APPARATUS AND METHOD FOR BINDING FABRICS

Abstract

A device for connecting two or more pieces of fabric. The devices is formed as a bonding strip having a base and a plurality of spikes extending from the base. The bonding strip is formed of a material having a forming temperature that is lower than that of the fabric to be bonded. To bond the two or more pieces of fabric, the spikes are pushed through the fabric. The spikes are then formed at a temperature that is at least as high as the forming temperature of the bonding strip but lower than the forming temperature of the fabric. The forming can be performed so that the spikes bend over and press against the fabric. The spikes can be arranged on first and second rows along the bonding strip, and the forming can be performed such that spikes from the first strip connect with spikes of the second strip.

Description

FIELD OF THE INVENTION

The presently disclosed embodiments relate to garment manufacture and more particularly to a novel device for binding two pieces of fabric with a mechanical bond.

BACKGROUND

The art of textile and garment manufacturing has been around for many centuries. Often the fabrication of garments requires various pieces of fabric to be joined together at a seam. Traditionally, this has been performed by sewing, wherein a thread is used to stitch two or more pieces of fabric together in a desired manner to form a garment.

More recently adhesive bonds have been used to join fabrics together. This can involve the use of an adhesive material such as glue or could also involve heating certain textile materials to the point where they diffuse and melt together.

All of the previously used forming methods suffer from disadvantages. For example, once the fabrics have been joined together in this manner, they are difficult or impossible to take apart for rework. Attempting to undo an adhesive bond can be impossible and can lead to damage of the fabric. Undoing a stitched seam is very tedious and labor intensive. In addition, certain marks and damage can remain on the fabric after the stitching has been undone.

In addition, each of these methods of connecting fabric can be very tedious and labor intensive. This increases manufacturing costs and reduces manufacturing throughput. The labor intensiveness has led to garment manufacturing being located primarily in regions with access to inexpensive labor.

In addition, the tooling and skill required to bond fabrics by stitching or adhesive bonding has limited the ability of hobbyists, people without proper tooling or those with limited sewing skills to be able to construct garments on their own.

SUMMARY

The present embodiments provide a device for bonding two or more pieces of fabric. The device includes a base and a plurality of spikes extending from the base. The base and the plurality of spikes are formed of a polymer material having a forming temperature lower than a forming temperature of an intended fabric to be bonded.

The present embodiments can also provide a garment including first and second pieces of fabric and a bonding strip having a base and a plurality of spikes extending through the first and second pieces of fabric. The spikes can be bent over to press the first and second pieces of fabric against the base so as to secure the first and second pieces of fabric to the bonding strip.

The bonding strip can be constructed of a material having a lower forming temperature than the first and second pieces of fabric. In one embodiment, the bonding strip can comprise a polymer, and the first and second pieces of fabric can comprise a natural fiber.

The base of the device can have an elongated shape having a long dimension such as a rectangular shape or a strip. The spikes can be formed on two rows arranged along the long dimension of the strip. The two rows of spikes can be arranged along the first and second edges of the base.

The spikes of the device can be configured to extend through one or more pieces of fabric in order to connect the two pieces of fabric. The spikes and base can be integral with one another and formed as a single piece of polymer material.

The device, spikes and base, can be formed of a material having a forming temperature that is less than 200 F, or between 175 F and 250 F. The device spikes and base can be constructed of for example, thermoplastic such as Worbla™ or thermoplastic elastomer composite.

The embodiments can also provide a method for joining one or more pieces of fabric. The method includes providing a bonding strip having a base and a plurality of spikes extending from the base, the bonding strip being formed of a material having a forming temperature. The spikes of the bonding strip are extended through the two or more pieces of fabric. The bonding strip is then brought to a temperature that is at least as high as the forming temperature of the bonding strip, and the spikes are then formed while the bonding strip is at this temperature.

The spikes can be deformed by bending the spikes and pressing them flat against the fabric. This can be performed by applying pressure from a seaming roll to press the spikes against the fabric.

The fabric to be joined can have a forming temperature higher than that of the bonding strip and the forming of the spikes can be performed at a temperature that is between the temperature of the bonding strip and the forming temperature of the fabric. The bonding strip can be constructed such that the spikes extend from the base in first and second rows and such that the spikes of the first row are aligned with the spikes of the second row. The deformation of the spikes can be performed such that the spikes of the first row contact and bond with spikes of the second row. In some embodiments the bonding strip can be a polymer, whereas the fabric can be an organic material such as cotton, wool or a blend of synthetic and organic material.

These and other features and advantages will be apparent to one of skill in the art upon reading of the following detailed description of the embodiments in conjunction with the figures. In the figures, like reference numerals used in more than one figure indicate a like element, and may be considered in light of the description of the like element presented in any of the other figures having the like element.

BRIEF DESCRIPTION OF THE DRAWINGS

For a fuller understanding of the nature and advantages, as well as the preferred mode of use, reference should be made to the following detailed description read in conjunction with the accompanying drawings. The drawings are not presented to scale unless specified otherwise on an individual basis.

FIG. 1A is a perspective view of a synthetic strip for binding together two separate pieces of fabric.

FIGS. 1B-1E are enlarged, cross-sectional views of bonding strips according to various embodiments.

FIG. 1F is a top-down view of a bonding strip according to another embodiment.

FIG. 2 is a top-down view as seen from line 2-2 of FIG. 1.

FIG. 3 is a cross sectional end view of a bonding strip in a preliminary stage of bonding two pieces of fabric together.

FIG. 4 is a side, cross-sectional view of the bonding strip and fabric as seen from line 4-4 of FIG. 3.

FIG. 5 is a side, cross-sectional view similar to that of FIG. 4, in a later stage of manufacture, showing a seam roller forming the bonding strip to bond the two pieces of fabric.

FIGS. 6A-6B are end, cross-sectional views of a partially formed bonding strip connecting two pieces of fabric as seen from line 6a-6b of FIG. 5.

FIG. 7 is a top-down view of a fully formed bonding strip joining two pieces of fabric.

FIG. 8A is an end, cross sectional view of two pieces of fabric being joined by a fully formed bonding strip, as seen from line 8-8 of FIG. 7, wherein the two pieces of fabric have an abutting joint.

FIG. 8B is an end, cross sectional view, similar to that of FIG. 8A, wherein the two pieces of fabric have an overlapping joint.

FIG. 8C is an end, cross-sectional view, similar to that of FIGS. 8A and 8B, wherein the two pieces of fabric have a folded abutting joint.

FIG. 9 is a perspective view of a forming wheel such as might be used to form a bonding strip.

FIG. 10A is a cross-sectional view showing an edge profile of the forming wheel of FIG. 9 according to one possible embodiment.

FIG. 10B is a cross-sectional view showing an edge profile of a forming wheel according to an alternate embodiment.

FIG. 11 is a top-down view of a bonding strip according to an alternate embodiment.

FIG. 12 is a top-down view of the bonding strip of FIG. 11 after forming to bond two pieces of fabric together.

FIG. 13 is a top-down view of a bonding strip according to yet another embodiment, wherein the bonding strip is configured to bond elastic fabric.

FIG. 14 is a flow chart summarizing a method for bonding fabrics.

DETAILED DESCRIPTION

The following description includes the best embodiments presently contemplated for carrying out the embodiments. This description is made for the purpose of illustrating the general principles and is not meant to limit the inventive concepts claimed herein in any way.

The bonding of fabrics in the garment industry involves technologies that include stitching with thread or bonding with adhesive. While these technologies have been used for many years, they each have drawbacks. For example, stitching garments can be time consuming and does not allow for easy reworking if the stitching process was not performed correctly. Reworking such stitched garment requires laborious, careful cutting of the stitching thread. In addition, even if the stitches are successfully removed, they can leave marks on the fabric that can be visible in the finished garment.

Adhesive bonding does not form a mechanical bond, and therefore does not necessarily provide a secure connection of the fabric. In addition, to an even greater extent than stitching adhesive bonding does not allow for reworking if the bonding process is not perfectly performed. As there is no way to undo the adhesive bonding process, a garment must be scrapped if the process is performed incorrectly.

The embodiments which are described herein below provide a quick and easy mechanism for bonding that can be easily reworked especially in an intermediate stage of manufacture.

FIG. 1A shows a perspective view of a bonding strip 102 according to an embodiment. The bonding strip 102 is preferably formed of a synthetic material, such as a polymer, that has a relatively low forming temperature, as will be described herein below. The bonding strip 102 has a base 104 and a plurality of needles or spikes (hereinafter referred to as spikes) 106 extending from the surface of the base 104. As shown in FIG. 1A, the spikes 106 can have a narrow conical shape. However, the spikes 106 could have many other shapes and configurations, such as narrow pyramidal shape, cylindrical shape, mushroom shape, spikes with jagged edges, spikes that have varying girth along their heights, spikes that may be discontinuous increasing and decreasing girth, or some other shape.

For example, as shown in FIG. 1B, as mentioned above, the spikes 106 can have a mushroom shape wherein the top of the spike 106 can have an enlarged, bulbous shape. With reference to FIG. 1C, according to an alternate embodiment, the spikes 106 can have a variable shape such as a zig-zag shape. With reference to FIG. 1D, according to an alternate embodiment, the spikes 106 can have a step-wise variable width, radius or other dimension. With reference to FIG. 1E, according to yet another embodiment, the spikes 106 can have a variable density, pitch or spacing. In addition, as shown in FIG. 1E, the spikes 106 can have a serrated shape. Various other configurations of bonding strips and or spike configurations are possible and are considered to fall within the scope of this disclosure.

FIG. 1F is a top-down view according to yet another embodiment. In this embodiment, the spikes 106 can be arranged in rows that are not parallel with the long edge of the base 104, but are actually perpendicular to the length. Other embodiments are also possible, such as wherein the spikes 106 are at a diagonal to the length or any other configuration such as randomly grouped, or in rows that are not parallel with one another and which may or may not intersect one another.

FIG. 2 is a top-down view of the bonding strip of FIG. 1, as seen from line 2-2 of FIG. 1. With reference to FIG. 2 it can be seen that the spikes 106 can be formed in first and second rows 202, 204 along opposite edges and running along the length of the base 104. In the embodiment shown in FIG. 2 it can be seen that the spikes 106a are formed in a row 202 and spikes 106b are formed in a row 204. Also, in FIG. 2 it can be seen that each of the spikes 106a in row 202 is aligned with a corresponding spike 106b in row 204. In other words, each spike 106a in row 202 is at location as measured in the longitudinal direction (shown by arrow 206) that is the same as a corresponding spike 106b in row 204. This can be beneficial for reasons that will become apparent herein below. However, in some embodiments, the spikes in different rows may be designed not to line up. Furthermore, the spacing, orientation, number of rows, distribution and the shapes of the spikes along one row, or differing rows may vary along a row and/or in between one or more rows.

FIG. 3 shows a cross-sectional end view of the bonding strip 102 and FIG. 4 shows a cross-sectional side view as seen from line 4-4 of FIG. 3. FIGS. 3 and 4 show how the bonding strip 102 can connect fabric pieces 302, 304. In FIGS. 3 and 4, the fabric pieces 302, 304 are in an intermediate state of bonding. The spikes 106 of the bonding strip 102 poke through the fabric pieces 302, 304 holding the fabric pieces 302, 304 in a partially bonded or connected state.

At this point in the bonding process, if the connection of the fabric pieces 302, 304 is not quite right, for example, there is an unintended wrinkle in one or more of the fabric pieces 302, 304 or one pieces is too tight or too loose, either of the fabric pieces 302, 304 can be easily removed and reattached by pulling the fabric piece 302, 304 off of the spikes correcting the position of the fabric pieces pressing the fabric piece back onto the bonding strip 102. This ability to easily rework the attachment of the fabric pieces provides a great advantage over previously available attachment methods such as sewing or adhesive bonding wherein the attachment would be permanent and does not allow for rework.

Fabrics and textile products more generally can be formed of many different products having many different properties. For example, fabrics can be formed of synthetic materials which are generally polymer materials such as polyether, rayon, etc. Fabrics can also be organic, plant-based products such as cotton, hemp, etc. or can be natural animal-based products such as wool. Fabrics can also be a blend of these materials.

As mentioned above, each of these different materials has unique material properties. One of the properties is forming temperature. The forming temperature of the material is the temperature at which the material can be permanently deformed and lies somewhere between the temperature at which the material is between a solid and liquid state. In most instances, the forming temperature is a temperature at or above the glass transition temperature of the material.

With reference again to FIGS. 3 and 4, the bonding strip 102 is constructed of a material that has a lower forming temperature than that of the fabric pieces 302, 304. For example, the bonding strip can be constructed of a synthetic material such as polyether having good properties for use in garments, and the fabric pieces 302, 304 can be constructed of a natural, organic fiber material such as cotton, hemp or wool or a (or a synthetic/organic blend) which has significantly higher forming temperature than the synthetic material of the bonding strip 102. In some embodiments, the bonding strip 102 can be constructed of a material having a forming temperature of less than 200 degrees F. or having a forming temperature between 175 degrees F. and 250 degrees F. While such a bonding strip 102 can be used with advantage in organic or organic/synthetic blends, the usefulness of such as bonding technique is not limited to use only with these materials and can be used with synthetic fabrics too, so long as the synthetic fabric material has a higher forming temperature than the bonding strip 102.

FIG. 5 is a side, cross-sectional view of some illustrative embodiments showing how the bonding strip 102 can be formed to securely bond the two pieces of fabric 302, 304. As discussed above, the bonding strip 102 and fabric 302, 304 are heated to a temperature that is above at or above the forming temperature of the bonding strip 102. With the bonding strip 102 and fabric 302, 304 at this temperature, a tool such as a seaming roller 502 can be used to form the bonding strip 102. Movement of the seaming roller is indicated by arrow 504. There are several ways in which the bonding strip 102 and fabric 302, 304 can be brought to this temperature. For example, the bonding strip 102 and fabric 302, 304 can be heated in an oven. In alternative embodiments, other types of heat including convection or radiant heat such as infrared heat can be applied to the fabric 302, 304 and bonding strip 102 at the point of forming. In other embodiments, the seam roller itself can be held at this desired temperature to heat the bonding strip 102 right at the point of forming. Other heating methods will likely occur to one skilled in the art and are contemplated as falling within the scope of this disclosure.

FIG. 6A shows a cross-sectional end view similar to FIG. 5, but showing the spikes 106a, 106b of the bonding strip 102 in a partial forming stage. FIG. 6A illustrates how the spikes 106a, 106b can be bent inward toward each other to form a mechanical bond to hold the two pieces of fabric 302, 304 together. This process is continued so that the spikes 106a, 106b can be pressed flat against the fabric 302, 304 as shown in FIG. 6B. This forming process is performed at a temperature that is at or above the forming temperature of the material of the bonding strip 102, but below the forming temperature of the fabric pieces 302, 304. Once the fabric 302, 304 and bonding strip 102 are cooled to room temperature, the bent spikes 106a, 106b remain fixed in this shape as shown in FIG. 6b, thereby forming a permanent, secure, mechanical bond to hold the fabric pieces together.

The temperature at which this forming process is performed can also be sufficiently high to cause material diffusion between the spikes 106a, 106b. This can cause the spikes 106a to connect with and weld to the spikes 106b, forming a very secure bonding connection.

FIG. 7 shows a top-down view of the formed, bonded connection of the bonding strip 102 with the fabric pieces 302, 304. Edges of the bonding strip 102 are shown in dashed line to indicate that they are hidden beneath the fabric pieces 302, 304. Because the spikes 106a are aligned with the spikes 106b (as discussed above with reference to FIG. 2) the spikes 106a and 106b are able to contact one another and actually mechanically bond with one another.

As shown in FIG. 7, the formed spikes 106 of the bonding strip can resemble traditional stitches, which can be advantageous for esthetic purposes. The material of the bonding strip 102 can be chosen to match or nearly match the color of the fabric pieces 302, 304 or can be chosen to be a different color to provide a desired stylistic pattern.

FIGS. 8A, 8B and 8C show enlarged cross-sectional views as seen from line 8-8 of FIG. 7. These different views illustrate different ways in which the fabric pieces 302, 304 can be formed when bonded with the bonding strip 102. FIG. 8A shows a simple abutted configuration. In this configuration, the edges of the fabric are flat and abut one another, providing a smooth flat seam. FIG. 8B shows a configuration wherein the two pieces or fabric 302, 304 overlap one another. This configuration can provide a more secure connection between the two pieces of fabric 302, 304 by taking advantage of increased mechanical strength of the additional fabric layers 302, 304 in addition to the bonding strip 102. The spikes 106 of the bonding strip 102 can be formed sufficiently long that they can easily extend through both pieces of fabric 302, 304 before being formed to secure the fabric 302, 304. FIG. 8C shows a configuration, wherein the edges of the fabric pieces 302, 304 are each folded back on themselves. This configuration can provide an esthetically appealing, secure seam between the fabric pieces 302, 304. This embodiment also increases the strength of the seam by taking advantage of the added mechanical strength of the multiple layers of fabric 302, 304 in addition to the bonding strip 102 Again, the spikes 106 of the bonding strip 102 can be made sufficiently long to extend through the two layers of fabric 302, 304. In addition, the fabric 302, 304 can be folded multiple times for even greater seam strength.

FIG. 9 shows a perspective view of a seaming roller 502 such as might be used to form a bonding strip 102 as described above with reference to FIG. 5. The seaming roller 502 can be formed with an outer edge 902 that can be configured with a shape to facilitate the desired forming of the spikes 106 of the bonding strip 102 (FIG. 5). FIGS. 10A and 10B show different configurations of the outer edge 902 of the seaming roller 502. FIG. 10A shows a configuration wherein the outer edge 902 of the seaming roller 502 has a concave or scalloped shape. This concave shape can help to guide the spikes 106 inward as desired during forming.

FIG. 10B shows an embodiment of a seaming roller 502 with a dual-concave shape. This configuration can be useful in pressing the outer ends of the spikes 106 firmly downward during forming.

FIG. 11 is top-down view of a bonding strip 1100 according to an alternate embodiment. The bonding strip 1100 has a base 1102 and spikes 1104a, 1104b, where the spikes 1104a are formed in a first row 1106 and the spikes 1104b are formed on a second row 1108b. Whereas the above-described embodiments have spikes that are aligned with one another in the opposite rows, the bonding strip 1100 has spikes 1104a, 1104b that are staggered from one another so that the spikes 1104a are offset from the spikes 1104b.

FIG. 12 shows a top-down view of the bonding strip 1100 after forming to bond two pieces of fabric 302, 304. As can be seen in FIG. 12, the spikes 1104a and 1104b are bent over to securely hold the fabric, but are not bonded to one another across the fabric. This embodiment may be advantageous in a situation wherein it is desirable to be able to break free from the seam when needed. If a sufficient force is applied to the fabric the bent spikes 1104a, 1104b can bend upward to release the fabric 302, 304 without damaging the fabric. Releasing the fabric can be further facilitated by heating the bonding strip 1100 to a temperature at or above the forming temperature. This embodiment can be useful in situations which require easy breakaway from the bonding seal, such as for safety reasons. This can also be advantageous where rework of the seam will likely be desirable at some point.

FIG. 13 illustrates a bonding strip 1302 according to yet another embodiment. This embodiment can be useful in the bonding of elastic materials wherein some amount of stretching is desirable. FIG. 13 shows the bonding strip 1302 applied to two pieces of fabric 302, 304. As seen in the top-down view of FIG. 13, the bonding strip 1302 has a serpentine shape. This shape allows the bonding strip to flex when the fabric is stretched, thereby allowing the fabric to take advantage of its naturally elastic nature. Like the other described embodiments, the bonding strip 1302 has spikes 1304, which are shown unformed (e.g. un-bent) here for clarity. The spikes can either be aligned with one another as in the embodiments of FIGS. 1 and 2, or can be staggered as in the embodiment of FIG. 12 depending upon the application.

FIG. 14 is a flowchart summarizing a method 1400 for joining fabrics using a bonding strip such as the various embodiments of bonding strips described above. In step 1402 a bonding strip provides a base and a plurality of spikes. The bonding strip can be formed of a polymer material having a forming temperature. In operation 1404, the spikes of the bonding strip are extended through the one or more fabrics. This can be performed by pressing the fabric onto the bonding strip. Then, in operation 1406 the bonding strip is brought to a temperature that is at or above its forming temperature. In operation 1408, while keeping the bonding strip at or above its forming temperature, the spikes are formed. The forming of the spikes can include bending the spikes and pressing them against the fabric and possibly against one another. The forming of the bonding strips can be performed, for example, using a seaming roller.

While various embodiments have been described above, it should be understood that they have been presented by way of example only and not limitation. Other embodiments falling within the scope of may also become apparent to those skilled in the art. Thus, the breadth and scope 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.

Claims

1. A garment product, comprising:

a first piece of fabric;

a second piece of fabric;

a bonding strip having a base and a plurality of spikes extending from the base, wherein the spikes extend through the first and second pieces of fabric and are bent over the first and second pieces of fabric to secure the first and second pieces of fabric to the bonding strip, wherein the bonding strip is selected to substantially match a color of the fabric pieces.

2. The garment product as in claim 1, wherein the base has an elongated shape having a long dimension and wherein the plurality of spikes are formed in one or more rows arranged along the long dimension of the base.

3. The garment product as in claim 1, wherein the base is formed as an elongated strip having first and second edges, and wherein the spikes are formed in one or more rows.

4. The garment product as in claim 1, wherein the bonding strip is constructed of a material having a lower forming temperature than the first and second pieces of fabric.

5. The garment product as in claim 1, wherein the base and the spikes are integral with one another and formed of the same material.

6. The garment product as in claim 1, wherein the base and the spikes are constructed of a material having a forming temperature less than 200 degrees F.

7. The garment product as in claim 1, wherein the base and the spikes are formed of a material having a forming temperature between 175 degrees F. and 250 degrees F.

8. The garment product as in claim 1, wherein bonding strip comprises a polymer and the first and second pieces of fabric comprise a natural fiber.

9. A garment product for joining two or more pieces of fabric, the garment product comprising:

a strip having a surface;

a plurality of spikes extending from the surface of the strip;

wherein the strip and the spikes are formed of a material having a forming temperature selected to be lower than a fabric forming temperature of the two or more pieces of fabric;

wherein the bonding strip is selected to substantially match the color of the fabric pieces.

10. The garment product as in claim 9, wherein the strip and the spikes are formed of a polymer.

11. The garment product as in claim 9, wherein the strip and the spikes are formed of the material having a forming temperature less than 200 degrees F.

12. The garment product as in claim 9, wherein the strip and the spikes are formed of a material having a forming temperature between 175 degrees F. and 200 degrees F.

13. The garment product as in claim 9, wherein the spikes are formed in one or more rows along the length of the strip, and wherein spikes on the first row are aligned with spikes on the second row.

14. The garment product as in claim 13, wherein the spikes are formed in one or more rows along the length of the strip and wherein the spikes on the first strip are staggered from the spikes on the second strip.

15. A method for joining one or more pieces of fabric, the method comprising:

providing a bonding strip having a base and a plurality of spikes extending from the base, the bonding strip being formed of a material having a forming temperature;

extending the spikes of the bonding strip through two or more pieces of fabric;

bringing the bonding strip to a temperature at least as high as the forming temperature of the bonding strip; and

forming the spikes of the bonding strip while the bonding strip is at the temperature that is at least as high as the forming temperature of the bonding strip.

16. The method as in claim 15, wherein the forming of the spikes comprises bending the spikes and pressing them flat against the at least one of the pieces of fabric.

17. The method as in claim 15, wherein the comprises, applying pressure from a seaming roller to press the spikes against at least one of the pieces of fabric.

18. The method as in claim 15, wherein the two or more pieces of fabric having a forming temperature, and wherein the forming is performed at a temperature that is between the forming temperature of the bonding strip and the forming temperature of the two or more pieces of fabric.

19. The method as in claim 15, wherein the spikes are formed in first and second rows with the spikes of the first row being aligned with spikes of the second row, and wherein the forming is performed so as to cause spikes from the first row to contact and bond with spikes of the second row.

20. The method as in claim 15, wherein the bonding strip is formed of a polymer and the one or more pieces of fabric comprise an organic material.