Abstract:
Garments having one or more laser-cured polymeric regions, methods of making, and laser-cured polymers are provided. The polymeric regions can have cure levels that different from one another. Further, the polymeric regions can have a variable cure level within the individual region.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application claims the benefit of U.S. Provisional Application Ser. No. 60/466,480, filed on Apr. 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 is related to garments and methods of manufacturing garments. More particularly, the present invention is related to garments having laser curable polymers and methods of making such garments.  
         [0004]     2. Description of Related Art  
         [0005]     Polymers, such as polypropylene elastomers and liquid silicone rubbers (LSR&#39;s), have found a wide-variety of uses in the garment industry. For example, polymers have been used in the manufacture of hosiery, such as socks and stockings, to aid in maintaining the hosiery in a desired position. In this use, the polymer can increase friction between the garment and the skin of the wearer.  
         [0006]     A liquid form of the polymer can be applied to the garment in a desired location and a desired amount, and then converted to an elastomeric (e.g., rubbery) state by vulcanization or curing. For example, LSR can be vulcanized at high temperatures, in the presence of organic-peroxide curing agents.  
         [0007]     It has been common to use convection heat to cure the polymer on the garment. However, convection heating can cause undesired effects. Convection heating can add time and expense to the manufacturing process. For example, the use of convection heat to cure LSR&#39;s can-take over thirty (30) seconds at a temperature of over 150 degrees Celsius. In addition, convection heating requires that the entire garment be exposed to the heat condition, which can cause deleterious effects in the garment. Further, all areas or regions of the garment are cured to the same degree in such convection curing processes.  
         [0008]     There is a continuing desire for lower cost, higher quality garments. Accordingly, there is a continuing desire for garments and methods of forming such garments that avoid one or more of the aforementioned drawbacks of the prior art.  
       BRIEF SUMMARY OF THE INVENTION  
       [0009]     It is an object of the present invention to provide a garment having one or more laser-cured polymeric regions.  
         [0010]     It is another object of the present invention to provide a garment having one or more laser-cured polymeric regions, where such regions can have elasticity levels and/or cure levels different from one another.  
         [0011]     It is yet another object of the present invention to provide a method of forming garments with laser cured polymers.  
         [0012]     It is still another object of the present invention to provide a laser curable polymer mixture.  
         [0013]     These and other objects and advantages of the present invention are provided by a garment having a fabric portion and a first polymeric region cured on the fabric portion. The first polymeric region has a dimension and a first cure level that differs along the dimension.  
         [0014]     The present invention also provides a garment having a fabric portion, a first polymeric region, and a second polymeric region. The first and second polymeric regions are cured on the fabric. The first polymeric region has a first cure level, while the second polymeric region has a second cure level. The second cure level differs from the first cure level.  
         [0015]     The present invention also provides a method of manufacturing a garment. The method includes applying a polymer to a selected area of the garment and emitting laser energy at the polymer to cure the polymer on the selected area to a selected cure level.  
         [0016]     A laser curable polymeric mixture is also provided by the present invention. The mixture includes a polymer selected from the group consisting of polypropylene elastomer, liquid silicone rubber, and any combinations thereof and an infrared absorbing agent selected from the group consisting of carbon black, an infrared absorbing ink, an infrared absorbing dye, and any combinations thereof.  
         [0017]     Further, the present invention provides a brassiere having a shoulder-engaging region, a body-encircling region, and an underwire region. The shoulder-engaging region has a first polymeric area cured thereon. The first polymeric area has a first polymer quantity and a first cure level for imparting a selected cushioning to the shoulder-engaging region. The second polymeric area has a second polymer quantity and a second cure level for imparting a selected elasticity to the body-encircling region. The third polymeric area has a third polymer quantity and a third cure level for imparting a selected rigidity to the underwire region.  
         [0018]     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  
       [0019]      FIG. 1  is a plan view of a garment of the present invention;  
         [0020]      FIG. 2  is a sectional view of the garment of  FIG. 1  taken along lines  2 - 2 ;  
         [0021]      FIG. 3  is an alternate embodiment of the garment of  FIG. 2 ; and  
         [0022]      FIG. 4  is a block diagram of an exemplary embodiment of a garment manufacturing method according to the present invention. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0023]     Referring to the drawings and in particular to  FIG. 1 , there is provided a substrate generally referred to by reference numeral  10 . For purposes of clarity, substrate  10  is illustrated herein as a garment, particularly a brassiere.  
         [0024]     It is contemplated by the present invention for substrate  10  to be a non-garment substrate. In addition, substrate  10  can be a garment other than a brassiere, such as, but not limited to, a pair of pants, a pair of shorts, a skirt, a shirt, a blouses, a sock, a pair of stockings, a pair of underwear, a panty, a bathing suit, a leotard, a medical brace, and other wearing apparel.  
         [0025]     Brassiere  10  has a polymer  12 . Polymer  12  can be cured on brassiere  10  in a first area  14 , a second area  16 , a third area  18 , or any combinations thereof.  
         [0026]     It has been determined that the physical properties of polymer  12  can be varied to provide brassiere  10  with one or more desired characteristics in each of the first, second, and third areas  14 ,  16 ,  18 , respectively.  
         [0027]     The physical properties of polymer  12  can be varied by varying the cure level of the polymer and/or by varying the quantity of the polymer that is applied to each area  14 ,  16 ,  18 .  
         [0028]     The cure level of polymer  12  can effect the durometer of the cured polymer. As used herein, the durometer of polymer  12  is determinant of the hardness of the polymer. For example, low durometer polymer  12  exhibits softness and elasticity, while high durometer polymer  12  exhibits hardness and rigidity. Thus, polymer  12  can be cured to a first level (e.g., standard cure) to provide softness and elasticity to brassiere  10  in one or more of the first, second, and third areas  14 ,  16 ,  18 . Alternately, polymer  12  can be cured to a second, higher cure level (e.g., over cure) to provide hardness and rigidity to brassiere  10  in one or more portions of first, second, and third areas  14 ,  16 ,  18 .  
         [0029]     In addition, the quantity of polymer  12  that is applied to each area  14 ,  16 ,  18  can effect the resultant physical property the polymer imparts to that area. Namely, as the quantity of polymer  12  applied in areas  14 ,  16 ,  18  is increased, the level of elasticity and/or rigidity imparted to that area can also be increased.  
         [0030]     Accordingly, the physical properties of polymer  12  can be varied to provide brassiere  10  with one or more desired characteristics in each of the first, second, and third areas  14 ,  16 ,  18 , respectively.  
         [0031]     It has been found that polymer  12  can be provided with the selected cure level using energy emitted from a laser (e.g., light amplification by stimulated emission of radiation). The laser can emit a light beam of a desired wavelength into polymer  12  to heat and, thus, cure the polymer.  
         [0032]     Preferably, the emitted light is non-visible and has a wavelength between about 0.81 microns and about 10.6 microns. For example, a laser, such as, but not limited to, a carbon dioxide laser, a diode laser, or a neodynium-yttrium-aluminum-garnet (Nd:YAG) laser, can emit non-visible light in the aforementioned ranges.  
         [0033]     The cure level of polymer  12  can be customized by adjusting the wavelength of the laser, the intensity of the laser, time the polymer is exposed to the laser, or any combination of the foregoing.  
         [0034]     In the exemplary embodiment of brassiere  10  illustrated in  FIG. 1 , first area  14  is cured on the brassiere at a shoulder-engaging region  20  of the brassiere. Polymer  12  in first area  14  is preferably applied in a first quantity and cured to the first cure level. Polymer  12  in this first amount and first cure level provides first area  14  with a desired cushioning effect between shoulder-engaging region  20  and the shoulder (not shown) of a wearer. In addition, polymer  12  provides first area  14  with a select level of friction or grippability between shoulder-engaging region  20  and the shoulder.  
         [0035]     For example, it has been determined that applying polymer  12  in a first quantity of less than about 0.05 grams per square centimeter is sufficient to provide first area  14  with the aforementioned cushioning and anti-slip physical properties.  
         [0036]     Second area  16  is cured on brassiere  10  at a body-encircling region  22  of the brassiere. In second area  16 , polymer  12  can be applied in a second quantity and cured to the first cure level. Polymer  12  in this second amount and first cure level provides second area  16  with sufficient elasticity to retain body-encircling region  22  of brassiere  10  against a wearer. Thus, second area  16  can be used in place of, or in addition to, traditional elastic bands.  
         [0037]     For example, it has been determined that applying polymer  12  in a second quantity of about 0.05 grams per square centimeter is sufficient to provide a level of elasticity suitable for second area  16 . Accordingly, the second quantity of polymer  12  provides a level of elasticity to retain body-encircling region  22  against the wearer in this example.  
         [0038]     Third area  18  is cured on brassiere  10  at an underwire region  24  of the brassiere, which preferably defines a periphery of a breast cup  26 . In third area  18 , polymer  12  can be applied in a third amount and can be cured to a second cure level. Polymer  12  in this third amount and second cure level provides third area  18  with sufficient rigidity to support breast cup  26 . In this manner, third region  18  can replace the traditional metal underwire of prior art brassieres, which required metal under wires costly and time consuming sewing processes to secure the under wires to the brassiere.  
         [0039]     For example, it has been determined that applying polymer  12  in a third quantity of about 0.1 grams per square centimeter and the second cure level is sufficient to provide sufficient level of rigidity suitable for third area  18 .  
         [0040]     The use of a laser to cure polymer  12  allows the cure level of polymer  12  within each area  14 ,  16 ,  18  to be varied. For example, third area  18  can have a curved shape defining a length  28  with a tip region  30  formed at each end. Advantageously, the cure level of third area  18  can be varied along length  28  to enhance the comfort of brassiere  10 . For example, tip region  30  can have a lower durometer (i.e., softer) as compared to other portions of third area  18  along length  28  (i.e., harder). Thus, the cure level of third area  18  can be varied along length  28  to enhance the comfort of the third area.  
         [0041]     Referring to  FIG. 2 , a sectional view of brassiere  10  is illustrated. Brassiere  10  has a first or body facing surface  32  and a second or outward facing surface  34 . In the illustrated embodiment, third area  18  has a width  36  formed on first surface  32 . Width  36  defines an upper portion  38  and a lower portion  40  of third area  18 . Upper portion  38  is proximate breast cup  26 , while lower portion  40  is remote from the breast cup. In this position, upper portion  38  contacts the wearer&#39;s breast (not shown).  
         [0042]     Again, the quantity and cure level of polymer  12  within third area  18  can be varied to enhance the comfort of brassiere  10 . For example, upper portion  38  can be cured to the first level (i.e., softer and more elastic) as compared to lower portion  40  (i.e., harder and more rigid). Thus, the cure level of third area  18  can be varied along width  36  to enhance the comfort of the third area.  
         [0043]     Referring now to  FIG. 3 , an alternate embodiment of the sectional view of  FIG. 2  is illustrated. In this embodiment, third area  18  has a thickness  42  formed on second surface  34 . Thickness  40  defines an inner portion  44  and an outer portion  46  of third area  18 . Inner portion  44  is proximate breast cup  26 , while outer portion  46  is remote from the breast cup. In this position, inner portion  44  interfaces with the wearer&#39;s breast (not shown) through the fabric of brassiere  10 .  
         [0044]     In this embodiment, inner portion  44  can be selectively cured to the first cure level (i.e., softer) as compared to outer portion  46  (i.e., harder) to enhance the comfort of the wearer. Thus, the cure level of third area  18  can be varied along thickness  42  to enhance the comfort of the rigid third area.  
         [0045]     Accordingly, third area  18  can have a number or plurality of varying cure levels disposed along its length  28 , width  36 , and/or thickness  42  to provide brassiere  10  with enhanced comfort and support capabilities.  
         [0046]     It should be recognized that second and third areas  16 ,  18  are illustrated in  FIGS. 2 and 3  by way of example as either both on first surface  32  or both on second surface  34 . However, it is contemplated by the present invention for any of the first, second, and/or third areas  14 ,  16 ,  18  to be formed on any combination of the first and second surfaces  32 ,  34 .  
         [0047]     It should also be recognized that third area  18  is described herein by way of example as being cured to the second (e.g., over cured) level. Of course, it is contemplated by the present invention for polymer  12  in third area to be cured to the first level (e.g., standard cure) to provide underwire region  24  with a selected level of elasticity.  
         [0048]     Polymer  12  can be the same polymer in first, second, and third areas  14 ,  16 ,  18 . Alternately, different polymers  12  can used in first, second, and third areas  14 ,  16 ,  18 . Polymer  12  can be, for example, a liquid silicone rubber. For example, polymer  12  can be LR 3003/30A and/or LR 3003/30B that are commercially available from Wacker Silicone Corporation.  
         [0049]     Referring now to  FIG. 4 , an exemplary embodiment of a garment manufacturing method  50  is illustrated. Method  50  includes a substrate forming process  52 , a polymer application process  54 , and a curing process  56 .  
         [0050]     Substrate forming process  52  can form any desired substrate. In the example described herein where the substrate is illustrated as a garment, forming process  52  can be any garment manufacturing process, such as, but not limited to, a traditional cut-and-sew process, a circular knitting process, a lamination process, any other garment forming process, or any combinations of the foregoing.  
         [0051]     After the desired substrate is formed in process  52 , polymer  12  is applied to the substrate in application process  54 . Application process  54  can be any process suitable to apply polymer  12  in the desired locations, amounts, and shapes. For example, application process  54  can include spraying, screen-printing, wipe-on or brush-on processes, other application process, or any combination of the foregoing.  
         [0052]     After or substantially simultaneous to the application of polymer  12  by application process  54 , the polymer is cured by curing process  56 . Curing process  56  exposes polymer  12  to laser energy to cure the polymer to the desired level. The curing process  56  can include moving the laser energy source with respect to polymer  12 , moving the polymer with respect to the laser energy source, and/or combinations of the foregoing.  
         [0053]     Curing process  56  exposes polymer  12  to laser energy of desired power and wavelength for a desired time. For example, curing process  56  can expose polymer  12  to energy emitted by a carbon dioxide laser having a wavelength of about 10.6 microns and a power level of up to about 1000 watts. In this example, polymer  12  in the first, second, and third areas  14 ,  16 ,  18  can be cured at a speed of about 25 meters per minute.  
         [0054]     Alternate exemplary embodiments of method  50  are illustrated in phantom in  FIG. 4 . It has been found that the absorption of laser energy by polymer  12  can be increased by including an infrared absorbing agent  58  in laser curing process  50 . By increasing the absorption of laser energy by polymer  12 , the power of the laser can be reduced, the exposure time can be reduced, the wavelength can be modified, the cure level can be modified, or any combination of the foregoing.  
         [0055]     Infrared absorbing agent  58  can include any agent capable of absorbing infrared energy at least at the emitted wavelength. Thus, absorbing agent  58  can be, for example, a universal infrared absorber, such as, carbon black. Alternately, infrared absorbing agent  58  can absorb infrared energy only at the emitted wavelength. For example, infrared absorbing agent  58  can be an absorbing ink or dye. Preferably, infrared absorbing agent  58  is an absorbing ink or dye commercially available from Gentex Corporation and described in published U.S. patent application Ser. Nos. 2002/0124952 A1, 2002/0148386 A1, or 2003/0010251, the contents of which are incorporated herein by reference in their entirety.  
         [0056]     In a first embodiment, infrared absorbing agent  58  can be applied in an absorbing agent application process  60 . Agent application process  60  applies infrared absorbing agent  58  prior to curing process  56 .  
         [0057]     For example, infrared absorbing agent  58  can be applied to polymer  12  subsequent to and/or simultaneous to polymer application process  54 . Agent application process  60  can print or spray infrared absorbing agent  58  onto polymer  12  that is resident on brassiere  10 .  
         [0058]     In a second, preferred embodiment, method  50  includes a mixing step  62 . Mixing step  62  dissolves or disperses (hereinafter “mixes”) infrared absorbing agent  58  in polymer  12  to form a mixture  64 . Next, mixture  64  is applied to brassiere  10  by application process  54 .  
         [0059]     Mixture  64  includes an amount of infrared absorbing agent  58  sufficient to provide the desired energy absorption. In a preferred embodiment, mixture  64  has a selected amount of LR 3003/30A, a selected amount of LR 3003/30B, and a selected amount of absorbing ink, which is commercially available from Gentex Corporation.  
         [0060]     First, second, and third areas  14 ,  16 ,  18  are described above by way of example as being located in shoulder-engaging region  20 , body-encircling region  22 , and underwire region  24 , respectively. Of course, it is contemplated by the present invention for brassiere  10  to have polymer  12  at regions other than and/or in addition to regions  20 ,  22 ,  24 .  
         [0061]     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.  
         [0062]     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.