Composite elastic edge trim of a selection of fabric

Abstract

A composite elastic edge trim and a method of making are presented. The composite elastic edge trim is made of fabric and includes an outermost edge formed by folding the fabric over itself, a distal zone, and a proximal zone between the distal zone and the fold. The proximal zone features a double adhesive layer bonding the fabric, while the distal zone has a single adhesive layer for fabric bonding. The method involves applying an adhesive layer to cover more than 50% of the fabric and folding the fabric, which may be performed in a single manufacturing operation using a heat press or continuous lamination. The proximal zone provides higher compression than the distal zone, resisting roll-over during use.

Description

CROSS-REFERENCE TO RELATED APPLICATION(S)

[0001] This application claims priority to, and the benefit of, co-pending U.S. Provisional Application 63 / 748,552, filed Jan. 23, 2025, for all subject matter common to both applications. The disclosure of said provisional application is hereby incorporated by reference in its entirety.FIELD OF THE INVENTION

[0002] The present invention relates to elastic edge trim. In particular, the present

[0003] invention relates to a composite elastic edge trim of a selection of fabric used for, e.g., waistbands, that has increased resistance to “roll-over” or body-mapped compression.BACKGROUND

[0004] Generally, conventional bonded waistbands consist of a layer of elastic adhesive bonding two layers of fabric together. In some cases, the same fabric is folded over and bonded by the elastic adhesive layer. An example of this is shown in FIG. 1. Here, the waistband 100 comprises a fabric layer 102 that is folded 104 over an elastic adhesive layer 106, which bonds the fabric layer 102 to itself to form the waistband 100.

[0005] However, this conventional approach has some shortcomings. The resulting waistband 100 typically offers identical modulus and recovery across the waistband 100. Furthermore, end users recurrently complain about the top of such waistbands having “roll-over” during exercise. To combat such “roll-over”, manufacturers sometimes bond an additional second layer 108 of elastic adhesive or silicone to the top of such waistbands to increase compression and reduce “roll-over” of the waistband 100.SUMMARY

[0006] There is a need for an elastic edge trim for waistbands that addresses the “roll-over”drawback and provides customizable levels of compression along the elastic edge. The present invention is directed toward further solutions to address this need, in addition to having other desirable characteristics.

[0007] In accordance with embodiments of the present invention, a composite elastic edge trim of a selected fabric comprises an outermost edge comprising a fold formed by the fabric being folded over itself along an edge, a distal zone, and a proximal zone disposed between the distal zone and the fold. A double adhesive layer is disposed in the proximal zone and bonds the fabric to itself, while a single adhesive layer is disposed in the distal zone and bonds the fabric to itself. The double adhesive layer is comprised of twice a thickness of the adhesive layer contained in the single adhesive layer. In some embodiments, the double adhesive layer comprises a portion of the single adhesive layer that has been folded over itself at the fold to create the doubled thickness, forming an adhesive layer fold. The fabric may comprise an elastic fabric. In certain embodiments, one or more of the double adhesive layer and single adhesive layer comprise an elastic adhesive. The elastic adhesive may comprise an open structure, such as a perforated solid elastic adhesive or a mesh elastic adhesive. In some embodiments, the elastic adhesive comprises multiple zones, each having a different elasticity, where each zone may have a different open structure. In certain embodiments, an area of the proximal zone is about 50% or less of an area of the distal zone. In some embodiments, the proximal zone is between 10-20 mm inward distance from the fold toward the distal zone. The proximal zone may provide a higher compression level than the distal zone, and the composite elastic edge trim may be configured to resist roll-over during use.

[0008] In accordance with aspects of the present invention, the double adhesive layer includes a portion of the single adhesive layer that has been folded over itself at the fold to create the doubled thickness.

[0009] In accordance with aspects of the present invention, the fabric comprises an elastic fabric.

[0010] In accordance with aspects of the present invention, one or more of the double adhesive layer and single adhesive layer comprise an elastic adhesive. In certain respects, the elastic adhesive comprises an open structure. In further aspects, the elastic adhesive comprises a perforated solid elastic adhesive. In other aspects, the elastic adhesive comprises a mesh elastic adhesive. In other aspects, the elastic adhesive comprises multiple zones each having a different elasticity. In some such other aspects, each zone has a different open structure.

[0011] In accordance with aspects of the present invention, an area of the proximal zone is about 50% or less of an area of the distal zone. In some such aspects, the proximal zone is between 10-20 mm inward distance from the fold toward the distal zone.

[0012] In accordance with aspects of the present invention, the double adhesive layer covers more than 50% of the selection of fabric, such that forming the fold results in the double adhesive layer in the proximal zone.

[0013] In accordance with aspects of the present invention, the composite elastic edge trim is configured to resist roll-over during use.

[0014] In accordance with aspects of the present invention, the proximal zone provides a higher compression level than the distal zone.

[0015] In accordance with embodiments of the present invention, a method of making a composite elastic edge trim involves providing a selection of fabric, applying an adhesive layer to a portion of the fabric, and forming a fold by folding the selection of fabric over itself along an edge. In some embodiments, the adhesive layer is applied to cover more than 50% of the selection of fabric, such that forming the fold results in a double adhesive layer in a proximal zone near the fold and a single adhesive layer in a distal zone. In certain embodiments, applying the adhesive layer and forming the fold may be performed in a single manufacturing operation to create both the single adhesive layer in the distal zone and the double adhesive layer in the proximal zone. The proximal zone may provide a higher compression level than the distal zone, and the composite elastic edge trim may be configured to resist roll-over during use. In some embodiments, the adhesive layer may be applied by heat press or continuous lamination.

[0016] In accordance with aspects of the present invention, the double adhesive layer is comprised of a portion of the single adhesive layer that has been folded over itself at the fold to create the doubled thickness.

[0017] In accordance with aspects of the present invention, the fabric comprises an elastic fabric.

[0018] In accordance with aspects of the present invention, one or more of the double adhesive layer and single adhesive layer comprise an elastic adhesive. In some such aspects, the elastic adhesive comprises an open structure. In further aspects, the elastic adhesive comprises a perforated solid elastic adhesive. In other aspects, the elastic adhesive comprises a mesh elastic adhesive. In other such aspects, the elastic adhesive comprises multiple zones, each having a different elasticity. In other such aspects, each zone has a different open structure.

[0019] In accordance with aspects of the present invention, an area of the proximal zone is less than about 50% of an area of the distal zone. In some such aspects, the proximal zone is between 10-20 mm inward distance from the fold.

[0020] In accordance with aspects of the present invention, applying the adhesive layer to a portion of the fabric comprises applying the adhesive layer to cover more than 50% of the selection of fabric, such that forming the fold results in the double adhesive layer in the proximal zone.

[0021] In accordance with aspects of the present invention, applying the adhesive layer and forming the fold are performed in a single manufacturing operation to create both the single adhesive layer in the distal zone and the double adhesive layer in the proximal zone.

[0022] In accordance with aspects of the present invention, the composite elastic edge trim is configured to resist roll-over during use.

[0023] In accordance with aspects of the present invention, the proximal zone provides a higher compression level than the distal zone.

[0024] In accordance with aspects of the present invention, applying the adhesive layer comprises applying the adhesive layer by heat press or continuous lamination.BRIEF DESCRIPTION OF THE FIGURES

[0025] These and other characteristics of the present invention will be more fully understood by reference to the following detailed description in conjunction with the attached drawings, in which:

[0026] FIG. 1 is an example of a conventional waistband made by bonding two layers of fabric together with a stretch adhesive;

[0027] FIG. 2 depicts an example composite elastic edge trim of a selection of fabric in accordance with embodiments of the present invention;

[0028] FIG. 3 depicts an example composite elastic edge trim of a selection of fabric in accordance with embodiments of the present invention, where the elastic adhesive used to make the double adhesive layer and single adhesive layer comprises multiple zones, each having a different elasticity;

[0029] FIG. 4 is a flow diagram for a method of making a composite elastic edge trim of a selection of fabric in accordance with embodiments of the present invention;

[0030] FIG. 5 depicts a top view and side view of the selection of fabric provided when making a composite elastic edge trim using the method of FIG. 4;

[0031] FIG. 6 depicts a top view and side view of the adhesive layer applied to a portion of the selection of fabric when making a composite elastic edge trim using the method of FIG. 4;

[0032] FIG. 7 depicts a top view and side view of forming a fold by folding the selection of fabric over itself along an edge when making a composite elastic edge trim using the method of FIG. 4;

[0033] FIG. 8 depicts a top view and side view of the resulting composite elastic edge trim following method of FIG. 4;

[0034] FIG. 9 depicts examples of an adhesive layer having multiple zones, each having a different elasticity, in accordance with embodiments of the present invention; and

[0035] FIG. 10 depicts a front view of an embodiment where an adhesive layer comprising an elastic adhesive having multiple zones, each having a different elasticity has been applied to the selection of fabric and is being folded over to form a composite elastic edge trim in accordance with embodiments of the present invention.DETAILED DESCRIPTION

[0036] An illustrative embodiment of the present invention relates to a composite elastic

[0037] edge trim and a method of making. The composite elastic edge trim is made of fabric and includes an outermost edge formed by folding the fabric over itself, a distal zone, and a proximal zone between the distal zone and the fold. The proximal zone features a double adhesive layer bonding the fabric, while the distal zone has a single adhesive layer for fabric bonding. The double adhesive layer is twice the thickness of the single adhesive layer. This design resists “roll-over” and simplifies the manufacturing process by reducing the number of steps involved. The use of elastic adhesives with different zones provides variable compression across the edge trim.

[0038] FIG. 2 through FIG. 10, wherein like parts are designated by like reference

[0039] numerals throughout, illustrate an example embodiment or embodiments of a composite elastic edge trim of a selection of fabric and a method of making, according to the present invention. Although the present invention will be described with reference to the example embodiment or embodiments illustrated in the figures, it should be understood that many alternative forms can embody the present invention. One of skill in the art will also appreciate various ways to alter the parameters of the disclosed embodiment(s), such as the size, shape, or type of elements or materials, in a manner consistent with the spirit and scope of the present invention.

[0040] FIG. 2 depicts an example composite elastic edge trim 200 of a selection of

[0041] fabric 210 in accordance with embodiments of the present invention. The composite elastic edge trim 200 comprises an outermost edge 202, a distal zone 206, and proximal zone 204. The outermost edge 202 is comprised of a fold 208 formed by the fabric 210 having been folded over itself along the edge 202. The proximal zone 204 of the composite elastic edge trim 200 is disposed between the distal zone 206 and the fold 208. A double adhesive layer 212 is disposed in the proximal zone 204 and bonds the fabric 210 to itself. A single adhesive layer 214 is disposed in the distal zone 206 and bonds the fabric 210 to itself. The double adhesive layer 212 is comprised of twice the thickness of the adhesive layer contained in the single adhesive layer 214. In certain embodiments, the double adhesive layer 212 is comprised of a portion of the single adhesive layer 214 folded over itself, shown here as fold 216.

[0042] The proximal zone 204, with its double adhesive layer 212, provides twice the compression level of the distal zone 206, with its single adhesive layer 214. The increased compression level of the proximal zone helps keep the elastic edge trim 200 in place for an end user and prevents “roll-over.”

[0043] The edge trim 200 can be used for waistbands or other edges of clothing for which an elastic fit is desired, such as cuffs or the bands of support garments. The fabric 210 can be any fabric suitable for clothing. In certain embodiments, the fabric is suitable for athletic wear. In some such embodiments, the fabric comprises an elastic fabric. Examples of such fabrics include synthetic stretch fabrics, such as nylon / polyester with a % of spandex (e.g., Lycra® from The Lycra Company LLC), or elastane yarns or natural fibers, such as cotton with a % of spandex, Lycra®, or elastane. Other possible deployments of the edge trim 200 and / or fabric 210 will be apparent to one skilled in the art, given the benefit of this disclosure. As used herein, the term “selection of fabric” refers to a piece or portion of fabric.

[0044] In certain embodiments, the area of the proximal zone 204 is about 50% or less of an area of the distal zone 206. In some such embodiments, the proximal zone 204 is between 10-35 mm (such as 10-20 mm) inward distance from the fold 208 toward the distal zone 206.

[0045] In certain embodiments, one or more of the double adhesive layer 212 and single adhesive layer 214 comprise an elastic adhesive. In some such embodiments, the elastic adhesive comprises an open structure. Open structure refers to “holes” in the adhesive that offer the benefits of a softer hand feel and improved breathability. In still further embodiments, the elastic adhesive comprises a perforated solid elastic adhesive. In other further embodiments, the elastic adhesive comprises a mesh elastic adhesive. Examples of such elastic adhesives include single or multi-layer thermoplastic polyurethane (TPU) and thermoplastic elastomer (TPE) or silicone adhesives.

[0046] If the product is a single-layer, it needs to function both as an adhesive and elastic with a high degree of stretch and recovery and a modulus suited to the application. However, it is also common to form a 3-layer system, with an adhesive layer on each side of a so-called barrier layer, in an A-B-A configuration. The purpose of this is to control the amount of the product that flows into the fabric and “wrap” around the fibers. The adhesive layers are formulated with tackifiers to allow them to melt and flow into the substrate, while the barrier layer is not and acts as a “stop” to the flow. Having both these options (single-layer adhesive and 3-layer adhesive-barrier-adhesive) allows the garment designer more options in assembling the product. For the 3-layer, it is easier to extrude a continuous film and simply punch holes in it (to improve breathability), while for the single-layer, it is possible to use a single melt extrusion technique to directly make the mesh without needing to punch the holes in a second step. These can be used in solid or open form (such as perforated or different construction, such as web or mesh construction). Other possible elastic adhesives will be apparent to one skilled in the art, given the benefit of this disclosure.

[0047] FIG. 3 depicts an example composite elastic edge trim 200 of a selection of fabric 210 in accordance with embodiments of the present invention, where the elastic adhesive used to make the double adhesive layer 212 and single adhesive layer 214 comprises multiple zones 300, 302, 304, each having a different elasticity. In this example, the first zone 300, second zone 302, and third zone 304 have different open structures that provide different levels of elasticity. Using holes of different sizes and shapes creates different levels of compression across the entire composite elastic edge trim 200. For Example, a waistband with more open holes in the middle height-wise (second zone 302) improves wearer comfort by reducing modulus (greater elasticity) in that area of the body, which tends to be more “expandable”. Other possible configurations will be apparent to one skilled in the art, given the benefit of this disclosure.

[0048] FIG. 4 is a flow diagram 400 for a method of making a composite elastic edge trim 200 of a selection of fabric in accordance with embodiments of the present invention. The method involves providing a selection of fabric 210 (Step 402), applying an adhesive layer 214 to a portion of the fabric 210 (Step 404), and forming a fold 208 by folding the selection of fabric 210 over itself along an edge (Step 406).

[0049] FIG. 5 depicts a top view 500 and side view 502 of the selection of fabric 210 provided in Step 402 of FIG. 4. As set forth previously, the fabric 210 can be any fabric suitable for clothing. In certain embodiments, the fabric is suitable for athletic wear. In some such embodiments, the fabric comprises an elastic fabric. Examples of such fabrics include synthetic stretch fabrics such as nylon / polyester with a % of spandex, Lycra®, or elastane yarns, or natural fibers such as cotton with a % of spandex, Lycra®, or elastane. Other possible deployments of the edge trim 200 and / or fabric 210 will be apparent to one skilled in the art, given the benefit of this disclosure.

[0050] FIG. 6 depicts a top view 600 and side view 602 of the adhesive layer 214 applied to a portion of the selection of fabric 210 provide in in Step 404 of FIG. 4. In certain embodiments, the application of the adhesive layer 214 to the portion of the selection of fabric 210 is performed by heat press or continuous lamination on one side of the fabric to cover slightly more than 50% of the selection of fabric. Other possible application techniques and configurations will be apparent to one skilled in the art, given the benefit of this disclosure.

[0051] As previously set forth, the adhesive layer 214 may comprise an elastic adhesive. In some such embodiments, the elastic adhesive comprises an open structure. In still further embodiments, the elastic adhesive comprises a perforated solid elastic adhesive. In other further embodiments, the elastic adhesive comprises a mesh elastic adhesive. Examples of such elastic adhesives include single or multi-layer thermoplastic polyurethane (TPU) and thermoplastic elastomer (TPE) adhesives. These may be used in solid or open form (e.g., perforated or constructed with web or mesh). If the product is a single-layer, it needs to function both as adhesive and elastic with a high degree of stretch and recovery and a modulus suited to the application. However, it is also common to form a 3-layer system, with an adhesive layer on each side of a so-called barrier layer, in an A-B-A configuration. The purpose of this is to control the amount of the product that flows into the fabric and “wrap” around the fibers. The adhesive layers are formulated with tackifiers to allow them to melt and flow into the substrate, while the barrier layer is not and acts as a “stop” to the flow. Having both these options (single-layer adhesive and 3-layer adhesive-barrier-adhesive) allows the garment designer more options in assembling the product. For the 3-layer it is easier to extrude a continuous film and simply punch holes in it (to improve breathability), while for the single-layer, it is possible to use a single melt extrusion technique to directly make the mesh without needing to punch the holes in a second step. These may be used in solid or open form (e.g., perforated or constructed with web or mesh). Other possible elastic adhesives will be apparent to one skilled in the art, given the benefit of this disclosure.

[0052] FIG. 7 depicts a top view 700 and side view 702 of forming a fold 208 by folding the selection of fabric 210 over itself along an edge 704 (Step 406).

[0053] FIG. 8 depicts a top view 800 and side view 802 of the resulting composite elastic edge trim 200 following the folding step (Step 406). Here, the composite elastic edge trim has a distal zone 206 and a proximal zone 204 disposed between the distal zone 206 and the fold 208 defining the outermost edge 202 of the composite elastic edge trim 200. The resulting distal zone 206 has a single-layer of adhesive 214 bonding the fabric 210 to itself, and the resulting proximal zone 204 has a double-layer of adhesive 212 bonding the fabric 210 to itself.

[0054] As previously set forth, the elastic adhesive used to form the double adhesive layer 212 and the single adhesive layer 214 may comprise multiple zones, each having a different elasticity. FIG. 9 depicts a first example 900 and a second example 902, each having different first zones 300, second zones 302, and third zones 304, with different open structures that provide different levels of elasticity. As shown here, the size and structure of zones 300, 302, and 204 may vary. For Example, a waistband with more open holes in the middle height-wise (second zone 302) improves wearer comfort by reducing modulus (greater elasticity) in that area of the body, which tends to be more “expandable”. Other possible configurations will be apparent to one skilled in the art, given the benefit of this disclosure.

[0055] FIG. 10 depicts front view 1000 of an embodiment where an adhesive layer 214 comprising an elastic adhesive having multiple zones 300, 302, 304, each having a different elasticity, has been applied to the selection of fabric 210 (step 402) and is being folded over (step 404) to form the composite elastic edge trim 200. Such customization enables a composite elastic edge trim 200 that uniquely adapts to the end user's body shape to provide the exact compression and comfort required for the garment, depending on the activities for which it is designed. Example: higher compression level for active sports vs lower compression for day-to-day wear.

[0056] The composite elastic edge trim 200 of the present invention resists “roll-over” and simplifies the manufacturing process by reducing the number of steps involved. That is the present invention replaces multiple assembly steps (i.e., assembling an elastic waistband with a first elastic adhesive layer and then adding a second elastic adhesive layer) with a single application of a single adhesive layer. Furthermore, the use of elastic adhesives that have different zones offers a uniquely variable level of compression across different areas of the edge trim, thanks to a fully customizable “holes” pattern which can be achieved through perforation or by application of an open mesh adhesive structure.

[0057] As utilized herein, the terms “comprises” and “comprising” are intended to be construed as being inclusive, not exclusive. As utilized herein, the terms “exemplary”, “example”, and “illustrative”, are intended to mean “serving as an example, instance, or illustration” and should not be construed as indicating, or not indicating, a preferred or advantageous configuration relative to other configurations. As utilized herein, the terms “about”, “generally”, and “approximately” are intended to cover variations that may exist in the upper and lower limits of the ranges of subjective or objective values, such as variations in properties, parameters, sizes, and dimensions. In one non-limiting example, the terms “about”, “generally”, and “approximately” mean at, or plus 10 percent or less, or minus 10 percent or less. In one non-limiting example, the terms “about”, “generally”, and “approximately” mean sufficiently close to be deemed by one of skill in the art in the relevant field to be included. As utilized herein, the term “substantially” refers to the complete or nearly complete extent or degree of an action, characteristic, property, state, structure, item, or result, as would be appreciated by one of skill in the art. For example, an object that is “substantially” circular would mean that the object is either completely a circle to mathematically determinable limits, or nearly a circle as would be recognized or understood by one of skill in the art. The exact allowable degree of deviation from absolute completeness may, in some instances, depend on the specific context. However, in general, the nearness of completion will be so as to have the same overall result as if absolute and total completion were achieved or obtained. The use of “substantially” is equally applicable when utilized in a negative connotation to refer to the complete or near complete lack of an action, characteristic, property, state, structure, item, or result, as would be appreciated by one of skill in the art.

[0058] Numerous modifications and alternative embodiments of the present invention

[0059] will be apparent to those skilled in the art in view of the foregoing description. Accordingly, this description is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the best mode for carrying out the present invention. Details of the structure may vary substantially without departing from the spirit of the present invention, and exclusive use of all modifications that come within the scope of the appended claims is reserved. Within this specification embodiments have been described in a way that enables a clear and concise specification to be written, but it is intended and will be appreciated that embodiments may be variously combined or separated without parting from the invention. It is intended that the present invention be limited only to the extent required by the appended claims and the applicable rules of law.

[0060] It is also to be understood that the following claims are to cover all generic and

[0061] specific features of the invention described herein, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.

Examples

Embodiment Construction

[0036]An illustrative embodiment of the present invention relates to a composite elastic

[0037]edge trim and a method of making. The composite elastic edge trim is made of fabric and includes an outermost edge formed by folding the fabric over itself, a distal zone, and a proximal zone between the distal zone and the fold. The proximal zone features a double adhesive layer bonding the fabric, while the distal zone has a single adhesive layer for fabric bonding. The double adhesive layer is twice the thickness of the single adhesive layer. This design resists “roll-over” and simplifies the manufacturing process by reducing the number of steps involved. The use of elastic adhesives with different zones provides variable compression across the edge trim.

[0038]FIG. 2 through FIG. 10, wherein like parts are designated by like reference

[0039]numerals throughout, illustrate an example embodiment or embodiments of a composite elastic edge trim of a selection of fabric and a method of making,...

CROSS-REFERENCE TO RELATED APPLICATION(S)

[0001] This application claims priority to, and the benefit of, co-pending U.S. Provisional Application 63 / 748,552, filed Jan. 23, 2025, for all subject matter common to both applications. The disclosure of said provisional application is hereby incorporated by reference in its entirety.FIELD OF THE INVENTION

[0002] The present invention relates to elastic edge trim. In particular, the present

[0003] invention relates to a composite elastic edge trim of a selection of fabric used for, e.g., waistbands, that has increased resistance to “roll-over” or body-mapped compression.BACKGROUND

[0004] Generally, conventional bonded waistbands consist of a layer of elastic adhesive bonding two layers of fabric together. In some cases, the same fabric is folded over and bonded by the elastic adhesive layer. An example of this is shown in FIG. 1. Here, the waistband 100 comprises a fabric layer 102 that is folded 104 over an elastic adhesive layer 106, which bonds the fabric layer 102 to itself to form the waistband 100.

[0005] However, this conventional approach has some shortcomings. The resulting waistband 100 typically offers identical modulus and recovery across the waistband 100. Furthermore, end users recurrently complain about the top of such waistbands having “roll-over” during exercise. To combat such “roll-over”, manufacturers sometimes bond an additional second layer 108 of elastic adhesive or silicone to the top of such waistbands to increase compression and reduce “roll-over” of the waistband 100.SUMMARY

[0006] There is a need for an elastic edge trim for waistbands that addresses the “roll-over”drawback and provides customizable levels of compression along the elastic edge. The present invention is directed toward further solutions to address this need, in addition to having other desirable characteristics.

[0007] In accordance with embodiments of the present invention, a composite elastic edge trim of a selected fabric comprises an outermost edge comprising a fold formed by the fabric being folded over itself along an edge, a distal zone, and a proximal zone disposed between the distal zone and the fold. A double adhesive layer is disposed in the proximal zone and bonds the fabric to itself, while a single adhesive layer is disposed in the distal zone and bonds the fabric to itself. The double adhesive layer is comprised of twice a thickness of the adhesive layer contained in the single adhesive layer. In some embodiments, the double adhesive layer comprises a portion of the single adhesive layer that has been folded over itself at the fold to create the doubled thickness, forming an adhesive layer fold. The fabric may comprise an elastic fabric. In certain embodiments, one or more of the double adhesive layer and single adhesive layer comprise an elastic adhesive. The elastic adhesive may comprise an open structure, such as a perforated solid elastic adhesive or a mesh elastic adhesive. In some embodiments, the elastic adhesive comprises multiple zones, each having a different elasticity, where each zone may have a different open structure. In certain embodiments, an area of the proximal zone is about 50% or less of an area of the distal zone. In some embodiments, the proximal zone is between 10-20 mm inward distance from the fold toward the distal zone. The proximal zone may provide a higher compression level than the distal zone, and the composite elastic edge trim may be configured to resist roll-over during use.

[0008] In accordance with aspects of the present invention, the double adhesive layer includes a portion of the single adhesive layer that has been folded over itself at the fold to create the doubled thickness.

[0009] In accordance with aspects of the present invention, the fabric comprises an elastic fabric.

[0010] In accordance with aspects of the present invention, one or more of the double adhesive layer and single adhesive layer comprise an elastic adhesive. In certain respects, the elastic adhesive comprises an open structure. In further aspects, the elastic adhesive comprises a perforated solid elastic adhesive. In other aspects, the elastic adhesive comprises a mesh elastic adhesive. In other aspects, the elastic adhesive comprises multiple zones each having a different elasticity. In some such other aspects, each zone has a different open structure.

[0011] In accordance with aspects of the present invention, an area of the proximal zone is about 50% or less of an area of the distal zone. In some such aspects, the proximal zone is between 10-20 mm inward distance from the fold toward the distal zone.

[0012] In accordance with aspects of the present invention, the double adhesive layer covers more than 50% of the selection of fabric, such that forming the fold results in the double adhesive layer in the proximal zone.

[0013] In accordance with aspects of the present invention, the composite elastic edge trim is configured to resist roll-over during use.

[0014] In accordance with aspects of the present invention, the proximal zone provides a higher compression level than the distal zone.

[0015] In accordance with embodiments of the present invention, a method of making a composite elastic edge trim involves providing a selection of fabric, applying an adhesive layer to a portion of the fabric, and forming a fold by folding the selection of fabric over itself along an edge. In some embodiments, the adhesive layer is applied to cover more than 50% of the selection of fabric, such that forming the fold results in a double adhesive layer in a proximal zone near the fold and a single adhesive layer in a distal zone. In certain embodiments, applying the adhesive layer and forming the fold may be performed in a single manufacturing operation to create both the single adhesive layer in the distal zone and the double adhesive layer in the proximal zone. The proximal zone may provide a higher compression level than the distal zone, and the composite elastic edge trim may be configured to resist roll-over during use. In some embodiments, the adhesive layer may be applied by heat press or continuous lamination.

[0016] In accordance with aspects of the present invention, the double adhesive layer is comprised of a portion of the single adhesive layer that has been folded over itself at the fold to create the doubled thickness.

[0017] In accordance with aspects of the present invention, the fabric comprises an elastic fabric.

[0018] In accordance with aspects of the present invention, one or more of the double adhesive layer and single adhesive layer comprise an elastic adhesive. In some such aspects, the elastic adhesive comprises an open structure. In further aspects, the elastic adhesive comprises a perforated solid elastic adhesive. In other aspects, the elastic adhesive comprises a mesh elastic adhesive. In other such aspects, the elastic adhesive comprises multiple zones, each having a different elasticity. In other such aspects, each zone has a different open structure.

[0019] In accordance with aspects of the present invention, an area of the proximal zone is less than about 50% of an area of the distal zone. In some such aspects, the proximal zone is between 10-20 mm inward distance from the fold.

[0020] In accordance with aspects of the present invention, applying the adhesive layer to a portion of the fabric comprises applying the adhesive layer to cover more than 50% of the selection of fabric, such that forming the fold results in the double adhesive layer in the proximal zone.

[0021] In accordance with aspects of the present invention, applying the adhesive layer and forming the fold are performed in a single manufacturing operation to create both the single adhesive layer in the distal zone and the double adhesive layer in the proximal zone.

[0022] In accordance with aspects of the present invention, the composite elastic edge trim is configured to resist roll-over during use.

[0023] In accordance with aspects of the present invention, the proximal zone provides a higher compression level than the distal zone.

[0024] In accordance with aspects of the present invention, applying the adhesive layer comprises applying the adhesive layer by heat press or continuous lamination.BRIEF DESCRIPTION OF THE FIGURES

[0025] These and other characteristics of the present invention will be more fully understood by reference to the following detailed description in conjunction with the attached drawings, in which:

[0026] FIG. 1 is an example of a conventional waistband made by bonding two layers of fabric together with a stretch adhesive;

[0027] FIG. 2 depicts an example composite elastic edge trim of a selection of fabric in accordance with embodiments of the present invention;

[0028] FIG. 3 depicts an example composite elastic edge trim of a selection of fabric in accordance with embodiments of the present invention, where the elastic adhesive used to make the double adhesive layer and single adhesive layer comprises multiple zones, each having a different elasticity;

[0029] FIG. 4 is a flow diagram for a method of making a composite elastic edge trim of a selection of fabric in accordance with embodiments of the present invention;

[0030] FIG. 5 depicts a top view and side view of the selection of fabric provided when making a composite elastic edge trim using the method of FIG. 4;

[0031] FIG. 6 depicts a top view and side view of the adhesive layer applied to a portion of the selection of fabric when making a composite elastic edge trim using the method of FIG. 4;

[0032] FIG. 7 depicts a top view and side view of forming a fold by folding the selection of fabric over itself along an edge when making a composite elastic edge trim using the method of FIG. 4;

[0033] FIG. 8 depicts a top view and side view of the resulting composite elastic edge trim following method of FIG. 4;

[0034] FIG. 9 depicts examples of an adhesive layer having multiple zones, each having a different elasticity, in accordance with embodiments of the present invention; and

[0035] FIG. 10 depicts a front view of an embodiment where an adhesive layer comprising an elastic adhesive having multiple zones, each having a different elasticity has been applied to the selection of fabric and is being folded over to form a composite elastic edge trim in accordance with embodiments of the present invention.DETAILED DESCRIPTION

[0036] An illustrative embodiment of the present invention relates to a composite elastic

[0037] edge trim and a method of making. The composite elastic edge trim is made of fabric and includes an outermost edge formed by folding the fabric over itself, a distal zone, and a proximal zone between the distal zone and the fold. The proximal zone features a double adhesive layer bonding the fabric, while the distal zone has a single adhesive layer for fabric bonding. The double adhesive layer is twice the thickness of the single adhesive layer. This design resists “roll-over” and simplifies the manufacturing process by reducing the number of steps involved. The use of elastic adhesives with different zones provides variable compression across the edge trim.

[0038] FIG. 2 through FIG. 10, wherein like parts are designated by like reference

[0039] numerals throughout, illustrate an example embodiment or embodiments of a composite elastic edge trim of a selection of fabric and a method of making, according to the present invention. Although the present invention will be described with reference to the example embodiment or embodiments illustrated in the figures, it should be understood that many alternative forms can embody the present invention. One of skill in the art will also appreciate various ways to alter the parameters of the disclosed embodiment(s), such as the size, shape, or type of elements or materials, in a manner consistent with the spirit and scope of the present invention.

[0040] FIG. 2 depicts an example composite elastic edge trim 200 of a selection of

[0041] fabric 210 in accordance with embodiments of the present invention. The composite elastic edge trim 200 comprises an outermost edge 202, a distal zone 206, and proximal zone 204. The outermost edge 202 is comprised of a fold 208 formed by the fabric 210 having been folded over itself along the edge 202. The proximal zone 204 of the composite elastic edge trim 200 is disposed between the distal zone 206 and the fold 208. A double adhesive layer 212 is disposed in the proximal zone 204 and bonds the fabric 210 to itself. A single adhesive layer 214 is disposed in the distal zone 206 and bonds the fabric 210 to itself. The double adhesive layer 212 is comprised of twice the thickness of the adhesive layer contained in the single adhesive layer 214. In certain embodiments, the double adhesive layer 212 is comprised of a portion of the single adhesive layer 214 folded over itself, shown here as fold 216.

[0042] The proximal zone 204, with its double adhesive layer 212, provides twice the compression level of the distal zone 206, with its single adhesive layer 214. The increased compression level of the proximal zone helps keep the elastic edge trim 200 in place for an end user and prevents “roll-over.”

[0043] The edge trim 200 can be used for waistbands or other edges of clothing for which an elastic fit is desired, such as cuffs or the bands of support garments. The fabric 210 can be any fabric suitable for clothing. In certain embodiments, the fabric is suitable for athletic wear. In some such embodiments, the fabric comprises an elastic fabric. Examples of such fabrics include synthetic stretch fabrics, such as nylon / polyester with a % of spandex (e.g., Lycra® from The Lycra Company LLC), or elastane yarns or natural fibers, such as cotton with a % of spandex, Lycra®, or elastane. Other possible deployments of the edge trim 200 and / or fabric 210 will be apparent to one skilled in the art, given the benefit of this disclosure. As used herein, the term “selection of fabric” refers to a piece or portion of fabric.

[0044] In certain embodiments, the area of the proximal zone 204 is about 50% or less of an area of the distal zone 206. In some such embodiments, the proximal zone 204 is between 10-35 mm (such as 10-20 mm) inward distance from the fold 208 toward the distal zone 206.

[0045] In certain embodiments, one or more of the double adhesive layer 212 and single adhesive layer 214 comprise an elastic adhesive. In some such embodiments, the elastic adhesive comprises an open structure. Open structure refers to “holes” in the adhesive that offer the benefits of a softer hand feel and improved breathability. In still further embodiments, the elastic adhesive comprises a perforated solid elastic adhesive. In other further embodiments, the elastic adhesive comprises a mesh elastic adhesive. Examples of such elastic adhesives include single or multi-layer thermoplastic polyurethane (TPU) and thermoplastic elastomer (TPE) or silicone adhesives.

[0046] If the product is a single-layer, it needs to function both as an adhesive and elastic with a high degree of stretch and recovery and a modulus suited to the application. However, it is also common to form a 3-layer system, with an adhesive layer on each side of a so-called barrier layer, in an A-B-A configuration. The purpose of this is to control the amount of the product that flows into the fabric and “wrap” around the fibers. The adhesive layers are formulated with tackifiers to allow them to melt and flow into the substrate, while the barrier layer is not and acts as a “stop” to the flow. Having both these options (single-layer adhesive and 3-layer adhesive-barrier-adhesive) allows the garment designer more options in assembling the product. For the 3-layer, it is easier to extrude a continuous film and simply punch holes in it (to improve breathability), while for the single-layer, it is possible to use a single melt extrusion technique to directly make the mesh without needing to punch the holes in a second step. These can be used in solid or open form (such as perforated or different construction, such as web or mesh construction). Other possible elastic adhesives will be apparent to one skilled in the art, given the benefit of this disclosure.

[0047] FIG. 3 depicts an example composite elastic edge trim 200 of a selection of fabric 210 in accordance with embodiments of the present invention, where the elastic adhesive used to make the double adhesive layer 212 and single adhesive layer 214 comprises multiple zones 300, 302, 304, each having a different elasticity. In this example, the first zone 300, second zone 302, and third zone 304 have different open structures that provide different levels of elasticity. Using holes of different sizes and shapes creates different levels of compression across the entire composite elastic edge trim 200. For Example, a waistband with more open holes in the middle height-wise (second zone 302) improves wearer comfort by reducing modulus (greater elasticity) in that area of the body, which tends to be more “expandable”. Other possible configurations will be apparent to one skilled in the art, given the benefit of this disclosure.

[0048] FIG. 4 is a flow diagram 400 for a method of making a composite elastic edge trim 200 of a selection of fabric in accordance with embodiments of the present invention. The method involves providing a selection of fabric 210 (Step 402), applying an adhesive layer 214 to a portion of the fabric 210 (Step 404), and forming a fold 208 by folding the selection of fabric 210 over itself along an edge (Step 406).

[0049] FIG. 5 depicts a top view 500 and side view 502 of the selection of fabric 210 provided in Step 402 of FIG. 4. As set forth previously, the fabric 210 can be any fabric suitable for clothing. In certain embodiments, the fabric is suitable for athletic wear. In some such embodiments, the fabric comprises an elastic fabric. Examples of such fabrics include synthetic stretch fabrics such as nylon / polyester with a % of spandex, Lycra®, or elastane yarns, or natural fibers such as cotton with a % of spandex, Lycra®, or elastane. Other possible deployments of the edge trim 200 and / or fabric 210 will be apparent to one skilled in the art, given the benefit of this disclosure.

[0050] FIG. 6 depicts a top view 600 and side view 602 of the adhesive layer 214 applied to a portion of the selection of fabric 210 provide in in Step 404 of FIG. 4. In certain embodiments, the application of the adhesive layer 214 to the portion of the selection of fabric 210 is performed by heat press or continuous lamination on one side of the fabric to cover slightly more than 50% of the selection of fabric. Other possible application techniques and configurations will be apparent to one skilled in the art, given the benefit of this disclosure.

[0051] As previously set forth, the adhesive layer 214 may comprise an elastic adhesive. In some such embodiments, the elastic adhesive comprises an open structure. In still further embodiments, the elastic adhesive comprises a perforated solid elastic adhesive. In other further embodiments, the elastic adhesive comprises a mesh elastic adhesive. Examples of such elastic adhesives include single or multi-layer thermoplastic polyurethane (TPU) and thermoplastic elastomer (TPE) adhesives. These may be used in solid or open form (e.g., perforated or constructed with web or mesh). If the product is a single-layer, it needs to function both as adhesive and elastic with a high degree of stretch and recovery and a modulus suited to the application. However, it is also common to form a 3-layer system, with an adhesive layer on each side of a so-called barrier layer, in an A-B-A configuration. The purpose of this is to control the amount of the product that flows into the fabric and “wrap” around the fibers. The adhesive layers are formulated with tackifiers to allow them to melt and flow into the substrate, while the barrier layer is not and acts as a “stop” to the flow. Having both these options (single-layer adhesive and 3-layer adhesive-barrier-adhesive) allows the garment designer more options in assembling the product. For the 3-layer it is easier to extrude a continuous film and simply punch holes in it (to improve breathability), while for the single-layer, it is possible to use a single melt extrusion technique to directly make the mesh without needing to punch the holes in a second step. These may be used in solid or open form (e.g., perforated or constructed with web or mesh). Other possible elastic adhesives will be apparent to one skilled in the art, given the benefit of this disclosure.

[0052] FIG. 7 depicts a top view 700 and side view 702 of forming a fold 208 by folding the selection of fabric 210 over itself along an edge 704 (Step 406).

[0053] FIG. 8 depicts a top view 800 and side view 802 of the resulting composite elastic edge trim 200 following the folding step (Step 406). Here, the composite elastic edge trim has a distal zone 206 and a proximal zone 204 disposed between the distal zone 206 and the fold 208 defining the outermost edge 202 of the composite elastic edge trim 200. The resulting distal zone 206 has a single-layer of adhesive 214 bonding the fabric 210 to itself, and the resulting proximal zone 204 has a double-layer of adhesive 212 bonding the fabric 210 to itself.

[0054] As previously set forth, the elastic adhesive used to form the double adhesive layer 212 and the single adhesive layer 214 may comprise multiple zones, each having a different elasticity. FIG. 9 depicts a first example 900 and a second example 902, each having different first zones 300, second zones 302, and third zones 304, with different open structures that provide different levels of elasticity. As shown here, the size and structure of zones 300, 302, and 204 may vary. For Example, a waistband with more open holes in the middle height-wise (second zone 302) improves wearer comfort by reducing modulus (greater elasticity) in that area of the body, which tends to be more “expandable”. Other possible configurations will be apparent to one skilled in the art, given the benefit of this disclosure.

[0055] FIG. 10 depicts front view 1000 of an embodiment where an adhesive layer 214 comprising an elastic adhesive having multiple zones 300, 302, 304, each having a different elasticity, has been applied to the selection of fabric 210 (step 402) and is being folded over (step 404) to form the composite elastic edge trim 200. Such customization enables a composite elastic edge trim 200 that uniquely adapts to the end user's body shape to provide the exact compression and comfort required for the garment, depending on the activities for which it is designed. Example: higher compression level for active sports vs lower compression for day-to-day wear.

[0056] The composite elastic edge trim 200 of the present invention resists “roll-over” and simplifies the manufacturing process by reducing the number of steps involved. That is the present invention replaces multiple assembly steps (i.e., assembling an elastic waistband with a first elastic adhesive layer and then adding a second elastic adhesive layer) with a single application of a single adhesive layer. Furthermore, the use of elastic adhesives that have different zones offers a uniquely variable level of compression across different areas of the edge trim, thanks to a fully customizable “holes” pattern which can be achieved through perforation or by application of an open mesh adhesive structure.

[0057] As utilized herein, the terms “comprises” and “comprising” are intended to be construed as being inclusive, not exclusive. As utilized herein, the terms “exemplary”, “example”, and “illustrative”, are intended to mean “serving as an example, instance, or illustration” and should not be construed as indicating, or not indicating, a preferred or advantageous configuration relative to other configurations. As utilized herein, the terms “about”, “generally”, and “approximately” are intended to cover variations that may exist in the upper and lower limits of the ranges of subjective or objective values, such as variations in properties, parameters, sizes, and dimensions. In one non-limiting example, the terms “about”, “generally”, and “approximately” mean at, or plus 10 percent or less, or minus 10 percent or less. In one non-limiting example, the terms “about”, “generally”, and “approximately” mean sufficiently close to be deemed by one of skill in the art in the relevant field to be included. As utilized herein, the term “substantially” refers to the complete or nearly complete extent or degree of an action, characteristic, property, state, structure, item, or result, as would be appreciated by one of skill in the art. For example, an object that is “substantially” circular would mean that the object is either completely a circle to mathematically determinable limits, or nearly a circle as would be recognized or understood by one of skill in the art. The exact allowable degree of deviation from absolute completeness may, in some instances, depend on the specific context. However, in general, the nearness of completion will be so as to have the same overall result as if absolute and total completion were achieved or obtained. The use of “substantially” is equally applicable when utilized in a negative connotation to refer to the complete or near complete lack of an action, characteristic, property, state, structure, item, or result, as would be appreciated by one of skill in the art.

[0058] Numerous modifications and alternative embodiments of the present invention

[0059] will be apparent to those skilled in the art in view of the foregoing description. Accordingly, this description is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the best mode for carrying out the present invention. Details of the structure may vary substantially without departing from the spirit of the present invention, and exclusive use of all modifications that come within the scope of the appended claims is reserved. Within this specification embodiments have been described in a way that enables a clear and concise specification to be written, but it is intended and will be appreciated that embodiments may be variously combined or separated without parting from the invention. It is intended that the present invention be limited only to the extent required by the appended claims and the applicable rules of law.

[0060] It is also to be understood that the following claims are to cover all generic and

[0061] specific features of the invention described herein, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.

Examples

Embodiment Construction

[0036]An illustrative embodiment of the present invention relates to a composite elastic

[0037]edge trim and a method of making. The composite elastic edge trim is made of fabric and includes an outermost edge formed by folding the fabric over itself, a distal zone, and a proximal zone between the distal zone and the fold. The proximal zone features a double adhesive layer bonding the fabric, while the distal zone has a single adhesive layer for fabric bonding. The double adhesive layer is twice the thickness of the single adhesive layer. This design resists “roll-over” and simplifies the manufacturing process by reducing the number of steps involved. The use of elastic adhesives with different zones provides variable compression across the edge trim.

[0038]FIG. 2 through FIG. 10, wherein like parts are designated by like reference

[0039]numerals throughout, illustrate an example embodiment or embodiments of a composite elastic edge trim of a selection of fabric and a method of making,...

Claims

1. A composite elastic edge trim of a selection of fabric, the composite elastic edge trim comprising:an outermost edge comprised of a fold formed by the fabric having been folded over itself along an edge;a distal zone of the composite elastic edge trim;a proximal zone of the composite elastic edge trim disposed between the distal zone and the fold;a double adhesive layer disposed in the proximal zone and bonding the fabric to itself;and a single adhesive layer disposed in the distal zone and bonding the fabric to itself;wherein the double adhesive layer is comprised of twice a thickness of the adhesive layer contained in the single adhesive layer.

2. The composite elastic trim of claim 1, wherein the double adhesive layer is comprised of a portion of the single adhesive layer that has been folded over itself at the fold to create the doubled thickness.

3. The composite elastic trim of claim 1, wherein the fabric comprises an elastic fabric.

4. The composite elastic trim of claim 1, wherein one or more of the double adhesive layer and single adhesive layer comprise an elastic adhesive.

5. The composite elastic trim of claim 4, wherein the elastic adhesive comprises an open structure.

6. The composite elastic trim of claim 5, wherein the elastic adhesive comprises a perforated solid elastic adhesive.

7. The composite elastic trim of claim 5, wherein the elastic adhesive comprises a mesh elastic adhesive.

8. The composite elastic trim of claim 4, wherein the elastic adhesive comprises multiple zones each having a different elasticity.

9. The composite elastic trim of claim 8, wherein each zone has a different open structure.

10. The composite elastic trim of claim 1, wherein an area of the proximal zone is about 50% or less of an area of the distal zone.

11. The composite elastic trim of claim 10, wherein the proximal zone is between 10-20 mm inward distance from the fold toward the distal zone.

12. The composite elastic edge trim of claim 1, wherein the double adhesive layer covers more than 50% of the selection of fabric such that forming the fold results in the double adhesive layer in the proximal zone.

13. The composite elastic edge trim of claim 1, wherein the composite elastic edge trim is configured to resist roll-over during use.

14. The composite elastic edge trim of claim 1, wherein the proximal zone provides a higher compression level than the distal zone.

15. A method of making a composite elastic edge trim of a selection of fabric, the method comprising:providing a selection of fabric;applying an adhesive layer to a portion of the fabric; andforming a fold by folding the selection of fabric over itself along an edge, resulting in the composite elastic edge trim having a distal zone and a proximal zone disposed between the distal zone and the fold;wherein the distal zone has a single adhesive layer bonding the fabric to itself;wherein the proximal zone has an adhesive layer bonding the fabric to itself.

16. The method of claim 15, wherein the double adhesive layer is comprised of a portion of the single adhesive layer that has been folded over itself at the fold to create the doubled thickness.

17. The method of claim 15, wherein the fabric comprises an elastic fabric.

18. The method of claim 15, wherein one or more of the double adhesive layer and single adhesive layer comprise an elastic adhesive.

19. The method of claim 18, wherein the elastic adhesive comprises an open structure.

20. The method of claim 19, wherein the elastic adhesive comprises a perforated solid elastic adhesive.

21. The method of claim 19, wherein the elastic adhesive comprises a mesh elastic adhesive.

22. The method of claim 15, wherein the elastic adhesive comprises multiple zones each having a different elasticity.

23. The method of claim 22, wherein each zone has a different open structure.

24. The method of claim 15, wherein an area of the proximal zone is less than about 50% of an area of the distal zone.

25. The method of claim 24, wherein the proximal zone is between 10-20 mm inward distance from the fold.

26. The method of claim 15, wherein applying the adhesive layer to a portion of the fabric comprises applying the adhesive layer to cover more than 50% of the selection of fabric such that forming the fold results in the double adhesive layer in the proximal zone.

27. The method of claim 15, wherein applying the adhesive layer and forming the fold are performed in a single manufacturing operation to create both the single adhesive layer in the distal zone and the double adhesive layer in the proximal zone.

28. The method of claim 15, wherein the composite elastic edge trim is configured to resist roll-over during use.

29. The method of claim 15, wherein the proximal zone provides a higher compression level than the distal zone.

30. The method of claim 15, wherein applying the adhesive layer comprises applying the adhesive layer by heat press or continuous lamination.

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