91  is seen. The eye loop connector  91  is typically made from a small wire that has been cut and bent to a shape similar to that shown. A pair of base eyelets  93  are formed with each having an opening  95  which may or may not be effectively closed depending upon the precision of the machine forming the eye loop connector  91 . The use of the eyelets  93  are provided so that any sewing which ventures into those areas will hold the eye loop connector  91  securely. This type of arrangement works well with linear sewing across the bottom of the eye loop connector  91  which is so small and smooth that it can easily deflect the sewing action of any needle directed toward the right hand base. 
     The eye loop connector  91  also has a pair of arms  97  which terminates at an end bar  99 . The end bar  99  is typically compatible with any hook to be used with the eye loop connector  91 . Where a hook (not shown) has a pair of evenly spaced members, the straight end bar  99  provides a balanced connection. Further, the arms  97  enable the manufacturer to determine the extent to which the end bar  99  is to extend from the accommodating connection of the eyelets  93 . 
     Referring to  FIG. 3 , a series of separated eye loop tape assembly  21  are seen. A side sectional view of any of the eye loop tape assemblies  21  would correspond to the side sectional view of  FIG. 1 , illustrating that it may be preferable to make a laterally extending, very long structure seen into the view of  FIG. 1 , from which multiple ones of the eye loop tape assemblies  21  can be cut into separate units. The positioning of the eye loop tape assemblies  21  in  FIG. 3  illustrates that if the eye loop connectors  27  are appropriately spaced, that a continuous band structure can be made from which the eye loop tape assemblies  21  can be formed automatically. 
     In  FIG. 3 , the individual eye loop tape assemblies  21  are formed by cutting, ultrasonic sealing, cutting while sewing, or sewing before or after cutting to name but a few examples. Note also that covering layer  51  which was very strongly reinforced with a central strength layer  53 , and the end base made up of the central strength layer  23  covered by the softer finishing layer  25 , together form a pair of structures which can surround, clamp and become sewably attached to another structure, such as a bra main strap. In the form seen in  FIG. 3 , the eye loop tape assemblies  21  could be utilized with clothing, but the rough ends  39 ,  49  and  59 , as well as roughness from any other source on the underside of the eye loop tape assemblies  21  would contact the user. 
     At the point after the eye loop tape assemblies  21  are formed, is the best place to introduce the attachment of the reversible roughness insulating covering layer  71 . Referring to  FIG. 4 , a eye loop tape assembly  21  is seen underlying a reversible roughness insulating covering layer  71  which is shown as about to be brought down into place over the eye loop tape assembly  21 . The shape of the reversible roughness insulating covering layer  71  may generally match the outer peripheral shape of the eye loop tape assembly  21 . The reversible roughness insulating covering layer  71  has a first side edge  101 , an opposite second side edge  103 , and a third side edge  105  and a fourth side edge  107 . Also reversible roughness insulating covering layer  71  has a first planar side  109  and a second planar side  111 . As can be seen, the second side  111  is about to be placed opposite the side of the eye loop tape assembly  21  with the exposed loops of the eye loop connectors  27 . After the folding operation is completed, it is the first side  109  which will be exposed and the first side  109  will lie opposite the rough ends  39 ,  49  &amp;  59 . The second side  111  will then lie outside and facing away from the eye loop tape assembly  21  on the side of eye loop tape assembly  21  opposite the exposed eye loop connectors  27 . As a result, where the reversible roughness insulating covering layer  71  is available having a softer side and a more rough or more padded side to accommodate the rough ends  39 ,  49  &amp;  59 , the reversible roughness insulating covering layer  71  should be oriented accordingly. However, many of the reversible roughness insulating covering layers  71  may be expected to have two sides of the same softness and texture. 
     As has been shown in  FIG. 1 , the eye loop tape assembly  21 , even if made of outwardly soft materials, is somewhat resistant to bending and folding due to its layered nature. The ability of the eye loop tape assembly  21  to form a pocket and then be turned inside out will typically be permissible based upon the ability of the combination of the flexibility of the eye loop tape assembly  21  and the flexibility of reversible roughness insulating covering layer  71  to contort more than the eye loop tape assembly  21 . This is stated to emphasize that the points of connection of the reversible roughness insulating covering layer  71  need not include a whole side for attachment, and nor must one side be left un-attached; namely that it is the provision of a break in the periphery of attachment which enables an “inside out” reversal action. In the embodiment shown, it is proposed that side edges  105 ,  103  and  107  be attached and that side edge  101  be left un-attached until the time that the eye loop tape assembly  21  is attached to some other structure, such as a back wing (not shown). In reality, in order to perform an “inside-out” operation where the reversible roughness insulating covering layer  71  moves to the other side, all that is necessary is a minimum peripheral area of non attachment which will enable the inside portion of the remaining structure to pass from the inside to the outside, and which will allow the external areas to move from the outside to the inside. In the present example, a whole side edge  101  will be left unattached in order to facilitate entry and sewing of the reversible roughness insulating covering layer  71  at the time that another structure is added so that attachment and closure of the non attached side edge  101  can occur at one time. 
     In terms of exact position of attachment, the more inwardly of the eye loop tape assembly  21  at which reversible roughness insulating covering layer  71  is attached, the more of that side of the eye loop tape assembly  21  will be covered once the inside-out operation is performed. Referring to  FIG. 5  a plan view of reversible roughness insulating covering layer  71  lying atop the eye loop tape assembly  21  is shown. Many of the details of the eye loop tape assembly  21  are shown in phantom. However, a stitch line  121  is shown which is slightly inside of the side edges  103 ,  107 , and  109 . The location of the stitch line  121 , if stitching is used to attach the reversible roughness insulating covering layer  71 , should be inboard of the side edges  103 ,  107 , and  103  sufficient to insure that the reversible roughness insulating covering layer  71  will not be disconnected due to fraying of any material at its edge. Of course, the selection of the material can affect the closeness to the side edges  103 ,  107  and  109  to which stitch line  121  can approach. Where the reversible roughness insulating covering layer  71  is glued, welded, melted or otherwise bonded, the peripheral attachment point can be closer the outer edges of the reversible roughness insulating covering layer  71 . Also, side edge  101  is seen as extending somewhat longer than the terminal edge of the eye loop tape assembly  21 . This will enable a greater range of options to be had upon final attachment of the eye loop tape assembly  21  to some other structure, and may be accompanied by cutting or welding or melting or simultaneous attachment and removal of a certain length of the reversible roughness insulating covering layer  71  to form a finished appearance. The lower line indicating extension of the covering layer  71  over the end of the central strength layer  23  covered by the softer finishing layer  25  is omitted to prevent confusion with stitch line  121 . 
     Referring to  FIG. 6 , a sectional view taken along line  6 - 6  of  FIG. 5  illustrates the position of the various layers with the reversible roughness insulating covering layer  71  at the top. A pocket space  125  exists between the reversible roughness insulating covering layer  71  and the eye loop tape assembly  21  and can be used to accept insertion of an optional additional roughness insulating member  129 . The additional roughness insulating member  129  is shown as having an optional form of attachment. Such attachment may be (1) via extension of the stitch line  121 , emphasizing that the insert can be an additional layer of softening material sewably attached, or (2) some other method of attachment, such as by gluing on insertion or, additional additional roughness insulating member  129  can be unattached, and may preferably be oversized to insure that it coverably protects without significantly moving around. 
     Referring to  FIG. 7 , a view of the orientation of the eye loop tape assembly  21  similar to that seen in  FIG. 5  is seen, but after the inside-out operation has caused the reversible roughness insulating covering layer  71  to become flipped around to cover the back side of the eye loop tape assembly  21 . The welding or stitching line  121  will not be directly seen as the most adjacent structure to this is the inner edge of the reversible roughness insulating covering layer  71 . As can be seen, a narrow extent of the reversible roughness insulating covering layer  71  can be see just inside the periphery of three sides of the eye loop tape assembly  21 . This illustrates that the reversible roughness insulating covering layer  71  extends to cover a portion of the top surface of the eye loop tape assembly  21  on the same side as the exposed eye loop connectors  27 , and extending around three edges of the eye loop tape assembly  21  and covering the back surface of the eye loop tape assembly  21  covering the rough ends  39 ,  49  and  59 . The softer finishing layer  25  and covering layer  51  can be seen, and any excess of the reversible roughness insulating covering layer  71  has been trimmed away. Either before the reversible roughness insulating covering layer  71  is trimmed away, it can be seen that the eye loop tape assembly  21  is ready to accept connection to another structure, and that reversible roughness insulating covering layer  71  is in place to protect the user&#39;s body. With respect to the orientation of  FIG. 7 , a male hook member would enter from the top of  FIG. 7  and engage the eye loop connectors  27  and thus be held away from the body of the user. As a result a male hook connector would not need any soft layers. The opposite side of eye loop tape assembly  21  than that seen in  FIG. 7  would then be the only member resting against the user&#39;s body. 
     Referring to  FIG. 8 , a sectional view taken along line  8 - 8  of  FIG. 7  illustrates the position of the layers after the pocket space  125  moves to the other side of the eye loop tape assembly  21 . Further, since the pocket space  125  has been formed while one side edge  101  has remained open, and before any other structure has been attached, the pocket space  125  is temporarily available for the addition of any further insulating inserts, such as a cotton pad, smooth length of plastic or any other structure which will help to increase comfort and attenuate the protrusion of the rough ends  39 ,  49  and  59 . This capability may be even more advantageous when it is considered that the thinner the reversible roughness insulating covering layer  71  is, the more it stretches and the better equipped it will be to perform the inside-out reversal procedure with an eye loop tape assembly  21  which may be more stiff and less foldable or bendable. In this manner, an insert can be quickly and cleanly supplied into the pocket space  125  before attachment of the eye loop tape assembly  21  to another structure such as a bra main strap. 
     While the present invention has been described in terms of a soft clothing connector which utilizes an inside-out movement of a soft cover to insure that both the surface and side edges of the portion exposed to the consumer&#39;s body will be softened, one skilled in the art will realize that the structure and techniques of the present invention can be applied to many clothing appliances and especially appliances which utilize the embodiments of the invention or any process which utilizes the steps of the invention. 
     Although the invention has been derived with reference to particular illustrative embodiments thereof, many changes and modifications of the invention may become apparent to those skilled in the art without departing from the spirit and scope of the invention. Therefore, included within the patent warranted hereon are all such changes and modifications as may reasonably and properly be included within the scope of this contribution to the art.