The present invention relates to garments that are fastened with a plurality of hook and eye pairs. More specifically the present invention comprises elastically elongatable hook or eye tape with improved wear and comfort characteristics that is useful for brassieres and will dynamically adjust the girth of the garment to conform to the needs and movements of the wearer.
Garments such as brassieres have used hook and eye fasteners for more than ninety years. The hooks and eyes are mounted on a stabilized (non-stretchable) fabric, usually referred to as a “tape.” The tape is then mounted on the garment. Typically, a set of vertical columns and rows of eyes, usually between two and four in number, are aligned on a tape. Similarly there is a tape containing one corresponding vertical column of hooks such that the number of eyes per each column corresponds to the number of hooks. If there are three hooks in the hook column, there will be three eyes in each vertical column of eyes.
The use of multiple, horizontally-spaced columns of eyes allows for minor horizontal adjustment to the garment's fit. Typically, multiple eye columns are separated by about five eighths of an inch, or approximately 16 millimeters on a portion of the stabilized fabric eye tape. In such a case, if there were three columns of eyes mounted on the tape, the wearer would have and adjustment range of five eighths to one and a quarter of an inch (16 to 32 millimeters). If the brassiere is of an incorrect size, discomfort and poor fit are experienced. Studies show that 30% of women buy brassieres of a size too small. Often the brassiere size requirements change over time or even during the day. Multiple columns of eyes provide for some relief, but the wearer is limited to a few fixed positions. Additionally, when the hook row gets inserted into an eye row, the back of the hook can often be felt through the fabric of the eye tape by the wearer due to the pressure of the closure. Furthermore, the back of the bra where the tapes are attached has a tendency to ride up on the wearer's back, requiring the wearer to re-adjust the garment.
Adjustment capabilities greater than that provided by multiple eye columns was desired. Further, it was desirable to have a garment automatically adjust (expand and contract) without intervention by the wearer. A prior attempt to address this adjustment issue is disclosed in commonly-owned U.S. Pat. No. 6,520,832. While the decreased tension in the garment due to the horizontal flexibility lessened the pressure of the hook as it pressed against the wearer, it did not totally eliminate the discomfort. Additionally, the present inventors have found that the flexible knitted fabrics used to achieve the girth adjustment as disclosed in commonly-owned U.S. Pat. No. 6,520,832 caused other problems. When manufactured with ordinary sewing techniques, the edges of the flexible knitted fabrics tended to fray, causing premature wear of the edges of the hook and eye tape and discomfort to the user. When the edges of the tape were heat sealed to prevent fraying, the heat sealed edges were uncomfortably hard/sharp and would later crack when stretched, making audible cracking noises. Again, this cracking caused premature wear of the edges of the hook and eye tape and discomfort to the user. Further, the uni-directional stretch tape of U.S. Pat. No. 6,520,832 had sufficient vertical rigidity in the hook and eye tapes to cause the tapes to shift vertically out of place when the wearer moved, requiring the wearer to adjust the garment.
What would be desirable is an apparatus and method for dynamically adjusting the girth of a garment fasted by hook and eye that has markedly increased comfort to the wearer and improved durability.
The present invention incorporates a laminated base tape for a hook and eye closure that provides for dynamic adjustment of the girth of a garment by using an elastically elongatable fabric that has been laminated to at least one additional elastically elongatable layer. The glue or adhesive used for the lamination of the layers effectively prevents unacceptable fraying of the edges of the elastically elongatable fabric and, when an additional elastically elongatable layer on the eye tape is formed from a elastically elongatable cushioning material such as stretchable foam, discomfort due to pressure of the hook pressing against the user can be substantially eliminated. The laminated base tape allows for a smooth, comfortable, and durable edge, whether ultrasonically sealed and cut, laser cut, scissor/blade cut, or die cut. Omni-directional elastic elongation of the base tape allows the base tape to move with the wearer to remain comfortably in place.
It is an aspect of the invention to provide flexibility to garment size without the wearer having to make a manual adjustment by use of an elastically elongatable, laminated base tape in a hook and eye closure of the garment.
It is a further aspect of the invention to provide size flexibility to a brassiere without the wearer having to make an adjustment by use of an elastically elongatable, laminated base tape in a hook and eye closure of the brassiere.
It is an aspect of the invention to provide a garment or brassiere that moves with the wearer through use of an elastically elongatable, laminated base tape in a hook and eye closure.
It is another aspect of the invention to provide a smooth, comfortable edge to a hook and eye closure through use of an elastically elongatable, laminated base tape.
It is another aspect of the invention to provide flexibility to a garment size with improved wearer comfort through use of an elastically elongatable cushioning layer on the eye tape of a hook and eye closure of the garment.
It is another aspect of the invention to provide flexibility to a brassiere size in a horizontal dimension with improved wearer comfort through use of an elastically elongatable cushioning layer on the eye tape of a hook and eye closure of the brassiere.
It is yet another aspect of the invention to provide an elastically elongatable eye tape for a hook and eye closure with cushioning for improved comfort.
As previously disclosed in commonly-owned U.S. Pat. No. 6,520,832, although the addition of flexibility to a hook and eye closure, such as used in a brassiere, may appear simple, a workable solution for use in a brassiere is by no means trivial. Proper manufacture of a hook and eye closure for a brassiere was believed to depend on stability of the hook and eye tape used so as to assure proper alignment of the fastener during sewing operations on conventional machinery. Mere substitution of the stabilized tape material with single or multiple plies of stretchable material resulted in unacceptable misalignment of the fasteners.
In an attempt to solve these problems, the inventor in commonly-owned U.S. Pat. No. 6,520,832 selected a material for the tape that stretched in only one direction so as to enable elastic horizontal elongation while maintaining vertical stability to allow for proper alignment of hooks and eyes during sewing operations with existing production machinery. However, these unidirectional elongatable base tapes suffered from problems with fraying of blade-cut edges and uncomfortably sharp heat-sealed edges.
Upon further investigation by the present inventors, it has been found that substitution of the stabilized tape material with a stretchable material does not result in unacceptable misalignment of the fasteners if the stretchable material is formed of laminated layers of elastically elongatable material. Additionally, use of omni-directional elastically elongatable material increases user comfort by moving better with the wearer. Furthermore, the lamination of the elastically elongatable layers prevents fraying of blade-cut edges and forms comfortably smooth heat-sealed and/or ultrasonically-cut edges.
Embodiments of the present invention provide flexibility to a hook and eye closure, such as used in a brassiere, by forming a base tape of a hook and eye closure from a first elastically elongatable fabric layer laminated to at least one additional elastically elongatable layer. The elastically elongatable fabric layer will typically be formed of a knitted fabric with elastic fibers, such as DuPont Lycra®. The at least one additional flexible layer can be formed of a knitted fabric with elastic fibers, a stretchable foam, or a rubber-based product. In some embodiments, the base tape will include more than one additional elastically elongatable layer. The elastically elongatable layers are laminated to one another using a suitably flexible glue or adhesive so as to form laminated packages. While it is possible to use elastically elongatable layers with unidirectional stretch in the horizontal direction, the present invention does not require this property, and preferably uses elastically elongatable layers that stretch in various directions (e.g., omni-directional stretch) for improved wearer comfort.
In another embodiment, illustrated in
The elastically elongatable base tape 14 illustrated in
As illustrated by the arrow between
The base tape on the hook side further includes laminated, elastically elongatable layers 26 and 27, although only one of these is needed for practice of the invention on the hook-side base tape. While layers 26 or 27 could be made of stretchable foam, the primary purpose of the stretchable foam is to provide cushioning between the hook and the wearer. Since layers 26 and 27 are not positioned between the hook and the wearer, use of cushioning material is not critical for these layers, which will typically be formed of elastically elongatable fabric or rubber. Additionally, where a rubber layer is used, an additional elastically elongatable fabric layer is preferably laminated to the lower side so as a soft backing material to place fabric next to the skin of the wearer, which is typically more comfortable and tactilely pleasing than rubber.
In use, either one of the eye tape and hook tape or both can be fabricated in this manner. When the eye tape is elastic, a stable hook tape with one column of hooks can be used. When the hook tape is stretchable, it is preferable to provide an extended elastically elongatable tape portion so as to provide for adequate elongation, as shown between the seams in
The typical elongation for use in a brassiere will be between 10-50% with 20-30% being a preferred range, although this is not meant as a limitation. Of course, other applications can have different requirements and preferred ranges.
A suitable, elastically-elongatable material is nylon fabric with elastic fibers such as spandex in a proportion needed to provide the desired elongation in the horizontal direction. Varying the cross section of the base tape can be used to vary the elongation properties. For example, if a trapezoidal base tape is used, with the large end abutting the garment, the tape will have less elongation when worn in a “tight” position, which is acceptable since the wearer can use the other eye hooks to loosen the fit. However, when worn in the “loose” position, the tape will allow additional elongation due to the smaller cross-section of the base tape at that end. This is desirable since the wearer does not have the option of loosening the garment further when worn in this position.
The process to manufacture the item as shown in
In a preferred embodiment, the comfort and aesthetics of the base tape are improved by the addition of an elastically elongatable back cover layer 68, as illustrated in
In use with a brassiere, the hook tape is attached to one of two back sections of the brassiere. In this embodiment, the hooks are facing inward toward the opposite side of the brassiere to interface with the eyes opposite thereto. The tapes vertical axis is aligned with the back sections' vertical edge. The eye tape is attached to the brassiere's other back section, facing outward such that the eyes and hooks align and face each other. The wearer fastens the brassiere by inserting each hook into each eye of a corresponding column. Some adjustment will be achieved when the wearer selects the column to use when fastening. If the inboard column of eyes is used, then the minimum horizontal brassiere size will be achieved. If the outboard column of eyes is used, then the maximum horizontal brassiere size will be achieved.
In the event that the brassiere is still too small, the elastically elongatable tape holding eyes (or the hooks, or both) will stretch. The elastically elongatable material has the ability to recover back to its original dimensions and shape. While the closure of the present invention can provide virtually any desirable amount of elongation, the practical limits are about 10% to 100% elongation, although this is not meant as a limitation. In most embodiments, about 20% to 30% elongation should be sufficient to provide measurable comfort to the wearer.
While discussed herein for use in a brassiere, the invention has utility for other garments, including, but not limited to, body slimmers, corsets, trusses, lingerie, bikini tops, and halter tops.
As used herein, the term hardware used in reference with hook and eye closures refers to the discrete, rigid hooks and eyes, which can be made of metal, plastic, and combinations thereof. The terms sewing and sewn, as used herein, refer to any suitable attachment process, including, but not limited to, using thread, using adhesives, and using ultrasonic fabric sealing methods commonly known as ultrasonic sewing. The term base tape, as used herein, refers to garment portions to which hook and eye hardware are attached. While disclosed herein as being sewn or bonded to a garment, base tape can also be formed integral with the garment.
A first embodiment is drawn to a base tape for a hook and eye closure to allow dynamic girth adjustment of a garment, comprising: a first elastically elongatable fabric layer; at least one additional elastically elongatable layer laminated with adhesive to the first elastically elongatable fabric layer to form an elastically elongatable base tape; and hook or eye closure hardware sewn to the elastically elongatable base tape. This embodiment is not limited to these elements and can include additional structure.
Variations on this first embodiment include: those wherein the at least one additional elastically elongatable layer comprises a second elastically elongatable layer consisting of cushioning material and a third elastically elongatable layer consisting of fabric that is laminated to the second elastically elongatable layer, wherein the cushioning material can be selected from the group consisting of fabric, stretchable foam, flex foam, and rubber; those wherein the closure hardware consists of a plurality of spaced eyes; those wherein the closure hardware comprises at least one hook; those further comprising an elastically elongatable cover strip fabric attached to the elastically elongatable base tape to conceal attachment points of the closure hardware; and those wherein the garment consists of a brassiere.
A second embodiment is drawn to a hook and eye closure for allowing dynamic girth adjustment of a garment, comprising: an eye tape, said eye tape comprising: an elastically elongatable base fabric that elongates elastically in a first direction; at least one additional elastically elongatable layer laminated to the base fabric to form a laminated base tape; at least one eye column positioned on said laminated base tape wherein said at least one eye column extends in a second direction perpendicular to the first direction; and at least one eye row in said at least one eye column, each row containing an eye secured to said laminated base tape; a hook tape, said hook tape comprising: a hook base tape; one hook column positioned on said hook base tape in said second direction; and at least one hook row in said at least one hook column, each row containing a hook secured to said hook base tape.
Variations on this embodiment include: those further comprising: a plurality of parallel eye columns spaced apart from each other in said first direction, a plurality of eye rows in each eye column spaced apart from each other in said second direction, and a plurality of hook rows in said one hook column spaced apart from each other in said second direction and corresponding in number to said plurality of eye rows; those wherein said hook base tape is stabilized; those wherein said hook base tape further comprises an elastically elongatable base fabric that elongates elastically in a first direction, and at least one additional elastically elongatable layer laminated to the base fabric to form a laminated base tape; those wherein said closure allows between about 10% and about 100% elongation; those wherein said closure allows between about 20% and about 30% elongation; those wherein said elastically elongatable base fabric is nylon or polyester with a percentage of elastic fibers oriented in said first direction; those wherein said at least one additional elastically elongatable layer laminated to the base fabric is a cushioning material; and those wherein said eye tape and said hook tape are attached to corresponding girth portions of a brassiere.
Another embodiment is drawn to a method of allowing dynamic girth adjustment of a garment, comprising providing the hook and eye closure of the previous embodiment to corresponding girth portions of said garment, and securing said garment to a wearer using said hook and eye closure. A variation on this method includes further comprising providing said hook and eye closure to corresponding girth portions of a brassiere.
Yet another embodiment is drawn to a method of forming a stretchable hook and eye closure for a garment, comprising: forming an eye tape, said forming comprising: providing a base fabric that elongates elastically, laminating at least one additional elastically elongatable layer to the base fabric to form an elastically elongatable base tape, securing at least one eye column on said elastically elongatable base tape by securing at least on eye to said base fabric to form at least one eye row in said at least one eye column; and forming a hook tape, said forming a hook tape comprising: providing a hook base fabric, and positioning one hook column in said second direction on said hook base fabric by securing at least one hook to form at least one hook row in said at least one hook column.
Variations on this method include: those further comprising: positioning a plurality of parallel eye columns spaced apart from each other in a first direction, positioning a plurality of eye rows in each eye column spaced apart from each other in a second direction perpendicular to the first direction, and securing a plurality of hook rows in said one hook column spaced apart from each other in said second direction and corresponding in number to said plurality of eye rows; those wherein providing said hook base fabric comprises: providing a base fabric that elongates elastically, and laminating at least one additional elastically elongatable layer to the base fabric to form an elastically elongatable base tape; those wherein said closure allows between about 10% and about 100% elongation; those wherein said closure allows between about 20% and about 30% elongation; those wherein said base fabric is nylon or polyester with a percentage of elastic fibers; those wherein said eye tape and said hook tape are attached to corresponding girth portions of a brassiere; those wherein said at least one additional elastically elongatable layer is formed of cushioning material; and those wherein said at least one additional elastically elongatable layer further comprises an elastically elongatable fabric layer laminated to the cushioning material.
Although described herein with reference to particular embodiments, one of ordinary skill in the art will recognize that numerous additional embodiments are possible and that various modifications can be made without departing from the scope of the present invention, which is limited only by the claims below. For example, the number of eyes/hooks per column, the number of eye columns, the eye spacing, the column spacing, the materials used, the fabric layering arrangements, the sewing or other fastening used, the type of garment, the orientation of the hooks/eyes with respect to the garment, the base tape shapes, etc. can all be varied for particular applications without departing from the scope of the invention. Similarly, one of skill in the art would recognize the utility of practicing the invention with similar fasteners, such as used on snap tapes of teddys. Further, any reference to claim elements in the singular, for example, using the articles “a,” “an,” or “the” is not to be construed as limiting the element to the singular.
This application claims the benefit of U.S. Provisional Application No. 60/892,730, filed Mar. 2, 2007, which is hereby incorporated by reference.
Number | Name | Date | Kind |
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6520832 | Devita et al. | Feb 2003 | B2 |
6837771 | Falla | Jan 2005 | B2 |
Number | Date | Country | |
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20080214090 A1 | Sep 2008 | US |
Number | Date | Country | |
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60892730 | Mar 2007 | US |