Abstract:
A method of forming a garment trim is provided. The method includes folding a peripheral edge of a fabric to a selected position to form a cavity, inserting a binding in the cavity, securing the binding in the cavity and the peripheral edge in the selected position with a seam, and exposing the fabric to at least one condition sufficient to cause the binding to bond to the cavity and to dissipate the seam.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    1. Field of the Invention  
           [0002]    The present invention relates to methods of producing garments. More particularly, the present invention relates to methods of producing seamless, elastic trim for garments.  
           [0003]    2. Description of Related Art  
           [0004]    A garment can include an intimate apparel item such as, for example, a brassiere, a pair of underwear, and a pair of panties. Such intimate apparel is 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.  
           [0005]    Many intimate apparel garments include a trim or edging (hereinafter “trim”) formed 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.  
           [0006]    The trim can be a separate piece that is secured to the garment. Alternately, the trim can be a portion of the garment that has been folded over an elastic band and the secured again to the main portion of the garment. The folded trim has commonly been secured to the garment by a line of stitching or a seam. However, this seam defines an area of discontinuity in the 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.  
         SUMMARY OF THE INVENTION  
         [0008]    It is an object of the present invention to provide a method of providing a seamless trim to a garment.  
           [0009]    It is another object to provide a method of forming an elastic, seamless trim.  
           [0010]    It is another object to provide a reliable method of forming an elastic, seamless trim.  
           [0011]    These and other objects and advantages of the present invention are provided by a method of forming a garment trim. The method includes folding a peripheral edge of a fabric to a selected position to form a cavity; inserting a binding in the cavity; securing the binding in the cavity and the peripheral edge in the selected position with a seam; and exposing the fabric to at least one condition sufficient to cause the binding to bond to the cavity and the seam to dissipate.  
           [0012]    These and other objects and advantages of the present invention are provided by a method including folding a peripheral edge of the fabric to a selected position, with the selected position being a fold over a binding to define a curved edge; maintaining the peripheral edge in the selected position with a seam; applying heat and pressure to the trim to cause the binding to maintain the peripheral edge in the selected position; and applying a selected process condition to the trim to cause the seam to dissipate.  
           [0013]    Further, the present invention provides a method including applying a binding to a first side of the fabric at a peripheral edge of the fabric, with the binding having heat activatable adhesive properties and elastic properties; folding the peripheral edge over the binding to form a curved edge; sewing the peripheral edge and the binding with a seam having heat dissipatable properties; and activating the heat activatable adhesive properties of the binding and the heat dissipatable properties of the seam so as to bond the binding to the fabric and to dissipate the seam.  
           [0014]    Still further, the present invention provides a method including applying a binding to a first side of the fabric at a peripheral edge of the fabric, with the binding having heat activatable adhesive properties and elastic properties; folding the peripheral edge over the binding to form a curved edge; sewing the peripheral edge and the binding with a seam having solvent dissipatable properties, activating the heat activatable adhesive properties of the binding to bond the binding to the fabric, and activating the solvent dissipatable properties of the seam to dissipate the seam.  
           [0015]    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 DRAWINGS  
       [0016]    [0016]FIG. 1 is a perspective view of an exemplary embodiment of a garment blank for use with the method of the present invention;  
         [0017]    [0017]FIG. 2 is a partial sectional view of the peripheral edge of the blank of FIG. 1; and  
         [0018]    [0018]FIGS. 3 through 6 illustrate an exemplary embodiment of a method for providing a seamless trim to the peripheral edge 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. For purposes of clarity, blank  10  is illustrated for use as a garment, particularly, a panty where peripheral edges  12  define a set of leg holes  14 .  
         [0020]    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 for first side  16  to face away from the wearer and second side  18  to face the skin of the wearer.  
         [0021]    A method  20  of providing edges  12  with a seamless trim  22  is illustrated with simultaneous reference to FIGS. 3 through 6. As used herein, the term “trim” is a portion of blank  10  that has been folded over and secured to the blank. Thus, the fold of trim  22  moves edge  12  internal to blank  10  and provides a curved edge  24  to blank  10 .  
         [0022]    During method  20 , 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 face  16  in the cavity after blank  10  has been folded. Alternately, binding  28  can be inserted into cavity  26  as the cavity is formed.  
         [0023]    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 .  
         [0024]    Method  20  includes temporarily securing trim  22  in place using a temporary seam  30 . 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 face  16 .  
         [0025]    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 .  
         [0026]    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 herein, the term “dissipate” means that the seam substantially disappears both visually and tactilely.  
         [0027]    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 edge  12  in the selected position, which forms curved edge  24  on blank  10 .  
         [0028]    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 selected seamless trim  22 , but can also provide the seamless trim in a minimal amount of time.  
         [0029]    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.  
         [0030]    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.  
         [0031]    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 .  
         [0032]    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 .  
         [0033]    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.  
         [0034]    Further, method  20  does not slow the manufacture of blank  10  into a garment. Specifically, 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 .  
         [0035]    Blank  10  is illustrated for use with a panty by way of example. It is contemplated by the present invention for blank  10  to find use with other garments. It should be recognized that blank  10  is illustrated 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.  
         [0036]    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.  
         [0037]    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.