Note: Descriptions are shown in the official language in which they were submitted.
PATCH POCKET AND FLAP CONSTRUCTIONS
TECHNICAL FIELD
The present invention relates generally to a method
of constructing pockets for garments. More particularly,
S this invention concerns a method of constructing patch
pockets and flaps by utilizing adhesives.
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_ACKGROUND ~RT
In the manufacture of garments, pockets are provided
chiefly for carrying useful items. Such useful items can
include, for example, keys, money, wallet, hand~erchief
and so forth. The pockets are integrated into the garment
and take the general form of a pouch open at one ~nd for
convenient access to the contents.
There are two basic types of pockets: the standard
pocket and the patch pocket. The standard pocket is
located on the inside of the garment, which includes a
pocket slot for access thereto. A standard pocket thus
occupies a concealed and protected location in the
.
garment.
In contrast to the standard pocket, a patch pocket is
located on the outside of the garment. In its simplest
form, a patch pocket comprises a layer or patch of
material sewn only at the bottom and side edges to the
garment so that articles can be received therebetween.
Patch pockets are most popular in less formal garments
such as shirts, trousers, jeans and the like. Patch
pockets are also very popular with jackets, sport coats
and so on. In many cases, a flap is provided on the
garment to cover the open end of the patch pocket. While
the standard pocket is relatively more complex and time-
consuming, the construction of patch pockets and flaps also
~ involves numerous manual operations including material
cutting, positioning, sewing and trimming. ~or example,
the material turnunder in a patch pocket causes unsightly
puckering which must be remedied. Such manual operations
are time-consuming and tend to increase the cost of
garment production.
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As an alternative to traditional tailoring and sewing
procedures, there have been some efforts directed to the
use of adhesives in garment construction. For example,
in copending Canadian patent application serial number
351,743, filed on May 12, 1980 and assigned to the as-
signee hereof, there are shown inventions concerning the
construction of standard pockets with the aid of adhesives.
Heretofore, however, adhesives have not been employed in
the construction of patch pockets or flaps. There is
thus a need for patch pocket and flap constructions which
utilize adhesive connec~ion techniques to reduce garment
production costs.
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Disclosure of Invention
According to one aspect of the invention there is
provided a method of constructing a patch pocket on a
garment including the steps of: providing a layer of
pocket material having opposed side edges spaced apart a
predetermined distance, a bottom edge interconnecting the
side edges, and an upper edge including an extension
extending upwardly beyond the upper ends of the side edges
and having a width less than the space in between the side
edges; folding the extension downwardly down along a line
extending between the upper ends of the side edges;
adhesively securing the extension in the folded condition
to define a folded top edge of the pocket blank; said
layer of pocket material having the extension folded and
adhesively secured defining a patch pocket blank including
a reverse side comprising the side having the extension
secured thereto and an obverse side comprising the
opposite side thereof; attaching fusible adhesive to the
obverse side of the patch pocket blank along the side and
bottom edges thereof; folding the side and bottom edges of
the patch pocket blank inwardly so that the fusible
adhesive attached thereto faces in the direction of the
reverse side of the patch pocket blank; positioning the
patch pocket blank on the outside surface of a garment
with the fusible adhesive engaging the outside surface of
the garment and with the reverse side of the patch pocket
blank positioned adjacent thereto; and activating the
fusible adhesive to secure the patch pocket blank in
engagement with the outside surface with the garment being
carried out by forming a stitch along the side bottom
edges along the patch pocket blank, said stitch including
at least one thread comprising a fusible adhesive.
Other aspects of this invention are claimed in a
divisional application.
According to the preferred construction, the bottom
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and side edges of the patch pocket blank are then folded
inwardly to orient the adhesive in the reverse direction.
Alternatively, the adhesive can be provided on the reverse
side of the patch pocket blank to eliminate the
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step of folding the edges which is required when the
adhesive is provided on the obverse side.
The blank is then positioned reverse side against
, a garment wherein a patch pocket is desired. After
positioning, the patch pocket blank is adhesively
secured to the garment by activating the fusible
adhesive material. Preferably, activation of the
fusible adhesive material is effected by engaging the
pocket blank with a heated press, ultrasonic means,
or a radiant source capable of converting the
adhesive from solid to plastic condition. If desired,
a reinforcing stitch can be provided along the
adhesively secured edges of the patch pocket.
If desired, a flap can be attached to the garment
using similar techniques. Fusible adhesive material
is deposited adjacent to the top edge of a flap blank.
The adhesive can be attached to either side of the
flap blank. Preferably, the adhesive is deposited
on the obverse side, after which the top edge of the
flap bank is folded inwardly to orient the adhesive
in the reverse direction. The flap blank is then
positioned reverse side against the garment, and the
fusible adhesive material is activated to adhesively
secure the flap in place. If desired, a reinforcing
stitch through the top edge of the flap can be added.
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BRIEE` DESCRIPTION OF DRAWINGS
A ~ore complete understanding of the invention can
be had by reference to the following Detailed ~escription
in conjunction with the accompanying Drawings, wherein:
FIGURE 1 is a plan view of one side of a patch
pocket blank useful in the practice of the invention;
FIGURE 2 is a plan view of the other side of the
pocket blank shown in FIGURE l;
FIGURE 2a is an enlarged partial sectional view
taken generally along lines 2a-2a of FIGURE 2 in the
direction of the arrows;
FIGURE 3 is a partial plan view of an alternate
form of. the pocket blank shown in FIGURE l;
FIGURE 4 is a plan view of one side of an alternate
patch pocket blank;
FIGURE 5 is a plan view of the other side of the
pocket blank shown in FIGURE 4;
FIGURE 6 is a partial plan view of a modification
: of the pocket blank shown in FIGURE 4;
FIGURE 7 is a plan view of the pocket blank
modifications of FIGURES 3 and 6 after partial folding;
FIGURE 8 is a plan view of a folded patch pocket
blank;
FIGURE 9 is an enlarged sectional view taken
generally along lines 9-9 of FIGURE 8 in the direction of
the arrows;
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FIGURE 10 is an illustration of a garment having
a ~atch pocket constructed in accordance with the
invention;
, FIGURE 11 is a sectional view taken generally
S along lines 11-11 of FIG~RE 10 in the direction of the
arrows;
FIGURE 12 is a plan view of one side of a flap blank
useful in the practice of the invention;
FIGURE 12a is an enlarged partial sectional view
taken generally along lines 12a-12a of FIGURE 12 in
. the directlon of the arrows;
FIGURE 13 is a plan view of one side of an alternate
flap blank;
FIGURE 14 is a plan view of a flap blank after
folding;
FIGURE 15 is an illustration of a garment having a
; flap constructed in accordance with the invention; and
FIGURE 16 is an enlarged sectional view taken
generally along lines 16-16 of FIGURE 15 in the direction
of the arrows. -
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DETAILED DESCRIPTION
Keferring now to the Drawings, wherein like referencenumerals desiynate like or corresponding parts throughout
the several views, tllere is illustrated a method of
constructing patch pockets and flaps incorporating the
invention. The patch pocket and flap constructions
utilize fusible adhesive materials to eliminate several
time-consulning and costly manual procedures which have
been required heretofore. The method of the invention can
be advantageously employed in the manufacture of shirts,
trousers, jackets, or any other garment with patch pockets
and/or flaps. The method reduces garment manufacturing
costs and results in strong patch pocket and flap
constructions of good looking appearance.
Referring to FIGURES 1 and 2, there is shown a patch
pocket blank 10 which is used in the practice of the
invention. Patch pocket blank 10 is shown in FIGURE 1
with the obverse side up, the other or reverse side being
up in FIGURE 2. Patch pocket blank 10 is formed from a
suitable piece of pocket material 12 of sufficient size
to permit construction of the desired patch pocket.
Tyl~ically, pocket material 12 comprises self goods
matching the fabric of the garment. Material 12 can
comprise any natural or synthetic cloth material suitable
for use in the construction of a patch pocket. It will
be understood that the exact composition of pocket material
12 is not critical to the practice of the invention.
For purposes of illustration, patch pocket blank 10
comprises a generally rectangular section of material 12
having rounded bottom corners. This is a popular shape
for patch pockets. It will be understood that this
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particular shape is shown only for purposes of illustra-
tion, and that the method of the invention applies equally
well to patch pockets of other peripheral shapes, such as
those having square corners.
As is best shown in FIGURES 2 and 2a, patch pocket blank
10 is illustrated with material 12 folded down at the top with
a conventional liner 14 attached to the reverse side of the
material. Preferably, the top edge of liner 14 is also folded
down and secured to material 12. The folded top edges of mate-
rial 12 and liner 14 are typically fastened together with a
stitch 13. Adhesive could be utilized in place of stitch 13.
It has been found that a liner material of the fusible type
works well as liner 14. For example, material dot coated with
adhe~sive on one side is easily attached to pocket material
12 in noncontinuous fashion. Patch pocket blank 10 is thus
depicted with a typical rolled top edge and liner. It will be
understood, however, that the method of the invention works
equally well whether or not pocket blank 10 includes a rolled
top edge or a liner 14. The particular construction of the
patch pocket blank 10 is not critical to practice of the
invention.
The material 12 is then provided with adhesive 16 adja-
cent to the bottom and side edges. Adhesive 16 is preferably
located continuously about the lower periphery of pocket blank
10. Adhesive 16 can be provided on either the obverse or
reverse side of material 12. FIGURE 1 illustrates adhesive 16
positioned on the obverse side of pocket blank 10, which is in
accordance with the preferred practice of the invention. If
desired, adhesive 16 can be provided along the bottom and side
edges of both sides of pocket blank 10. As shown in FIGURE 1,
adhesive 16 comprises a strip or ribbon of fusible material
having a predetermined width. Adhesive 16 preferably comprises
a fusible material, such as polyamide, nylon or polyester
materials of the type manufactured by General Fabric Fusing
Company of Cincinnati, Ohio. If desired, adhesive 16 can be
extruded directly onto pocket material 12.
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Referrin~J to FIGURES 4 and 5, there is illustrated
an alternate technique for providing patch pocket blank
10 with adhesive 16. If desired, adhesive 16 can be
applied with a covering or overedyin~ stitch. A serge
stitch is one such stitch. A serye stitch is
typically provided around tlle edges of a piece of fabric
to prevent fraying. In a two-thread serge stitch,
one or both of the threads can be formed of a fusible
adhesive material, such as polyester, so that the
adhesive is simultaneously attached during serginy.
FIGURE 4 illustrates adhesive 16 attached only to the
obverse side of poc~et blank 10 by means of one fusible
thread of a serge stitch, with the other non-fusible
thread of the serge stitch being located on the reverse
side shown in FIGURE 5. It will be understood that
adhesive 16 can be applied along the edges of both sides
of patch pocket blan~ 10 with a serge stitch having both
threads formed of fusible adhesive material.
Referring now to FIGURES 3, 6 and 7, there is shown
a modification of patch pocket blank 10. If desired,
pocket blank 10 can be formed from a piece of material
18. The reverse side of material 18 faces up in
FIGURES 3, 6 and 7. Adhesive 20 is next provided along
the top edge of material 18 on the reverse side thereof.
Adhesive 20 can be attached in the form of a strip of
fusible adhesive material, as shown in FIGURE 3, or in
the form of adhesive threàd in a serge stitch, as shown
in FIGURE 6. Adhesive 20 comprises a fusible adhesive
material similar to that utilized for adhesive 16. The
top edge of material 18 is then folded down as shown in
FIGURE 7 to position adhesive 20 between adjacent layers
of material 18. As will be described more fully
hereinafter, adhesive 20 is then activated to adhesively
secure the rolled top edge of material 18. Preferably,
the top corners of material 18 are notched as shown to
allow for~adhe$iv~ 16 when the top edge of material 18
is folded down.
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Referring to FIGURES 8 and 9, the bottom and side
edges of patch pocket blank 10 are next folded inwardly
in the preferred embodiment of the invention. The reverse
,side of pocket blank 10 faccs up in FIG~RE 8. If adhesive
S 16 is positioned on the obverse side of pocket blank 10,
the bottom and side edges are thus folded inwardly to
orient the adhesive in the reverse direction. The use of
adhesive 16 adjacent to the bottom and side ed~es minimizes
the amount of turnunder required, resulting in less
1~ puckering and material waste. It will be understood that
if adhesive 16 is applied to the reverse side of pocket
blank 10, then the inward folding of the bottom and side
edges~fs unnecessary.
Referring to FIGU~ES 10 and 11, patch pocket blank
10 is next positioned on the outside of a garment 22
wherein a patch pocket is desired. For example, garment
22 can comprise a shirt, trousers~ jacket or the like.
Garment 22 can be formed of any natural or synthetic
cloth material, the exact composition of which is not
critical to the practice of the invention. The reverse
side of patch pocket blank 10 is positioned against the
outside surface of garment 22 with adhesive 16
therebetween. In the preferred embodiment of the
invention, the bottom and side edges of patch pocket
blank 10 are folded inwardly to properly orient adhesive
16. Of course, if adhesive 16 is provided along the
edges of both sides of pocket blank 10, then adhesive
will be positioned between adjacent layers of the
pocket blank as well as between garment 22 and the
pocket blank.
After positioning, the patch pocket blank 10 is
adhesively secured in place. Fusible adhesive 16 is
activated to convert it from a solid to a plastic
condition. Activation of adhesive 16, as well
as adhesive 20 if desired, is preferably accomplished
by engaging the obverse side of pocket blank 10 with
a heated press, ultrasonic or microwave means, or a
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radiant source. The temperature and duration of
engagement are sufficient to melt the adhesive so that
adjacent portions of patch pocket blank 10 and garment
22 become permeated to form a bonded connection. It will
be appreciated that tile use of a heated pr~ss to activate
adhesive 16 simultaneously presses the periphery of the
patch pocket. After activation, it will be understood
that the patch pocket is secured with an adhesive
connection which is strong and durable as well as
resistant to garment cleaning processes. Preferably, a
stitch 24 is sewn along the lower periphery of the patch
pocket to reinforce the connection between pocket blank
10 and garment 22, and to lend a finished appearance to
the patch pocket.
Referring now to FIGURES 12, 12a and 13, there is
shown a flap blank 30 which can be used in adding a flap to
the patch pocket hereinabove described, if desired. Flap
blank 30 can be formed of a single piece of flap material
32 comprising any natural or synthetic cloth material
~0 suitable for such use. Typically, however, the flap blank
30 comprises two pieces of material 32 and 33. The bottom
edges of material 32 and 33 are folded inward and
fastened together with a stitch 34 as is best shown in
FIGURE 12a. Adhesive can be used in place of stitch 3~1, if
desired. The exact composition of pieces of flap material
32 and 33 is not critical to the practice of the invention.
- It will be understood that the particular construction of
flap blank 30 is not critical to the invention.
The flap construction is carried out using techniques
similar to the patch pocket construction. Adhesive 35 is
deposited adjacent to the top edge of flap blank 30.
Adhesive 35 comprises a fusible adhesive material such as
polyamide, nylon, polyester or the like. Adhesive 35 can
be applied in the form of a strip of material, as shown
in FIGURE 12, or in the form of a thread of fusible
material in a serge stitch, as shown in FIGURE 13. In
accordance with ~he preferred embodiment of the flap
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construction, adhesive 35 is provided on the obverse side
of flap material 32. If desired, adhesive 35 can be
provided along the top edge of both sides of flap material
32, or only on the reverse side thereof.
S ReferrincJ to FIGURE 14, the top edge of the preferred
embodiment of flap blank 30 is folded downwardly to orient
adhesive 35 in the reverse direction. The reverse side
of 1ap blank 30 faces up in FIGURE 14. If adhesive 35
is provided only on the reverse side of material 32, it
will be apparent that downward folding of the top edye
of pocket blank 30 is unnecessary.
Referring to FIGURES 15 and 16, flap blank 30 is next
positioned on garment 22 wherein a flap is desired. The
reverse side of flap blank 30 is positioned against the
outside surface of garment 22 with adhesive 35 there-
between. For purposes of illustration, flap blank 30 is
shown in conjunction with a patch pocket 36 constructed
according to the invention. ~lap blank 30 is thus located
on garment 22 so as to cover the top end of patch pocket
- 36. However, it will be appreciated that flap blank 30 is
a separate component which can be added to garment 22 with
or without an accompanying patch pocket.
After location, the flap blank 30 is adhesively
secured in place. Adhesive 35 is activated with a heated
press, ultrasonic or microwave means, or a radiant source
to securely bond flap blank 30 to garment 22. The use
of a heated press is desirable because it presses the
folded ~op edge of pocket blank 30 during activation of
adhesive 35. Preferably, a stitch 38 is sewn along the
upper edge of the flap to give it an attractive appearance
and to reinforce the connection between flap blank 30 and
garment 22.
Ir. view of the foregoing description, it will be
understood that the present invention comprises a method
of constructing patch pockets and flaps which incorporates
numerous advantages over the prior art. One important
advantage ~nvolves'the use of fusible adhesive materials
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in place of traditional sewincJ operations. Sewn patch
pockets have heretofore required ~ore material turned
under along the edges, resulting in unsightly puckeriny
and additional manual steps to correct the puckering.
Also there is greater material waste when more turnunder
is required. The use of fusible adhesives minirnizes
both material turnunder and puckering therefrom, and
eliminates several manual operations which were heretofore
~-e~uired in the construction of patch pockets and flaps.
- Other advantages from the use of the invention will
readily suggest themselves to those skilled in the art.
Although particular embodiments of the invention have
been illustrated in the accompanying Drawings and
described in the foregoing Detailed Description, it will
be understood that the present application is not limited
to the embodiments disclosed but is intended to embrace
any alternatives, modifications, rearrangements and
substitutions of parts and/or elements as fall within
the spirit and scope of the invention.
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