Stretchable garments and manufacturing method

Abstract

A one-size-fits-all garment ( 10 ) is formed of multiple stretchable fabric portions ( 2 ) joined together by a PBT (polybutylene terephthalate) thread ( 38 ). The garment includes a waistband ( 6 ) that uses a paper fusing technique to fuse a fusing material from a paper backing sheet ( 18, 18 A, 18 B), onto the waistband which is also joined to the stretchable fabric portions using PBT thread. A method for forming the garment includes using a sheet of carrier paper with a fusing material such as a plurality of discrete dots of fusing material, to the waistband and sewing the multiple stretching stretchable fabric portions together and to the waistband using the PBT thread.

1 . A stretchable garment comprising:
 stretchable fabric portions joined together by PBT (polybutylene terephthalate) thread; and   an elastic waistband joined to one or more of said stretchable fabric portions by PBT thread.   
     
     
         2 . The stretchable garment as in  claim 1 , said stretchable waistband having an additional material applied thereto. 
     
     
         3 . The stretchable garment as in  claim 2 , wherein different stretchable fabric portions of the waistband are joined directly one another via said additional material, without a further layer interposed therein. 
     
     
         4 . The stretchable garment as in  claim 2 , wherein said stretchable fabric portions include elastic and/or elastomeric yarns, containing spandex fiber. 
     
     
         5 . The stretchable garment as in  claim 1 , wherein said stretchable fabric portions are formed of a material characterized by having at least a 50% stretch in weft direction. 
     
     
         6 . The stretchable garment as in  claim 1 , wherein said stretchable fabric portions are joined together by said PBT thread in a chain stitch configuration. 
     
     
         7 . The stretchable garment as in  claim 1 , wherein said PBT thread is 100% PBT. 
     
     
         8 . The stretchable garment as in  claim 2 , wherein said additional material applied to said waistband comprises a plurality of discrete elements spaced from each other. 
     
     
         9 . The stretchable garment as in  claim 1 , wherein said stretchable fabric portions comprise denim. 
     
     
         10 . The stretchable garment as in  claim 2 , wherein said additional further material comprises a polyamide-based nylon material. 
     
     
         11 . The stretchable garment as in  claim 1 , wherein said garment comprises tight fitting legwear. 
     
     
         12 . A stretchable garment according to  claim 1 , comprising:
 stretchable denim fabric portions joined together by polybutylene terephthalate (PBT) thread in a chain stitch configuration;   an elastic waistband joined to one or more of said stretchable denim fabric portions by PBT thread,   hems formed of PBT thread, and   said elastic waistband having a plurality of discrete elements of a polyamide-based nylon material fused thereto.   
     
     
         13 . A method for manufacturing a one-size-fits-all garment, said method comprising:
 sewing stretchable fabric portions together using polybutylene terephthalate (PBT) thread;   applying a material, onto at least a waistband portion of the garment; and   joining said waistband or other portion of the garment to one or more of said stretchable fabric portions by sewing with PBT thread.   
     
     
         14 . The method as in  claim 13 , wherein said stretchable fabric portions are formed of a fabric including elastic and or elastomeric yarn, and said fusing material comprises a polyamide-based material. 
     
     
         15 . The method as in  claim 13 , wherein said stretchable fabric portions are formed of a material characterized by having at least a 60% stretch in weft direction. 
     
     
         16 . The method as in  claim 13 , further comprising hemming said stretchable fabric portions by sewing with PBT thread. 
     
     
         17 . The method as in  claim 13 , wherein said PBT thread is 100% PBT and said waistband and said stretchable fabric portions are formed of the same material. 
     
     
         18 . The method as in  claim 13 , wherein said material is applied as a plurality of discrete spaced elements to said waistband. 
     
     
         19 . The method as in  claim 13 , wherein the stretchable fabric portions comprise denim. 
     
     
         20 . The method as in  claim 13 , wherein different portions of said waistband are joined via said fusing material, so that said different portions are directly joined by said material, without a further layer interposed therein.