Patch for Performance Garments and Methods of Using and Making

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.

1 . A patch for a performance garment, comprising:
 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.   
     
     
         2 . The patch of  claim 1 , wherein the sheet of fabric includes a material selected from the group consisting of polyester, spandex, nylon, polypropylene, polyethylene, rayon, and combinations thereof 
     
     
         3 . The patch of  claim 1 , wherein at least one of the sheet of fabric and the elastomeric adhesive has a stretch of at least about 5%. 
     
     
         4 . The patch of  claim 1 , wherein at least one of the sheet of fabric and the elastomeric adhesive has a stretch of at least about 40%. 
     
     
         5 . The patch of  claim 1 , wherein the patch includes a removable backing sheet for protectively covering the adhesive prior to application of the patch to the garment. 
     
     
         6 . The patch of  claim 1 , wherein the sheet of fabric has a fabric weight of about 100 to about 350 grams per square meter. 
     
     
         7 . The patch of  claim 1 , wherein the adhesive is made of an ester polyurethane. 
     
     
         8 . The patch of  claim 1 , wherein the adhesive has a softening point of about 65 to about 100 degrees Celsius. 
     
     
         9 . The patch of  claim 1 , wherein the adhesive has a melt flow index of about 40 to about 60 dg/min. 
     
     
         10 . The patch of  claim 1 , wherein both the patch and the garment each have a stretch of at least about 5%. 
     
     
         11 . The patch of  claim 1 , wherein both the patch and the garment each have a stretch of at least about 10%. 
     
     
         12 . The patch of  claim 1 , further comprising a reinforcing layer. 
     
     
         13 . The patch of  claim 12 , wherein the reinforcing layer includes a resin containing a hard material. 
     
     
         14 . The patch of  claim 12 , wherein the reinforcing layer includes para-aramid synthetic fiber. 
     
     
         15 . 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; 
 an elastomeric adhesive adhered to one side of the sheet; 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.   
     
     
         16 . The method of  claim 15 , wherein the user cuts the patch into a piece larger than the size and shape of the opening in the garment. 
     
     
         17 . The method of  claim 15 , wherein the patch includes a removable backing sheet for protectively covering the adhesive prior to application of the patch to the garment. 
     
     
         18 . The method of  claim 15 , wherein the sheet of fabric has a fabric weight of about 100 to about 350 grams per square meter. 
     
     
         19 . The method of  claim 15 , wherein the adhesive is made of an ester polyurethane. 
     
     
         20 . The method of  claim 15 , wherein the adhesive has a softening point of about 65 to about 100 degrees Celsius. 
     
     
         21 . The method of  claim 15 , wherein the adhesive has a melt flow index of about 40 to about 60 dg/min. 
     
     
         22 . The method of  claim 15 , wherein at least one of the sheet of fabric and the adhesive has a stretch of at least about 40%. 
     
     
         23 . The method of  claim 15 , wherein both the patch and the material of the garment in the area of application each have a stretch of at least about 5%. 
     
     
         24 . The method of  claim 15 , 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%. 
     
     
         25 . The method of  claim 15 , wherein the garment is selected from the group consisting of a hockey jersey, a hockey pant, and a hockey sock. 
     
     
         26 . A repair kit for reinforcing or repairing an opening in a garment, comprising:
 a plurality of sheets of fabric each having a backing and an elastomeric adhesive disposed between the sheet and the backing, wherein at least one of the sheet and the elastomeric adhesive have an independent stretch greater than the stretch of the garment; and   a container adapted to hold the plurality of sheets.   
     
     
         27 . The repair kit of  claim 26 , 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. 
     
     
         28 . The repair kit of  claim 26 , wherein the garment is selected from the group consisting of a hockey jersey, a hockey pant, and a hockey sock. 
     
     
         29 . A method of manufacturing a patch for a performance garment comprising:
 (a) providing a sheet of fabric; and   (b) adhering an elastomeric adhesive and a removable backing to the fabric,   wherein at least one of the sheet and the elastomeric adhesive have an independent stretch greater than the stretch of the performance garment.   
     
     
         30 . The method of  claim 29 , wherein the adhesive is laminated to the fabric by pressing under heat. 
     
     
         31 . The method of  claim 29 , wherein the adhesive is extruded directly onto the fabric. 
     
     
         32 . The method of  claim 29 , wherein the adhesive is screen printed onto the fabric. 
     
     
         33 . The method of  claim 29 , wherein the adhesive is adhered to the fabric via rotogravure.