US20070204783A1

US20070204783A1 - Method of making raised, embroidered design and article made therefrom

Info

Publication number: US20070204783A1
Application number: US11/307,977
Authority: US
Inventors: Phillip Chong
Original assignee: Creative Foam Design Inc
Current assignee: Creative Foam Design Inc
Priority date: 2006-03-01
Filing date: 2006-03-01
Publication date: 2007-09-06

Abstract

A method of making raised, embroidered design on a foundation fabric with top and bottom surfaces includes steps of placing a soluble spacer layer on the foundation fabric, embroidering a predetermined pattern over the stack of the foundation fabric and the spacer layer, and dissolving the soluble spacer layer away. Embroidering a predetermined pattern over the stack of the foundation fabric and the spacer layer is performed with a plurality of stitches of threads. Dissolving the soluble spacer layer away is performed with a predetermined solvent. The type of solvent is determined by the type of the soluble spacer layer. Water can be used for the solvent in case of starch spacer layer.

Description

BACKGROUND OF THE INVENTION

The present invention relates to a method of making raised and embroidered design and article made therefrom.
More particularly, this invention relates to a method for making a raised and embroidered fabric that use a soluble spacer layer.
Also, the invention relates to a fabric manufactured by the method with raised embroiders with changing height and color according to the pattern.
Embroidery has been well known in many cultures around the world through the history. It is one of ways to decorate fabric with stitches of threads. Comparing with the other types of decoration, the embroidery is unique in its quality. It gives an impression of almost three dimensional look. Since the stitches stand out over the flat surface of the fabric, the pattern formed by embroidering may look more beautiful than just a flat drawing with dye.
If the standing out of the pattern is the key to the secret of the beauty of the embroidery, then it would be possible to enhance the beauty remarkably by doing something on the relief nature of the embroidery.
The present invention is about such an enhancing the three-dimensional quality of embroidery and other features.
Accordingly, a need for a method of making raised and embroidered design and article made therefrom has been present for a long time considering the long history of the embroidery in the art. This invention is directed to solve the related problems and satisfy the long-felt need.

SUMMARY OF THE INVENTION

The present invention contrives to solve the disadvantages of the prior art.
An object of the invention is to provide a method of making raised and embroidered design and article made therefrom.
Another object of the invention is to provide a method of making raised and embroidered design using a soluble spacer layer.
Still another object of the invention is to provide a fabric design with a raised and embroidered pattern which stands out of the surface of the foundation sheet.
A method of making raised, embroidered design on a foundation sheet with top and bottom surfaces includes steps of placing a soluble spacer layer on the foundation sheet, embroidering a predetermined pattern over the stack of the foundation sheet and the spacer layer, and dissolving the soluble spacer layer away.
In the step of placing a soluble spacer layer with top and bottom surfaces of a predetermined thickness on the top surface of the foundation sheet, the bottom surface of the soluble spacer layer touches the top surface of the foundation sheet.
Embroidering a predetermined pattern over the stack of the foundation sheet and the spacer layer is performed with a plurality of stitches of threads.
Dissolving the soluble spacer layer away is performed with a predetermined solvent. The type of solvent is determined by the type of the soluble spacer layer.
In an embodiment of the present invention, the spacer layer is water-soluble. Preferably, the water-soluble spacer layer is made of starch.
The starch has a foam structure to enhance sewing through it and dissolving away after the embroidering.
The predetermined solvent includes water. If the material of the soluble spacer layer is starch, then the first choice of the solvent would be water or water mixture.
The thickness of the spacer layer is determined by the optical characteristics across the predetermined pattern. According to the thickness of the spacer layer, the height of the resulting embroider will change.
Each stitch of the threads holds the top surface of the soluble spacer layer and the bottom surface of the foundation sheet in the step of embroidering.
The step of placing a soluble spacer layer on the top surface of the foundation sheet may further include steps of aligning the spacer layer and the foundation sheet and fixing the bottom surface of the spacer layer on the top surface of the foundation sheet.
The spacer layer covers a part of the foundation sheet. The spacer layer can cover only the part of the foundation sheet for the embroidered pattern, or may cover all of the foundation sheet, especially in the case the total size of the foundation sheet is relatively small.
The step of embroidering a predetermined pattern over the stack of the foundation sheet and the spacer layer may include a step of changing the texture and color of the threads according to the optical characteristics of the predetermined pattern. The predetermined pattern is formed on the top surface of the spacer layer.
The step of dissolving the soluble spacer layer away with a predetermined solvent may further include steps of immersing the embroidered stack of the soluble spacer layer and the foundation sheet into the predetermined solvent, and then washing away the solution leaving the foundation sheet embroidered with the threads.
The foundation sheet includes a fabric.
In another embodiment of the present invention, a fabric embroidered with raised threads may be provided by the above method.
The fabric embroidered with raised threads includes a foundation fabric, a plurality of threads, a raised embroider, and a predetermined pattern formed by the raised embroider.
The foundation fabric has top and bottom surfaces. The plurality of threads of predetermined color and texture is stitched through the foundation fabric. The raised embroider, provided on the top surface of the foundation fabric, includes the plurality of threads.
The color and the texture of the threads are determined according to the optical characteristics of the predetermined pattern.
The stitch of the threads is raised on the top surface of the foundation fabric according to the optical characteristics of the predetermined pattern, wherein the stitch of the threads is tight on the bottom surface of the foundation fabric.
The raised embroider forms a relief over the flat foundation fabric.
The height of the raised embroider varies according to the location of a portion of embroider in the predetermined pattern.
The predetermined pattern may include an optical representation of predetermined objects and letters.
The raised embroider is substantially resilient against a stress along the thread and sideways, resuming an original optical pattern when the stress disappears.
The advantages of the present invention are: (1) the method of making raised and embroidered design and article made therefrom is unique and quite useful; (2) the soluble spacer layer is easy to dissolve and wash away with a non-toxic and abundant solvent, water, which incur no threat to the environment; and (3) the method enables to make a high quality of embroidery with a varying height of pattern quite easily.
Although the present invention is briefly summarized, the fuller understanding of the invention can be obtained by the following drawings, detailed description and appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects and advantages of the present invention will become better understood with reference to the accompanying drawings, wherein:
FIG. 1 is a flow chart of a method according to the present invention;
FIG. 2 is another detailed flow chart of the method of FIG. 1;
FIG. 3 is a perspective view of a fabric with raised embroider along with a soluble spacer layer;
FIG. 4 is a cross-sectional view along the line IV-IV of FIG. 3;
FIG. 5 is a cross-sectional view of a foundation sheet;
FIG. 6 is a cross-sectional view of a soluble spacer layer stacked on the foundation sheet of FIG. 5;
FIG. 7 is a cross-sectional view of the embroidered threads through the soluble spacer layer and the foundation sheet of FIG. 6;
FIG. 8 is a cross-sectional view of the raised embroidered fabric with the soluble spacer layer dissolved away from FIG. 7;
FIG. 9 is a cross-sectional view of the embroidered threads through the soluble spacer layer of varying height and the foundation sheet;
FIG. 10 is a cross-sectional view of the raised embroidered fabric with the soluble spacer layer dissolved away from FIG. 9; and
FIG. 11 is a plan view of a pattern embodied by the present invention.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 and FIG. 2 are flow charts of a method S100 of making raised and embroidered design 100 and FIGS. 3 through 11 show an article 100 made by the method S100.
The method S100 of making raised, embroidered design on a foundation sheet 10 with top and bottom surfaces 12, 14 includes steps of placing a soluble spacer layer 50 on the foundation sheet (S020), embroidering a predetermined pattern 40 over the stack of the foundation sheet 10 and the spacer layer 50 (S040), and dissolving the soluble spacer layer 50 away (S060).
In the step S020 of placing a soluble spacer layer 50 with top and bottom surfaces 52, 54 of a predetermined thickness on the top surface 12 of the foundation sheet 10, the bottom surface 54 of the soluble spacer layer 50 touches the top surface 12 of the foundation sheet 10.
Embroidering a predetermined pattern 40 over the stack of the foundation sheet 10 and the spacer layer 50 (S040) is performed with a plurality of stitches of threads 20.
Dissolving the soluble spacer layer 50 away (S060) is performed with a predetermined solvent. The type of solvent is determined by the type of the soluble spacer layer 50.
In an embodiment of the present invention, the spacer layer 50 is water-soluble. Preferably, the water-soluble spacer layer 50 is made of starch.
The starch has a foam structure to enhance sewing through it and dissolving away after the embroidering.
The predetermined solvent includes water. If the material of the soluble spacer layer 50 is starch, then the first choice of the solvent would be water or water mixture.
The thickness of the spacer layer 50 is determined by the optical characteristics across the predetermined pattern 40. According to the thickness of the spacer layer 50, the height of the resulting embroider 30 will change.
Each stitch of the threads 20 holds the top surface 54 of the soluble spacer layer 50 and the bottom surface 14 of the foundation sheet 10 in the step of embroidering S040.
The step S020 of placing a soluble spacer layer 50 on the top surface 12 of the foundation sheet 10 may further include steps of aligning the spacer layer 50 and the foundation sheet 10 (S022) and fixing the bottom surface 54 of the spacer layer 50 on the top surface 12 of the foundation sheet 10 (S022) as shown in FIG. 2.
The spacer layer 50 covers a part of the foundation sheet 10. The spacer layer 50 can cover only the part of the foundation sheet 10 for the embroidered pattern 40 as shown in FIG. 3, or may cover all of the foundation sheet 10, especially in the case the total size of the foundation sheet 10 is relatively small.
The step (S040) of embroidering a predetermined pattern 40 over the stack of the foundation sheet 10 and the spacer layer 50 may include a step S042 of changing the texture and color of the threads 20 according to the optical characteristics of the predetermined pattern 40. The predetermined pattern 40 is formed on the top surface 52 of the spacer layer 50.
The step S060 of dissolving the soluble spacer layer 50 away with a predetermined solvent may further include steps of immersing the embroidered stack of the soluble spacer layer 50 and the foundation sheet 10 into the predetermined solvent (S062), and then washing away the solution leaving the foundation sheet 10 embroidered with the threads 20 (S064).
The foundation sheet 10 includes a fabric.
In another embodiment of the present invention as shown in FIGS. 3 through 11, the fabric embroidered with raised threads 100 may be provided by the above method S100.
The fabric embroidered with raised threads 100 includes a foundation fabric 10, a plurality of threads 20, a raised embroider 30, and a predetermined pattern 40 formed by the raised embroider 30.
The foundation fabric 10 has top and bottom surfaces 12, 14. The plurality of threads 20 of predetermined color and texture is stitched through the foundation fabric 10. The raised embroider 30, provided on the top surface 12 of the foundation fabric 10, includes the plurality of threads 20.
The color and the texture of the threads 20 are determined according to the optical characteristics of the predetermined pattern 40.
The stitch of the threads 20 is raised on the top surface 12 of the foundation fabric 10 according to the optical characteristics of the predetermined pattern 40, wherein the stitch of the threads 20 is tight on the bottom surface 14 of the foundation fabric 10.
The raised embroider 30 forms a relief over the flat foundation fabric 10 as shown in FIG. 8 and FIG. 10.
The height of the raised embroider 30 varies according to the location of a portion of embroider 30 in the predetermined pattern 40, which can be controlled by the thickness of the spacer layer 50 as shown in FIG. 10.
The predetermined pattern 50 may include an optical representation of predetermined objects and letters as shown in FIG. 11.
The raised embroider 30 is substantially resilient against a stress along the thread 20 and sideways, resuming an original optical pattern 40 when the stress disappears.
While the invention has been shown and described with reference to different embodiments thereof, it will be appreciated by those skilled in the art that variations in form, detail, compositions and operation may be made without departing from the spirit and scope of the invention as defined by the accompanying claims.

Claims

1. A method of making raised, embroidered design on a foundation sheet with top and bottom surfaces comprising steps of:

a) placing a soluble spacer layer with top and bottom surfaces of a predetermined thickness on the top surface of the foundation sheet, wherein the bottom surface of the soluble spacer layer touches the top surface of the foundation sheet;

b) embroidering a predetermined pattern over the stack of the foundation sheet and the spacer layer with a plurality of threads;

c) dissolving the soluble spacer layer away with a predetermined solvent.

2. The method of making raised, embroidered design of claim 1, wherein the spacer layer is water-soluble.

3. The method of making raised, embroidered design of claim 2, wherein the water-soluble spacer layer is made of starch.

4. The method of making raised, embroidered design of claim 3, wherein the starch has a foam structure.

5. The method of making raised, embroidered design of claim 2, wherein the predetermined solvent comprises water.

6. The method of making raised, embroidered design of claim 1, wherein the thickness of the spacer layer is determined by the optical characteristics across the predetermined pattern.

7. The method of making raised, embroidered design of claim 1, wherein each stitch of the threads holds the top surface of the soluble spacer layer and the bottom surface of the foundation sheet.

8. The method of making raised, embroidered design of claim 1, wherein the step of placing a soluble spacer layer on the top surface of the foundation sheet comprises steps of:

a) aligning the spacer layer and the foundation sheet; and

b) fixing the bottom surface of the spacer layer on the top surface of the foundation sheet.

9. The method of making raised, embroidered design of claim 8, wherein the spacer layer covers a part of the foundation sheet.

10. The method of making raised, embroidered design of claim 1, wherein the step of embroidering a predetermined pattern over the stack of the foundation sheet and the spacer layer comprises a step of changing the texture and color of the threads according to the optical characteristics of the predetermined pattern, wherein the predetermined pattern is formed on the top surface of the spacer layer.

11. The method of making raised, embroidered design of claim 1, wherein the step of dissolving the soluble spacer layer away with a predetermined solvent comprises steps of:

a) immersing the embroidered stack of the soluble spacer layer and the foundation sheet into the predetermined solvent; and

b) washing away the solution leaving the foundation sheet embroidered with the threads.

12. The method of making raised, embroidered design of claim 1, wherein the foundation sheet comprises a fabric.

13. A fabric embroidered with raised threads comprising:

a) a foundation fabric having top and bottom surfaces;

b) a plurality of threads of predetermined color and texture stitched through the foundation fabric;

c) a raised embroider, provided on the top surface of the foundation fabric, comprising the plurality of threads; and

d) a predetermined pattern formed by the raised embroider,

wherein the color and the texture of the threads are determined according to the optical characteristics of the predetermined pattern.

14. The fabric embroidered with raised threads of claim 13, wherein the stitch of the threads is raised on the top surface of the foundation fabric according to the optical characteristics of the predetermined pattern, wherein the stitch of the threads is tight on the bottom surface of the foundation fabric.

15. The fabric embroidered with raised threads of claim 13, wherein the raised embroider forms a relief over the flat foundation fabric.

16. The fabric embroidered with raised threads of claim 13, wherein the height of the raised embroider varies according to the location of a portion of embroider in the predetermined pattern.

17. The fabric embroidered with raised threads of claim 13, wherein the predetermined pattern comprises an optical representation of predetermined objects and letters.

18. The fabric embroidered with raised threads of claim 13, wherein the raised embroider is substantially resilient against a stress along the thread and sideways, resuming an original optical pattern when the stress disappears.