METHOD OF MANUFACTURING A STRETCHABLE TEXTILE FABRIC ARTICLE

The invention relates particularly, but not exclusively, to a method of manufacturing a stretchable textile fabric article.

During the manufacture of garments and other textile fabric articles sewing is conventionally used to finish edges of fabric, create hems and seams, and to generally secure components of textile fabric articles together. However the use of sewing results in the creation of stitches, which are often undesirable in the fashion industry and can create discomfort in garments where the stitches lay directly against a wearer's skin. Consequently, so as to improve the aesthetic appearance and, where appropriate, the comfort of textile fabric articles, it is becoming increasingly desirable to use adhesives as an alternative to sewing.

One such method includes the use of polyurethane film which is laid between pieces of textile fabric and heated so as to melt the film. The melted film then sets so as to adhere to the pieces of. textile fabric and thereby adhere the pieces of textile fabric together. However -a drawback with the use of polyurethane film resides in the fact that, once set, the film locks the individual yarns in the pieces of textile fabric in place. As a consequence the set film inhibits the natural stretch of the textile fabric, which is undesirable in the manufacture of stretchable textile fabric articles.

Other methods include the use of adhesive elastomers, which are more likely to permit a textile fabric to retain its natural stretch. However a drawback associated with the use of adhesive elastomers resides in the need to cure the adhesive elastomer following application to a piece of textile fabric so as to bond the adhesive elastomer to the textile fabric, and difficulties associated with controlling the commencement of the curing process and the rate of curing.

According to a first aspect of the invention there is provided a method of manufacturing a stretchable textile fabric article comprising the steps of: applying an adhesive in the form of an uncured silicone elastomer requiring UV radiation to trigger curing thereof to at least one portion of a piece of textile fabric;

CONFUTATION COPY

exposing the uncured silicone elastomer on the piece of textile fabric to UV radiation; and curing the uncured silicone elastomer or allowing the uncured silicone elastomer to cure to bond the silicone elastomer to the piece of textile fabric.

The use of an uncured silicone elastomer requiring UV radiation to trigger curing ensures the elastomer does not start to cure until it is exposed to UV radiation and thereby provides a means for controlling commencement of the curing process. This in turn allows a user to ensure the elastomer does not cure until after it is applied to the textile fabric.

Following exposure of the uncured silicone elastomer to UV radiation, the uncured silicone elastomer may be allowed to cure under ambient conditions. A relatively high rate of cure is however desirable in the manufacture of textile fabric articles in order to permit each step in the manufacturing process to be performed consecutively in a relatively short period of time, and preferably at the same work station.

The rate of curing of an uncured silicone elastomer may be increased through the application of heat, the more heat energy that is applied to the elastomer within a period of time the greater the rate of curing. Conventionally ovens have been used to supply sufficiently large quantities of heat energy in order to accelerate the rate of curing. However the use of an oven does not lend itself to the manufacture of a textile fabric article at a single work station.

In order to increase the rate of curing of the uncured silicone elastomer without the need for an oven, the uncured silicone elastomer may be heated prior to its application to the textile fabric. Pre-heating the uncured silicone elastomer accelerates curing of the uncured silicone elastomer once it is exposed to UV radiation and thereby allows a user to achieve a higher rate of cure than would otherwise be achieved unless the textile fabric was heated following application of the uncured silicone elastomer.

The use of an uncured silicone elastomer requiring UV radiation to trigger curing allows for pre-heating of the elastomer since it ensures the elastomer does not start to cure until after it is applied to the textile fabric.

CONϊϊRMATION COPY

In order to further increase the rate of curing of the uncured silicone elastomer once it is exposed to UV radiation, or in circumstances where a relatively slow rate of curing is required, heat may be applied to the uncured silicone elastomer following exposure of the uncured silicone elastomer to UV radiation by means of heated elements such as, for example, heated plates, heated rollers and/or heat lamps.

Preferably curing of the uncured silicone elastomer is completed within five seconds; is more preferably completed with two seconds; and is most preferably completed within one second.

Depending on the composition of the adhesive, the application of an adhesive onto a textile fabric can lead to adjacent yarns of the textile fabric becoming chemically adhered to one another following curing of the adhesive. In such circumstances, adjacent yarns are unable to move relative to one another, thereby rigidifying the textile fabric and restricting the ability of the textile fabric to stretch.

By altering the composition of the adhesive, it is possible to reduce the degree of chemical bonding outlined above and produce a less rigid, mechanical bond in which the adhesive penetrates the piece of textile fabric so as to surround the yarns without chemically adhering the yarns to one another. In such circumstances, adjacent yarns are able to move relative to one another, thereby leading to a more flexible piece of textile fabric that is able to stretch whilst maintaining its structure by virtue of the presence of the cured adhesive.

However, increasing the degree of mechanical bonding presents its own problems in that the absence of chemical bonding between adjacent yarns means that the adhesive is more easily pulled away from the textile fabric, and is therefore prone to peel away from the textile fabric once it is cured.

Preferably therefore an uncured silicone elastomer constituted from two or more mixable parts is used so as to permit variance of the physical properties of the elastomer following its application to the textile fabric and curing thereof.

This allows a user, in dependence on the nature of the textile fabric, to control the degree of chemical versus mechanical bonding following curing of the elastomer and therefore

allows a user to impart desirable physical characteristics, such as a particular elastic modulus or a particular friction generating quality, to the silicone elastomer following curing.

The relative proportions of the respective mixable parts of the uncured silicone elastomer are preferably chosen immediately prior to the step of applying the uncured silicone elastomer to the textile fabric so as to impart desirable physical properties to the silicone elastomer following curing.

The relative proportions of the respective mixable parts of the uncured silicone elastomer may then be varied during the step of applying the uncured silicone elastomer to the textile fabric so as to impart varying physical properties to the silicone elastomer following the step of curing the uncured silicone elastomer.

This allows the creation of a continuous region of cured elastomer in which one area has more mechanical or chemical bonding than areas immediately adjacent thereto. This can be particularly advantageous in circumstances where the silicone elastomer is prone to peel away from the textile fabric following curing as a result of a high degree of mechanical bonding or due to the structure of the textile fabric. This is because it allows the provision of discrete regions of silicone elastomer having high degrees of chemical bonding following curing to securely bond the silicone elastomer to the textile fabric.

In order to vary the adhesive properties of the silicone elastomer following the step of curing, one or more mixable parts may be an adhesive promoter.

Preferably the step of applying the uncured silicone elastomer to the textile fabric involves controlling the extent to which the uncured silicone elastomer penetrates the textile fabric.

This improves any mechanical bond created between the elastomer and the textile fabric following curing and thereby reduces the risk of the cured elastomer peeling away from the textile fabric in embodiments where the composition of the silicone elastomer is chosen to favour mechanical bonding over chemical bonding.

CGNIϊRMArøttϊ COPY

The extent to which the uncured silicone elastomer penetrates the textile fabric may be controlled by laying the uncured silicone elastomer on the textile fabric and scraping the uncured silicone elastomer into the textile fabric.

The extent to which the uncured silicone elastomer penetrates the textile fabric may also be controlled by one or more of the following:

(i) the application of pressure to the textile fabric following application of the uncured silicone elastomer; (ii) varying the quantity of uncured silicone elastomer applied to the textile fabric; and (iii) varying the rate at which the uncured silicone elastomer cures.

As discussed earlier, the rate at which the uncured silicone elastomer cures may be varied through the application of heat before and/or after exposure of the uncured silicone elastomer to UV radiation.

The uncured silicone elastomer is preferably applied in the form of a liquid.

The use of a liquid silicone is advantageous in that it facilitates good penetration of the textile fabric, produces good elastic properties following curing and facilitates pumping and mixing of the uncured silicone elastomer.

In other embodiments, where less penetration is required and the elastic properties of the elastomer following curing are less important, the uncured silicone elastomer may be applied in the form of a paste.

The adhesive properties of the silicone elastomer following curing means that, optionally, the method may include the step of folding the or each portion of textile fabric onto an adjacent portion thereof prior to curing of the silicone elastomer so as to define a half- turn hem.

The method may then be repeated and the textile fabric folded again so as to define a full hem.

XW x.

The ability to create a half-turn or full hem in this manner permits the creation of a hem in which the textile fabric retains its ability to stretch. In addition the elastic resilience of the cured elastomer improves the fabric's ability to resume its structure following stretch.

The adhesive properties of the silicone elastomer following curing also means that, optionally, the method may include the step of laying another component of a textile fabric article onto the textile fabric following application of the uncured silicone elastomer to the textile fabric so as to sandwich the uncured silicone elastomer therebetween. The uncured silicone elastomer may then be exposed to UV radiation through one or both of the component and the textile fabric so as to trigger curing of the uncured silicone elastomer so that the silicone elastomer following curing adheres the component to the textile fabric.

In such embodiments the other component of the textile fabric article may include another piece of textile fabric, such as another panel of a garment or a piece of trim for a garment, or a non-textile component.

In one particular embodiment, where the piece of textile fabric and the other component are adjacent panels of a garment, the uncured silicone elastomer may be applied along the edge of a first of the panels. The other panel may then be arranged relative to the first panel so as to sandwich the uncured silicone elastomer between edges of the panels such that the silicone elastomer adheres the edges of the panels together and thereby creates a seam between the panels.

In another particular embodiment, the other component may include an elasticated piece of textile fabric or a silicone tape, either of which may be laid onto the piece of textile fabric under tension such that, following curing of the silicone elastomer and removal of the tension, a ruched effect is created in the textile fabric.

This allows the creation of a stretchable and/or shaped opening or edge to a garment.

In any of these embodiments it is envisaged that the uncured silicone elastomer could be applied to the elasticated piece of textile fabric or other piece of decorative trim and the piece of textile fabric could then be positioned relative to the elasticated piece of textile

^mWMATiOfJ CCFW

fabric or other piece of decorative trim in order to sandwich the uncured silicone elastomer therebetween.

In a further preferred embodiment, the step of applying the uncured silicone elastomer involves applying the elastomer so as to define a desired path and the method further includes the step of trimming the textile fabric following curing of the silicone elastomer so as to shape the textile fabric in accordance with the path of the cured silicone elastomer.

In such embodiments the cured elastomer fixes the edge of the trimmed textile fabric so as to prevent fraying whilst allowing the trimmed textile fabric to retain its ability to stretch according to the needs of a user.

In such embodiments and in any other embodiments in which the uncured silicone elastomer is exposed during curing, a release paper may be laid onto the surface of the uncured silicone elastomer during curing.

The provision of the release paper serves to protect the surface of the uncured silicone elastomer during curing and also serves to prevent removal of the uncured silicone elastomer from the surface of the piece of textile fabric. The release paper is therefore particularly advantageous in arrangements where one or more roller is provided to draw the piece of textile fabric through a work station during curing of the uncured silicone elastomer.

The release paper is preferably formed from a material that is readily releasable from the silicone elastomer following curing.

According to a second aspect of the invention there is provided an apparatus for bonding a silicone elastomer in the form of an elastomer requiring UV radiation to trigger curing thereof to at least one portion of a piece of textile fabric comprising: an applicator to apply uncured silicone elastomer to at least one portion of a piece of textile fabric, the applicator including a darkened supply passage to prevent irradiation of the uncured silicone elastomer to UV radiation prior to application of the uncured silicone elastomer to the textile fabric; and

a UV light source to irradiate the uncured silicone elastomer following application of the uncured silicone elastomer to the textile fabric to trigger curing of the uncured silicone elastomer so as to bond the silicone elastomer to the textile fabric.

So as to increase the rate of curing of the uncured silicone elastomer after its exposure to UV radiation, the apparatus may further include one or more heat sources to heat the uncured silicone elastomer upstream of the applicator and/or downstream of the UV light source.

The nature and combination of heat sources are preferably determined by the rate of curing required.

The apparatus may further include a folding device for folding the or each portion of the piece of textile fabric onto an adjacent portion thereof so as to define a hem.

The foregoing features of the apparatus share the advantages of the corresponding features of the method according to the first aspect of the invention.

According to a third aspect of the invention there is provided a stretchable textile fabric article comprising a piece of textile fabric folded to define a half-turn hem along at least a section of an edge thereof, the half-turn hem being secured by means of a cured silicone elastomer sandwiched between folded portions of the piece of textile fabric.

In embodiments of this aspect of invention the half-turn hemmed edge section may be folded again to define a full hem along at least a section of an edge of the piece of textile fabric, the full hem being secured by means of a cured silicone elastomer sandwiched between the half hemmed edge section and an adjacent portion of the piece of textile fabric.

The hemmed edge section, whether it is hemmed to define a half-turn hem or a full hem, may be shaped to define a curve.

The elastic modulus of the cured silicone elastomer securing the hemmed edge section may vary in the widthwise and/or lengthwise direction of the hemmed edge section.

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cmwsM&πm COP T

According to a fourth aspect of the invention there is provided a stretchable textile fabric article comprising a piece of textile fabric and another component adhered to the piece of textile fabric by means of a cured silicone elastomer.

In one embodiment, the other component may include a decorative trim adhered to the piece of textile fabric in a flat configuration.

In another embodiment, the other component may include an elastic trim adhered to the piece of textile fabric under tension and thereby producing a ruched effect in the piece of textile fabric.

In a yet further embodiment, the piece of textile fabric and the other component may be adjacent panels in a garment and the cured silicone elastomer may adhere adjacent edges of the panels together so as to define a seam between the panels.

In any of these embodiments, the elastic modulus of the cured silicone elastomer may vary in the widthwise and/or lengthwise direction of the other component.

According to a fifth aspect of the invention there is provided a method of adhering first and second components of a textile fabric article together comprising the steps of: applying an uncured silicone elastomer in the form of a liquid to at least a portion of a first component of a textile fabric article; positioning a second component of the textile fabric article relative to the first component such that the uncured silicone elastomer is located therebetween; and curing the uncured silicone elastomer or allowing the uncured silicone elastomer to cure to bond the first and second components together.

The use of an uncured silicone elastomer in the form of a liquid is advantageous in that it facilitates good penetration of the textile fabric, produces good elastic properties following curing and facilitates pumping and mixing of the uncured silicone elastomer.

The uncured silicone elastomer preferably requires a trigger to initiate curing and thereby ensure that the elastomer does not start to cure until it is exposed to certain conditions. This provides a means for controlling commencement of the curing process and, in turn,

allows a user to ensure the elastomer does not cure until after it is applied to the textile fabric.

The trigger may require that the uncured silicone elastomer is heated to a specific temperature before it will begin to cure. In such embodiments, heating of the uncured silicone elastomer to the trigger temperature may occur before, during or after the step of positioning the second component of the textile fabric article relative to the first component.

In other embodiments the uncured silicone elastomer may be in multi-part form and curing of the silicone elastomer may be triggered by mixing of the respective mixable parts immediately prior to, or during, application of the uncured silicone elastomer to the first component of the textile fabric article.

In embodiments where curing of the uncured silicone elastomer is triggered by heating the uncured silicone to a specific temperature the time taken to heat the uncured silicone elastomer to the trigger temperature may be accelerated by heating the uncured silicone elastomer prior to the step of applying the uncured silicone elastomer to the first component of the textile fabric article.

In such embodiments it is of course important that any pre-heating is limited to ensure that curing of the silicone elastomer is not initiated before the silicone elastomer is applied to the first component of the textile fabric article.

Once curing is initiated, the uncured silicone elastomer may be allowed to cure under ambient conditions. A relatively high rate of cure is however desirable in the manufacture of textile fabric articles in order to permit each step in the manufacturing process to be performed consecutively in a relatively short period of time, and preferably at the same work station.

The rate of curing of an uncured silicone elastomer may be increased through the application of heat, the more heat energy that is applied to the elastomer within a period of time the greater the rate of curing. Conventionally ovens have been used to supply sufficiently large quantities of heat energy in order to accelerate the rate of curing.

However the use of an oven does not lend itself to the manufacture of a textile fabric article at a single work station.

In embodiments where a trigger is required to initiate curing of the uncured silicone elastomer, the rate of curing of the uncured silicone elastomer may be increased without the need for an oven by heating the uncured silicone elastomer or mixable parts of the uncured silicone elastomer prior to the step of applying the uncured silicone elastomer to the first component of the textile fabric article. Pre-heating the uncured silicone elastomer in this manner accelerates curing of the uncured silicone elastomer once curing is initiated and thereby allows a user to achieve a higher rate of cure than would otherwise be achieved unless the textile fabric was heated following application of the uncured silicone elastomer.

As outlined above, in embodiments where curing of the uncured silicone elastomer is triggered by heating the uncured silicone to a specific temperature it is of course important that any pre-heating is limited to ensure that curing of the silicone elastomer is not initiated before the silicone elastomer is applied to the first component of the textile fabric article.

Regardless of the nature of the uncured silicone elastomer, the rate of curing may be increased by applying heat to the uncured silicone elastomer during curing by means of heated elements such as, for example, heated plates, heated rollers or heat lamps.

Preferably curing of the uncured silicone elastomer is completed within five seconds; is more preferably completed with two seconds; and is most preferably completed within one second.

Depending on the composition of the adhesive, the application of an adhesive onto a textile fabric can lead to adjacent yarns of the textile fabric becoming chemically adhered to one another following curing of the adhesive. In such circumstances, adjacent yarns are unable to move relative to one another, thereby rigidifying the textile fabric and restricting the ability of the textile fabric to stretch.

By altering the composition of the adhesive, it is possible to reduce the degree of chemical bonding outlined above and produce a less rigid, mechanical bond in which the

adhesive penetrates the piece of textile fabric so as to surround the yarns without chemically adhering the yarns to one another. In such circumstances, adjacent yarns are able to move relative to one another, thereby leading to a more flexible piece of textile fabric that is able to stretch whilst maintaining its structure by virtue of the presence of the cured adhesive.

However, increasing the degree of mechanical bonding presents its own problems in that the absence of chemical bonding between adjacent yarns means that the adhesive is more easily pulled away from the textile fabric, and is therefore prone to peel away from the textile fabric once it is cured.

Preferably therefore an uncured silicone elastomer constituted from two or more mixable parts is used so as to permit variance of the physical properties of the elastomer following its application to the textile fabric and curing thereof.

This allows a user, in dependence on the nature of the textile fabric, to control the degree of chemical versus mechanical bonding following curing of the elastomer and therefore allows a user to impart desirable physical characteristics, such as a particular elastic modulus or a particular friction generating quality, to the silicone elastomer following curing.

The relative proportions of the respective mixable parts of the uncured silicone elastomer are preferably chosen immediately prior to the step of applying the uncured silicone elastomer to the textile fabric so as to impart desirable physical properties to the silicone elastomer following curing.

The relative proportions of the respective mixable parts of the uncured silicone elastomer may then be varied during the step of applying the uncured silicone elastomer to the textile fabric so as to impart varying physical properties to the silicone elastomer following the step of curing the uncured silicone elastomer.

This allows the creation of a continuous region of cured elastomer in which one area has more mechanical or chemical bonding than areas immediately adjacent thereto. This can be particularly advantageous in circumstances where the silicone elastomer is prone to peel away from the textile fabric following curing as a result of a high degree of

12

€ONϊBIMATION COFF

mechanical bonding or due to the structure of the textile fabric. This is because it allows the provision of discrete regions of silicone elastomer having high degrees of chemical bonding following curing to securely bond the silicone elastomer to the textile fabric.

In order to vary the adhesive properties of the silicone elastomer following the step of curing, one or more mixable parts may be an adhesive promoter.

Preferably the step of applying the uncured silicone elastomer to the textile fabric involves controlling the extent to which the uncured silicone elastomer penetrates the textile fabric.

This improves any mechanical bond created between the elastomer and the textile fabric following curing and thereby reduces the risk of the cured elastomer peeling away from the textile fabric in embodiments where the composition of the silicone elastomer is chosen to favour mechanical bonding over chemical bonding.

The extent to which the uncured silicone elastomer penetrates the textile fabric may be controlled by laying the uncured silicone elastomer on the textile fabric and scraping the uncured silicone elastomer into the textile fabric.

The extent to which the uncured silicone elastomer penetrates the textile fabric may also be controlled by one or more of the following:

(i) the application of pressure to the textile fabric following application of the uncured silicone elastomer;

(ii) varying the quantity of uncured silicone elastomer applied to the textile fabric; and (iii) varying the rate at which the uncured silicone elastomer cures.

As discussed earlier, the rate at which the uncured silicone elastomer cures may be varied through the application of heat during curing of the silicone elastomer.

The first and second components of the textile fabric article may be formed from a single piece of textile fabric and may be adhered together to form a half-turn hem or a full hem along at least a section of an edge of the piece of textile.

13

CONFISMAIiON CUF^

The ability to create a half-turn or full hem in this manner permits the creation of a hem in which the textile fabric retains its ability to stretch. In addition the elastic resilience of the cured elastomer improves the fabric's ability to resume its structure following stretch.

In another particular embodiment the first and second components of the textile fabric article may be adjacent panels of a garment and the uncured silicone elastomer may be applied along the edge of a first of the panels. The other panel may then be arranged relative to the first panel so as to sandwich the uncured silicone elastomer between edges of the panels such that the silicone elastomer adheres the edges of the panels together and thereby creates a seam between the panels.

In a yet further particular embodiment, the second component may include an elasticated piece of textile fabric or a silicone tape, either of which may be laid under tension onto a first component in the form of a piece of textile fabric such that, following curing of the silicone elastomer and removal of the tension, a ruched effect is created in the first component. This allows the creation of a stretchable and/or shaped opening or edge to a garment, for example.

Embodiments of the various aspects of the invention will now be described by way of non-limiting examples with reference to the accompanying drawings in which:

Figures 1 and 2 illustrate steps of a method according to a first embodiment of the invention;

Figure 3 illustrates steps of a method according to a second embodiment of the invention;

Figures 4 and 5 illustrate steps of a method according to a third embodiment of the invention;

Figure 6 illustrates steps of a method according to a fourth embodiment of the invention; Figure 7 shows a schematic illustration of an apparatus according to a fifth embodiment of the invention; and

Figure 8 shows a schematic view of an applicator and controller according to a sixth embodiment of the invention.

A method of manufacturing a stretchable textile fabric article according to an embodiment of the invention will be described with reference to Figures 1 and 2.

The method involves the step of applying an uncured silicone elastomer 10 that requires UV radiation to trigger curing thereof to a first portion 14 of a piece of textile fabric 12 (Figure 1 ). The textile fabric may be a knitted or woven fabric, or form part of a seamless or paneled garment or a hosiery leg.

Following application of the uncured silicone elastomer 10, which is in the form of a liquid, the piece of textile fabric 12 is folded upon itself so that the uncured silicone elastomer 10 is sandwiched between the portion 14 to which the uncured silicone elastomer 10 was applied and an adjacent, second portion 16 of the piece of textile fabric so as to define a half-turn hem 18 (Figure 2).

The half-turn hem 18 is then exposed to UV radiation, which penetrates the textile fabric 12 so as to trigger curing of the uncured silicone elastomer 10.

Following curing of the uncured silicone elastomer 10, the first and second portions 14,16 of the piece of textile fabric 12 are adhered together so as to secure the half-turn hem 18.

In other embodiments, the step of folding the piece of textile fabric 12 may be performed simultaneously as the step of applying the uncured silicone elastomer 10 to the first portion 14 of the piece of textile fabric 12.

In order to form a full hem, the method outlined above is repeated and uncured silicone elastomer 10 is applied to the opposite side of the first portion 14 of the piece of textile fabric 12. The piece of textile fabric 12 is then folded so as to sandwich the uncured silicone elastomer 10 between the opposite side of the first portion 14 of the piece of textile fabric 12 and a third portion 20 of the piece of textile fabric 12 to define a full hem. The full hem is then exposed to UV radiation, which penetrates the textile fabric 12 so as to trigger curing of the uncured silicone elastomer 10.

In other embodiments, the steps of applying the uncured silicone elastomer 10 and folding the piece of textile fabric 12 may be repeated before exposing the uncured

silicone elastomer 10 to UV radiation. The layers of uncured silicone elastomer 10 sandwiched between the portions 14,16,20 of the piece of textile fabric may then be exposed to UV radiation to trigger curing thereof at the same time.

In the method outlined above, curing of the silicone elastomer is allowed to occur at ambient room temperature.

In other embodiments, the rate of curing of the silicone elastomer may be increased by pre-heating the uncured silicone elastomer 10 prior to its application to the piece of textile fabric 12. Following exposure of the uncured silicone elastomer 10 with UV radiation, the heat present in the silicone elastomer 10 accelerates the rate of curing thereof.

In further embodiments of the invention, the rate of curing of the silicone elastomer may be increased by heating the textile fabric and the silicone elastomer following exposure of the uncured silicone elastomer 10 with UV radiation. Such heating may be performed by means of heat lamps and/or heated plates.

In yet further embodiments of the invention, the rate of curing of the silicone elastomer may be increased further by pre-heating the uncured silicone elastomer 10 prior to its application to the piece of textile fabric 12 and heating the textile fabric 12 and the silicone elastomer following exposure of the uncured silicone elastomer 10 with UV radiation.

The use of cured silicone elastomer 10 to form the half-turn hem 18 shown in Figure 2 permits the textile fabric 12 to retain its natural ability to stretch and return to its original shape.

The extent to which the textile fabric 12 retains its natural ability to stretch is determined by the composition of the uncured silicone elastomer 10, which in turn determined the degree of mechanical versus chemical bonding of the silicone elastomer with the textile fabric 12 following curing.

So as to vary the physical properties of the silicone elastomer 10 following its application to the textile fabric 12 and curing thereof, the uncured silicone elastomer 10 is preferably formed from three mixable parts, one of those parts including an adhesion promoter.

It is envisaged that in other embodiments, the uncured silicone elastomer 10 may be formed from one part. The uncured silicone elastomer 10 may also be formed from two mixable parts. In such embodiments, one part may be the uncured silicone elastomer and the other part may be an adhesion promoter.

In a particularly preferred embodiment of the invention, the relative proportions of the respective mixable parts of the uncured silicone elastomer 10 are chosen immediately prior to the step of applying the uncured silicone elastomer 10 to the first portion 14 of the piece of textile fabric 12 depending on the structure of the textile fabric 12 and the desired physical characteristics of the silicone elastomer 10 following curing.

The relative proportions of the respective mixable parts are preferably variable during the step of applying the uncured silicone elastomer 10 so as to impart varying physical properties to the silicone elastomer once it is cured. This allows the creation of a continuous region 22 of silicone elastomer (Figure 3) in which discrete regions 24 have a higher degree of chemical bonding to regions 26 located either side thereof.

In order to improve any mechanical bond created between the silicone elastomer 10 and the textile fabric 12 following curing, the extent to which the uncured silicone elastomer 10 penetrates the textile fabric 12 is controlled.

Such control may be achieved by controlling the depth to which the uncured silicone elastomer 10 is applied to the piece of textile fabric 12. Preferably the depth of the uncured silicone elastomer 10 is in the region of 0.1mm - 10.0mm.

Such control may also be achieved by scraping the uncured silicone elastomer 10 into the textile fabric 12 following its application and prior to its exposure to UV radiation. It may also be achieved by applying pressure to the uncured silicone elastomer 10 and/or by varying the rate at which the silicone elastomer 10 cures. As will be appreciated, the longer the silicone elastomer 10 takes to cure the deeper into the textile fabric 12 the silicone elastomer 10 is likely to penetrate.

A method of manufacturing a stretchable textile fabric article according to another embodiment of the invention will now be described with reference to Figures 4 and 5.

The method involves the step of applying an uncured silicone elastomer 30 requiring UV radiation to trigger curing thereof to a portion 34 of a piece of textile fabric 32 (Figure 4).

Following application of the uncured silicone elastomer 30, another component 36 of the textile fabric article is laid onto the piece of textile fabric 32 such that uncured silicone elastomer 30 is sandwiched between the component 36 and the textile fabric 32 (Figure 5).

The component 36 and textile fabric 32 are then exposed to UV radiation, which penetrates the component 36 and the textile fabric 32 so as to trigger curing of the uncured silicone elastomer 30.

Following curing of the uncured silicone elastomer 30, the component 36 and the piece of textile fabric 32 are adhered together.

The component 36 of the textile fabric article may be another piece of textile fabric, such as another panel of a garment or article, a piece of lace or other decorative trim. It may also be a non-textile garment such as a length of silicone tape.

In circumstances where the component 36 is a stretchable member such as, for example, a strip of elasticated textile fabric or a length of cured silicone tape, the method may further include the step of tensioning the component prior to laying it onto the piece of textile fabric 32. The tension is maintained until curing of the silicone elastomer 30 is complete. This creates a ruched effect in the piece of textile fabric 32 and allows the creation of a stretchable and/or shaped opening or edge to a garment, for example.

A method of manufacturing a stretchable textile fabric article according to another embodiment of the invention will now be described with reference to Figure 6.

The method involves the step of applying an uncured silicone elastomer 40 requiring UV radiation to trigger curing thereof to a portion 44 of a piece of textile fabric 42 (Figure 6) so as to define a shaped path.

Following application of the uncured silicone elastomer 40 to the textile fabric 42, the uncured silicone elastomer 40 is exposed to UV radiation so as to trigger curing of the uncured silicone elastomer 40.

Once curing of the silicone elastomer 40 is complete, the textile fabric 42 is trimmed so as to shape the textile fabric 42 in accordance with the path of the cured silicone elastomer.

In each of the embodiments described with reference to Figure 4-6, the rate of cure of the silicone elastomer may be varied, the physical properties of the silicone elastomer following curing and the extent of penetration of the silicone elastomer into the textile fabric may be controlled in similar manners as outlined above with reference to the methods described with reference to Figures 1-3.

While the embodiments described above with reference to Figures 1-6 involve the use of an uncured silicone elastomer requiring UV radiation to trigger curing, it is envisaged that other uncured silicone elastomers may be used.

For example, in circumstances where the uncured silicone elastomer is in a multi-part form, curing of the uncured silicone elastomer may be triggered by mixing of the respective mixable parts immediately prior to, or during, application of the uncured silicone elastomer to the textile fabric. In such embodiments, pre-heating of the respective mixable parts could be performed to increase the rate of curing the silicone elastomer on mixing of the respective mixable parts.

In other embodiments curing of the uncured silicone elastomer may be triggered by heating the uncured silicone elastomer to a specific temperature. In such embodiments, heating of the uncured silicone elastomer to the trigger temperature may occur during or after application of the uncured silicone elastomer to the textile fabric.

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CONFIRMATION COPT

In embodiments where curing of the uncured silicone elastomer is triggered by heating the uncured silicone to a specific temperature it is of course important that any preheating is limited to ensure that curing of the silicone elastomer is not initiated before the silicone elastomer is applied to the textile fabric.

In yet further embodiments a trigger may not be required to initiate curing of the silicone elastomer. In such embodiments the shelf-life of the uncured silicone elastomer is such that the uncured silicone elastomer does not cure before it is applied to the textile fabric.

In such embodiments, the rate of curing of the uncured silicone elastomer may be accelerated following application to the textile fabric through the application of heat.

Apparatus 50 for manufacturing a stretchable textile fabric article according to an embodiment of the invention is illustrated schematically in Figure 7.

The apparatus 50 includes an applicator 52 including a darkened supply passage 54 for applying an uncured silicone elastomer 56 requiring UV radiation to trigger curing to at least one portion 58 of a piece of textile fabric 60. The apparatus 50 also includes a UV light source 62 to irradiate the uncured silicone elastomer 56 following application of the uncured silicone elastomer 56 so as to trigger curing of the uncured silicone elastomer to bond the silicone elastomer to the at least one portion 58 of the textile fabric 60.

The provision of the darkened supply passage 54 in the applicator 52 prevents the uncured silicone elastomer 56 being irradiated with UV radiation prior to its application to the textile fabric 60. This in turn ensures that the silicone elastomer 56 does not cure within the supply passage 54, which could cause a blockage in the supply passage 54.

The apparatus 50 also includes a heat source 64 upstream of the applicator 52 to heat the uncured silicone elastomer 56 before it is applied to the textile fabric 60, and a heat source 66 downstream of the applicator 52 to heat the silicone elastomer 56 during curing.

In other embodiments of the invention, the darkened supply passage 54 may include a plurality of tubes, each tube carrying one of a plurality of mixable parts of the uncured silicone elastomer 56. The darkened supply passage 54 may also include a controller to

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control the amounts of the respective mixable parts that are mixed together prior or during application of the uncured silicone elastomer 56.

In further embodiments of the invention, the apparatus 50 may also include a folding device for folding the or each portion 58 of the piece of textile fabric 60 so as to define a hem.

In yet further embodiments of the invention, the apparatus 50 may also include a controller in the form of a blade 68 (Figure 8) arranged to scrape the uncured silicone elastomer into the textile fabric as it is applied so as to cause the uncured silicone elastomer to penetrate further into the textile fabric, and thereby assist in controlling the extent to which the uncured silicone elastomer penetrates into the textile fabric. In such embodiments, the speed at which the textile fabric and the applicator move relative to one another may be measurable so as to allow for the control of the rate at which the uncured silicone elastomer is applied, thereby helping to ensure that the correct amount and thickness of uncured silicone elastomer is applied.

In each of the embodiments described with reference to Figures 1-8, the textile fabric may be a knitted or woven textile fabric. The textile fabric may form part of a seamless garment, a paneled garment or a hosiery leg. It is also envisaged that the textile fabric may be a separate piece of textile fabric, not forming part of a garment, such as a length of elasticated fabric or lace, thereby permitting the production of lengths of silicone coated elastic or lace.