Multi-ply Belt For Waistband Construction

Abstract

A multi-ply belt adapted to be sewn into a garment to form a waistband, and consisting of a knitted fabric sheath and a rubber core separably attached thereto by means of a temporary band which is sufficient to hold the sheath and core together while they are sewn to a garment, but insufficient to hold them together after they are sewn to the garment and under conditions of normal use and laundering of the garment.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to the construction of elastic waistbands for garments such as pajamas and boxer shorts.

2. Description of the Prior Art

The closest art known to applicants is shown in the following patents:

UNITED STATES PATENTS

3,078,469 Lynam 3,118,803 Lynam British Patents 1,111,786 May 1, 1968

Laminated elastic belts for garment waistband use, that is, rubber cored-knit fabric sheathed belts, are known to the art, as the above cited patents clearly show. However, in all cases known to applicants, the laminations are permanent, that is, made to last for the life of the garment.

SUMMARY OF THE INVENTION

Applicants have discovered that permanent rubber-knit fabric laminations interfere with the proper functioning of the waistbands. It is important, according to applicants' findings, that the rubber core and the knit fabric sheath be separate and free from each other, except for the stitching which attaches them both to the garment, when the garment is worn on the person. However, it is also important, for manufacturing purposes, that the rubber core and knit fabric sheath be temporarily attached to each other, that is, held together long enough to be sewn to the garment.

Accordingly, it is applicants' invention to provide a rubber cored - knit fabric sheathed belt wherein the rubber core and the knit fabric sheath are separably attached to each other by means of a temporary bond, that is, a bond which is sufficient to hold them together while they are sewn to the garment, but insufficient to hold them together after they are sewn to the garment and under conditions of normal use and laundering thereof.

The importance of a temporary bond to hold the rubber core and knit fabric sheath together for the sewing operation is magnified when the rubber core consists of a plurality of separate rubber strips. In one preferred embodiment of this invention four rubber strips are incorporated into a single waistband. If they were not temporarily bonded to the knit fabric sheath, it would be necessary to supply, handle, feed, guide and sew five separate strips of material, four of rubber and one of knit fabric. This would be a difficult, time-consuming and costly procedure which garment manufacturers would not countenance. To adapt the teaching of the prior art and to provide a permanent bond between the rubber core and the knit fabric sheath would solve this manufacturing problem but it would produce an unsatisfactory garment.

It is the object of this invention to provide a bond sufficient to hold the rubber core and knit fabric sheath together for the purposes and duration of the sewing operation, and to insure rupture or separation of the bond under conditions of normal use and laundering of the garment.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a sectional perspective view showing a multi-ply belt made in accordance with one preferred form of the invention, wherein the rubber core consists of a single rubber strip separably attached to the knit fabric sheath by means of temporary bonds between the rubber strip and the inner panel and the side flaps of the knit fabric sheath.

FIG. 2 is a sectional perspective view similar to that of FIG. 1 but showing a variation in the number and location of the temporary bonds.

FIG. 3 is another sectional perspective view similar to that of FIG. 1 but showing a further variation in the number and location of the temporary bonds.

FIG. 4 is a sectional perspective view showing a multi-ply belt made in accordance with another preferred form of the invention, wherein the rubber core consists of a plurality of rubber strips separably attached to the knit fabric sheath by means of temporary bonds between the rubber strips and the inner panel and side flaps of the knit fabric sheath.

FIG. 5 is a sectional perspective view similar to that of FIG. 4 but showing a variation in the number and location of the temporary bonds.

FIG. 6 is another sectional perspective view similar to that of FIG. 4 but showing a further variation in the number and location of the temporary bonds.

FIG. 7 is a sectional perspective view showing the multi-ply belt of FIG. 4, showing the temporary bonds intact for the sewing operation and showing the belt sewn to a garment to form a waistband.

FIG. 8 is a sectional perspective view similar to that of FIG. 7, but showing the temporary bonds severed or broken by reason of normal use and laundering of the garment.

DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

Referring to the first embodiment of the invention as illustrated in FIG. 1, it will be seen that multi-ply belt 10 comprises two basic elements: a rubber core 12 and a knit fabric sheath 14 to which the rubber core is separably attached. As will be seen in FIG. 1, rubber core 12 is a single calendered rubber strip which, in one application of the invention (boxer shorts and pajama waistband construction) is approximately 1 1/4 inches wide and approximately one-tenth of an inch thick. The knit fabric strip, from which the sheath is made, is approximately 2 inches in width before its sides are folded over to form flaps. These dimensions are, however, purely illustrative.

A temporary bond is provided between rubber core 12 and inner panel 14a and side flaps 14b, 14c of the knit fabric sheath. For the purposes of this application and its appended claims, the term "temporary" is not intended to relate to an interval or measure of time, but rather to the sufficiency of the bond to hold the rubber core and knit fabric sheath together during the sewing operation whereby they are sewn together and to the garment 16. This term is intended to distinguish over the term "permanent" which, in the context of this specification and appended claims, is intended to designate a bond which is sufficient to hold the rubber core and knit fabric sheath together during the sewing operation and for the life of the garment under conditions of normal use and laundering thereof. Multi-ply belts of the prior art, as illustrated by the patent art herein cited, are bonded together in the form of permanently bonded laminates, that is, laminates which are bonded together for the life of the garment.

The permanent bonds of the prior art utilize adhesives which are strong enough to hold the rubber core and knit fabric sheath together under conditions of normal use and laundering of the garment. The rubber and the knit fabric have, however, different elastic coefficients and they behave differently when worn on the person. They are hampered in their respective functions when permanently bonded together. Moreover, these adhesives strike through the knit fabric sheath and discolor and deface it.

In the present invention natural or synthetic latex 20 is used to provide a temporary bond between the rubber core and the knit fabric sheath. It is applied in liquid form and when it sets it provides a separable bond between the rubber core and the knit fabric sheath and its sole function is to hold them together for the sewing operation, whereby they are sewn to each other and to the garment. Thereafter, reliance is placed on the stitching alone to hole the core and sheath together during the normal life and use of the garment.

The latex does not strike through or discolor or deface the fabric. It is not an adhesive and does not function as an adhesive and care is taken that it does not permanently bond the rubber core and the knit fabric sheath together. Its volatile solvent content is such that the contacting surfaces of the rubber core (cured, calendered rubber) are not dissolved sufficiently to bond permanently with the latex. Anti-wetting agents are used to further insure against such permanent bonding, such anti-wetting agents being applied to the rubber core prior to contact with the liquid latex.

Illustrations of the liquid latex used in the present invention are the heat reactive, self-curing nitrile latexes which are made and sold by the B. F. Goodrich Chemical Company division of the B. F. Goodrich Company, under the trademark HYCAR. An illustration of the anti-wetting agents which may be used in this invention is talc powder. As applicant Joseph P. Maggio's copending U.S. Pat. application Ser. No. 117,324 shows, the liquid latex is applied to the knit fabric and the talc is applied to the rubber core. The liquid latex is exposed to heat and partially cured and its volatile solvent content is substantially reduced before it is brought into contact with the rubber core.

The use of liquid latex instead of an adhesive, its application to the knit fabric instead of the rubber core, the partial curing of the latex before contact is made with the rubber core, the reduction in the volatile solvent content of the latex before such contact is made, and the use of a talc (anti-wetting) coating on the surface of the rubber core, all combine to insure against the establishment of a permanent bond between the rubber core and the knit fabric sheath.

As is above indicated, the embodiment of the invention illustrated in FIG. 1 shows the rubber core 12 separably bonded to the knit fabric sheath 14 by means of latex 20 applied between said rubber core and the inner panel 14a and side flaps 14b, 14c of said sheath. FIG. 2 shows a variation wherein the latex 20 is applied only between the rubber core and said inner panel 14a of the knit fabric sheath. The side flaps 14b and 14c are held in place on rubber core 12 by means of longitudinal creases 18a and 18b formed between said side flaps and said inner panel of the sheath. FIG. 3 provides a further variation wherein the latex 20 is applied only between the rubber core 12 and the side flaps 14b and 14c.

It should be firmly understood that the invention is not limited to a rubber core which consists of a single rubber strip. This is clearly shown in applicant JOSEPH P. MAGGIO's co-pending U.S. Pat. application Ser. No. 117,324, which shows a method and a machine for making a multi-ply belt as herein claimed having a rubber core consisting of four rubber strips arranged in spaced, parallel relationship and encased within the same knit fabric sheath.

A four-strip belt 30 is shown in FIG. 4 of the present drawing, and it will be understood that the invention contemplates the use of any number of rubber strips suited for particular uses and applications, e.g., two strips, three strips, etc. Referring now to FIG. 4, it will be seen that multi-ply belt 30 comprises a rubber core consisting of four parallel transversely spaced, longitudinally extending rubber strips 32a, 32b, 32c, 32d separably bonded to knit fabric sheath 34 by means of latex 20. The latex is applied between said rubber strips and inner panel 30a of the knit fabric sheath. It is also applied between rubber strips 32a, 32d and side flaps 30b, 30c.

As an illustration, rubber strips 32a- 32d are each one-fourth inch wide and one-tenth inch thick, and they are spaced one-eighth inch apart. An example of the variations contemplated herein is the use of rubber strips of different thickness (or different elastic coefficient) in the same belt. Thus upper rubber strip may be thicker or it may have greater elastic tension than the other rubber strips.

The multi-ply belt which is shown in FIG. 5 differs from the one which is shown in FIG. 4 only to the extent that in FIG. 5 the latex is applied only between the four rubber strips and the inner panel 30a of the knit fabric sheath. As is the case with the belt shown in FIG. 2, side flaps 30b and 30c of the belt shown in FIG. 5 are held in place on the rubber core, more specifically on rubber strips 32a and 32d, by means of creases 34a, 34b formed between said side flaps and the inner panel 30a of the knit fabric sheath.

FIG. 6 shows a further variation wherein the latex 20 is applied between rubber strips 32b, 32c and the inner panel 30a of the knit fabric sheath and between rubber strips 32a, 32d and the side flaps 30b, 30c.

FIG. 7 shows one of the aforementioned belts, to wit, the belt of FIG. 4, sewn to garment 16. The temporary bond between the rubber core (rubber strips 32a, 32b, 32c, 32d) and the knit fabric sheath is shown intact for the sewing operation by which the belt was sewn to the garment. Lines of stitching 40a, 40b, 40c and 40d respectively secure rubber strips 32a, 32b, 32c and 32d and the adjacent parts of the knit fabric sheath to the garment. This is the condition which obtains at the conclusion of the sewing operation, resulting in the formation of a rubber cored, knit fabric sheathed waistband affixed to the garment.

FIG. 8 shows the same waistband after being subjected to a period of normal use and laundering, e.g., the first laundering and the initial period of use preceding the first laundering. The temporary latex bond between the rubber core and the knit fabric sheath is now ruptured and all that holds them together is the stitching by which the belt is sewn to the garment.

The present invention is concerned with the condition of FIG. 7 for purposes of garment manufacture and with the condition of FIG. 8 for purposes of garment use. The invention attains both conditions by holding the rubber core and knit fabric sheath together for the sewing operation and by providing for their separation (except for the stitching which secures them to the garment) during conditions of normal use and laundering.

The prior art does not attain both conditions with the same belt. To the extent that a prior art belt attains the condition of FIG. 7, it does not attain the condition of FIG. 8; to the extent that a prior art belt attains the condition of FIG. 8, it does not attain the condition of FIG. 7.

Claims

The foregoing illustrates preferred forms of the invention, and it will be understood that further variations and modifications are contemplated and included within the broad scope of the appended claims.

1. A multi-ply belt adapted to be sewn into a garment to form a waistband, said multi-ply belt comprising:

a. a knitted fabric sheath, and

b. a rubber core separably bonded to said knitted sheath,

c. said rubber core being separably bonded to the knitted sheath by means of latex applied between them,

d. the bond between the latex and the rubber core being sufficient only to hold the rubber core and knitted sheath together while they are sewn to a garment,

e. said latex bond being insufficient to hold the rubber core and knitted sheath together after they are sewn to the garment, and under conditions of normal use and laundering thereof.

2. A multi-ply belt in accordance with claim 1, wherein:

a. the latex is free of sufficient volatile solvents to appreciably dissolve the surface of the rubber core,

b. thereby preventing the formation of a permanent bond between the latex and the rubber core and between the rubber core and the knitted sheath sufficient to hold them together after they are sewn to a garment, and under conditions of normal use and laundering thereof.

3. A multi-ply belt is accordance with claim 1, wherein:

a. an anti-wetting agent is provided between the latex and the rubber core,

b. thereby preventing the formation of a permanent bond between the latex and the rubber core and between the rubber core and the knitted sheath sufficient to hold them together after they are sewn to a garment and under conditions of normal use and laundering thereof.

4. A multi-ply belt in accordance with claim 1, wherein:

a. the rubber core comprises a plurality of rubber strips,

b. said rubber strips being transversely spaced and extending longitudinally of and parallel to said knitted sheath.

5. A multi-ply belt in accordance with claim 4, wherein the rubber strips are of equal width and gauge and uniformly spaced.

6. A multi-ply belt in accordance with claim 4, wherein:

a. the knitted sheath has an inner and an outer face,

b. the side edges of the knitted sheath being folded over upon its inner face to form a pair of marginal flaps,

c. said rubber core comprising a pair of outer and a pair of inner rubber strips which are individually, separably attached to the inner face of the knitted sheath,

d. said marginal flaps of the knitted sheath extending over the outer pair of rubber strips to cover same.

7. A multi-ply belt in accordance with claim 6, wherein the marginal flaps of the knitted sheath are individually, separably attached to the outer pair of rubber strips.

8. A multi-ply belt in accordance with claim 7, wherein:

a. the rubber strips are separably bonded to the inner face of the knitted sheath by latex applied between said rubber strips and said inner face of the knitted sheath,

b. the outer pair of rubber strips being also individually, separably bonded to the marginal flaps of the knitted sheath by means of latex applied between said outer pair of rubber strips and said marginal flaps.

9. A multi-ply belt in accordance with claim 8, wherein at least one of the outer pair of rubber strips has greater elastic strength than the inner pair of rubber strips.