Abstract:
A method of forming a garment blank having a seamless trim is provided. The method includes applying an adhesive layer in a selected position on the garment blank; applying a fabric layer to the adhesive layer; securing the adhesive and fabric layers in the selected position with a seam; and exposing the garment blank to at least one condition sufficient to cause the adhesive layer to bond the fabric layer to the garment blank and the seam to dissipate.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application is a continuation-in-part application of U.S. application Ser. No. 10/452,779 filed May 30, 2003, the contents of which are incorporated by reference herein. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1. Field of the Invention  
         [0003]     The present invention relates to methods of producing garment blanks. More particularly, the present invention relates to methods of producing garment blanks having a seamless trim.  
         [0004]     2. Description of Related Art  
         [0005]     Intimate apparel garments are worn directly next to the skin. Thus, it can provide particular challenges with respect to maximizing the user&#39;s comfort while wearing the garment. Many intimate apparel garments include a trim or edging (hereinafter “trim”) at the periphery of the garment. The trim provides one or more benefits to the garment. For example, the trim can mitigate unraveling of the garment at the periphery. Further, the trim can be used to provide elastic properties to the garment. Further, the trim can provide a decorative or aesthetically pleasing appearance to the garment.  
         [0006]     The trim can be a separate piece that is secured to a garment blank during manufacture of the desired garment. Alternately, the trim can be a portion of the garment blank that has been folded over an elastic band and the secured again to the main portion of the blank. The trim has commonly been secured to the garment blank by a line of stitching or a seam. However, this seam defines an area of discontinuity in the resultant garment, which can be aesthetically and/or physically displeasing.  
         [0007]     Accordingly, there is a desire for garments that have the benefits available from prior trims, but without one or more of the aforementioned drawbacks and deficiencies of the prior trims.  
       BRIEF SUMMARY OF THE INVENTION  
       [0008]     It is an object of the present invention to provide methods of providing a garment blank with a seamless trim.  
         [0009]     It is another object to provide methods of forming a garment blank having a seamless elastic trim.  
         [0010]     It is another object to provide reliable methods of forming garment blanks having a seamless trim.  
         [0011]     These and other objects and advantages of the present invention are provided by a method of forming a garment blank having a seamless trim. The method includes applying an adhesive layer in a selected position on the garment blank; applying a fabric layer to the adhesive layer; securing the adhesive and fabric layers in the selected position with a seam; and exposing the garment blank to at least one condition sufficient to cause the adhesive layer to bond the fabric layer to the garment blank and the seam to dissipate.  
         [0012]     The present invention also provides a method of forming a garment blank having a seamless trim where the method includes applying a laminated member to the garment blank so that an adhesive layer of the laminated member contacts the garment blank and a fabric layer of the laminated member has a selected position with respect to the garment blank; maintaining the laminated member in the selected position with a seam; activating the adhesive layer with a first level of heat to secure the fabric layer in the selected position; and applying a second level of heat to the laminated member to cause the seam to dissipate.  
         [0013]     The present invention further provides a method of forming a garment blank having a seamless trim where the method includes applying an adhesive layer of a laminated member to a first side of the garment blank at a peripheral edge of the garment blank; sewing the laminated member to the garment blank with at least one seam; activating the adhesive layer to secure a fabric layer of the laminated member to the garment blank; and dissipating the at least one seam.  
         [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 SEVERAL VIEWS OF THE DRAWINGS  
       [0015]      FIG. 1  is a perspective view of an exemplary embodiment of a garment blank for use with the methods of the present invention;  
         [0016]      FIG. 2  is a partial sectional view of the peripheral edge of the garment blank of  FIG. 1 ;  
         [0017]      FIGS. 3 through 6  illustrate an exemplary embodiment of a method for providing a seamless trim to the garment blank of  FIG. 2 ; and  
         [0018]      FIGS. 7 through 9  illustrate a second exemplary embodiment of a method for providing a seamless trim to the garment blank of  FIG. 2 . 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0019]     Referring to the drawings and in particular to  FIGS. 1 and 2 , an exemplary embodiment of a garment blank generally represented by reference numeral  10  is illustrated. Blank  10  has one or more peripheral edges  12  defined therein.  
         [0020]     For purposes of clarity, blank  10  is illustrated for use as an intimate apparel garment, particularly, a panty where peripheral edges  12  define, for example, a set of leg holes  14 . Of course, it is contemplated by the present invention for blank  10  to find use with other garments such as, but not limited to, a brassiere, a pair of underwear, and other such intimate apparel garments.  
         [0021]     Blank  10  has a first side  16  and a second side  18 . In the exemplary embodiment, first side  16  faces the skin of the wearer, while second side  18  faces away from the wearer. Of course, it is contemplated by the present invention for first side  16  to face away from the wearer and second side  18  to face the skin of the wearer.  
         [0022]     An exemplary embodiment of a method  20  according to the present invention for providing blank  10  with a seamless trim  22  is illustrated with simultaneous reference to  FIGS. 3 through 6 . In this embodiment, trim  22  is a portion of blank  10  that has been folded over and secured to the blank. Thus, the fold of trim  22  moves peripheral edge  12  internal to blank  10 , shown in  FIG. 1 , and provides a curved edge  24  to blank  10 .  
         [0023]     During method  20 , peripheral edge  12  is folded toward first side  16  to form curved edge  24  facing outward of blank  10  and a cavity  26  facing inward of the blank. Before or simultaneous to the formation of cavity  26 , method  20  applies an adhesive binding  28  to blank  10 . For example, binding  28  can be applied to first side  16  in the cavity after blank  10  has been folded. Alternately, binding  28  can be inserted into cavity  26  as the cavity is formed.  
         [0024]     In addition, binding  28  can exhibit elastic properties. Thus upon completion of method  20 , binding  28  can secure trim  22  in the selected position and can aid in providing elasticity to blank  10 .  
         [0025]     Method  20  includes temporarily securing trim  22  in place using one or more temporary seams  30  (only one shown). Seam  30  can aid in securing binding  28  in cavity  26 . Seam  30  can also aid in maintaining edge  12  in the selected position with respect to first side  16 .  
         [0026]     Seam  30 , similar to the application of binding  28  discussed above, can be incorporated into blank  10  substantially simultaneous to the folding of the blank. Accordingly, a first step of method  20  provides for the substantially simultaneous folding to form trim  22 , application of binding  28 , and sewing to form seam  30 .  
         [0027]     However, seam  30  is a temporary seam. Specifically, seam  30  is formed with a yarn (not shown) that dissipates upon further processing. For example, seam  30  can be a heat labile seam that dissipates upon application of heat. As used in this application, the term “dissipate” means that the seam substantially disappears both visually and tactilely.  
         [0028]     In an exemplary embodiment, binding  28  can be a heat-activated adhesive binding that is activated at a first level of heat exposure. During exposure of heat to binding  28 , trim  22  is maintained under a selected compression to ensure that binding  28  is firmly secured in cavity  26 . Thus, binding  28  bonds first side  16  to itself to maintain peripheral edge  12  in the selected position, which forms curved edge  24  on blank  10 .  
         [0029]     In this same embodiment, seam  30  can be formed from a heat labile yarn that dissipates at a second level of heat exposure. Advantageously, the second level of heat exposure is less than the first level of heat exposure. Thus, the activation of binding  28  and the dissipation of seam  30  can occur at the same time, namely within the first level of heat exposure that is required to activate the binding. In this manner, method  20  not only provides the seamless trim  22 , but can also provide the seamless trim in a minimal amount of time.  
         [0030]     For example, binding  28  can be an EB 3106 adhesive commercially available from Bemis. Further, seam  30  can be formed with a Thermolux yarn that is commercially available from Luxilon Industries of Belgium. In this example, binding  28  is activated at a level of heat exposure of about 160 degrees Celsius to about 190 degrees Celsius for about 19 seconds. However, seam  30  dissipates at a level of heat exposure of about 15 seconds at about 140 degrees Celsius.  
         [0031]     Thus, method  20  provides a simple, two step operation to form seamless trim  22  on blank  10 . During the first step, edges  12  of blank  10  are folded, binding  28  is applied, and temporary seam  30  is sewn. During the second step, binding  28  is activated and seam  30  is dissipated.  
         [0032]     In an alternate embodiment, seam  30  is formed from a soluble yarn that dissipates upon exposure to a selected solvent, such as water. Thus, seam  30  dissipates during further common solvent containing processes that blank  10  is exposed to instead of during the activation of binding  28 . For example, seam  30  can be dissipated by one or more solvents associated with any conventional dyeing process used to color blank  10 .  
         [0033]     Seam  30  can instead be dissipated by the steam and/or heat associated with any conventional heat setting process used to shape blank  10 . Further, seam  30  can instead be dissipated by water associated with any common washing process used to clean blank  10 .  
         [0034]     Advantageously, method  20  provides for trim  22  to be of a higher quality control than would be expected if the method did not include seam  30 . Namely, seam  30  maintains trim  22  in the selected position until binding  28  has been activated. Thus, blanks  10  can be quickly bulk manufactured with trim  22  in substantially the same location from blank to blank.  
         [0035]     Further, method  20  does not slow the manufacture of blank  10  into a garment. It has been determined that seam  30  can be applied and removed within the time frame of one or more of the further processing steps that are common in the manufacture of blank  10 .  
         [0036]     In this manner, trim  22  can mitigate unraveling of blank  10  at peripheral edge  12  by moving the peripheral edge to the inside of the blank. Further, trim  22  can be used to provide elastic properties to blank  10  and/or provide a decorative or aesthetically pleasing appearance to the blank.  
         [0037]     A second exemplary embodiment of a method  32  according to the present invention for providing peripheral edges  12  with a seamless trim  34  is illustrated with simultaneous reference to  FIGS. 7 through 9 . In this embodiment, trim  34  is a fabric layer glued to first and/or second side  16 ,  18  of blank  10 .  
         [0038]     Trim  34  includes a fabric layer  36  and an adhesive layer  38 . During method  32 , trim  34  is placed in a selected position on blank  10  so that adhesive layer  38  contacts the blank.  
         [0039]     In one embodiment of the present invention, fabric layer  36  and adhesive layer  38  are separate layers. Here, method  32  applies fabric and adhesive layers  36 ,  38  to blank  10  either sequentially or simultaneously. In a preferred embodiment, trim  34  is a unitary member of fabric layer  36  and adhesive layer  38 . For example, trim  34  can be a laminated member  40  formed from fabric layer  36  and adhesive layer  38  as shown in  FIG. 8 . In this embodiment, fabric and adhesive layers  36 ,  38  are simultaneously applied to blank  10  by method  32 . In a preferred embodiment of laminated member  40 , fabric layer  36  is a fabric having nylon and elastane fibers, and adhesive layer  38  is a layer of polyurethane adhesive layer.  
         [0040]     Preferably, method  32  positions trim  34  on blank  10  so that a peripheral edge  42  of fabric layer  36  is co-planar with peripheral edge  12  of the blank. Namely, it is preferred that peripheral edges  12  and  42  form a linear plane through the edges as shown in  FIG. 9 .  
         [0041]     Next, method  32  temporarily secures trim  34  to blank  10  in the selected position using one or more seams  44  (only one of which is shown). Seam  44  aids in maintaining trim  34  in the selected position with respect to first side  16 . For example, seam  44  can maintain peripheral edges  12 ,  42  in a co-planar relationship. Preferably, trim  34  is simultaneously positioned on blank  10  and seam  44  is applied to the trim.  
         [0042]     Fabric layer  36  preferably exhibits elastic properties. In addition, adhesive layer  38  preferably exhibits elastic properties. For example, adhesive layer  38 , before fusing, can exhibit recovery of about 98 percent, and a modulus of about 0.13 pounds. Thus, adhesive layer  38  can both secure fabric layer  36  in the selected position on blank  10  and aid fabric layer  36  in providing elasticity to the blank.  
         [0043]     Seam  44  is formed with a yarn (not shown) that dissipates upon further processing. For example, seam  44  can be a heat labile seam that dissipates upon application of heat.  
         [0044]     In one embodiment, adhesive layer  38  can be a heat-activated adhesive, which is activated upon exposure to a first level of heat. During exposure to the first level of heat, trim  34  is compressed to ensure that fabric layer  36  is firmly secured to blank  10 . Thus, adhesive layer  38  bonds fabric layer  36  in the selected position to blank  10 . For example, activation of adhesive layer  38  can cause the adhesive layer to melt and penetrate into at least a portion of blank  10  and fabric layer  36  as shown in  FIG. 9 . It has been found that penetration of adhesive layer  38  into blank  10  at peripheral edge  12  mitigates instances of the blank unraveling at the peripheral edge.  
         [0045]     In this same embodiment, seam  44  can be formed from a heat labile yarn that dissipates at a second level of heat exposure. Advantageously, the second level of heat exposure is less than the first level of heat exposure. Thus, the activation of adhesive layer  38  and the dissipation of seam  44  can occur at the same time, namely within the first level of heat exposure that is required to activate the adhesive. In this manner, method  32  not only provides seamless trim  34  in a selected position, but can also provide the seamless trim in a minimal amount of time.  
         [0046]     Adhesive layer  38  can be a polyurethane adhesive layer  38  commercially available from Bemis Adhesive Films and Coatings. Further, seam  44  can be formed with a Thermolux yarn that is commercially available from Luxilon Industries of Belgium. In this example, adhesive layer  38  is Bemis part number 3410 (0.001″) that is activated at a first level of heat exposure of about 175° C. degrees Celsius to about 200° C. degrees Celsius for about 20 to about 30 seconds, with a pressure of about 40 to about 60 pounds per square inch. However, seam  44  dissipates at a second level of heat exposure of about 15 seconds at about 140 degrees Celsius. Thus, method  32  provides a simple, two step operation to form seamless trim  34  on blank  10 . During the first step, trim  34  is applied to blank  10  and temporary seam  44  is sewn. During the second step, adhesive layer  38  is activated and seam  44  is dissipated.  
         [0047]     It has also been determined that the heat and pressure of the second step of method  32  can be used to heat set blank  10  to a desired size and/or shape. In this manner, the second step can simultaneously activate adhesive layer  38 , dissipate seam  44 , and heat set blank  10 . For example, blank  10  can be placed on a mold sized to shape blank  10  to the desired shape. The mold can expand blank  10  to the desired shape and to remove any wrinkles from the blank prior to activation of adhesive layer  38 .  
         [0048]     In an alternate embodiment, seam  44  is formed from a soluble yarn that dissipates upon exposure to a selected solvent, such as water. Thus, seam  44  dissipates during further common solvent containing processes that blank  10  is exposed to instead of during the activation of adhesive layer  38 . For example, seam  44  can be dissipated by one or more solvents associated with any conventional dyeing process used to color blank  10 . Alternately, seam  44  can be dissipated by water associated with any common washing process used to clean blank  10 . In still other exemplary embodiments, seam  44  can be dissipated by the steam and/or heat associated with any conventional heat setting process used to shape blank  10 .  
         [0049]     In other embodiments, method  32  can include an edge-trimming step. The edge-trimming step can ensure peripheral edges  12  and  42  form the linear plane shown in  FIG. 9 . For example, the edge-trimming step can alleviate or correct any deviations between the position of peripheral edges  12  and  42  induced by the activation of adhesive layer  38  or other processes. It is also contemplated for edge-trimming step to define a finished outline shape to peripheral edges  12 ,  42 . The finished outline can be a straight edge, a curved edge, a lace edge, or and other decorative edge shapes.  
         [0050]     Advantageously, method  32  provides for trim  34  to be of a higher quality control than would be expected if method  32  did not include seam  44 . Namely, seam  44  maintains trim  34  in the selected position on blank  10  until adhesive layer  38  has been activated. Thus, blanks  10  can be quickly bulk manufactured with trim  34  in substantially the same location from blank to blank. Blanks  10  can also be manufactured using standard sewing machines instead of special equipment such as edge banding fusing machines.  
         [0051]     Further, method  32  does not slow the manufacture of blank  10  into a garment. It has been determined that seam  44  can be applied and removed within the time frame of one or more of the further processing steps that are common in the manufacture of blank  10 .  
         [0052]     In the illustrated embodiment, trim  34  is applied in a selected position to first side  16  of blank  10 , which faces the skin of the wearer. Thus, trim  34  is not visible from the exterior of blank  10 . Of course, it is contemplated by the present invention for first side  16  to face away from the wearer so that trim  34  is applied to the exterior of blank  10 . It is also contemplated by the present invention for trim  34  to be applied to both the first and second sides  16 ,  18 , respectively, of blank  10 .  
         [0053]     Accordingly, method  32  seamlessly secures trim  34  to blank  10 . The penetration of adhesive layer  38  in blank  10  at peripheral edge  12  can mitigate unraveling of the peripheral edge. In the embodiments where fabric layer  36  is elastic, method  32  can also seamlessly provide elastic properties to blank  10 . In the embodiments where trim  34  is exterior to blank  10 , the trim can provide a decorative or aesthetically pleasing appearance to the blank.  
         [0054]     It should be recognized that blank  10  is illustrated by way of example as a tubular blank. Such tubular blanks  10  can be formed using circular knitting machines that are commercially available from, for example, Santoni of Italy. Of course, blank  10  can be formed by other methods such as traditional cut-and-sew methods.  
         [0055]     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.  
         [0056]     While the present invention 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 invention. 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 invention not be limited to the particular embodiment(s) disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.