Distressed fabric patch and method

Abstract

Many garments made of denim material have factory created one or more discontinuities exposing a group of parallel threads and referred to as distressed denim. Sometimes, some or all of these threads become torn or rips or tears occur in the denim garment to create a discontinuity. A patch to cover the discontinuity is made of a plurality of side by side threads attached to one side of an adhesive panel and fabric material is attached to the other side of the adhesive panel. A plurality of adhesive strips essentially circumscribing the discontinuity adhere the patch to the rear side of the denim material and expose the threads through the discontinuity.

Claims

1. A method for covering a discontinuity in an article of denim clothing, said method comprising the steps of: (a) adhering a plurality of side by side threads to one side of a double-sided adhesive panel; (b) attaching a fabric material to the other side of the panel to form a patch; (c) securing one or more double sided adhesive strips in proximity to the edges of the discontinuity; and (d) laying the patch on the one or more double sided adhesive strips to expose the side by side threads through the discontinuity.

2. The method as set forth in claim 1 wherein said step of adhering includes the step of applying a heat source to the double sided adhesive panel.

3. The method as set forth in claim 2 including the step of removing a release paper in turn from each side of the double sided adhesive panel prior to exercise of said step of applying.

4. The method as set forth in claim 1 wherein said step of attaching includes the step of applying a heat source to the fabric material.

5. The method as set forth in claim 4 wherein the heat source is an iron.

6. The method as set forth in claim 1 including the step of trimming the edges of the discontinuity prior to exercise of said step of laying.

7. The method as set forth in claim 1 wherein said panel is a double sided polyurethane adhesive.

8. The method as set forth in claim 3 wherein said panel is a double sided polyurethane adhesive.

9. A method for covering a discontinuity in an article of clothing, said method comprising the steps of: (a) adhering a plurality of side by side threads to one side of a double sided adhesive panel; (b) attaching a fabric material to the other side of the panel; (c) securing a second double-sided adhesive along an edge of the discontinuity; (d) laying the panel on the second double-sided adhesive; and (e) exposing at least a portion of the plurality of side by side threads through the discontinuity.

10. The method as set forth in claim 9 wherein the double sided adhesive panel includes a heat activated adhesive and further including the step of applying heat to the double-sided adhesive panel to exercise said steps of adhering and attaching.

11. The method as set forth in claim 9 wherein said step of laying provides for coupling the panel to the article of clothing with the second double-sided adhesive.

12. The method as set forth in claim 11 including the step of trimming the edges of the discontinuity prior to exercise of said step of securing.

13. The method as set forth in claim 9 wherein the second double-sided adhesive circumscribes the discontinuity.

14. The method as set forth in claim 9 wherein said step of laying comprises setting the plurality of side by side threads adjacent the second double-sided adhesive.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The present invention will be described with greater specificity and clarity with reference to the following drawings, in which:

(2) FIG. 1 illustrates the leg of a pair of vintage jeans and showing a distressed area;

(3) FIG. 2 illustrates the components of a patch for repairing the distressed area of a pair of vintage jeans;

(4) FIG. 3 illustrates the patch incorporating the elements shown in FIG. 2;

(5) FIG. 4 illustrates a cross sectional view taken along lines 4-4, as shown in FIG. 3;

(6) FIG. 5 illustrates a method of securing the patch to the distressed area of a pair of vintage jeans;

(7) FIG. 6 is a cross sectional view taken along line 6-6 as shown in FIG. 5; and

(8) FIG. 7 is a cross sectional view taken along lines 7-7, as shown in FIG. 6, and illustrates a section of a pair of vintage jeans wherein the distressed area has been repaired.

DESCRIPTION OF THE PREFERRED EMBODIMENT

(9) The term distressed in the context of denim jeans is a style of denim that is given a vintage look through manufacturing processes. This provides these denim jeans with a look that replicates the look found in conventional denim jeans that have been well worn by a wearer. Many manufacturers purposely fade or age the denim to give a vintage, worn look through methods set by stone washing, enzyme washing, acid washing, sand blasting, emerizing, micro sanding, etc. When these processes are taken to an extreme, fraying hems and seams create whiskers and even ripping and tearing of the denim. However, denim that comes through the stress does not mold to a user's body in the same way as conventional denim jeans.

(10) Typically, distressed denim jeans have areas or discontinuities that are defined by parallel, vertically or horizontally oriented threads. Over a period of time, these threads may become broken to a greater or lesser extent. With some or more of the threads compromised, the skin or undergarment becomes visible. Sometimes, denim jeans become torn inadvertently or they are cut purposely to create a void or discontinuity.

(11) Generally, vintage jeans provided by a manufacturer are relatively expensive because of the additional labor and equipment required to create a vintage (well worn) look. The present invention provides a patch for repairing the worn or damaged distressed area. Alternatively, the patch can be used to cover a deliberately cut void to create an inexpensive pair of vintage jeans.

(12) Referring to FIG. 1 there is illustrated a pant leg 10 of a pair of distressed jeans covering the leg of a user 12. A distressed area 14 is located on the front portion of pant leg 10. The distressed area may be representative of a pair of distressed denim jeans or it may be representative of a patch attached to the inside surface of pant leg 10 to cover the discontinuity in the denim material and create/maintain the look of vintage jeans. For example, this could be an area cut out by the user in order to attach a patch constructed in accordance with the present invention and to thereby provide a vintage look to the pair of denim jeans.

(13) Referring to FIG. 2, the components of a patch 20 constructed in accordance with the teachings of the present invention are shown. A distressed thread bare front 22 may be constructed by either of two methods. First, a manufacturer may take a 36 inch by 60 inch fabric of bleached (white), natural, dyed, stretch or standard denim (also known as twill). Two 28 inch by 36 inch rectangles are distressed using cutting with various pressures and washings to break down the denim to nothing but thread bare horizontal weft fibers held together by a small frame of solid denim. Alternatively, cotton or a polyblend, both 20/2 and 10/2, of unmercerized standard stretchy yarn is wrapped around a 38 inch by 28 inch frame. The yarn is evenly wrapped across the surface of the frame to produce a plurality of spaced apart parallel threads. To positionally maintain the yarn, cotton muslin strips are glued along the edge of the frame to cover the threads that extend across the frame. This is done on opposed sides of the frame to produce sturdy borders to hold the threads in place. Irrespective of which process is used, it produces a plurality of parallel threads 24 retained in place by opposed borders 26, 28. As depicted by hash lines 30, 32, these borders are preferably of a fabric material.

(14) A sheet 40 of double sided polyurethane panel having an adhesive on either side is cut to size with a margin commensurate with the distressed area 14 to be repaired. A suitable polyurethane panel with double sided adhesive is available from Adhesive Films, Inc., located in New Jersey and identified as EXF 546 0.003 or 0.006 gauge. Release paper is disposed on each side of the panel. Release paper 42 is peeled from one side of panel 40 to expose the underlying adhesive 44. Panel 40 is mated with distressed thread bare front 22 to adhere the threads thereto. Preferably, the adhesive is responsive to form a strong bond between threads 24 and panel 40. Backside 46 of panel 40 includes a further release paper 48 to protect the adhesive on the backside of the panel. A stability fabric sheet 50, which may be sheer cotton, tricot, denim, polyblend, organza, chiffon or other material, is adhered to backside 46 of panel 40 after removal of release paper 48.

(15) The adhesive attendant both sides of panel 40 is heat responsive. A heat source, such as a conventional iron, may be applied to either or both parallel threads 24 and/or sheet 50 to ensure permanence.

(16) Patch 20 is depicted in FIGS. 3 and 4. In particular, threads 24 are adhered to panel 40 by adhesive and thereby somewhat protected against damage. Sheet 50 is adhered to the backside of panel 40. As panel 40 may be transparent, the color and texture of sheet 50 may be more or less visible between threads 24. Accordingly, the selection of sheet 50 may be a function to complement or contrast with the surrounding material of pant leg 10.

(17) Referring jointly to FIGS. 5 and 6, the method for attaching patch 20 to cover and overlap a distressed area 14 will be described. The distressed area is represented as a space without any threads extending from the perimeter thereof. However, this is not critical but the final effect will be more pleasing and acceptable if the perimeter of the distressed area is trimmed.

(18) Inside surface 54 of pant leg 10 is depicted in FIG. 5 and patch 20 to be attached thereto. A plurality of strips, such as strips 56, 58, 60, and 62 are like polyurethane panel 40 in having adhesive on opposed sides and covered by release paper. As depicted, strip 56 is attached along one edge of distressed area 14 after the release paper in the rear side of the strip has been removed. Strips 58, 60 and 62 are similarly attached around the perimeter of distressed area. Before removal of the release papers 64, 66, 68 and 70, heat may be applied to activate the adhesive adjacent the uncovered bottom of the strips 56, 58, 60 and 62.

(19) After removal of strips 64, 66, 68 and 70, patch 20, after being trimmed to essentially correspond with the outside perimeter of the plurality of strips, is placed on the adhesive side of the strips. To activate the adhesive, heat may be applied to the patch to ensure that a firm or permanent bond will not fail during bending or twisting of the underlying material. A conventional iron used to iron garments has been found particularly useful to not only apply heat but also to compress the materials and form a strong bond.

(20) FIG. 7 illustrates the exterior surface 64 of pant leg 10 after attachment of patch 20. As depicted, patch 20, at which threads 24 are clearly visible, extends across distressed area 14.

(21) From the above description, it is self evident that a pair of vintage denim jeans which have been damaged or are damaged resulting in a void/opening can be reconstructed to provide the same visual impression as the original vintage denim jeans. Additionally, any tears or other damaged section of the garment can be trimmed to provide a distressed area for attaching a patch constructed in accordance with the present invention and thereby provide a pair of denim jeans with a vintage look.