US3043311A - Deposited latex articles - Google Patents

Description

July 10, 1962 H. J. BARTH DEPosITED LATEX ARTICLES 5 Sheets-Sheet 1 Filed Sept. 9, 1958 INV ENTOR HARRY J. BARTH ATTORNEY July 10, 1962 H. J. BARTH DEPOSITED LATEX ARTICLES 3 Sheets-Sheet 2 Filed sept. 9, 195e R m m m HARRY J. BARTH ATTORNEY July 10, 1962 H. J. BARTH DEPosITED LATEX ARTICLES 3 Sheets-Sheet 3 Filed Sept. 9, 1958 INVENTOR HARRY J. BARTH ATTORNEY 3,643,311 DEPGSITED LATEX ARTICLES Harry J. Barth, Dover, Del., assigner to International Latex Corporation, Dover, Del., a corporation of Dela- Wre Fried sept. 9, 195s, ser. No. 760,021 4 claims. (ci. 12s- 521) This invention relates to deposited latex articles and methods for forming such articles and, more particularly, to deposited latex articles having integrally formed pockets in the wall of the article, which pockets may be used to anchor garters, straps and the like therein, and to the forming of such integral pockets during the fabrication of the deposited latex article.

A major problem encountered in producing serviceable deposited latex articles, such as girdles or brassieres, of the type which have accessories (e.g., garter straps, shoulder straps or other attachments) affixed to the marginal portions thereof, has been the limited ability of these portions of the deposited latex articles to which these attachments are joined to withstand the repeated flexing and concentrated tension to which such portions are subjected by stressing and/or straining the attachments during wearing. Various devices have previously been employed to attach such straps to deposited latex articles, but these involve either complicated methods of manufacture or attachment or employ exposed ends (buttons or tabs) which will interfere with the clothes or the body of the wearer. i

The present invention provides a simple and inexpensive method for forming potential pockets for the anchoring of accessories within the contines of the wall of a deposited latex article during the formation thereof, and subsequently processing such potential pockets to form open integral pockets at or along at least one marginal edge of the deposited latex article. Subsequently anchorage of a support strap or other accessory within the pocket can be effected by various fastening or attaching devices or fastening, as by sewing, the strap within the pocket. Articles having such integral pockets have superior service- -ability under the stresses occurring during use and superior consumer acceptance, yet are relatively inexpensive to produce. y

In accordance with the present invention, the integral pocket in the wall of the deposited article is formed by preventing adhesion, within a small selected area, between successive depositions of the latex so as to form a closed pocket or envelope and subsequently cutting or trimming the article so as to open the pocket. Adhesion between successive depositions or layers of latex can be prevented by placing a latex-separating material, shaped generally similarly to the open portion of the final or ultimate pocket but extending a small distance beyond what becomes the open portion of the pocket, on a deposited latex film having only a portion of the ultimate or finished thickness of the deposited latex article and subsequently depositing thereon additional latex. Thus, a closed pocket is formed that is potentially an open pocket, the latter being formed when the closed pocket is cut or trimmed to expose or open a portion of the boundary of the closed pocket. After interior of the pocket is accessible, the successive layers of latex on either side of the latex-separating material can be separated or parted at the plane of the latex-separating material and thus form an open pocket. The latex-separating material may be a single piece of film, such as polyethylene to which latex does not adhere, or it may lbe a piece or pieces of film folded and/or sealed at the edges to form a closed envelope. In the latter instance, the envelope may be made of material, such as fabric impregnated with latex, to which latex adheres. Such 3,043,311 Patented July 10, 1962 ice a material has the advantage that it remains in the pocket to reinforce it or make the inside smooth. When the film is positioned at a desired place on the article (for example, partially extending over what will be the finished edge of the garment, in the case of garter or brassiere support attachments) during deposition of the latex and the finished dipped article is trimmed along predetermined lines to expose generally a portion of the boundary of the pocket, an integral pocket, open at the margin of the article, is formed.

The area or region on one or both sides of the latexseparating material can be advantageously reinforced,

such as by a piece of reinforcing fabric capable of becoming impregnated with latex during the dipping operation or, as pointed out above, the latex-separating material itself may incorporate a reinforcing fabric. Thus, a piece of film to which latex does not adhere may be placed between a folded piece of fabric to form a reinforcing patch assembly and the assembly placed on the surface of the wet latex of a partially dipped article. The wet latex Strikes through or impregnates the fabric next to it and subsequent dipping (to form the completed article) impregnates the other side of the fabric assembly. Under these conditions, the reinforcing fabric patch is integrally embedded in the latex with the piece of film separating the two impregnated pieces of fabric thus providing a reinforced pocket within the confines of the wall of the article which can be opened to form an integral pocket.

When an integral pocket is positioned as described above with respect to the wall of the deposited article, the plane of stress resulting from tension on the attachment is positioned somewhat centrally with respect to the wall thickness of the article (i.e., since the inside of the pocket has approximately equal wall thicknesses on both sides of it) and any pull on it tends to be transmitted to both adjacent walls with resulting uniform distribution of the stress. This avoids undesirable concentrations of stress at any point in the region of attachment of a strap to the article so that the region of attachment is capable of withstanding more intense flexing and straining without tearing. Also, by reinforcing the inner face of the attachment pocket, there is provided a structure with improved strength and resistance to tear in a highly stressed region of the article.

The invention is described in greater detail in connection with the drawings in which embodiments of the invention, as exemplified in girdles and brassieres, are illustrated, it being understood that these embodiments are shown as examples of various forms that the invention may take and not by way of limitation thereof.

In-the drawings:

FIGURE 1 is a front View in elevation showing a* deposited latex girdle vhaving integral reinforced pockets for the attachmentof garter straps;

FIGURE 2 is a cross-sectional view taken along the line 2 2 of FIGURE 1 showing 'an integral reinforced pocket and attached garter strap; y

FIGURE 3 is a plan View of an assembly used to form a reinforced garter attaching pocket;

FIGURE 4 is a cross-sectional viewA taken along the line 4-4 of FIGURE 3 showing the position of the film in the assembly;

FIGURE 5 is a View in elevation of a portion of the girdle before trimming showing a potential pocket in the Wall of the girdle and the line along which it will be trimmed;

FIGURE 6 is a cross-sectional View taken along the` FIGURE 8 is a cross-sectional view taken along the line 8-S of FIGURE 7 showing the reinforced pocket produced in the wall of the girdle by cutting along the trim line and removal of the non-adhering film;

FIGURE 9 is a fragmentary view of back and front portions of -a deposited latex brassiere having integral pockets in the wall of the brassiere with the ends of a shoulder strap mounted therein;

FIGURE 10 is a plan View of a fabric reinforced patch grommet assembly having an attaching grommet shielded by a latex-separating film on each side thereof;

FIGURE 11 is a cross-sectional view taken along the line 11-11 of FIGURE l0 showing the grommet ernbedded in fabric with a latex-separating film on each side thereof yand a piece of fabric on the outside of each piece of film;

FIGURE 12 is a View in elevation of a portion of latex dipped girdle before trimming showing the position of grommet assembly;

FIGURE 13 is a cross-sectional view taken along the line 13-13 of FIGURE 12 showing the grommet assembly centrally located within the wall of the girdle;

FIGURE 14 is a view of the portion of the girdle shown in FIGURE 12 with the bottom edge thereof cut along its trim line; and

FIGURE 15 is a cross-sectional View taken along the line 15-15 of FIGURE 14 showing a dual compartment with the gromrnet attachment forming a central wall therein.

In the drawings, FIGURE 1 illustrates in general a deposited latex girdle 2li having a front wall 21 and a back wall 22 which form a continuous body-encircling elastic garment. Positioned in both the front `and back walls of the girdle at the bottom marginal edge 23 thereof are spaced garter tab, strap or ribbon receiving pockets 24 which extend from the edge of the girdle vertically upwardly within the connes of the wall thereof (see FIG- URE 2). Each side of pocket 24 has embedded therein a fabric reinforcement 25 which forms a reinforced wall defining .a wall of the pocket. The pocket is formed so that the vertical opening therein lies in the plane passing through approximately the median of the wall of the girdle.

Within pocket 24 is positioned the free end of a garter strap or loop 26. The free end of the garter loop 26 is held in fixed position by suitable stitching 27, suc-h as by sewing with nylon thread or any other thread strong enough tol resist tension and repeated stressing. Other anchoring or attaching means such as rivets, staples, plastic fasteners, or the like which permanently or releasably anchor or fasten the strap or loop in lthe pocket may be used. Although the wall having the fabric embedded therein is less resilient, it is understood, unless otherwise refered to hereinafter, that the remainder of the wall of the girdle is of such an elastic character and thickness as to be stretchable and to provide form fitting control for contouring the human form.

The support pockets 24 are formed within the wall of the deposited latex girdle during a dipping operation, conducted in a manner similar to the methods described in US. Patent No. 2,360,736, issued to A. N. Spanel October 17, 1944. When the deposited latex girdle has, by successive dipping, yacquired a partial wall thickness, such as about 0.005 to Aabout 0.015, the dipping operation is interrupted and a reinforcing patch 28 placed on the partially formed girdle. Reinforcing patch 28 (see FIGURES 3 and 4) is formed from two layers of an impregnable fabric 25, such .as nylon tricot, rayon, silk, or cotton net and the like, with a rectangular piece of latexseparating film 29 therebetween. It will be appreciated that a woven or knitted fabric or other sheet material which is foraminous in structure, capable of latex impregnation and providing strength to the wall of the article may be used to form the patch. The fabric portion 25 of the patch 28 has an oval body 30 terminating in a downwardly projecting section 31 which gives the patch the appearance of a projected knob. Sandwiched between the two fabric layers 25 is the rectangular shaped film 29 having surface characteristics such that it does not adhere to either the wet latex or the latex film after curing thereof.

Film 29 is positioned between the sheets of tricot so that a portion of the rectangle extends into the downwardly projecting section 3l. Film 2? may be held in place by spot cementing which aids in holding the patch together and facilitates ease of handling of the patch when it is applied to the wet partially formed latex girdle (see FIGURES 3 and 4). The patch is positioned on the partially formed wet latex girdle in appropriateV positions where the garter straps `are to be located. When the patch is pressed against the wet latex, the latex is ernbedded in the interstices of the fabric on the surface of the patch. The surface of the film,- due to its non-adherent characteristics, resists surface adhesion and a wall of the potential pocket is created. Subsequent dipping of the girdle in the bath of latex completes the impregnation of the fabric so that the patch assembly is confined within the wall of the deposited latex girdle thereof as an integral part. This forms, within the wall of the girdle, a closed pocket or pouch of the size and shape corresponding to the size and shape of the film (see FIGURE 6). It will be appreciated that, by making the fabric portion of the patch larger in `area, the immediate area around the pocket has a two-ply reinforcement therein which adds strength to the pocket and absorbs la large portion of the strain placed on the portion of the wall of the girdle immediately surrounding the pocket.

Upon completion of the dipping operation, the girdle y is passed through la further processing step to effect curing of the latex to give it rubber-like quality. After curing the girdle, it is stripped from the form and the top and bottom of the girdle are finished trimmed along their i trim lines which correspond to the edges of the top and bottom. Trim line 32 in FIGURES 5 and 6 corresponds to the bottom edge 23 ofthe girdle. The trimming operation removes the excess latex which has been used to assure complete coverage of the girdle generating surf-ace of the dipping form. Since the patch 28 is positioned so that projection section 31 extends past the trim line, it is simple and easy to open the closed pocket along a locus positioned on the bottom marginal edge of the girdle. Such trimming converts the closed pocket into a rectangular, vertically extending opening or open pocket 24 which is located within the wall of the girdle and is reinforced on each side by fabric embedded in the adjacent deposited latex (see FIGURE 8). This construction provides reinforced pockets or pocket-like openings or slots within the wall of the girdle so that support straps, ribbons and other attachments may be associated with the girdle by the simple expedient of sewing or by lche use of other equivalent fastening means to position within the open pocket the unsightly ends of a garter loop or other supporting member and thus prevent the wearers clothing and skin from coming into contact with the edge of the end of the attachment.

As heretofore described, the support pockets of this invention may be rformed in a deposited latex brassiere, such -as the brassiere described in the patents to L. A. Spanel et al. Nos. 2,721,323 and 2,797,415. FIGURE 9 illustrates a fragmentary section of a typical deposited latex brassiere 40 having `a frontal section 41, spaced breast receiving cups 42 and back portions 43 (only one shown) to form a body-encircling band. Positioned along the top and the bottom marginal edges of the brassiere are bands or edgings 44 and 45, respectively, which define the edges of the garment and act as reinforcements. Above each breast cup in the marginal edge of the gan ment, is `a rectangularly shaped pocket-like opening or slot 46. Each side of the pocket is faced with a fabric Y section 47 embedded in ythe walls forming the pocket in `the manner heretofore described. The pocket extends downwardly from the top edge of the bnassiere separating the -waJl so that the pocket is substantially centralized with respect to the median of the wall thickness of the brassiere. Each back section of the brassiere has a similar rectangular pocket 48 `formed in the same manner yas heretofore described. Pocket 48 together with pocket 46 provides means for anchoring the ends of a shoulder strap 49 to the brassiere, one end of the shoulder strap 49 being positioned in pocket 46 and the other end in pocket 48. The ends are aiixed in the support pocket in the wall of the brassiere by stitching 50 which pierces the wall of the brassiere and the end of the shoulder strap to form an attachment at this point. In this manner both shoulder straps are attached to the brassiere in a` manner which results in a strong and durable attachment to a relatively thin rubber article. yIt will be appreciated that many types of support attachments may be anchored in support pockets in -brassieres and the like, such as zippers, hook `and eye fastening strips and the like which must be attached to facilitate assembly on the body of the wearer or for comfort of the wearer.

An alternate form of the present invention is illustrated in lFIGURES through 15 in which a supporting element is positioned in a pocket formed in Ithe wall of a dipped latex article as heretofore described for providing a means for making attachments to the article. In this arrangement, the supporting element is fixed or mounted in lthe pocket so that it separates the pocket into two compartments so that a strap, ribbon, or other attachment may be securely xed to the supporting element.

FIGURES 14 and 15 show this type of construction in which a portion of a girdle 51 has formed in the wall thereof a support pocket 52. Centrally located in the integral pocket 52 is Ia grommet 53 encased between two pieces of nylon tricot lby heat sealing to `form a unit 54 and position the grommet. 'Ihe top and sides of grommet unit 54 extend into the wall of the girdle and are embedded therein so as to firmly anchor a portion of the periphery of the unit in the Wall of the girdle and maintain the grommet centrally with respect to the pocket. Each side of the pocket 52 has a fabric piece 55 embedded therein (see FIGURE l5). Through the grommet is placed la suitable garter strap (not shown) for supporting the stockings of the wearer of the girdle.

The integral pocket containing the grommet is formed by interrupting the dipping operation and placing on the deposited latex film a grommet patch 56. .FIGURES 10 and 11 show a grommet patch assembly in which a grommet 53 is placed between two pieces of nylon tricot and heat sealed to form a unit. The center of the grommet is cut out so that the grommet is completely supported in the tricot. The grommet unit thus formed is preferably rectangular in form, but, of course, may be in other forms depending 'on the style desired and the type -of support to be enclosed in the pocket. On each side of the grommet unit 54 is placed a piece of latexseparating lm 57 smaller in rectangular area than the grommet unit so that there is an exposed vborder around the sides and top edge fof the grommet unit (see.fFIGURE 1v1). A rectangular piece of nylon tricot fabric 55 which has the same area as the grommet unit is positioned so as to cover the outside surface of each piece of lm in the manner shown in FIGURES 10 and 11. 'Ihis assembly forms the grommet patch`unit which may be held toget'her by spot cementing to avoid slipping of the various pieces forming the unit.

This assembly is pressed against the wet latex to impregnate one side of the patch and hold it in position. When used with a girdle, the assembly is positioned so that a portion of the bottom thereof extends below a trim line S8. Subsequent dipping of the girdle builds up its finished thickness, embeds the yfabric in the wall of the girdle with the sides and top border portion of the lilm forming the body of the girdle.

6 grommet assembly 54 and the outside nylon tricot piece becoming an integral part o-f the wall of the girdle. This embedding of the sides and the top border provides a firm anchoring of the grommet 'assembly in the pocket. The ilm positioned on the outside of the grommet assembly prevents the adherence of the latex thereto so that the grommet assembly forms a dual compartment with the grommet assembly as a wall therebetweenl (see FIGURE 15).

As heretofore described, trimming along trim line S8 to remove excess deposited latex, provides an opening of oneend of the pocket so that a garter strap or other similar attachment can be -attamed to the grommet within the confines of the wall of the girdle.

It will be appreciated that the pockets forming a part of this invention may be formed by the use of any material which will produce an area of separation or nonadherence within the wall of the deposited latex garment when applied between one of the successive dippings thereof. Exemplary tof latex-separating materials are plastic tilms, such .as cellophane, polyethylene, and the like, or metal foils, such as aluminum or tin foil, etc. It has been found that when film is used that a film thickness of fro-m a few thousandths of an inch to 1/32 provides good results and facilitates ease of handling of the patch assembly. However, such thickness can be Varied in accordance with designl requirements, such as the amount of stress imposed on the attachment.

Alternatively, an effective latex-separating material `can' be made by forming a pocket, sealed around the edges,- of or sheet to which latex may adhere but does not penetrate. IUnder these conditions, the potential pocket (the interior `of the pocket, sealed against entry of latex) is formed prior to association with the deposited latex Y Exemplary of suitable films or sheets are latex impregnated light fabrics, plastic coated fabric (with the plastic coating on the inside) and the like.

The reinforcing :fabric advantageously is a tricot type fabric woven of nylon, rayon, silk or other fibers but other woven, knitted or foraminous material, such as marquisettes, bobinettes, Helanca types and the like which will become impregnated so as to form part of the walls of the deposited latex may be used, depending on the use and function of the pocket.

The position and size of the pockets for attachments and accessories depend on the particular use of the attachment and the article. For example, where a grommet is included within the pocket, the size and shape of the pocket will be somewhat larger than a pocket which is to contain the end of a garter strap sewn in the pocket. If the pocket is located in the wall of the article 'in such a fashion that it is not close to a trimming edge, the pocket may be formed by slitting one wall of the article so that an attachment may be associated with the pocket. Both inside and outside attachments can be made at the same location on the article by slitting through both walls of the pocket so as to form an opening available from both sides of the article, the free ends of the attachments Ibeing anchored through both of such openings. Although the latex-separating film used to form the pocket may be removed from the pocket after the pocket has been opened, under some conditions it may be allowed to remain in the pocket to add additional strength.Y

Ihe wall thickness of the deposited article depends upon its intended use and, in the case of girdles, a wall thickness of about 0,015 to 0.030 is an effective range. It has been found that each Wall of the pocket may vary in thickness, an effective range being 0.003 to about 0.025, depending upon the thickness of the garment, the stress to be applied thereto, and the amount and type of reinforcement. Generally, thickness, size and shape of the pockets will depend upon the nature of the attachment made thereto and the stress and strain to be transmitted through the Wall of the garment.

Although the present invention has been described with particularity with reference to preferred embodiments, it will be obvious to those skilled in the art, after understanding the invention, that various changes and modiications may be therein Without departing from the spirit and scope of the invention, and the appended claims should therefore be interpreted to cover such changes and modications.

Having described my invention, I claim:

1. A deposited latex undergarment adapted to encircle and elastical-ly shape the human torso which comprises a stretchable deposited latex Wall having an edge and subject to repeated flexing and stretching during Wear having at least one open pocket positioned Within the contines of said Wall and forming part of an edge of said Wall, said pocket having closed sides and an open side, the outside surface of said pocket yform-ing a smooth continuous surface with the surface of the Wall adjacent thereto, said pocket having been integrally made during deposition of the latex Wall by the formation of a completely closed pocket Within the thickness of the Wall and subsequent cutting of said closed'pocket to form an open pocket, the region of the Wall containing said open pocket comprising pliable, stretch-resistant reinforcing means embedded in said wall for resisting stretch occasioned duri-ng -Wear by an accessory secured Within said pocket.

2. The undergarment of claim 1 wherein the reinforcing means is fabric.

3. The method of `forming a deposited latex article with a stretchable wall subject to repeated exing and stretching having at least one open pocket positioned Within the confines of said Wall which comprises first formi-ng a deposited latex Wall having only a portion of the thickness of the Wall of the nished article; Vplacing Von the surface of said latex Wall adjacent a marginal edge References Cited in the le of this patent UNITED STATES PATENTS 1,492,953 Bender 1 May 6, 1924 1,523,119 Guinzburg Jan. 13, 1925 1,628,195 Rost May 10, 1927 2,365,016 Spanel Dec. 12, 1944 2,428,127 Sidnell Sept. 30, 1947 2,440,664 yIrons Apr. 27, 1948 2,648,619 Alderfer Aug. 11, 1953 2,726,396 Rosenberg Dec. 13, 1955- 2,806,221 Dorsey Sept. 17, 1957 2,813,526 Beebe Nov. 19, 1957 2,898,257 Carver Aug. 4, 1959 -1 www

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