Abstract:
A pucker free garment seam providing a garment with a tailored and wrinkle free appearance. The pucker free seam and method for production utilizes a bonding strip which contains at least a thermal adhesive component which is inserted between first and second surfaces of a garment component along the seam. A sufficient amount of heat and pressure is applied to the seam which causes the adhesive of the bonding strip to flow onto the surfaces of the garment components thereby creating a compressed seam and permanently bonding the first and second surfaces of the garment component together along the seam to eliminate puckering associated with shrinkage of the sewing thread.

Description:
RELATED INVENTION 
     This application is a continuation-in-part of applicant&#39;s prior application Ser. No. 08/613,656 filed Mar. 11, 1996, entitled &#34;Pucker Free Garment Seam and Method of Manufacture&#34; now U.S. Pat. No. 5,590,615 which is a continuation of applicant&#39;s prior application Ser. No. 08/245,122, filed May 17, 1994, entitled &#34;Pucker Free Garment Seam and Method of Manufacture&#34; now U.S. Pat. No. 5,568,779, all of common assignment herewith. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates to a pucker free garment seam and method for production. More specifically, the invention is directed to an improved garment seam and method for production which facilely eliminates a tendency of the seam to bunch or pucker at a right front hem seam attachment area and other similar areas following conventional laundering procedures. 
     A puckering phenomenon at seam lines has long plagued the garment industry. Seam pucker is typically caused by thread shrinkage which occurs during the laundering of a garment. In particular, after a garment is purchased by a garment consumer it is subjected to laundering cycles as the shirt is worn and becomes soiled. During these laundering and drying cycles the sewing thread typically undergoes longitudinal shrinkage. It is this shrinkage, at a rate greater than the surrounding shirt material, that creates puckering at a seam joining two panels of fabric. In this, the sewing thread contracts upon being laundered and pulls on opposing garment components at the garment seam which in turn causes the garment components to buckle and thereby create wrinkles along the garment seam. This effect is noticeable in the right front hem seam of dress shirts. Accordingly, it would be highly desirable to provide a method for production and a garment which would be free of this pucker phenomenon and which would maintain a seam which would be smooth and pucker free even after multiple laundering operations. 
     Several attempts have been made to reduce seam pucker in a dress shirt. One such attempt utilizes an interlining having a thermoplastic component in the interlining matrix. During the manufacture process the seam is ironed which reduces the cross-sectional thickness of the seam along the stitch line. The reduced thickness allows for slack in the sewing thread such that during subsequent laundering the sewing thread is permitted to shrink an amount equal to the slack. This technique is not entirely effective in reducing seam pucker. First, the garment components sewn together at the seam are allowed to pull apart between outer stitches of the seam which results in buckling of the garment fabric. Second, the thread which is compressed in the interlining matrix becomes bound within the matrix thus shrinkage of the thread still results in at least a degree of seam pucker. Third, producing an interlining results in an overall increase in garment manufacturing cost. This cost is compounded if the interlining is a composite interlining. 
     Another prior attempt at reducing seam pucker utilizes special garment material. Specifically, the garment components sewn together at the seam are manufactured from material which stretches during the is sewing process and which relaxes after the sewing process is complete. This relaxation provides for slack in the sewing thread. This attempt is also ineffective at reducing seam pucker. First, as before, the garment components sewn together at the seam are allowed to pull apart between outer stitches of the seam which results in buckling of the garment fabric. Second, only garments manufactured from certain stretch materials may be utilized to manufacture the garments. The disadvantages associated with this are clear. 
     Still other prior art attempts alter the nature of the sewing thread used in the sewing process. For example, one such attempt utilizes a composite sewing thread whereby one component of the thread is water soluble. During the laundering process the water soluble component dissolves thereby creating slack in the sewing thread which compensates for thread shrinkage. First, as before, the garment components sewn together at the seam are allowed to pull apart between outer stitches of the seam which results in buckling of the garment fabric. Second, the high cost of producing a sewing thread altered in this way increases the overall garment cost. Third, thread strength can be compromised by a composite design. Last, commercial sewing machines are not well adapted to utilize altered thread. Other prior art attempts which alter the nature of the sewing thread are not believed to be fully effective for the same noted reasons. 
     The difficulties and limitations suggested in the preceding are not intended to be exhaustive, but rather are among many which demonstrate that although significant attention has been devoted to reducing pucker in garment seams, puckerless garment seams and method for production appearing in the past will admit to worthwhile improvement. 
     OBJECTS AND BRIEF SUMMARY OF THE INVENTION 
     It is therefore a general object of the invention to provide a novel, smooth garment seam and method for production which will obviate or minimize difficulties of the type previously described. 
     It is a specific object of the invention to provide a smooth garment seam and method for production which will eliminate seam pucker at a right front hem of a shirt. 
     It is another object of the invention to provide a smooth garment seam and method for production which may be used in a variety of garments to provide a pucker free tailored appearance. 
     It is still another object of the invention to provide a smooth garment seam and method for production for advantageous use in a right front hem seam of a dress shirt. 
     It is yet another object of the invention to provide a smooth right front hem garment seam and method for production which provides for a cost effective solution to seam pucker and does not involve significant modification of existing production apparatus. 
     SUMMARY OF A PREFERRED EMBODIMENT OF THE INVENTION 
     A preferred embodiment of the invention which is intended to accomplish the foregoing objects includes a bonding strip which contains at least a thermal adhesive component which is inserted between layers of a garment component along a seam line of a garment. The seam is subjected to a sufficient amount of heat and pressure to cause the adhesive of the bonding strip to flow over the surfaces of the garment component thereby creating a compressed seam and permanently bonding the garment component along the seam to eliminate puckering associated with sewing thread shrinkage. 
    
    
     DRAWINGS 
     Other objects and advantages of the present invention will become apparent from the following detailed description of a preferred embodiment thereof taken in conjunction with the accompanying drawings, wherein: 
     FIG. 1 is a front view showing a shirt having at least a right front hem seam produced in accordance with the present invention; 
     FIG. 2 is a segmental detail view showing a portion of the front hem seam of the dress shirt depicted in FIG. 1 in which the front hem seam has been produced in accordance with the present invention; and 
     FIGS. 3a and 3b show a cross-sectional view of a method for producing a dress shirt right front hem seam in accordance with the present invention. 
    
    
     DETAILED DESCRIPTION 
     Referring now to the drawings and particularly to FIG. 1, there is shown a dress shirt 10. The shirt 10 includes a front shirt panel 12, a collar 14, sleeves 16 and a center placket 18 which covers a right front hem seam 20 produced in accordance with the present invention. FIG. 2 depicts a segment of the dress shirt right front hem seam 20, a right front panel 22, and left front panel 24 of the shirt. The phenomenon of seam pucker is troubling in a right front hem seam 20 because of its location which impacts the highly visible center placket 18. Moreover the front hem 20 can be visible at the neck of the shirt if a wearer removes his tie and opens the top shirt button. 
     FIGS. 3a and 3b show the production steps for producing the hem seam 20 of the present invention. FIG. 3b shows a cross-sectional view of a completed right front hem seam 20 produced in accordance with the present invention. 
     Referring to FIG. 3a there is shown a garment component 22. In the right front hem embodiment of the present invention, the garment component 22 comprises a right front panel of the shirt. The garment component 22 has a first surface 26 and a second surface 28. 
     A bonding strip 30 forms an integral part of the present invention. The bonding strip 30 has a first surface 32 and a second surface 34. In the preferred embodiment of the invention, and as shown in the Figures, the bonding strip 30 is an adhesive web consisting entirely of an adhesive material. The adhesive material is preferably composed of a polyamide, polyester, or an olefinic material such as a low density polyethylene. Other thermoplastic materials such as polyurethane and ethylene vinylacetate copolymer can also be used. The aforementioned adhesives are preferable because they all have a low melting point in the range of 60-160 degree celsius. In the preferred embodiment, the adhesive web is produced from a plurality of filaments having a diameter ranging between 20-80 microns. Furthermore, the adhesive web of the present invention has a density of approximately 10-100 grams per square meter. Alternatively, a more solid structured net adhesive may be used having a density preferably in a range of 8-80 grams per square meter. Of course, other types of adhesives are contemplated in the present invention. 
     The garment component 22 is reverse folded at its edge 36 and the first surface 26 extends along the second surface of the bonding strip 30. The garment component 22 is reversed folded a second time at 38 such that the second surface 28 of the twice folded garment component 22 abuts the first surface 32 of the bonding strip 30. 
     A stitch 40 is sewn along the seam line defined by the garment component 22, the bonding strip 30, the twice reverse folded layer of the garment component 22 which abuts the second surface 34 of the bonding strip 30, and the reverse folded layer of the garment component 22. As shown in FIG. 3a, this stitch 40 traverses the garment component 22, the bonding strip 30, and the twice reverse folded layer of the garment component 22. In the embodiments of FIGS. 3a through 3b this stitch is a single needle stitch. In certain instances a double stitch can be used to enhance the strength of the seam. 
     Production of the improved seam 20 of the present invention is completed with the application of heat and pressure to the seam. This can be accomplished with an ironing process. For improved control and quality this process is usually carried out on a heated press, as schematically depicted by arrows 42, with a temperature of up to 160 degrees celsius for 5 to 10 seconds followed with a vacuum step to cool and set the adhesive. The applied heat and pressure 42 cause the adhesive of the bonding strip 30 to melt and flow onto the surfaces 26 and 28 of the garment component 22. That is, the adhesive flows onto a portion 44 of the twice reverse folded first or upper surface 26 of the garment component 22 along a second or lower surface 34 of the bonding strip 30 and concomitantly onto a second or lower 28 portion of the unfolded garment component 22. Significantly, during the ironing/pressing process 42, the flowing adhesive becomes interposed in the interstices of the garment fabric of the component 22. This is advantageous because it creates a strong bond between the surfaces 26 and 28 of the garment component 22 along the seam 20. It is this bond that prevents seam pucker during subsequent laundering operations. In particular, because the garment component 22 is bonded along the seam, it cannot pull apart during laundering and, therefore, buckling of the seam fabric will be prevented. This is a significant advantage over the prior art seams which permit the fabric layers to become separated during subsequent laundering operations which, in turn, results in seam pucker. The ironing/pressing 42 process also compresses the seam 20 to reduce the seam thickness. 
     The unfolded portion 46 of the garment component 22 is where the buttons of the dress shirt 10 are attached. If this seam 20 puckers, the buttons, in turn, will be pulled closer together or exhibit an irregular spacing. As this happens, parts of the center placket 18, the most visible portion of a dress shirt 10, may begin to bulge outward. As such, for maximum prevention of pucker it is important to have the adhesive of the bonding strip 30 flow over the entire surface of the seam width. This will ensure complete bonding of the garment layer 22 which abuts the top surface 32 of the bonding strip 30 and the twice reverse folded surface 26 of the garment component 22 which abuts the lower surface 34 of the bonding strip 30. 
     Although in the preferred embodiment the bonding strip 30 consist of an adhesive web as described above, other elements are contemplated. In an alternative embodiment the bonding strip 30 consist of an interlining having an adhesive coating on its outer surfaces. Interlinings are known in the art to provide stiffness to garment components. For example, interlinings are used in shirt collars and center plackets to provide a degree of stiffness. However, the interlining of the present invention utilizes an adhesive on its outer surfaces and is specifically used for garment seams. More specifically, the interlining body of the present invention is preferably a woven interlining made from cotton or a polyester/cotton blend. Alternatively, a nonwoven interlining body made from polyester, nylon, viscose or blends of these materials may be used. Preferably, the interlining body is fabricated from a single material so as to avoid the high cost associated with producing composite interlinings. The interlinings have a coating of an adhesive on an upper and lower surface. The adhesive is preferably one of the same thermal adhesives previously mentioned in the adhesive web embodiment discussed above. The adhesive may be applied on the upper and lower surfaces of the interlining as an adhesive layer or as a series of adhesive dots. Significantly, a quantity of adhesive sufficient to flow over the garment surfaces as described above is needed in order to provide complete bonding as contemplated by the present invention. 
     The pucker free right front hem garment seam 20 depicted in the figures is an exemplary seam and is not intended to limit the scope of the invention. 
     Although the specific embodiment as shown in the Figures is directed to a right front hem seam 20 of a dress shirt 10, it is to be understood that the seam 20 and method for production of the present invention can advantageously be utilized in a variety of garments, for example, in various seams of dress slacks. 
     SUMMARY OF MAJOR ADVANTAGES OF THE INVENTION 
     After reading and understanding the foregoing detailed description of an inventive right front hem garment seam and method for production in accordance with preferred embodiments of the invention, it will be appreciated that several distinct advantages of the subject garment seam and method for production are obtained. 
     Without attempting to set forth all of the desirable features of the instant garment seam and method for production, at least some of the major advantages include providing a pucker free garment seam consisting of a garment component, such as a component of a dress shirt right front panel and a bonding strip. 
     The use of the bonding strip provides a pucker free garment seam which has not been successfully accomplished by prior art attempts. Preferably, the bonding strip comprises an adhesive web which flows during ironing onto the abutting surfaces of the garment component to create a strong bond along the garment seam. This bond prevents the garment component from separating during subsequent laundering of the garment. Alternatively, bonding strip consist of an interlining body having a thermal adhesive coating on its outer surface. The interlining body can be fabricated from a single material thus avoiding the use of costly composite interlining body. 
     The right front hem garment seam and method for production of the present invention provides for a less costly alternative to other prior art attempts at eliminating seam pucker and without the need for substantial modification of current seam production operations. 
     In describing the invention, reference has been made to a preferred embodiment and illustrative advantages of the invention. Those skilled in the art, however, and familiar with the instant disclosure of the subject invention, may recognize additions, deletions, modifications, substitutions and other changes which fall within the purview of the subject invention.