Stretch cushion strap assembly and method and device for making same

• US 5,984,762 A
• Filed: 08/01/1997
• Issued: 11/16/1999
• Est. Priority Date: 12/03/1993
• Status: Expired due to Term

• Current Assignee: HBI Branded Apparel Enterprises LLC (Hanesbrands Incorporated)
• Original Assignee: Playtex Apparel Incorporated (Tyson Foods Incorporated)
• Inventors: Falla, Gloria, Poindexter, Billy II, Petrovich, Joseph M., Paschal, P. Benjamin, Tedeschi, Anthony J.
• Primary Examiner(s): CHAPMAN, JEANETTE E
• Application Number:
  US08/904,518
• Time in Patent Office: 837 Days
• Field of Search: 2/267, 2/268, 2/243.1, 2/22, 2/23, 2/24, 2/2, 2/162, 2/167, 2/170, 2/169, 2/171, 450/39, 450/40, 450/92, 450/93, 450/56, 450/53, 450/54, 450/55, 450/57, 156/219, 156/228, 156/251, 156/268, 156/581, 156/79, 156/220, 156/247
• US Class Current: 450/86
• CPC Class Codes: A41F 15/00 Shoulder or like straps
• CPC Class Codes: A41F 15/007 Shoulder cushioning attachments
• CPC Class Codes: Y10T 156/1054 and simultaneously bonding [e.g., cut-seaming]
• CPC Class Codes: Y10T 156/1077 Applying plural cut laminae to single face of additional lamina
• CPC Class Codes: Y10T 156/1085 One web only
• CPC Class Codes: Y10T 156/1095 Opposed laminae are running length webs
• CPC Class Codes: Y10T 156/1097 Lamina is running length web
• CPC Class Codes: Y10T 156/1313 Cutting element simultaneously bonds [e.g., cut seaming]
• CPC Class Codes: Y10T 156/1317 Means feeding plural workpieces to be joined
• CPC Class Codes: Y10T 156/1343 Cutting indefinite length web after assembly with discrete article
• CPC Class Codes: Y10T 156/1378 Cutter actuated by or secured to bonding element
• CPC Class Codes: Y10T 156/1734 Means bringing articles into association with web
• CPC Class Codes: Y10T 24/10 Miscellaneous

Abstract

A laminated stretch cushion strap assembly having a stretchable cover, a stretchable cushion filler and a stretchable bottom or bottom fabric. The cover includes a stretchable top fabric, a first adhesive web layer positioned on one side of the top fabric and a stretchable base layer positioned on the first adhesive layer on a side opposite that of the top fabric. The stretchable bottom fabric forms with the cover an enclosure. The stretchable cushion filler is adapted to be completely enclosed within the enclosure. The stretchable cushion filler has a first cushion layer, and adhesive for securing during lamination the cover to the stretchable cushion filler, and the cushion filler to the stretchable bottom fabric. The adhesive is a second adhesive web layer positioned between the stretchable base layer and the first cushion layer to secure the cushion filler to the cover, and a third adhesive web layer positioned on the first cushion layer to secure the bottom fabric to the cushion filler. The components of the cushion strap assembly are laminated together completely by heat and adhesive. The present invention also provides a method and device for making this cushion strap.

Claims

1. A laminated stretch cushion strap assembly comprising:

cover means that includes a stretchable top fabric, a first adhesive web layer positioned on one side of the top fabric and a stretchable base layer positioned on the first adhesive layer on a side opposite that of the top fabric;

a stretchable bottom fabric that forms with the cover means an enclosure;

a stretchable cushion filler adapted to be completely enclosed within the enclosure, the cushion filler comprising a first cushion means; and

means for securing during lamination the cover means to the cushion filler, and the cushion filler to the bottom fabric, wherein the securing means includes a second adhesive web layer positioned between the base layer and the first cushion means to secure the cushion filler to the cover means, and a third adhesive web layer positioned on the first cushion means to secure the bottom fabric to the cushion filler,

wherein the components of the cushion strap assembly are adhesively laminated together.

2. The laminated stretch cushion strap assembly according to claim 1, wherein the assembly is a brassiere shoulder strap.

3. The laminated stretch cushion strap assembly according to claim 1, wherein the first and third adhesive web layers are stretchable.

4. A laminated stretch cushion strap assembly comprising:

a top cover that includes a stretchable top fabric layer, a first adhesive web layer positioned on one side of the top fabric layer and a base fabric layer positioned on the first adhesive layer on a side opposite that of the top fabric layer;

a stretchable bottom cover that forms with the top cover an enclosure;

a stretchable cushion filler adapted to be completely enclosed within the enclosure; and

means for securing during lamination the top cover to the cushion filler, and the cushion filler to the bottom cover, wherein the securing means includes a second adhesive web layer positioned between the base layer and the cushion filler to secure the cushion filler to the top cover,

wherein the components of the cushion strap assembly are adhesively laminated together.

5. The laminated cushion strap assembly according to claim 4, wherein the securing means includes a third adhesive web layer positioned on the cushion filler to secure the bottom cover to the cushion filler.

6. The laminated cushion strap assembly according to claim 4, wherein the base layer is made of a fabric including nylon and spandex.

7. The laminated cushion strap assembly according to claim 6, wherein the base layer includes about 85% nylon and about 15% spandex.

8. The laminated cushion strap assembly according to claim 6, wherein the base layer is made of a moldable elastomeric raschel fabric.

9. The laminated cushion strap assembly according to claim 4, wherein the cushion filler is made of a fabric including nylon and spandex.

10. The laminated cushion strap assembly according to claim 9, wherein the cushion filler is made of a stretch Duplex fabric.

11. The laminated cushion strap assembly according to claim 9, wherein the cushion filler is made of a fabric including about 89% filament nylon and about 11% spandex.

12. The laminated cushion strap assembly according to claim 4, wherein the cushion filler is about 0.140 to about 0.170 inches thick.

13. The laminated cushion strap assembly according to claim 5, wherein the first and third adhesive web layers include an elastomeric copolymeric adhesive web.

14. The laminated cushion strap assembly according to claim 5, wherein the second adhesive web layer is a substantially non-stretch web.

15. The laminated cushion strap assembly according to claim 4, wherein the bottom cover is a bottom fabric layer.

16. The laminated cushion strap assembly according to claim 4, wherein the base fabric layer and the bottom cover are made of the same material.

17. The laminated cushion strap assembly according to claim 4, wherein the top fabric layer is made of an elastomeric raschel fabric of nylon and spandex.

18. The laminated cushion strap assembly according to claim 4, wherein the assembly is a brassiere shoulder strap.

19. The cushion strap assembly according to claim 4, wherein the base fabric layer and the second adhesive layer delaminate when said assembly is stretched.

20. The cushion strap assembly according to claim 19, wherein the assembly is a brassiere shoulder strap.

21. A method of making a stretch cushion strap assembly comprising:

laminating a top cover having a stretchable top fabric layer, a first adhesive web layer positioned on one side of the top fabric layer and a stretchable base fabric layer positioned on the first adhesive web layer on a side opposite that of the top fabric layer, to form a binder layer;

positioning a second adhesive web layer on the binder layer;

positioning a stretchable cushion filler having a first cushion layer on the second adhesive layer;

positioning a third adhesive web layer on the first cushion layer of the cushion filler, and positioning a bottom fabric layer on the third adhesive web layer on a side opposite that of the cushion filler; and

laminating together the binder layer, the cushion filler and the bottom fabric layer to form the cushion strap assembly.

22. The method according to claim 21, wherein laminating includes molding the binder layer, the cushion filler and the bottom fabric layer at a first location, said method further comprising cutting the binder layer and the bottom fabric layer at the first location.

23. The method according to claim 22, wherein molding includes heating the tightly held binder layer, cushion filler and bottom fabric layer.

24. The method according to claim 22, wherein the binder layer, the cushion filler and the bottom fabric layer are moved into and out of the first location by a first set of nip rollers and a second set of nip rollers, said first set of nip rollers located upstream of the first location, and the second set of nip rollers located downstream of the first location.

25. The method according to claim 24, wherein said first set of nip rollers and said second set of nip rollers are electronically synchronized by a controller to move the binder layer, the cushion filler and the bottom fabric layer evenly without tension.