CA2712717C

CA2712717C - Patch for performance garments and methods of using and making

Info

Publication number: CA2712717C
Application number: CA2712717A
Authority: CA
Inventors: Hongqing Shen; Paul E. Litchfield; Anna E. Newton
Original assignee: Reebok International Ltd
Current assignee: Reebok International Ltd
Priority date: 2010-08-02
Filing date: 2010-08-03
Publication date: 2014-12-09
Anticipated expiration: 2030-08-03
Also published as: US20120023641A1; CA2712717A1

Abstract

A patch for a performance garment including a sheet of fabric and an elastomeric adhesive adhered to one side of the sheet such that the sheet may be applied to the garment, wherein at least one of the sheet and the elastomeric adhesive have an independent stretch greater than the stretch of the garment. Embodiments of the invention further include methods of repairing an opening in or reinforcing a garment using the patch, repair kits for containing the patch, and methods of making the patch.

Description

PATCH FOR PERFORMANCE GARMENTS AND
METHODS OF USING AND MAKING
BACKGROUND OF THE INVENTION
Field of the Invention [0001] The present invention is directed to a patch for a performance garment and a method for applying the patch.
Background Art [0002]
It is well known that patches can be used for repairing tears or cuts in fabrics. In the past, some patches have been stitched or sewn onto an item of apparel.
Some patches include an adhesive on one side of the patch and can be adhered to the item of apparel using heat or pressure. Traditionally, patches used to repair tears or cuts in performance apparel for athletes have been made from relatively heavy and rigid woven fabrics.

[0003] Recently, it has become popular for apparel to be made from lightweight, stretchable fabric, particularly in performance apparel. However, because the apparel is lightweight and stretchable, it may rip or be cut easier than heavier clothing. For apparel designed to be worn during ice hockey or other skating sports, for example, this problem may be particularly apparent due to incidental contact with the blades of an ice skate.
When traditional patches are applied to such apparel, they can encumber the underlying garment and can hinder the wearer's movement during use. Moreover, such patches tend to be heavy and bulky and sewing or stitching them onto an item of apparel can be a time consuming process. In addition, sewing a patch can denigrate or otherwise weaken the underlying garment due to, for example, needle holes from the sewing process.
Any such weakening can be especially problematic for performance garments. Accordingly, there is a need in the art to develop innovative patches and methods of applying and producing said patches that are more suitable for such apparel.

BRIEF SUMMARY

[0004] In one aspect, there is provided a patch for a performance garment, comprising: a fabric substrate layer; a reinforcing layer including a plurality of plates affixed to the substrate layer, wherein the plurality of plates are arranged in a pattern such that a plurality of continuous gaps are defined between adjacent ones of the plates, and an elastomeric adhesive layer overlying the reinforcing layer, the adhesive layer for adhering the patch to the garment, wherein at least one of the sheet and the elastomeric adhesive is stretchable. In some embodiments, at least one of the sheet and the elastomeric adhesive has an independent stretch greater than the stretch of the garment.
[0004a] In another aspect, there is provided a performance garment having a patch comprising: a fabric substrate layer; a reinforcing layer including a plurality of plates affixed to the sheet, the plurality of plates being arranged in a pattern such that a plurality of continuous gaps are defined between adjacent ones of the plates; and an elastomeric adhesive layer overlying the reinforcing layer sheet and adhered to the garment, one or both of the substrate layer and the elastomeric adhesive layer having an independent stretch greater than that of the garment.

[0005] In another aspect, there is provided a method of reinforcing or repairing an opening in a performance garment using a patch, comprising: (a) providing a patch comprising: a sheet of fabric; a reinforcing layer including a plurality of plates affixed to the sheet, wherein the plurality of plates are arranged in a pattern such that a plurality of continuous gaps are defined between adjacent ones of the plates; an elastomeric adhesive overlying the reinforcing layer; and a backing sheet removably attached to the elastomeric adhesive; (b) preparing the garment for application, including arranging the garment so that the garment is inside out and an area of application of the garment is laid substantially flat;
(d) peeling off the removable backing sheet; (e) placing the adhesive side of the patch on the area of application; and (f) applying heat and pressure to the patch to bond it to the garment.

, .
- 3a -[0006] In another aspect, there is provided a repair kit for reinforcing or repairing an opening in a garment, comprising: a plurality of sheets of fabric, a reinforcing layer for each sheet including a plurality of plates affixed to the sheet and arranged in a pattern such that a plurality of continuous gaps are defined between adjacent ones of the plates, and an elastomeric adhesive overlying the reinforcing layer, and wherein at least one of the sheet and the elastomeric adhesive is stretchable; and a container adapted to hold the plurality of sheets.
In some embodiments, at least one of the sheet and the elastomeric adhesive has an independent stretch greater than the stretch of the garment.

[0007] In another aspect, there is provided a method of manufacturing a patch for a performance garment comprising: (a) providing a sheet of fabric; (b) affixing a reinforcing layer to the sheet such that continuous gaps are defined between adjacent ones of a plurality of plates of the reinforcing layer; and (c) adhering an elastomeric adhesive and a removable backing to the reinforcing layer, with at least one of the sheet and the elastomeric adhesive being stretchable. In some embodiments, at least one of the sheet and the elastomeric adhesive has an independent stretch greater than the stretch of the performance garment.
[0007a] In a further aspect, there is provided a patch for a lightweight, stretchable, and recoverable fabric, the patch comprising: a substrate; an adhesive configured to adhere the substrate to the fabric; a reinforcing layer attached to the substrate, wherein the reinforcing layer includes discrete, spaced-apart plates that impart cut-resistance to the patch; wherein the patch is configured to flex with the fabric without substantially restricting movement of the wearer; and wherein the adhesive overlies the reinforcing layer.
BRIEF DESCRIPTION OF THE DRAWINGS/FIGURES

[0008] The accompanying drawings, which are incorporated herein and form a part of the specification, illustrate the present invention and, together with the description, further serve to explain the principles of the invention and to enable a person skilled in the pertinent art to make and use the invention.

serve to explain the principles of the invention and to enable a person skilled in the pertinent art to make and use the invention.

[0009] FIG. 1 is a perspective view of the top of an exemplary patch according to an embodiment of the present invention;

[0010] FIG. 2 is a top plan view of the patch of FIG. 1;

[0011] FIG. 3 is a side view of the patch of FIG. 1;

[0012] FIG. 4 is a view of an exemplary article of clothing having a tear or cut in it according to an embodiment of the present invention;

[0013] FIG. 5 is a view of the inner side of the article of clothing having a tear or cut in it of FIG. 4, with the patch of FIG. 1 covering the tear or cut according to an embodiment of the present invention;

[0014] FIG. 6 is a view of the outer side of the article of clothing having a tear or cut in it of FIG. 4, with the patch of FIG. 1 covering the tear or cut on the inner side of the article of clothing according to an embodiment of the present invention;

[0015] FIG. 7 is a view of the patch of FIG. 1 being cut into a suitable size for application to an article of clothing;

[0016] FIG. 8 is a view of an exemplary athletic apparel repair kit for reinforcing and/or repairing an opening in athletic apparel according to an embodiment of the present invention; and [0017] FIG. 9 is a flowchart of an exemplary method for applying a patch to an article of clothing according to an embodiment of the present invention.

[0018] FIG. 10 is a front view of a portion of an alternative fabric that can be used with an exemplary patch according to an embodiment of the present invention.

[0019] FIG. 11 is a side view of the portion of the alternative fabric of FIG. 10 according to an embodiment of the present invention.

[0020] FIG. 12 is a perspective view of an alternative embodiment of a portion of an alternative fabric according to an embodiment of the present invention.

[0021] FIG. 13 is a side view of the portion of the alternative fabric of FIG. 12 according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0022] The present invention will now be described in detail with reference to embodiments thereof as illustrated in the accompanying figures. While specific configurations and arrangements are discussed, it should be understood that this is done for illustrative purposes only. References to "an embodiment", "one embodiment", "another embodiment," etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases do not necessarily refer to the same embodiment. Further, a person skilled in the relevant art will recognize that other configurations and arrangements can be used without departing from the scope of the invention.

[0023] Patches can be used in hockey socks, jerseys, gloves, pants, track suits, hats, socks, shorts, shirts, shoes, and protective equipment for a variety of other sports (such as, for example, speed skating, football, lacrosse, baseball, and soccer). Some specific areas that the patches can be used for repair and/or reinforcement include the palms of gloves, the knee, groin, or buttocks areas of pants or shorts, and the cuff, collar, or elbow area of a shirt or jersey, for example.

[0024] In one embodiment, as shown in FIGs. 1-3, a patch 100 for repairing an opening, such as a tear or cut, and/or reinforcing an area in an article of clothing. The article of clothing preferably comprises athletic apparel. In one embodiment, the article of clothing comprises hockey apparel, such as, for example, a hockey sock or a hockey sweater. It is contemplated that patch 100 may be used to repair and/or reinforce other apparel. The apparel may include one or more natural or synthetic materials, or combinations thereof, suitable for athletic apparel. The apparel may include a woven, non-woven, or knit material.

[0025] In some embodiments, the apparel is made of a stretchable material or the portion to which the patch is applied is made of a stretchable material. In some embodiments, the stretchable material has a stretch of at least about 5%, at least about 10%, or at least about 20%. In some embodiments, the stretch of the stretchable material can be in a range of about 5% to about 30%, about 5% to about 50% or about 5% to about 100%. One method of determining the stretch of a material includes hanging the material with no load attached, then measuring a distance (Al) between two benchmarks on the material.
A ten pound force is then applied to the bottom of the material. A distance (D) between the two benchmarks is measured. Stretch is measured as a percentage and is determined by formula Stretch = 100 x [(D-A1)/A 1 . Accordingly, a completely non-stretchable material would have a 0% stretch. In some embodiments, the patch and the apparel each have an independent stretch (i.e., the stretches of each item are each measured when they are not joined together) of at least about 5%, at least about 10%, at least about 15%, or at least about 20%. For example, the patch and the apparel can each have independent stretch in the range of about 5 to about 40% such as a stretch in the range of about 5 to about 30% or about 5 to about 20%.

[0026] Some embodiments of the patch include one or more natural or synthetic materials, or combinations thereof, suitable for athletic apparel. Some embodiments include woven, non-woven, or knit material. Suitable materials include, but are not limited to, those made of cotton, flax, silk, polyester, aramid, acrylic, nylon, cellulose-based materials such as rayon or viscose, polyurethane, spandex, and/or olefin. In some embodiments, the article, or portions of the article to which the patch is applied can be made of a polyester/spandex blend material.

[0027]
In one embodiment, patch 100 can be made from a substrate, such as polyester fabric 110. In one embodiment, patch 100 may comprise a single substrate layer in order to provide a more lightweight and flexible patch. In other embodiments, patch 100 may comprise multiple substrate layers.

[0028] Examples of substrate fabrics that can be used include polyester/spandex blends.
In some embodiments, a polyester/spandex blend substrate includes about 70% to about 90% polyester fiber by weight such as, for example, about 78% to about 87%
polyester fiber by weight, with the balance being spandex fiber. In some embodiments, a polyester/spandex blend substrate has a warp knit construction. The polyester/spandex blend substrate can have a fabric weight of about 4 to about 8 ounces per square yard such as about 4.5 to about 7.5 or about 4.75 to about 7.35 ounces per square yard.
Examples of suitable polyester/spandex blends include those available from Darlington Fabrics (New York, NY) such as Style Nos. 00025KW09, 26050, 00191KW07, and 26480.

[0029] The patch substrate can be selected to have a thickness compatible with a performance garment such as a hockey uniform. In some instances, the patch substrate is no thicker than the underlying performance garment fabric. In some embodiments, the patch substrate is substantially thinner than the underlying performance garment fabric. For example, the substrate can have a thickness of less than about 4 mm, less than about 3 mm, or less than about 2 mm. In some embodiments, the substrate can have a thickness of, for example, about 0.1 mm to about 3 mm such as about 0.1 to about 2 mm, about 0.2 to about 1.5 mm, or about 0.2 mm to about 1.2 mm.

[0030] In some embodiments, the patch includes a stretchable patch substrate having a stretch of at least about 10%, at least about 20%, or at least about 40%.
For example, the stretch of the stretchable patch substrate can be in a range of about 20% to about 200% or about 40% to about 180%.

[0031] Suitable substrate materials can include, but are not limited to, those made of cotton, flax, silk, polyester, aramid, acrylic, nylon, cellulose-based materials such as rayon or viscose, polyurethane, polypropylene, spandex, olefin, polyethylene, para-aramid synthetic fiber (e.g., Kevlar0), carbon fiber, and combinations thereof In some embodiments, the patch substrate can include a polyester or a polyester blend.

[0032] In some embodiments the patches can be simply fabric and adhesive. In other embodiments, the patches can also include a reinforcing layer such as a cut or resistant material. Suitable materials for this reinforcing layer include, but are not limited to, a resin containing a hard material and cut resistant fabric such as para-aramid synthetic fiber (e.g., Kevlart). The reinforcing layer can further or alternatively include any of a variety of materials that increase the cut resistance of the patch. For example, the hard material could include ceramics, polymers, minerals, rocks, metals and combinations thereof In some embodiments, the hard material is a cut resistant resin-based material such as SUPERFABRICTM Custom Engineered High Performance Fabric (HDM, Inc.; Oakdale, MN). In some embodiments, the patch includes an adhesive applied over the reinforcing portion which was applied over a polyester/spandex substrate. The resulting patch has a stretch of at least about 5%, at least about 10%, or at least about 15%. For example, the stretch of such a patch can be in a range of about 5% to about 50% or about 15%
to about 40%.

[0033] In some embodiments, a patch including a hard material is no more flexurally rigid than the underlying apparel. In some embodiments, a patch including a hard material is substantially less flexurally rigid than the underlying apparel. In some embodiments, the patch itself can have flexural rigidity, for example, of less than about 10 milligram-centimeters (x 104) (mg cm x 0.0001) or about 1 to about 10 mg cm x 0.0001. In some embodiments, the reinforcing portion is attached to the patch substrate layer. In one embodiment, the adhesive layer then overlies the reinforcing portion. In other embodiments, the adhesive layer and the reinforcing portion overlie opposite sides of the patch substrate.

[0034] The method outlined in European Standard EN388 can be used to access cut resistance (cutting by sharp objects) of a patch of the present invention. For example, a circular blade can be moved back and forth across a sample under a fixed load while rotating in the opposite direction of the linear movement and the number of repetitive cuts needed to cut through the fabric can be compared to a standard such as, for example, cotton fabric. Cut Index can be calculated that compares the fabric sample to the standard. For example, a Cut Index of 3 means the sample has three-times better cut resistance than the standard.
According to International Skating Union Communication No 1159 (May 20, 2002), protective competition clothing/uniforms should have a Cut Index of 5.94 according to EN388 in a cut resistance test (resistance to cutting by sharp objects). In some embodiments of the present invention, patches and/or apparel which include the patches have a Cut Index greater than the apparel alone. In some embodiments the Cut Index of the patches and/or the apparel, which include the patches have a cut index of at least about 2, at least about 3, or at least about 4. In some embodiments the patches, particularly patches including a reinforcing portion, have a Cut Index that exceeds the International Skating Union's recommendation of 5.94. In some embodiments, the Cut Index of the patch is at least about 6, at least about 8, or at least about 10.

[0035]
In one embodiment, patch 100 may comprise a lightweight and flexible material such that the patch may flex with the article without substantially restricting movement of the wearer. In one embodiment, patch 100 may comprise a material having a stretch or modulus of elasticity substantially similar to that of the article of clothing.

[0036] The patch can be constructed to have a flexural rigidity compatible with a performance garment. In some instances, the patch itself is no more flexurally rigid than the underlying performance garment fabric. In some embodiments, the patch itself is substantially less flexurally rigid than the underlying performance garment fabric. In some embodiments, the patch itself can have flexural rigidity, for example, of less than about 10 milligram-centimeters (x 104) (mg cm x 0.0001) or about 1 to about 10 mg cm x 0.0001.

[0037] The patch adhesive layer can be selected to have a thickness compatible with a performance garment. The patch can have an adhesive layer thickness, for example, of about 0.002 inch to about 0.007 mm such as about 0.004 inch.

[0038] The patch can be constructed to have a thickness compatible with a performance garment. In some embodiments, the patch is no thicker than the underlying performance garment fabric. In some embodiments, the patch itself is substantially thinner than the underlying performance garment fabric. In some embodiments, the patch itself can have a thickness of less than about 4 mm, less than about 3 mm, or less than about 2 mm. For example, the patch can have a thickness of, for example, about 0.1 mm to about 3 mm such as about 0.2 to about 2 mm or about 0.25 mm to about 1.4 mm.

[0039]
In one embodiment, patch 100 may comprise a lightweight material. For example, patch 100 may include a fabric with a weight of less than 350 grams per square meter (g/m2), less than about 300 g/m2, or less than about 250 g/m2. In one embodiment, patch 100 may have a fabric with a weight in the range of from about 100 g/m2 to about 350 g/m2 such as about 100 to about 250 g/m2. In one embodiment, patch 100 may include a fabric with a weight of about 230 g/m2. The lightweight nature of patch 100 may enhance the wearability of the article of clothing.

[0040]
In one embodiment, patch 100 may comprise a material with little or no shrinkability. For example, patch 100 may comprise a material having a maximum of about 2.5% shrinkage. In one embodiment, patch 100 may comprise a hydrophobic material and/or may include a water repellent finish.

[0041] Fabric 110 may be generally rectangular, as shown in FIGs. 1-4, or it may be cut into any appropriate shape. Fabric 110 may be a single, solid piece of fabric, or it may contain holes or perforations. In preferred embodiments, fabric 110 is stretchable under tension and can substantially recover its shape and size when tension is removed.

[0042] Fabric 110 has a front surface 310 and an opposing back surface 320. In one embodiment, patch 100 includes an elastomeric adhesive adhered to back surface 320 for attaching patch 100 to fabric, such as an article of apparel. In one embodiment, patch 100 includes a removable backing sheet 330 adhered to the back surface 320 for protectively covering the adhesive prior to application of the patch to the article of clothing. Backing sheet 330 may be a polypropylene liner, or other suitable material.
The adhesive layer can be a continuous layer or a discontinuous layer. The layer can be uniform or not. The layer can be a film or a pattern in the form of dots, lines, areas of greater concentration of adhesive or any other suitable pattern.

[0043] In some embodiments, the stretchability of patch 100 may make it particularly suitable for attaching to an article of apparel made from a stretchable material, as patch 100 may stretch with the article of apparel. This may be an advantage over prior patches because when the article of apparel stretches but a patch does not, the attachment means can be weakened, increasing the likelihood that the patch will detach.
Accordingly, allowing patch 100 to stretch with the article of apparel to which it is attached may increase the durability of patch 100 and/or minimize the likelihood that patch 100 will become detached. Furthermore, when patch 100 is attached to stretchable and recoverable athletic apparel, such as apparel used for playing hockey, the apparel can better accommodate the wearer's movements as compared to when traditional patches are used on apparel. In addition, use of patch 100 on apparel can reduce misplacement or shifting relative to underlying protective equipment (e.g., protective pads) as compared to apparel with traditional patches. For example, patch 100 can be less likely to snag or hinder the movement of protective equipment underlying the apparel than traditional, bulky and rigid, patches.

[0044]
In preferred embodiments, the adhesive is stretchable. In some embodiments, the adhesive has an independent stretch of at least about 5%, at least about 25%, at least about 50%, or at least about 70%. In some embodiments, the adhesive is an adhesive film with an independent stretch of about 70% to about 100% such as about 80%
to about 90%.

[0045] The adhesive may have a low softening point ideal for heat sensitive fabrics and continuous processing operations. For example, the adhesive may be made of an ester polyurethane. The adhesive layer may be transparent, opaque, clear, white, or colored or any other suitable color or appearance. In some embodiments, the adhesive can have a weight of 31 gm/m2 per 25 microns. In some instances, the adhesive may have a softening point of about 65 to about 100 degrees Celsius such as about 70 to about 85 degrees Celsius or about 75 degrees Celsius. The adhesive may have a melt flow index of about 40 to about 60 decigrams/minute (dg/min) such as about 50 dg/min.
Examples of suitable adhesives include, but are not limited to, film nos. 3206, 3206D, 3218, 3287, 3405, 3410, 4220, 5214, 5250, 5290, 6218, 6343, 6344, 6371, and 6385 available from Bemis Associates (Shirley, MA) and tape nos. EXF-367 and UAF-442 available from Adhesive Films, Inc. (Pine Brook, NJ).

[0046] FIGs. 4-6 shows how patch 100 may be used. FIG. 4 shows article of clothing 410 having a tear or cut 420 in it. FIG. 5 shows the inner side of article of clothing 410 having tear or cut 420, with the patch 100 covering tear or cut 420 on the inner side of article of clothing 410. Alternatively, patch 100 may instead be placed on the outer side of article of clothing 410. In some embodiments, the patch is applied to the inside of the garment. There are several advantages to this placement and the fact that stitching is not used. In particular, (1) the chance of snagging an exterior patch or stitching during athletic events is lessened, and (2) better cosmetic appearance, which is particularly important because concealment of patch and lack of stitching permits uniformity of appearance and maintenance of team identity which is especially important in team, high-level amateur, and professional sports.

[0047]
The patch may further or alternately be used to reinforce an area in an article of clothing. The areas where the patch is applied for reinforcement can be those that are prone to cut, tearing, or ripping. By using the patches a user can customize the placement , of the reinforcement tailored to how the individual wearer experiences garment wear, cuts, tearing, ripping, etc.
[00481 FIG. 6 is a view of the outer side of article of clothing 410 having tear or cut 420, with patch 100 covering the tear or cut 420 on the inner side of article of clothing 410.
[0049] FIG. 7 shows patch 100 being cut into a suitable size for application to an article of clothing.
[0050] FIG. 8 is a view of an exemplary athletic apparel repair kit 800 for repairing an opening in hockey apparel according to an embodiment of the present invention.
Athletic apparel repair kit 800 includes container 810 that holds one or more of the above described embodiments, such as sheets of polyester fabric 820 and 830. In this embodiment, each sheet has a paper backing and an elastomeric adhesive disposed between the sheet and the backing and both the sheet and the elastomeric adhesive may have a modulus of elasticity substantially similar to the apparel. Each sheet may be a solid color or may include multiple colors. The athletic apparel repair kit may include any combination of sheets having a solid or multiple colors.
[0051] In one embodiment, patch 100 is made according to the method outlined in the flowchart of FIG. 9. In a step 900, a user obtains patch 100 including a sheet of polyester fabric 110 and an elastomeric adhesive adhered to back surface 320 of fabric 110. Next, in step 910, the user cuts the patch into a piece larger than the size and shape of the tear or cut in the article of clothing. If patch 100 is already an appropriate size and shape, this step may not be necessary. Next, in step 920, if necessary, the user turns the article of clothing inside out. This step may also be not necessary, if for example, the article of clothing is already inside out, or if the user would prefer to have the patch on the outside surface of the article of clothing.
[0052] In step 930, the user arranges the article of clothing so that the area of the tear or cut is laid flat without excessive pulling at the article of clothing so as to minimize the gap in the article of clothing caused by the tear or cut.
[0053] Next, in step 940, which is optional, the user preheats the area of the tear or cut.
Then, in step 950, if the patch includes removable backing sheet 330, the user peels off removable backing sheet 330. The user then, in step 960, places the adhesive side of patch 100 on the area of the tear or cut 420. Finally, in step 970, the user applies heat and pressure to patch 100 to bond it to the article of clothing. The user may place a thin sheet of material, such as teflon, between the patch and iron, so as to minimize the possibility of burning patch 100.
[0054] The order of steps shown in FIG. 9 is merely exemplary and the steps may be carried out in a variety of combinations. For example, in one embodiment, step 950 of peeling off a removable backing 330 may occur at any point before the patch is bonded to the article of clothing. In addition, step 910 of cutting the patch into a piece larger than the size and shape of the tear or cut in the article of clothing can be performed at any time. For example, it can be performed before the user receives the patch, or it can be performed after the patch is already adhered to the article of clothing. As discussed above for the purpose of description and not of limitation, it is also possible for one or more of the steps shown in FIG. 9 to be optional. The steps outlined in the flowchart of FIG. 9 are not limiting and additional steps may be included.
[0055] FIG. 10 is a front view of a portion 1000 of an alternative fabric assembly that can be used with an embodiment of the present invention. FIG. 11 is a side view of portion 1000 of the alternative fabric. Embodiments of the fabric assembly may be disclosed in greater detail in U. S. Patent Nos. 6,962,739 and 7,018,692 and U. S.
Publication Nos.
2009/0142535 and 2005/0170221. The fabric assembly may be a puncture, pierce, and cut resistant fabric including a flexible substrate 1110 (best shown in FIG. 11) having a top surface 1120, and a plurality of polymeric resin plates 1010 having a substantially uniform thickness Z of approximately 400 microns. The plurality of plates 1010 are affixed to the top surface 1120 of the flexible substrate 1110 and are arranged in a pattern such that a plurality of continuous gaps 1020 are defined between adjacent plates 1010. In one embodiment, the gaps 1020 have a width Y of approximately 10 mils.
[0056] In some embodiments, for example the embodiment shown in FIG. 10, the plurality of polymeric resin plates 1010 are arranged in a repeating pattern of polygonal shapes. As shown in FIG. 10, the repeating pattern may include a centrally located square-shaped plate having a side length X of about 100 mils, surrounded by pentagon-shaped plates.
Other suitable patterns, gap sizes, and arrangements may also be used. For example, as shown in FIGs. 12 and 13 an embodiment may include a pattern of polymeric resin plates 1210 and substrate 1220. The fabric assembly may be twistable, bendable, and flexible and may be constructed of substances that will withstand cutting, puncture, and piercing forces encountered in medical, athletic performance, or other environments.
[0057] In some embodiments, the plates are a cut resistant resin-based material such as SUPERFABRICTM Custom Engineered High Performance Fabric (HDM, Inc.; Oakdale, MN). In some embodiments, Hi-Cut GL5 epoxy resin is configured in a Penta 400 pattern, or in a 80/28 or a 83/11 pattern (both of these exemplary patterns are available from HDM, Inc.).
[0058] One or more of the hard materials can be present in the patch in a variety of configurations such as in a uniform or non-uniform layer. In some embodiments, the hard material is present in the patch in discrete, spaced-apart concentrations of hard material. Discrete, spaced-apart concentrations of hard material can include, for example, concentrations of hard material in dots, plates, lines, or combinations thereof.
In some instances, concentrations of hard material are spaced apart sufficiently such that the patch has flexibility compatible with the performance garment to which the patch will be applied.
[0059] In some embodiments, concentrations of hard material are spaced apart at least about 0.001 inch such as at least about 0.005 inch, at least 0.01 inch, or at least about 0.015 inch. In some embodiments, concentrations of hard material are spaced apart about 0.001 inch to about 0.02 inch such as about 0.005 inch to about 0.015 inch.
[0060]
Some embodiments of the patch for a performance garment having a sheet of fabric, an elastomeric adhesive, and a removable backing, wherein at least one of the sheet and the elastomeric adhesive have an independent stretch greater than the stretch of the performance garment, can be manufactured by adhering the adhesive directly to the fabric. Suitable methods of adhering the adhesive to the fabric include lamination, extruding, screen printing and rotogravure.
[0061] In some embodiments of a lamination process, the adhesive can be laminated to the fabric in roll form or flat, with a removable backing attached to the other side of the adhesive. In some embodiments of an extrusion, screen printing, or rotogravure process, the adhesive film is adhered to the fabric, and then the removable backing may optionally be applied over the adhesive.
[0062] The foregoing description of the specific embodiments will so fully reveal the general nature of the invention that others can, by applying knowledge within the skill of the art, readily modify and/or adapt for various applications such specific embodiments, without undue experimentation, without departing from the general concept of the present invention. Therefore, such adaptations and modifications are intended to be within the meaning and range of equivalents of the disclosed embodiments, based on the teaching and guidance presented herein. It is to be understood that the phraseology or terminology herein is for the purpose of description and not of limitation, such that the terminology or phraseology of the present specification is to be interpreted by the skilled artisan in light of the teachings and guidance.
[0063] The breadth and scope of the present invention 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 patch for a performance garment, comprising:
a fabric substrate layer;
a reinforcing layer including a plurality of plates affixed to the substrate layer, wherein the plurality of plates are arranged in a pattern such that a plurality of continuous gaps are defined between adjacent ones of the plates, and an elastomeric adhesive layer overlying the reinforcing layer, the adhesive layer for adhering the patch to the garment, wherein at least one of the sheet and the elastomeric adhesive is stretchable.

2. The patch of claim 1, wherein the fabric substrate layer includes a material selected from the group consisting of polyester, spandex, nylon, polypropylene, polyethylene, rayon, and combinations thereof.

3. The patch of claim 1 or 2, wherein one or both of the fabric substrate layer and the elastomeric adhesive layer has a stretch of at least about 5%.

4. The patch of any one of claims 1 to 3, wherein one or both of the fabric substrate layer and the elastomeric adhesive layer has a stretch of at least about 40%.

5. The patch of any one of claims 1 to 4, wherein the patch includes a removable backing sheet for protectively covering the adhesive layer prior to application of the patch to the garment.

6. The patch of any one of claims 1 to 5, wherein the fabric substrate layer has a fabric weight of about 100 to about 350 grams per square meter.

7. The patch of any one of claims 1 to 6, wherein the adhesive layer is made of an ester polyurethane.

8. The patch of any one of claims 1 to 7, wherein the adhesive layer has a softening point of about 65 to about 100 degrees Celsius.

9. The patch of any one of claims 1 to 8, wherein the adhesive layer has a melt flow index of about 40 to about 60 dg/min.

10. The patch of any one of claims 1 to 9, wherein the patch has a stretch of at least about 5%.

11. The patch of any one of claims 1 to 10, wherein the patch has a stretch of at least about 10%.

12. The patch of any one of claims 1 to 11, wherein the reinforcing layer includes a resin containing a material selected from the group consisting of ceramics, polymers, minerals, rocks, metals and combinations thereof.

13. The patch of any one of claims 1 to 11, wherein the reinforcing layer includes para-aramid synthetic fiber.

14. A method of reinforcing or repairing an opening in a performance garment using a patch, comprising:
(a) providing a patch comprising:
a sheet of fabric;
a reinforcing layer including a plurality of plates affixed to the sheet, wherein the plurality of plates are arranged in a pattern such that a plurality of continuous gaps are defined between adjacent ones of the plates;
an elastomeric adhesive overlying the reinforcing layer; and a backing sheet removably attached to the elastomeric adhesive; (b) preparing the garment for application, including arranging the garment so that the garment is inside out and an area of application of the garment is laid substantially flat;
(d) peeling off the removable backing sheet;
(e) placing the adhesive side of the patch on the area of application; and (f) applying heat and pressure to the patch to bond it to the garment.

15. The method of claim 14, wherein the user cuts the patch into a piece larger than the size and shape of the opening in the garment.

16. The method of claim 14 or 15, wherein the sheet of fabric has a fabric weight of about 100 to about 350 grams per square meter.

17. The method of any one of claims 14 to 16, wherein the adhesive is made of an ester polyurethane.

18. The method of any one of claims 14 to 17, wherein the adhesive has a softening point of about 65 to about 100 degrees Celsius.

19. The method of any one of claims 14 to 18, wherein the adhesive has a melt flow index of about 40 to about 60 dg/min.

20. The method of any one of claims 14 to 19, wherein at least one of the sheet of fabric and the adhesive has a stretch of at least about 40%.

21. The method of any one of claims 14 to 20, wherein both the patch and the material of the garment in the area of application each have a stretch of at least about 5%.

22. The method of any one of claims 14 to 21, wherein both the patch and the material of the garment in the area of the application each have a stretch of at least about 10%.

23. The method of any one of claims 14 to 22, wherein the garment is selected from the group consisting of a hockey jersey, a hockey pant, and a hockey sock.

24. A repair kit for reinforcing or repairing an opening in a garment, comprising:
a plurality of sheets of fabric, a reinforcing layer for each sheet including a plurality of plates affixed to the sheet and arranged in a pattern such that a plurality of continuous gaps are defined between adjacent ones of the plates, and an elastomeric adhesive overlying the reinforcing layer, and wherein at least one of the sheet and the elastomeric adhesive is stretchable; and a container adapted to hold the plurality of sheets.

25. The repair kit of claim 24, wherein one of the plurality of sheets comprises a first color and one of the plurality of sheets comprises a second color different from the first color.

26. A method of manufacturing a patch for a performance garment comprising:
(a) providing a sheet of fabric;
(b) affixing a reinforcing layer to the sheet such that continuous gaps are defined between adjacent ones of a plurality of plates of the reinforcing layer; and (c) adhering an elastomeric adhesive and a removable backing to the reinforcing layer, with at least one of the sheet and the elastomeric adhesive being stretchable.

27. The method of claim 26, wherein the adhesive is applied by lamination.

28. The method of claim 26 or 27, wherein the adhesive is applied by extrusion.

29. The method of claim 26 or 27, wherein the adhesive is applied by screen printing.

30. The method of any one of claim 26 or 27, wherein the adhesive is applied by a rotogravure process.

31. A performance garment having a patch comprising:
a fabric substrate layer;
a reinforcing layer including a plurality of plates affixed to the sheet, the plurality of plates being arranged in a pattern such that a plurality of continuous gaps are defined between adjacent ones of the plates; and an elastomeric adhesive layer overlying the reinforcing layer sheet and adhered to the garment, one or both of the substrate layer and the elastomeric adhesive layer having an independent stretch greater than that of the garment.

32. The garment of claim 31, wherein the fabric substrate layer includes a material selected from the group consisting of polyester, spandex, nylon, polypropylene, polyethylene, rayon, and combinations thereof.

33. The garment of claim 31 or 32, wherein one or both of the fabric substrate layer and the elastomeric adhesive layer has a stretch of at least about 5%.

34. The garment of any one of claims 31 to 33, wherein one or both of the fabric substrate layer and the elastomeric adhesive layer has a stretch of at least about 40%.

35. The garment of any one of claims 31 to 34, wherein the fabric substrate layer has a fabric weight of about 100 to about 350 grams per square meter.

36. The garment of any one of claims 31 to 35, wherein the adhesive layer is made of an ester polyurethane.

37. The garment of any one of claims 31 to 36, wherein the adhesive layer has a softening point of about 65 to about 100 degrees Celsius.

38. The garment of any one of claims 31 to 37, wherein the adhesive layer has a melt flow index of about 40 to about 60 dg/min.

39. The garment of any one of claims 31 to 38, wherein both the patch and the garment each have a stretch of at least about 5%.

40. The garment of any one of claims 31 to 39, wherein both the patch and the garment each have a stretch of at least about 10%.

41. The garment of any one of claims 31 to 40, wherein the reinforcing layer includes a resin containing a hard material.

42. The garment of any one of claims 31 to 40, wherein the reinforcing layer includes para-aramid synthetic fiber.

43. A patch for a lightweight, stretchable, and recoverable fabric, the patch comprising:
a substrate;
an adhesive configured to adhere the substrate to the fabric;
a reinforcing layer attached to the substrate, wherein the reinforcing layer includes discrete, spaced-apart plates that impart cut-resistance to the patch;
wherein the patch is configured to flex with the fabric without substantially restricting movement of the wearer; and wherein the adhesive overlies the reinforcing layer.

44. The patch of claim 43, further comprising a removable backing sheet for protectively covering the adhesive prior to application of the patch to the fabric.

45. The patch of claim 43 or 44, wherein the plates of the reinforcing layer include a centrally located substantially square shaped plate surrounded by substantially pentagon-shaped plates.

46. The patch of any one of claims 43 to 45, wherein the patch has an overall flexural rigidity from about 1 to about 10 mg cm x 0.0001.

47. The patch of any one of claims 43 to 46, wherein the substrate includes a material selected from the group consisting of polyester, spandex, nylon, polypropylene, polyethylene, rayon, and combinations thereof.

48. The patch of any one of claims 43 to 47, wherein one or both of the substrate and the adhesive has a stretch of at least about 5%.

49. The patch of any one of claims 43 to 48, wherein one or both of the substrate and the adhesive has a stretch of at least about 40%.

50. The patch of any one of claims 43 to 49, wherein the substrate has a fabric weight of about 100 to about 350 grams per square meter.

51. The patch of any one of claims 43 to 50, wherein the adhesive is made of an ester polyurethane.

52. The patch of any one of claims 43 to 51, wherein the adhesive has a softening point of about 65 to about 100 degrees Celsius.

53. The patch of any one of claims 43 to 52, wherein the adhesive has a melt flow index of about 40 to about 60 dg/min.

54. The patch of any one of claims 43 to 53, wherein the patch has a stretch of at least about 5%.

55. The patch of any one of claims 43 to 53, wherein the patch has a stretch of at least about 10%.

56. The patch of any one of claims 43 to 55, wherein the reinforcing layer includes a resin containing a material selected from the group consisting of ceramics, polymers, minerals, rocks, metals and combinations thereof.

57. The patch of any one of claims 43 to 56, wherein the reinforcing layer includes para-aramid synthetic fiber.

58. The patch of any one of claims 1 to 13, wherein the plates of the reinforcing layer include a centrally located substantially square shaped plate surrounded by substantially pentagon-shaped plates.

59. The patch of any one of claims 1 to 13 and 58, wherein the patch has an overall flexural rigidity from about 1 to about 10 mg cm x 0.0001.

60. The garment of any one of claims 31 to 42, wherein the plates of the reinforcing layer include a centrally located substantially square shaped plate surrounded by substantially pentagon-shaped plates.

61. The patch of any one of claims 31 to 42 and 60, wherein the patch has an overall flexural rigidity from about 1 to about 10 mg cm x 0.0001.