Sewing method to increase seam strength

Abstract

An improved garment seam with bonded fabric surfaces caused by the melting of at least one low-melt sewing thread that is used in conjunction with conventional high-melt sewing threads to construct the seam. The melted low-melt sewing thread acts like an adhesive to bond together the folds of fabric making up the seam. A sufficient amount of heat, and if necessary pressure, is applied to the seam which causes the low-melt thread to flow into the fabric interstices thereby creating a seam and permanently bonding the first and second garment components together along the seam to produce a stronger seam that is possible using stitches comprised of conventional high-melt sewing thread alone.

1 . A method for producing a garment seam between a first garment component and a second garment component, said method comprising the steps: 
 (a) placing the first garment component having a first and a second surface in an adjacent relationship to a second garment component having a first surface and a second surface so as to define a seam;    (b) providing a sewing machine set-up with at least one low-melt sewing thread and at least one high-melt sewing thread;    (c) sewing the first and second garment components together by using the sewing machine such that at least one stitch running along the seam contains the at least one low-melt sewing thread; and    (d) applying sufficient heat to the stitched seam to cause the low-melt sewing thread to melt and flow onto the two garment surfaces acting as an adhesive to form a bond along the garment surfaces of the seam and around the high melt sewing thread.    
   
   
       2 . A method for producing a garment seam between a first garment component and a second garment component, said method comprising the steps: 
 (a) placing the first garment component having a first and a second surface in an adjacent relationship to a second garment component having a first surface and a second surface so as to define a seam;    (b) reverse folding an edge portion of the first garment component over an edge portion of the second garment component along the seam wherein the first surface of the first garment component overlaps and abuts the first surface of the second garment component;    (c) providing a sewing machine set-up with at least one low-melt sewing thread and at least one high-melt sewing thread;    (d) sewing the first and second garment components together by a set stitch running along the seam;    (e) reverse folding the second garment component such that the first surface of the second garment component is folded over and abuts against the second surface of the first garment;    (f) sewing at least one top stitch containing at least one low-melt thread through the reverse folded second garment component, the reverse folded edge portion of the first garment component, an edge portion of the second garment component and the first garment component along the seam; and    (g) applying sufficient heat to the stitched seam to cause the low-melt thread to melt and flow onto the reverse folded portions of the seam acting as an adhesive to form a bond along the garment surfaces of the seam and around the high melt sewing threads.    
   
   
       3 . A method for producing a garment seam between a first garment and a second garment component as defined in  claim 2  wherein: 
 said step of providing a sewing machine with at least one low-melt sewing thread comprises loading a low-melt sewing thread composed of a thermoplastic material.    
   
   
       4 . A method for producing a garment seam between a first garment and a second garment component as defined in  claim 2  wherein: 
 said step of providing a sewing machine with at least one low-melt sewing thread comprises loading a low-melt sewing thread composed of a thermoplastic material selected from the group consisting of nylon, polyethylene, polypropylene, polyamide, polyester, olefinic, polyurethane, ethylene vinylacetate copolymer materials and mixtures thereof.    
   
   
       5 . A method for producing a smooth garment seam between a first garment and a second garment component as defined in  claim 2  wherein: 
 said step of providing a sewing machine with at least one low-melt sewing thread comprises loading a low-melt sewing thread having a melting point ranging from approximately 85° C. to about 120° C.    
   
   
       6 . A method for producing a garment seam between a first garment and a second garment component as defined in  claim 2  wherein: 
 said step of providing a sewing machine with at least one low-melt sewing thread comprises physically combining a low-melt sewing thread with a conventional high melt thread in at least one thread position on the sewing machine.    
   
   
       7 . A method for producing a garment seam between a first garment and a second garment component as defined in  claim 2  wherein: 
 said step of placing the first garment component comprises placing a front panel of a dress shirt in an adjacent relationship to the second garment component comprising a back panel of a dress shirt such that said seam comprises a side seam of a dress shirt.    
   
   
       8 . A method for producing a garment seam between a first garment and a second garment component as defined in  claim 2  wherein: 
 said step of placing the first garment component comprises placing said garment component such that said seam comprises a seam of a dress shirt.    
   
   
       9 . A method for producing a garment seam between a first garment and a second garment component as defined in  claim 2  wherein: the step of applying heat also includes applying pressure by ironing and pressing.  
   
   
       10 . In a clothing garment having a first garment component and a second garment component, a bonded seam connecting the two garment components comprising: 
 a first garment component having a first surface and a second surface;    a second garment component having a first surface and a second surface;    at least one stitch containing a low-melt sewing thread that when melted acts like an adhesive to form a bond between the garment surfaces;    the first garment component being reverse folded along an edge such that a portion of the first surface of the first garment component abuts an edge of the first surface of the second garment component;    a set stitch running along the seam sewing the first and second garment components together;    the second garment component being reverse folded around the first garment; and    at least one top stitch comprising a low-melt sewing thread sewn through the reverse folded second garment component, the reverse folded edge portion of the first garment component, an edge portion of the second garment component and the first garment component along the seam and wherein bonding the seam comprises subjecting the seam to a sufficient amount of heat to cause the low-melt thread to melt and flow onto the garment surfaces to bond the reverse folded portions.    
   
   
       12 . In a clothing garment having a first garment component and a second garment component as defined in  claim 10  wherein: 
 the low melt sewing thread is composed of a thermoplastic material.    
   
   
       13 . In a clothing garment having a first garment component and a second garment component as defined in  claim 10  wherein: 
 the low-melt sewing thread is composed of a thermoplastic material selected from the group consisting of nylon, polyethylene, polypropylene, polyamide, polyester, olefinic, polyurethane, ethylene file vinylacetate copolymer materials and mixtures thereof.