Patent Application
20180255854
The present application relates generally to garments and, more particularly, to garments with integrated reinforcement panels to improve garment durability.
A garment in accordance with one or more embodiments includes a plurality of material pieces and two reinforcement panels stitched together to form a clothing article shaped to cover a portion of a wearer's body. The reinforcement panels are integrated in the garment and stitched at edges thereof to edges of one or more adjacent material pieces. The reinforcement panels each comprise a plurality of layers overlaying one another, including: an inner layer having an inner surface facing the wearer when the garment is worn, an outer layer having an exposed exterior surface and an opposite interior surface, a fusible layer bonded to the interior surface of the outer layer, and a batting layer between the fusible layer and the inner layer. The outer layer includes a plurality of rows of pintuck stitches on the exposed exterior surface or, alternately, the outer layer, the fusible layer, and the batting layer are stitched together by a series of quilting stitches.
In accordance with one or more further embodiments, a method is disclosed for fabricating a garment, including the steps of: (a) forming a plurality of material pieces, each having a predetermined shape; (b) forming two reinforcement panels, each reinforcement panel comprising a plurality of layers overlaying one another, including: (i) an inner layer having an inner surface facing a wearer of the garment, (ii) an outer layer having an exposed exterior surface and an opposite interior surface, (iii) a fusible layer bonded to the interior surface of the outer layer, and (iv) a batting layer between the fusible layer and the inner layer; and (c) stitching the material pieces and reinforcement panels together to form a clothing article shaped to cover a portion of the wearer's body such that the reinforcement panels are integrated in the garment and stitched at edges thereof to edges of one or more adjacent material pieces. The method may further include in step (b) forming a plurality of rows of pintuck stitches on the exposed exterior surface of each reinforcement panel or, alternately, stitching the outer layer, the fusible layer, and the batting layer of each reinforcement panel together by a series of quilting stitches.
Many garments, especially children's pants and tops, tend to rip easily at the knees or elbows after a few wears and washes. Various embodiments disclosed herein are directed to garments with integrated reinforcement panels to increase durability. The panels can be integrated in pant legs at the knee area or top sleeves at the elbow area. The integrated reinforcement panels increase the life and wear of the garments as well as provide improved comfort to wearers. The reinforcement panels are integrated in the garments, providing a stylish appearance.
The reinforcement panels can be integrated in a variety of garments including, but not limited to, pants (especially children's pants) long-sleeved T-shirts, long-sleeved sweatshirts, long-sleeved hooded tops (with or without a zipped front closure), and other tops.
The outer layer 16 can be made of a variety of fabrics (e.g., cotton, polyester, and other materials) that can be selected based on the quality and content of the style of the pants incorporating the panels. It is typically made of the same fabric as the garment's body fabric. In the
The fusible layer 18 can comprise, e.g., an adhesive tricot interlining fusible that is heat sealed to the interior surface of the outer layer 16, after the outer layer has undergone the pintucking process. The fusible layer 18 provides strength to the outer layer 16, making the outer layer more resistant to stretching and tearing from abrasion.
Other fusible materials suitable for use in clothing can also be used including, e.g., a woven fusible, a knit tricot interlining fusible, or a polyurethane film. The fusible layer may incorporate a variety of adhesives including, e.g., dot lamination adhesive or a web adhesive. The fusible layer may have adhesive properties on one or both sides. Alternately, the fusible layer may have adhesive properties on one side and an abrasion resistant fabric on the other side. The fabric may be rigid or include stretch polymers. Additionally, the fusible layer may comprise a pre-laminated fabric with adhesive properties on both sides. The fusible layer may also comprise seam reinforcement tape, and can comprise one-sided or two-sided abrasion resistant laminate film.
The batting layer 20 can comprise a variety of batting materials including, e.g., a polyester, poly-fil batting. By way of example, the weight of the batting can range from 20-40 g/m2. The batting layer provides some cushioning or protection for the wearer's knees (or elbows in the case of tops). In addition, the batting layer enhances the appearance of the garment.
The inner layer 14 can be made of a variety of materials. However, it preferably comprises the same fabric as the garment's body fabric, and may be the same fabric as the outer layer 16.
Once the four layers are assembled to form the reinforcement panel 8, the panel is seamed into the rest of the garment. As shown in
The garments described herein involve reinforcement panels that are seamed into or integrated in the garments by being stitched at edges thereof to edges of one or more adjacent material pieces of the garments, rather than simply being layered over portions of existing garments. However, in one or more alternate embodiments, the reinforcement panels may be applied onto portions of existing garments.
Like the panel 8 shown in
In the panel 7 of
Once the panel 7 is formed, it is seamed into the rest of the garment similar to the panel 8 in
The following illustrates one example of a process for manufacturing a pair of pants with integrated reinforcement panels in accordance with one or more embodiments.
The fabric used in constructing the pants is cut into a plurality of pattern pieces using standard pattern design and cutting techniques.
The fabrics and materials needed for the reinforcement panels are also cut, and the reinforcement panels are assembled as previously described.
Next, the pattern pieces and reinforcement panels are stitched together. First, the front of each pant leg is assembled. By way of example,
The back of the pant (not shown) is also assembled in a standard process. For example, in the case of jeans, the pockets are stitched onto the back seat area of the pant and the top yolks are stitched onto the top portion near the waist with a flat feld seam. Once these operations have been performed for both back legs they are ready to be assembled to the front legs of the pants.
The inseam/seam at the inside of the leg is stitched first. This is seam 30 in
Next, both completed pant legs are assembled to each other at the rises. If the pant has a zipper opening, a zipper operation is done at this time. The seams are generally the same type of stitching technique as described above stitched and overlocked. In the case of jeans, the rises are flat feld seams, below the zipper fly.
Next the front pockets are constructed into the front of the pants near the waist.
The pants are then assembled at the side seams/outseams. This is seam 28 in
In the case of a jean or Chino pant, the inside and outside of waistband are joined together at the top of waist, while the top of the belt loops are sandwiched between the layers. The jean and chino pant styles may have an adjustable waist feature, which is an encased specialty elastic that has buttonholes built into it. There is one button stitched onto the inside of the waistband near each end of the waistband. This allows for waist adjustments as needed for children having different sized waists. The waistband is then seamed onto the pant. The bottoms of the belt loops are then stitched onto the pant.
The hem of the pant is folded in at the top and then folded again and stitched with a straight stitch for a clean finish. This is called a double bend back hem.
Once the garments are completed, the styles that need washing are washed, dried, and pressed. The pants are then labeled and tagged. Some of the bulk then gets reviewed by a quality control team for make and measurement verification. Pants are then folded and bagged and are ready to ship.
Having thus described several illustrative embodiments, it is to be appreciated that various alterations, modifications, and improvements will readily occur to those skilled in the art. Such alterations, modifications, and improvements are intended to form a part of this disclosure, and are intended to be within the spirit and scope of this disclosure. While some examples presented herein involve specific combinations of functions or structural elements, it should be understood that those functions and elements may be combined in other ways according to the present disclosure to accomplish the same or different objectives. In particular, acts, elements, and features discussed in connection with one embodiment are not intended to be excluded from similar or other roles in other embodiments. Additionally, elements and components described herein may be further divided into additional components or joined together to form fewer components for performing the same functions. Accordingly, the foregoing description and attached drawings are by way of example only, and are not intended to be limiting.
