Patent Application
20120023641
1. Field of the Invention
The present invention is directed to a patch for a performance garment and a method for applying the patch.
2. Background Art
It is well known that patches can be used for repairing tears or cuts in fabrics. In the past, some patches have been stitched or sewn onto an item of apparel. Some patches include an adhesive on one side of the patch and can be adhered to the item of apparel using heat or pressure. Traditionally, patches used to repair tears or cuts in performance apparel for athletes have been made from relatively heavy and rigid woven fabrics.
Recently, it has become popular for apparel to be made from lightweight, stretchable fabric, particularly in performance apparel. However, because the apparel is lightweight and stretchable, it may rip or be cut easier than heavier clothing. For apparel designed to be worn during ice hockey or other skating sports, for example, this problem may be particularly apparent due to incidental contact with the blades of an ice skate. When traditional patches are applied to such apparel, they can encumber the underlying garment and can hinder the wearer's movement during use. Moreover, such patches tend to be heavy and bulky and sewing or stitching them onto an item of apparel can be a time consuming process. In addition, sewing a patch can denigrate or otherwise weaken the underlying garment due to, for example, needle holes from the sewing process. Any such weakening can be especially problematic for performance garments. Accordingly, there is a need in the art to develop innovative patches and methods of applying and producing said patches that are more suitable for such apparel.
In some embodiments, a patch for a performance garment includes a sheet of fabric and an elastomeric adhesive adhered to one side of the sheet such that the sheet may be applied to the garment. At least one of the sheet and the elastomeric adhesive has an independent stretch greater than the stretch of the garment. Some embodiments of the invention include methods of repairing an opening in or reinforcing a garment using the patch, repair kits for containing the patch, and methods of making the patch.
In some embodiments, a method of reinforcing or repairing an opening in a performance garment using a patch includes: providing a patch including a sheet of fabric, an elastomeric adhesive adhered to one side of the sheet, and a backing sheet removably attached to the elastomeric adhesive; preparing the garment for application, including arranging the garment so that the garment is inside out and an area of application of the garment is laid substantially flat; peeling off the removable backing sheet; placing the adhesive side of the patch on the area of application; and applying heat and pressure to the patch to bond it to the garment.
In some embodiments, a repair kit for reinforcing or repairing an opening in a garment includes: a plurality of sheets of fabric each having a backing and an elastomeric adhesive disposed between the sheet and the backing, wherein at least one of the sheet and the elastomeric adhesive have an independent stretch greater than the stretch of the garment; and a container adapted to hold the plurality of sheets.
In some embodiments, a method of manufacturing a patch for a performance garment includes providing a sheet of fabric; and adhering an elastomeric adhesive and a removable backing to the fabric, wherein at least one of the sheet and the elastomeric adhesive have an independent stretch greater than the stretch of the performance garment.
The accompanying drawings, which are incorporated herein and form a part of the specification, illustrate the present invention and, together with the description, further serve to explain the principles of the invention and to enable a person skilled in the pertinent art to make and use the invention.
The present invention will now be described in detail with reference to embodiments thereof as illustrated in the accompanying figures. While specific configurations and arrangements are discussed, it should be understood that this is done for illustrative purposes only. References to “an embodiment”, “one embodiment”, “another embodiment,” etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases do not necessarily refer to the same embodiment. Further, a person skilled in the relevant art will recognize that other configurations and arrangements can be used without departing from the spirit and scope of the invention.
Patches can be used in hockey socks, jerseys, gloves, pants, track suits, hats, socks, shorts, shirts, shoes, and protective equipment for a variety of other sports (such as, for example, speed skating, football, lacrosse, baseball, and soccer). Some specific areas that the patches can be used for repair and/or reinforcement include the palms of gloves, the knee, groin, or buttocks areas of pants or shorts, and the cuff, collar, or elbow area of a shirt or jersey, for example.
In one embodiment, as shown in
In some embodiments, the apparel is made of a stretchable material or the portion to which the patch is applied is made of a stretchable material. In some embodiments, the stretchable material has a stretch of at least about 5%, at least about 10%, or at least about 20%. In some embodiments, the stretch of the stretchable material can be in a range of about 5% to about 30%, about 5% to about 50% or about 5% to about 100%. One method of determining the stretch of a material includes hanging the material with no load attached, then measuring a distance (A1) between two benchmarks on the material. A ten pound force is then applied to the bottom of the material. A distance (D) between the two benchmarks is measured. Stretch is measured as a percentage and is determined by formula Stretch=100×[(D−A1)/A1. Accordingly, a completely non-stretchable material would have a 0% stretch. In some embodiments, the patch and the apparel each have an independent stretch (i.e., the stretches of each item are each measured when they are not joined together) of at least about 5%, at least about 10%, at least about 15%, or at least about 20%. For example, the patch and the apparel can each have independent stretch in the range of about 5 to about 40% such as a stretch in the range of about 5 to about 30% or about 5 to about 20%.
Some embodiments of the patch include one or more natural or synthetic materials, or combinations thereof, suitable for athletic apparel. Some embodiments include woven, non-woven, or knit material. Suitable materials include, but are not limited to, those made of cotton, flax, silk, polyester, aramid, acrylic, nylon, cellulose-based materials such as rayon or viscose, polyurethane, spandex, and/or olefin. In some embodiments, the article, or portions of the article to which the patch is applied can be made of a polyester/spandex blend material.
In one embodiment, patch 100 can be made from a substrate, such as polyester fabric 110. In one embodiment, patch 100 may comprise a single substrate layer in order to provide a more lightweight and flexible patch. In other embodiments, patch 100 may comprise multiple substrate layers.
Examples of substrate fabrics that can be used include polyester/spandex blends. In some embodiments, a polyester/spandex blend substrate includes about 70% to about 90% polyester fiber by weight such as, for example, about 78% to about 87% polyester fiber by weight, with the balance being spandex fiber. In some embodiments, a polyester/spandex blend substrate has a warp knit construction. The polyester/spandex blend substrate can have a fabric weight of about 4 to about 8 ounces per square yard such as about 4.5 to about 7.5 or about 4.75 to about 7.35 ounces per square yard. Examples of suitable polyester/spandex blends include those available from Darlington Fabrics (New York, N.Y.) such as Style Nos. 00025KW09, 26050, 00191KW07, and 26480.
The patch substrate can be selected to have a thickness compatible with a performance garment such as a hockey uniform. In some instances, the patch substrate is no thicker than the underlying performance garment fabric. In some embodiments, the patch substrate is substantially thinner than the underlying performance garment fabric. For example, the substrate can have a thickness of less than about 4 mm, less than about 3 mm, or less than about 2 mm. In some embodiments, the substrate can have a thickness of, for example, about 0.1 mm to about 3 mm such as about 0.1 to about 2 mm, about 0.2 to about 1.5 mm, or about 0.2 mm to about 1.2 mm.
In some embodiments, the patch includes a stretchable patch substrate having a stretch of at least about 10%, at least about 20%, or at least about 40%. For example, the stretch of the stretchable patch substrate can be in a range of about 20% to about 200% or about 40% to about 180%.
Suitable substrate materials can include, but are not limited to, those made of cotton, flax, silk, polyester, aramid, acrylic, nylon, cellulose-based materials such as rayon or viscose, polyurethane, polypropylene, spandex, olefin, polyethylene, para-aramid synthetic fiber (e.g., Kevlar), carbon fiber, and combinations thereof. In some embodiments, the patch substrate can include a polyester or a polyester blend.
In some embodiments the patches can be simply fabric and adhesive. In other embodiments, the patches can also include a reinforcing layer such as a cut or resistant material. Suitable materials for this reinforcing layer include, but are not limited to, a resin containing a hard material and cut resistant fabric such as para-aramid synthetic fiber (e.g., Kevlar)). The reinforcing layer can further or alternatively include any of a variety of materials that increase the cut resistance of the patch. For example, the hard material could include ceramics, polymers, minerals, rocks, metals and combinations thereof. In some embodiments, the hard material is a cut resistant resin-based material such as SUPERFABRIC™ Custom Engineered High Performance Fabric (HDM, Inc.; Oakdale, Minn.). In some embodiments, the patch includes an adhesive applied over the reinforcing portion which was applied over a polyester/spandex substrate. The resulting patch has a stretch of at least about 5%, at least about 10%, or at least about 15%. For example, the stretch of such a patch can be in a range of about 5% to about 50% or about 15% to about 40%.
In some embodiments, a patch including a hard material is no more flexurally rigid than the underlying apparel. In some embodiments, a patch including a hard material is substantially less flexurally rigid than the underlying apparel. In some embodiments, the patch itself can have flexural rigidity, for example, of less than about 10 milligram-centimeters (×10−4) (mg cm×0.0001) or about 1 to about 10 mg cm×0.0001. In some embodiments, the reinforcing portion is attached to the patch substrate layer. In one embodiment, the adhesive layer then overlies the reinforcing portion. In other embodiments, the adhesive layer and the reinforcing portion overlie opposite sides of the patch substrate.
The method outlined in European Standard EN388 can be used to access cut resistance (cutting by sharp objects) of a patch of the present invention. The disclosure of this standard is incorporated in its entirety by reference thereto. For example, a circular blade can be moved back and forth across a sample under a fixed load while rotating in the opposite direction of the linear movement and the number of repetitive cuts needed to cut through the fabric can be compared to a standard such as, for example, cotton fabric. Cut Index can be calculated that compares the fabric sample to the standard. For example, a Cut Index of 3 means the sample has three-times better cut resistance than the standard. According to International Skating Union Communication No 1159 (May 20, 2002), which is incorporated in its entirety by reference thereto, protective competition clothing/uniforms should have a Cut Index of 5.94 according to EN388 in a cut resistance test (resistance to cutting by sharp objects). In some embodiments of the present invention, patches and/or apparel which include the patches have a Cut Index greater than the apparel alone. In some embodiments the Cut Index of the patches and/or the apparel, which include the patches have a cut index of at least about 2, at least about 3, or at least about 4. In some embodiments the patches, particularly patches including a reinforcing portion, have a Cut Index that exceeds the International Skating Union's recommendation of 5.94. In some embodiments, the Cut Index of the patch is at least about 6, at least about 8, or at least about 10.
In one embodiment, patch 100 may comprise a lightweight and flexible material such that the patch may flex with the article without substantially restricting movement of the wearer. In one embodiment, patch 100 may comprise a material having a stretch or modulus of elasticity substantially similar to that of the article of clothing.
The patch can be constructed to have a flexural rigidity compatible with a performance garment. In some instances, the patch itself is no more flexurally rigid than the underlying performance garment fabric. In some embodiments, the patch itself is substantially less flexurally rigid than the underlying performance garment fabric. In some embodiments, the patch itself can have flexural rigidity, for example, of less than about 10 milligram-centimeters (×10−4) (mg cm×0.0001) or about 1 to about 10 mg cm×0.0001.
The patch adhesive layer can be selected to have a thickness compatible with a performance garment. The patch can have an adhesive layer thickness, for example, of about 0.002 inch to about 0.007 mm such as about 0.004 inch.
The patch can be constructed to have a thickness compatible with a performance garment. In some embodiments, the patch is no thicker than the underlying performance garment fabric. In some embodiments, the patch itself is substantially thinner than the underlying performance garment fabric. In some embodiments, the patch itself can have a thickness of less than about 4 mm, less than about 3 mm, or less than about 2 mm. For example, the patch can have a thickness of for example, about 0.1 mm to about 3 mm such as about 0.2 to about 2 mm or about 0.25 mm to about 1.4 mm.
In one embodiment, patch 100 may comprise a lightweight material. For example, patch 100 may include a fabric with a weight of less than 350 grams per square meter (g/m2), less than about 300 g/m2, or less than about 250 g/m2. In one embodiment, patch 100 may have a fabric with a weight in the range of from about 100 g/m2 to about 350 g/m2 such as about 100 to about 250 g/m2. In one embodiment, patch 100 may include a fabric with a weight of about 230 g/m2. The lightweight nature of patch 100 may enhance the wearability of the article of clothing.
In one embodiment, patch 100 may comprise a material with little or no shrinkability. For example, patch 100 may comprise a material having a maximum of about 2.5% shrinkage. In one embodiment, patch 100 may comprise a hydrophobic material and/or may include a water repellent finish.
Fabric 110 may be generally rectangular, as shown in
Fabric 110 has a front surface 310 and an opposing back surface 320. In one embodiment, patch 100 includes an elastomeric adhesive adhered to back surface 320 for attaching patch 100 to fabric, such as an article of apparel. In one embodiment, patch 100 includes a removable backing sheet 330 adhered to the back surface 320 for protectively covering the adhesive prior to application of the patch to the article of clothing. Backing sheet 330 may be a polypropylene liner, or other suitable material. The adhesive layer can be a continuous layer or a discontinuous layer. The layer can be uniform or not. The layer can be a film or a pattern in the form of dots, lines, areas of greater concentration of adhesive or any other suitable pattern.
In some embodiments, the stretchability of patch 100 may make it particularly suitable for attaching to an article of apparel made from a stretchable material, as patch 100 may stretch with the article of apparel. This may be an advantage over prior patches because when the article of apparel stretches but a patch does not, the attachment means can be weakened, increasing the likelihood that the patch will detach. Accordingly, allowing patch 100 to stretch with the article of apparel to which it is attached may increase the durability of patch 100 and/or minimize the likelihood that patch 100 will become detached. Furthermore, when patch 100 is attached to stretchable and recoverable athletic apparel, such as apparel used for playing hockey, the apparel can better accommodate the wearer's movements as compared to when traditional patches are used on apparel. In addition, use of patch 100 on apparel can reduce misplacement or shifting relative to underlying protective equipment (e.g., protective pads) as compared to apparel with traditional patches. For example, patch 100 can be less likely to snag or hinder the movement of protective equipment underlying the apparel than traditional, bulky and rigid, patches.
In preferred embodiments, the adhesive is stretchable. In some embodiments, the adhesive has an independent stretch of at least about 5%, at least about 25%, at least about 50%, or at least about 70%. In some embodiments, the adhesive is an adhesive film with an independent stretch of about 70% to about 100% such as about 80% to about 90%.
The adhesive may have a low softening point ideal for heat sensitive fabrics and continuous processing operations. For example, the adhesive may be made of an ester polyurethane. The adhesive layer may be transparent, opaque, clear, white, or colored or any other suitable color or appearance. In some embodiments, the adhesive can have a weight of 31 gm/m2 per 25 microns. In some instances, the adhesive may have a softening point of about 65 to about 100 degrees Celsius such as about 70 to about 85 degrees Celsius or about 75 degrees Celsius. The adhesive may have a melt flow index of about 40 to about 60 decigrams/minute (dg/min) such as about 50 dg/min. Examples of suitable adhesives include, but are not limited to, film nos. 3206, 3206D, 3218, 3287, 3405, 3410, 4220, 5214, 5250, 5290, 6218, 6343, 6344, 6371, and 6385 available from Bemis Associates (Shirley, Mass.) and tape nos. EXF-367 and UAF-442 available from Adhesive Films, Inc. (Pine Brook, N.J.).
The patch may further or alternately be used to reinforce an area in an article of clothing. The areas where the patch is applied for reinforcement can be those that are prone to cut, tearing, or ripping. By using the patches a user can customize the placement of the reinforcement tailored to how the individual wearer experiences garment wear, cuts, tearing, ripping, etc.
In one embodiment, patch 100 is made according to the method outlined in the flowchart of
In step 930, the user arranges the article of clothing so that the area of the tear or cut is laid flat without excessive pulling at the article of clothing so as to minimize the gap in the article of clothing caused by the tear or cut.
Next, in step 940, which is optional, the user preheats the area of the tear or cut. Then, in step 950, if the patch includes removable backing sheet 330, the user peels off removable backing sheet 330. The user then, in step 960, places the adhesive side of patch 100 on the area of the tear or cut 420. Finally, in step 970, the user applies heat and pressure to patch 100 to bond it to the article of clothing. The user may place a thin sheet of material, such as teflon, between the patch and iron, so as to minimize the possibility of burning patch 100.
The order of steps shown in
In some embodiments, for example the embodiment shown in
In some embodiments, the plates are a cut resistant resin-based material such as SUPERFABRIC™ Custom Engineered High Performance Fabric (HDM, Inc.; Oakdale, Minn.). In some embodiments, Hi-Cut GL5 epoxy resin is configured in a Penta 100/10-400 pattern, or in a 80/28 or a 83/11 pattern (both of these exemplary patterns are available from HDM, Inc.).
One or more of the hard materials can be present in the patch in a variety of configurations such as in a uniform or non-uniform layer. In some embodiments, the hard material is present in the patch in discrete, spaced-apart concentrations of hard material. Discrete, spaced-apart concentrations of hard material can include, for example, concentrations of hard material in dots, plates, lines, or combinations thereof. In some instances, concentrations of hard material are spaced apart sufficiently such that the patch has flexibility compatible with the performance garment to which the patch will be applied.
In some embodiments, concentrations of hard material are spaced apart at least about 0.001 inch such as at least about 0.005 inch, at least 0.01 inch, or at least about 0.015 inch. In some embodiments, concentrations of hard material are spaced apart about 0.001 inch to about 0.02 inch such as about 0.005 inch to about 0.015 inch.
Some embodiments of the patch for a performance garment having a sheet of fabric, an elastomeric adhesive, and a removable backing, wherein at least one of the sheet and the elastomeric adhesive have an independent stretch greater than the stretch of the performance garment, can be manufactured by adhering the adhesive directly to the fabric. Suitable methods of adhering the adhesive to the fabric include lamination, extruding, screen printing and rotogravure.
In some embodiments of a lamination process, the adhesive can be laminated to the fabric in roll form or flat, with a removable backing attached to the other side of the adhesive. In some embodiments of an extrusion, screen printing, or rotogravure process, the adhesive film is adhered to the fabric, and then the removable backing may optionally be applied over the adhesive.
The foregoing description of the specific embodiments will so fully reveal the general nature of the invention that others can, by applying knowledge within the skill of the art, readily modify and/or adapt for various applications such specific embodiments, without undue experimentation, without departing from the general concept of the present invention. Therefore, such adaptations and modifications are intended to be within the meaning and range of equivalents of the disclosed embodiments, based on the teaching and guidance presented herein. It is to be understood that the phraseology or terminology herein is for the purpose of description and not of limitation, such that the terminology or phraseology of the present specification is to be interpreted by the skilled artisan in light of the teachings and guidance.
The breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents.
