Cushioning laminate insert for a garment shoulder strap, and method for making the same

Abstract

The present invention relates to a cushioning laminate insert for a garment shoulder strap, such as a brassiere strap. The cushioning laminate insert of the invention includes: (1) a first outer fabric layer; (2) a central cushioning area of cured polyurethane elastomer cushioning material; and (3) a second outer fabric layer. One surface of the first and second outer fabric layers is laminated with a thermoplastic urethane (“TPU”) film. The laminated surface of the first outer fabric layer is covalently bonded to a first lateral surface of the central cushioning area, and the opposite lateral surface of the central cushioning area is self-adhered to the laminated surface of the second outer fabric layer in an open-sandwich configuration to thereby form the cushioning laminate insert. Garment shoulder straps including the cushioning laminate insert of the invention, as well as methods for making the cushioning laminate insert are also provided.

1 . A cushioning laminate insert for a garment shoulder strap, comprising: 
 a first outer fabric layer;    a central cushioning area of cured polyurethane elastomer cushioning material; and    a second outer fabric layer;    wherein one surface of the first and second outer fabric layers is laminated with a thermoplastic urethane film;    wherein the laminated surface of the first outer fabric layer is adjacent a first lateral surface of the central cushioning area, and the laminated surface of the second outer fabric layer is adjacent the opposite lateral surface of the central cushioning area to thereby form a sandwich construction; and    wherein the first outer fabric layer is covalently bonded to the first lateral surface of the central cushioning area, and the second outer fabric layer is self-adhered to the opposite lateral surface of the central cushioning area to thereby form a cushioning laminate insert for a garment shoulder strap.    
   
   
       2 . The cushioning laminate insert according to  claim 1 , wherein the second outer fabric layer is self-adhered to the central cushioning area without the need for additional adhesive or heat fusing.  
   
   
       3 . The cushioning laminate insert according to  claim 1 , wherein the first and second outer fabric layers do not enclose the vertical edges of the central cushioning area such that the cushioning laminate insert is comprised of an open sandwich configuration.  
   
   
       4 . The cushioning laminate insert according to  claim 1 , wherein the first and second outer fabric layers comprise a fabric selected from the group consisting of: cotton, polyester, nylon, nylon-lycra blend fabric, a polyester-cotton blend, lace, plain tricot, simplex tricot, and jacquard.  
   
   
       5 . The cushioning laminate insert according to  claim 1 , wherein the polyurethane elastomer is an ether polyurethane.  
   
   
       6 . The cushioning laminate insert according to  claim 1 , wherein the central cushioning area is from about 0.05 inches to about 0.30 inches in thickness.  
   
   
       7 . The cushioning laminate insert according to  claim 1 , wherein the central cushioning area is from about 0.10 inches to about 0.20 inches in thickness.  
   
   
       8 . The cushioning laminate insert according to  claim 1 , wherein the semi-cured polyurethane elastomer cushioning material exhibits a durometer hardness ranging from about 10 shore 00 to about 30 shore 00.  
   
   
       9 . The cushioning laminate insert according to  claim 1 , wherein the cured polyurethane elastomer cushioning material exhibits a tackiness sufficient to adhere the second outer fabric layer to the cured polyurethane elastomer.  
   
   
       10 . A cushioning shoulder strap for a garment comprising: a cushioning laminate insert according to  claim 1 , wherein the central cushioning area of the cushioning laminate insert is positioned along the strap so as to rest on top of a shoulder of a wearer.  
   
   
       11 . The cushioning shoulder strap of  claim 1 , wherein the garment is selected from the group consisting of: a brassiere, a swim suit, a halter top, athletic wear, a camisole, yoga wear, daywear, and sportswear.  
   
   
       12 . A method for making a cushioning laminate insert for a garment shoulder strap, comprising: 
 providing a mold die comprising at least one molding cavity, wherein the at least one molding cavity is lined with a thermoformed polyolefin liner along its surface;    casting a polyurethane elastomer material into the at least one lined molding cavity;    positioning a first fabric layer over the at least one lined molding cavity cast with the polyurethane elastomer material, wherein the surface of the first fabric layer that is adjacent the polyurethane elastomer material is laminated with a thermoplastic urethane film;    molding the polyurethane elastomer material such that the polyurethane elastomer material is semi-cured and a covalent bond is formed between the semi-cured polyurethane elastomer and the thermoplastic urethane film of the first fabric layer;    removing the semi-cured polyurethane elastomer covalently bonded to the first fabric layer from the molding die without the use of a mold release agent;    positioning a second fabric layer adjacent the lateral surface of the semi-cured polyurethane elastomer opposite the first fabric layer to form a sandwich construction;    applying pressure to the outer surface of the second fabric layer such that the semi-cured polyurethane elastomer self-adheres to the second fabric layer as the polyurethane elastomer continues to cure; and    cutting the first and second fabric layers to a desired shape to thereby form the cushioning laminate insert for a brassiere strap.    
   
   
       13 . The method according to  claim 12 , wherein the first and second fabric layers do not enclose the vertical edges of the semi-cured polyurethane elastomer such that the cushioning laminate insert is comprised of an open sandwich configuration.  
   
   
       14 . The method according to  claim 12 , wherein the molding of the polyurethane elastomer material includes: (a) mixing a polyether isocyanate prepolymer with a polyol resin, and (b) allowing the mixture to cure for a curing time ranging from about 5 minutes to about 10 minutes.  
   
   
       15 . The method according to  claim 14 , wherein the curing time ranges from about 6 minutes to about 8 minutes.  
   
   
       16 . A cushioning shoulder strap for a brassiere including a cushioning laminate insert; 
 wherein the cushioning laminate insert comprises: a first outer fabric layer; a central cushioning area of cured polyurethane elastomer cushioning material; and a second outer fabric layer;    wherein one surface of the first and second outer fabric layers is laminated with a thermoplastic urethane film;    wherein the laminated surface of the first outer fabric layer is adjacent a first lateral surface of the central cushioning area, and the laminated surface of the second outer fabric layer is adjacent the opposite lateral surface of the central cushioning area to thereby form a sandwich construction;    wherein the first outer fabric layer is covalently bonded to the first lateral surface of the central cushioning area, and the second outer fabric layer is self-adhered to the opposite lateral surface of the central cushioning area to thereby form a cushioning laminate insert, and    wherein the central cushioning area of the cushioning laminate insert is positioned along the strap so as to rest on top of a shoulder of a wearer.