Abstract:
A new and improved garment includes support bands fabricated from an elastomeric adhesive and flocking with one end of the flocking fibers embedded within the elastomeric adhesive. In addition, a process for producing garments with flocking fibers manufactured using electrostatic or mechanical devices.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The invention relates to garments having support bands containing an elastomeric adhesive and flocking and a method for producing those garments. 
         [0003]    2. Description of the Prior Art 
         [0004]    In most previously known undergarments, seam connections are required in order to connect the different layers or parts of the undergarment with one another. However such seams have the disadvantage that the seam material has an elastic behavior which differs from the textile material itself such that the wearing properties are impaired. Further, the seams and/or elastic bands sewn to the undergarments typically present a significantly thicker area that can result in discomfort to the wearer and visible lines on the outside of form-fitting clothes. Fabricating the elastic band and sewing it onto the garment can also be costly and time consuming. 
         [0005]    While some undergarments may be formed without elastic bands sewn on, they often suffer the disadvantage that the support and bearing force is strongly impaired since the elasticity is provided by the fabric alone and not by other additional means. 
         [0006]    Additionally, although undergarments have been produced with, e.g., silicone rubber coated sections to provide support and adhere to the skin, the rubber tends to be uncomfortable where it contacts the skin. There exists a need for waistbands and other elastic portions of apparel that do not have separately connected seams, and that are more comfortable to the wearer than garments having rubber to skin contact. 
       SUMMARY OF THE INVENTION 
       [0007]    The invention is therefore generally based on providing garments with elastomeric support that is not sewn to the garment and that is comfortable against the wearer&#39;s skin. 
         [0008]    In one embodiment of the present invention, a garment includes a stretchable fabric, an elastomeric adhesive coating a portion of the inside of the fabric that would face the skin of a person wearing the garment, and fiber flocking with one end of each fiber embedded within the elastomeric adhesive. 
         [0009]    Another embodiment of the present invention is a method of fabricating a garment including cutting one or more panels of a stretchable fabric to form the garment, coating a portion of the inside of the fabric that would face the skin of a person wearing the garment with an elastomeric adhesive, and embedding one end of each fiber of fiber flocking within the elastomeric adhesive. The fiber flocking may be attracted to the adhesive by electrostatic charges. 
         [0010]    The invention will be explained in further detail in conjunction with drawings representing various embodiments. In the drawings and in the following descriptions, further characteristics and advantages associated with the invention are evident. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]      FIG. 1  shows a garment according to the present invention. 
           [0012]      FIG. 2  shows a silkscreen configuration for applying adhesive coating according to one aspect of the present invention. 
           [0013]      FIG. 3  shows a top view of the silk screen shown in  FIG. 3 . 
           [0014]      FIG. 4  shows a cross section taken through the waistband section of the garment shown in  FIG. 1 . 
           [0015]      FIG. 5  shows the application of charge and attraction of flocking to the adhesive coating according to one embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0016]      FIG. 1  shows a pair of panties  100  with a waistband  101  formed of an elastomeric adhesive on the side of the panties that faces the wearer&#39;s skin. The fabric of the panties  100  is preferably a stretchable material. The waistband  101  may be made of elastomeric adhesive, which may be silicone rubber or any other elastomeric adhesive suitable for coating the fabric, may be formed at the top of the panties and may replace both a traditional waistband and hem. The waistband  101  of elastomeric adhesive may extend to the edge of the fabric to prevent the unraveling of the fabric. 
         [0017]    The application of an elastomeric adhesive coating on a specific area of a garment, such as the waistband of the pair of panties  100 , may provide localized elastic properties which provide additional modulus to the garment as and where required. The wider the waistband or other support band of elastomeric adhesive coating of a given thickness, the greater the supporting force will be. Additional components of the panties  100 , if desired, may be joined by the elastomeric adhesive, however the components may also be joined by thermal methods, seams, or any other method of joining pieces of fabric. 
         [0018]    The elastomeric adhesive may be applied to the garment before the garment is finally cut to size. In a preferred embodiment, the cut may be made within the coated section to ensure even and complete coating of the garment. Alternatively, the elastomeric adhesive may be applied to the garment after it has been cut to size. 
         [0019]    The application of the elastomeric adhesive to the garment may take place with a silkscreen configuration according to  FIG. 2 . A garment  200  may be placed beneath a silkscreen  201  on an area where an elastomeric adhesive coating is desired.  FIG. 3  shows the top view of the silkscreen  201  with apertures  204 . The elastomeric adhesive substance  202  may be passed through corresponding screen apertures  204  using squeegees  203 , which may be moved in the direction of arrow  205 . The elastomeric adhesive substance  202  that is in fluid contact with apertures  204  may be transferred to the garment  200  by capillary action in controlled and prescribed quantities to form an elastomeric adhesive coating  206  on the garment  200 . Of course, apertures  204  may be provided in a wide variety of patterns and squeegees  203  may be operated in a number of orientations and directions. 
         [0020]    Alternatively, the elastomeric adhesive may be sprayed onto the garment with or without the silkscreen  201 . The thickness of the coating may vary, and depends on the type and configuration of the garment (e.g., the type of fabric used and the size of the garment), as well as customer requirements. The width of the bands may also vary, depending on the type and configuration of the garment, as well as customer requirements. 
         [0021]      FIG. 4  shows a cross section of the waistband  101  with flocking  102  added for the comfort of the wearer. After the elastomeric adhesive coating is applied, the flocking  102  may be given an electrostatic charge and may then be attracted to the coated area by an opposite electrostatic charge induced in the coated garment. Alternatively, mechanical flocking may also be used to attach flocking to the adhesive coating. In one aspect, the flock fibers penetrate and embed themselves in the elastomeric adhesive coating and assume a position substantially perpendicular to the plane of the elastomeric adhesive coating, with one fiber end embedded in the coating and the other end of the fiber extending above the elastomeric coating. The elastomeric adhesive coating may then be cured, forming bonds with the flocking and the garments. The flocking may be the same color as the fabric or a contrasting color. 
         [0022]    The fibers for the flocking  102  may be formed from any natural or synthetic material. Synthetic materials may include nylons, polyamides, polyesters such as terephthalate polymers and acrylic, and natural materials may include cotton, silk, rayon, and wool. A conductive coating or finish may be applied continuously or discontinuously over the exterior surface of the flocking fibers to permit the flocking fibers to hold an electrical charge. 
         [0023]    The length of fiber used for flocking can be varied as appropriate. For example, a short or long length may be preferred. Additionally, the fibers may be linear or shaped. For example, the fibers may be curled, crimped, or bent. The fibers may be substantially perpendicular to the elastomeric adhesive coating, but, alternatively may be randomly oriented, angled between perpendicular and parallel orientations, or substantially parallel depending on a variety of design factors. The fibers used for flocking may be made by chopping or cutting a length of filament to a desired length. During the chopping or cutting, the fiber ends produced may be jagged or have multiple projections extending therefrom. 
         [0024]    The flocking fibers may be attached to a sacrificial carrier layer or release sheet, with a release adhesive or binder applied to the carrier layer. The flocking fibers may then be transferred to the elastomeric adhesive by electrostatic or mechanical flocking. 
         [0025]    In electrostatic flocking, the portion of the garment coated with the elastomeric adhesive may be passed through a fiber metering station in which an electrostatic field is maintained around the elastomeric adhesive, using, e.g., electrodes situated above and below the coated portion of the garment. The fibers may be applied to the elastomeric adhesive in the presence of the electrostatic field, which may orient the flocking fibers at a desired angle as they contact the elastomeric adhesive. The elastomeric adhesive may then be cured, anchoring the flocking. 
         [0026]    Mechanical flocking may also be used to attach flocking to the elastomeric adhesive. In this aspect, the elastomeric adhesive may be coated with flocking by the beater-bar method. In a preferred aspect, the adhesive-coated portion of the garment may be passed over a series of polygonal rollers that rapidly vibrate that portion of the garment. This vibration may drive the fiber into the adhesive. The flocking fibers may then be delivered by a flock module for flat surfaces or by an airstream pump. Any excess and unattached fibers may be removed by vacuum. 
         [0027]    One aspect of the invention involves the application of charge to the flock fibers and attraction of the fibers to the elastomeric coating on the garment as is represented by the drawing provided in  FIG. 5 . A top inducer plate  207  may induce an electrostatic charge to the flock fibers  208  contained in a flock fiber storage compartment  209 . A bottom inducer plate  210  may induce an opposite electrostatic charge to the coated garment  200 , resulting in an electrostatic field between the coated garment  200  and the flock fibers  208 . According to this aspect the flock fibers  208  are attracted to and move towards the garment  200  and penetrate and embed themselves in the elastomeric adhesive coating  206 . In a preferred aspect, the fibers are oriented such that one fiber end is embedded in the elastomeric adhesive coating  206  and the other end of the fiber extends above the elastomeric adhesive coating  206  of the garment  200 . 
         [0028]    If heat curing is used with the elastomeric adhesive, the flocking may be protected by controlling the curing temperature and limiting the time the flocked garment is held in a dryer. 
         [0029]    The principles, preferred embodiments, and modes of operation of the present invention have been described in the foregoing specification. The invention should not, however, be construed as limited to the particular forms disclosed, as these are to be regarded as illustrative rather than restrictive. Variations and changes may be made by those skilled in the art without departing from the spirit of the present invention. Accordingly, the foregoing best mode of carrying out the invention should be considered exemplary in nature and not as limiting to the scope and spirit of the invention as set forth in the appended claims.