Adhesive seam and method and apparatus for its manufacture

Abstract

A garment seam is formed between two fabric panels by abutting the edges of at least two panels and placing a strip of material carrying adhesive on the abutted edges to form the seam. The fabric panels have opposing major surfaces, the edges of the fabric panels being minor surfaces. The strip of material is applied on at least one major surface of the abutted fabric panels, but is optionally applied to both major surfaces of the abutted fabric panels. The strip of material is preferably thinner than the fabric panels. In some embodiments, the adhesive is a thermosetting adhesive that is applied on the strip of material in liquid form. A seam manufactured according to the present invention is less detectable through clothing than conventional multi-ply seams. Also the adhesive seam enables the manufacturer to tailor the garment to provide support or shape in a particular area (i.e. the area of the seam) in addition to providing the desirable smooth appearance. For example, when used in a brassiere (bra) cup, the seam allows the garment to be designed to provide optimal comfort, shape and support to the wearer.

1 . A method for forming a seam at an interface between at least two panels of fabric, each panel having at least one edge comprising: 
 bringing into abutted alignment the edges of the at least two fabric panels, thereby defining an interface region;    applying liquid adhesive onto the interface region;    applying a material strip along the interface region; and    curing the adhesive to form an adhesive seam.    
     
     
         2 . The method of  claim 1  wherein each of the at least two fabric panels has a first side and a second side and wherein a first adhesive seam is formed on the interface on the first side and a second adhesive seam is formed on the interface on the second side.  
     
     
         3 . The method of  claim 1  wherein the fabric panels are made of a material selected from the group consisting of natural fibers, synthetic materials and blends of natural fibers and synthetic materials.  
     
     
         4 . The method of  claim 3  where in the synthetic fibers are selected from the group consisting of polyester, rayon, polyurethane foam, spandex and nylon.  
     
     
         5 . The method of  claim 3  wherein the natural fibers are selected from the group consisting of cotton and wool.  
     
     
         6 . The method of  claim 1  wherein the liquid adhesive is selected from the group consisting of thermosetting adhesive, thermoplastic adhesive and radiation-curable adhesive.  
     
     
         7 . The method of  claim 1  wherein the liquid adhesive is applied onto the material strip and the material strip carrying the liquid adhesive is applied along the interface.  
     
     
         8 . The method of  claim 3  wherein the fabric panels are synthetic materials selected from the group consisting of fiberfill and polyurethane foam having a thickness of at least 5 mils.  
     
     
         9 . The method of  claim 8  further comprising placing liquid adhesive on the edges of the fabric panels before the edges are brought into abutted alignment to form the interface region.  
     
     
         10 . The method of  claim 1  further comprising applying a paper backing to the material strip before the material strip is applied to the interface.  
     
     
         11 . The method of  claim 10  further comprising removing the paper backing from the material strip before the liquid adhesive is substantially cured.  
     
     
         12 . The method of  claim 8  wherein the adhesive is at least partially cured before the step of removing the paper backing.  
     
     
         13 . The method of  claim 1  wherein the adhesive is at least partially cured by exposing the adhesive to moist ambient air.  
     
     
         14 . The method of  claim 1  further comprising placing the seam on a contoured surface that substantially mimics the contour of the adhesive seam during at least some portion of the curing step.  
     
     
         15 . The method of  claim 1  wherein the thickness of the strip of material is thicker than the thickness of the adhesive applied thereon.  
     
     
         16 . The method of  claim 1  wherein the fabric panels are calendared.  
     
     
         17 . The method of  claim 1  wherein the fabric panels are finished and further comprising the step of selecting an adhesive that adheres to the fabric panels with the finish thereon.  
     
     
         18 . The method of  claim 17  wherein the finish and adhesive are both water-based.  
     
     
         19 . The method of  claim 17  wherein the finish and adhesive are both hydrophobic.  
     
     
         20 . The method of  claim 1  further comprising cutting fabric to form the panels.  
     
     
         21 . The method of  claim 20  wherein the step of cutting is selected from the group consisting of Gerber cutting, die cutting, sonic cutting, hydro cutting and laser cutting.  
     
     
         22 . The method of  claim 1  wherein the fabric panels are substantially the same thickness.  
     
     
         23 . The method of  claim 1  wherein the adhesive is applied to the interface region by one of either spray coating or nozzle coating.  
     
     
         24 . The method of  claim 7  wherein the adhesive is applied to the material strip by roller coating.  
     
     
         25 . The method of  claim 1  wherein the material strip has a thickness of about 1 mil to about 8 mils.  
     
     
         26 . The method of  claim 1  wherein the liquid adhesive is stored in an inert atmosphere prior to applying the adhesive to the material strip.  
     
     
         27 . The method of  claim 26  wherein the inert atmosphere is selected from the group consisting of nitrogen, argon and super-dried air.  
     
     
         28 . The method of  claim 1  wherein the uncured liquid adhesive melts at a temperature in the range of about 220° F. to about 280° F.  
     
     
         29 . The method of  claim 28  wherein the uncured liquid adhesive melts at a temperature in the range of about 220° F. to about 260° F.  
     
     
         30 . The method of  claim 13  wherein the moist ambient air has at least about forty percent relative humidity.  
     
     
         31 . The method of  claim 1  wherein the two fabric panels and adhesive seam together form a bra cup.  
     
     
         32 . The method of  claim 23  wherein the adhesive is applied onto the material strip by nozzle coating wherein the bead of adhesive applied onto the material strip has a thickness that is less than the thickness of the material strip.  
     
     
         33 . The method of  claim 7  wherein the adhesive is applied to the strip of material as the strip of material is applied along the interface.  
     
     
         34 . The method of  claim 1  wherein the fabric panels have a first color and the adhesive, when cured, has a color that substantially matches the color of the fabric panels.  
     
     
         35 . An apparatus for forming an adhesive seam comprising: 
 a fabric feeder that draws at least two pieces of fabric into abutted alignment as it moves the fabric through the apparatus; and    an adhesive dispenser that applies adhesive to the two pieces of fabric in the region of abutted alignment as they are moved through the apparatus by the fabric feeder.    
     
     
         36 . The apparatus of  claim 30  wherein the fabric feeder has a top portion and a bottom portion that together define a nip region into which the at least two pieces of fabric are drawn.  
     
     
         37 . The apparatus of  claim 35  wherein the top portion has a belt feeder and the bottom portion has a knurled roller.  
     
     
         38 . The apparatus of  claim 35  wherein the top portion and the bottom portion are knurled rollers and wherein at least one of the rollers is a driven roller.  
     
     
         39 . The apparatus of  claim 38  wherein each roller has a roller surface and the roller surface is selected from the groups consisting of flat, concave and convex.  
     
     
         40 . The apparatus of  claim 38  wherein both knurled rollers are driven.  
     
     
         41 . The apparatus of  claim 35  wherein the adhesive dispenser is connected to an adhesive reservoir that stores adhesive in an inert atmosphere until dispensed.  
     
     
         42 . The apparatus of  claim 35  wherein the adhesive dispenser has a material strip conveyor and an adhesive outlet and wherein the material strip conveyor is aligned with the adhesive outlet such that a first material strip is conveyed past the adhesive outlet along its length.  
     
     
         43 . The apparatus of  claim 42  wherein the adhesive outlet is in fluid communication with an adhesive container.  
     
     
         44 . The apparatus of  claim 43  wherein the fabric feeder has at least one roller which is aligned with the adhesive outlet, wherein the adhesive outlet is adapted to deposit adhesive on the material strip as it is conveyed past the adhesive outlet.  
     
     
         45 . The apparatus of  claim 43  wherein the adhesive container further comprises a heater.  
     
     
         46 . The apparatus of  claim 45  wherein the adhesive container further comprises an adhesive pump sized to pump adhesive from the adhesive container through the adhesive dispenser orifice.  
     
     
         47 . The apparatus of  claim 43  wherein the adhesive container is an air tight container.  
     
     
         48 . The apparatus of  claim 42  wherein the adhesive outlet is a nozzle.  
     
     
         49 . The apparatus of  claim 48  wherein the nozzle is selected from the group consisting of slot nozzle and spray nozzle.  
     
     
         50 . The apparatus of  claim 42  wherein the material strip conveyer cooperates with the fabric feeder to feed the first material strip that is conveyed past the adhesive outlet into the fabric feeder.  
     
     
         51 . The apparatus of  claim 42  wherein the fabric feeder is configured to press the first material strip into contact with the at least two pieces of fabric along the region of abutted alignment.  
     
     
         52 . The apparatus of  claim 42  further comprising a second material strip conveyor.  
     
     
         53 . The apparatus of  claim 52  wherein the fabric feeder receives a second material strip from the second material strip conveyor and presses it into contact with the at least two pieces of fabric along a second region of abutted alignment which is on a side of the at least two fabric panels opposite the first material strip.  
     
     
         54 . The apparatus of  claim 51  wherein the material strip conveyor has a paper backing conveyor adapted to place a paper strip into contact with a face of the material strip along its length wherein the material strip is interposed between the orifice and the paper backing.  
     
     
         55 . The apparatus of  claim 53  wherein the material strip conveyor and the second material strip conveyor each have a paper backing conveyor adapted to place a paper strip into contact with a face of the material strip along its length wherein the material strip is interposed between the orifice and the paper backing.  
     
     
         56 . The apparatus of  claim 54  wherein the fabric feeder is adapted to receive the paper strip along with the material strip.  
     
     
         57 . The apparatus of  claim 55  wherein the fabric feeder is adapted to receive the paper strip along with the material strip.  
     
     
         58 . The apparatus of  claim 42  wherein the adhesive dispenser further comprises a roller coater for transferring adhesive from the adhesive outlet to the material strip.  
     
     
         59 . The apparatus of  claim 44  wherein the adhesive dispenser further comprises a slot nozzle for transferring adhesive from the adhesive dispenser to the material strip.  
     
     
         60 . The apparatus of  claim 58  further comprising a doctor blade positioned adjacent to the surface of the roller coater that dispenses adhesive onto the material strip.  
     
     
         61 . The apparatus of  claim 42  further comprising a fluid outlet in the vicinity of the adhesive outlet.  
     
     
         62 . The apparatus of  claim 35  further comprising a fabric feeding surface on which the fabric is placed as it is fed into the fabric feeder wherein the fabric feeding surface has a sensor that detects the presence of fabric on the fabric feeder.  
     
     
         63 . The apparatus of  claim 62  wherein the detector is coupled with a switch that controls at least one of the fabric feeder and the adhesive dispenser.  
     
     
         64 . The apparatus of  claim 35  wherein the fabric feeder further comprises a guide for feeding the at least two pieces of fabric into abutted alignment.  
     
     
         65 . The apparatus of  claim 36  wherein the adhesive dispenser comprises a nozzle that has an outlet directed at the nip region.  
     
     
         66 . The apparatus of  claim 65  wherein the nozzle is selected from the group consisting of a slot nozzle and a spray nozzle.  
     
     
         67 . A curing holder for a fabric article having an adhesive seam during adhesive cure comprising: 
 a receiving surface with a contour that substantially mimics the contour of at least a portion of the adhesive seam of the fabric article.    
     
     
         68 . The curing holder of  claim 67  wherein the receiving surface is the exclusive supporting surface for the fabric article during cure.  
     
     
         69 . The curing holder of  claim 67  wherein the curing holder is a bra cup.  
     
     
         70 . The curing holder of  claim 68  wherein the receiving surface is configured to reduce the amount of mechanical stress on the seam compared to a non-contoured supporting surface.