Brush-type embroidery process

United States Patent Application 20040231577

A brush-type embroidery process, including the steps of placing a first layer of raised filler and a second layer of raised filler, which are made of EVA or foam sheet materials of the like, on a base fabric with the layer of raised fillers covering an area larger than that of the integral pattern to be embroidered; embroidering by a computerized embroidering machine through the first and second layer of raised fillers to the base fabric to present a specifically designed pattern; cutting off the threads in the crevice in-between the first and second layer of raised fillers; and taking away the remaining second layer of raised filler such that the surface stub threads will form a brush-type embroidery due to the second layer's being removed by force and the surface stub threads' being concomitantly combed by the second layer of raised filler to give the appearance of erect brush bristles.

Wang, Tai Kuang (Taipei, TW)

10/443056

11/25/2004

05/22/2003

Click for automatic bibliography generation

WANG TAI KUANG

112/475.19

112/475.23, 156/72, 156/93

D05C17/00; (IPC1-7): D05C15/38; D05C5/02; D05C15/00

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YAO, SAMCHUAN CUA

LEONG C. LEI (WALNUT CREEK, CA, US)

1. A brush-type embroidery process, including the following steps: (a) placing a first layer of raised filler and a second layer of raised filler on a base fabric with the first layer on the top of the second layer, the fillers cover an area greater than that of the integral pattern to be embroidered; (b) embroidering by threaded needle(s) of a computerized embroidering machine through the first and second layer of raised fillers to the base fabric to present a specifically designed pattern; (c) cutting off the threads in the crevice in-between the first and second layer of raised fillers; and (d) taking away the remaining second layer of raised filler such that the surface stub threads will form a brush-type embroidery due to the second layer's being removed by force and the surface stub threads' being concomitantly combed by the second layer of raised filler to appear the effect of erect brush bristles.

2. The brush-type embroidery process according to claim 1, wherein the first layer of raised filler and second layer of raised filler (interlayer) can be made of EVA material.

3. The brush-type embroidery process according to claim 1, wherein the first layer of raised filler and second layer of raised filler (interlayer) can be made of foam sheet materials.

4. The brush-type embroidery process according to claim 1, wherein the layer of raised fillers used in step (a) can be selected from a variety range of thickness of 1.5, 2.0, 2.5, 3.0, 3.5, 4.0 mm and/or any measurement in between these depending on the need in process.

5. The brush-type embroidery process according to claim 1, wherein during the step (a), to prevent the embroidering threads from sinking too deep inside of the first layer of raised fillers, a lining material such as a non-woven fabric may be additionally placed on the surface of the first layer of raised filler for sustaining purposes.

6. The brush-type embroidery process according to claim 1, wherein during the step (b), a paper underlayer can be additionally provided beneath the base fabric to make the embroidering threads tied up firmly.

7. The brush-type embroidery process according to claim 1, wherein during the step (c), the threads in the crevice in-between the first and second layer of raised fillers can be cut off by a knife.

8. The brush-type embroidery process according to claim 1, wherein after accomplishing the step (c), appropriate applicable resin (such as polyvinyl white resin) may be applied to the threads beneath the base fabric and dried up for setting purposes.

9. The brush-type embroidery process according to claim 1, wherein after accomplishing the step (c), resin may be applied to the threads beneath the base fabric and a fabric lining may be further adhered onto the threads beneath the base fabric for setting purposes.

10. The brush-type embroidery process according to claim 1, wherein after accomplishing the step (c), a self-adhesive lining fabric lining may be adhered to the undersurface of the threads beneath the base fabric.

11. The brush-type embroidery process according to claim 1, wherein during the step (a), each of the first and second layer of raised fillers may be an inclined or curved board having an uneven height.

12. The brush-type embroidery process according to claim 1, wherein during the step (c), the threads on the surface of the first layer of raised filler may be cut or ground off by manual or electric cutters or sanders.

13. The brush-type embroidery process according to claim 1 or 5, wherein during the step (c), the threads on the surface of the lining material may be cut or ground off by manual/electric cutters or sanders.

14. A brush-type embroidery process, including the following steps: (a) placing a sheet of raised filler on a base fabric, the raised filler covers an area larger than that of the integral pattern to be embroidered; (b) embroidering by threaded needle(s) of a computerized embroidering machine through the raised filler to the base fabric to present a specifically designed pattern; (c) cutting off the threads on the raised filler; and (d) taking away the raised filler such that the surface stub threads will form a brush-type embroidery due to the raised filler's being removed and the surface stub threads' being concomitantly combed by the raised filler to appear the effect of erect brush bristles.

15. The brush-type embroidery process according to claim 14, wherein the raised filler can be made of EVA material.

16. The brush-type embroidery process according to claim 14, wherein the raised filler can be made of foam sheet materials.

17. The brush-type embroidery process according to claim 14, wherein the raised filler used in step (a) can be selected from a variety range of thickness of 1.5, 2.0, 2.5, 3.0, 3.5 4.0 mm or any measurement in between these, depending on the need in process.

18. The brush-type embroidery process according to claim 14, wherein during the step (a), to prevent the embroidering threads from sinking too deep inside of the raised filler, a lining material such as a non-woven fabric may be additionally placed on the surface of the raised filler for preservation purposes.

19. The brush-type embroidery process according to claim 14, wherein during the step (b), a paper underlayer can be additionally provided beneath the base fabric to make the embroidering threads tied up firmly.

20. The brush-type embroidery process according to claim 18, wherein during the step (c), the threads in the crevice in-between the lining material and the raised filler can be cut off by a knife.

21. The brush-type embroidery process according to claim 14, wherein after accomplishing the step (c), appropriate resin (such as polyvinyl white resin) may be applied to the threads beneath the base fabric and dried up for setting purposes.

22. The brush-type embroidery process according to claim 14, wherein after accomplishing the step (c), resin may be applied to the threads beneath the base fabric and a fabric lining may be adhered onto the threads beneath the base fabric for setting purposes.

23. The brush-type embroidery process according to claim 14, wherein after accomplishing the step (c), a self-adhesive lining fabric may be adhered to the undersurface of the threads beneath the base fabric.

24. The brush-type embroidery process according to claim 14, wherein during the step (a), the raised filler may be an inclined or curved board having an uneven height.

25. The brush-type embroidery process according to claim 14, wherein during the step (c), the threads on the surface of the raised filler may be cut or ground off by manual/electric cutters or sanders.

26. The brush-type embroidery process according to claim 18, wherein during the step (c), the threads on the surface of the lining material may be cut or ground off by manual/electric cutters or sanders.

FILED OF THE INVENTION

[0001] The present invention relates to a process for making a brush-type embroidery having the effect as a brush, such that the raised effect is different from those of other plane or extruding embroideries, and is particularly applicable to all kinds of fabric and articles so as to obtain an alternative raised embroidery masterpiece.

DESCRIPTION OF THE PRIOR ART

[0002] There are many kinds of embroideries on general fabric, such as plane embroidery, extruding embroidery, etc. Plane embroidery is directly processed on a fabric without adding any filler such that the thread will be stitched through the fabric to appear like a plane embroidery pattern. Extruding embroidery used to be processed by pre-placing a soft foam material on the area to be embroidered and sewing said embroidering area having the soft foam material with thread, so as to accomplish an “extruding” embroidery work.

[0003] Although plane embroidery may present a gradation effect by way of stitching with the threads of different colors, 3-dimensional effect of the embroidery pattern can yet be obtained. As for extruding embroidery in the prior art, the raised effect is generally obtained via covering a soft foam material by threads. It cannot present a 3-dimensional effect in fine gradation.

[0004] Both the plane or extruding embroideries mentioned above present the embroidery pattern by way of paving threads on the base fabric. The brush-type embroidery obtained by the process according the present invention can present an embroidery work with an aesthetic feeling out of the ordinary.

SUMMARY OF THE INVENTION

[0005] The primary object of the invention is to provide a brush-type embroidery process which may obtain an embroidery with the surface stub threads positioned upward like those of the bristles of a brush, so as to accomplish a gradationally arranged artwork.

[0006] Another object of the invention is to provide an embroidery process totally different from the prior art for making plane or extruding embroideries, since the invention can produce a brush-type embroidery and make mass production much easier.

[0007] To reach the above objects, the present invention includes the following steps:

[0008] (a) placing at least two layers of raised filler on a base fabric with the fillers covering an area greater than that of the integral pattern to be embroidered;

[0009] (b) embroidering by threaded needle(s) of a computerized embroidering machine through the at least two layers of raised filler to the base fabric to present a specifically designed pattern;

[0010] (c) cutting off the threads in the crevice in-between at least two layers of raised filler having a pre-determined thickness; and

[0011] (d) taking away the remaining filler to present an embroidery having the effect of brush bristles.

[0012] By way of the above steps, threads vertically extrude from the base fabric and present a specially arranged embroidery pattern, the integral visual effect of which appears like brush bristles and presents an embroidery artwork out of ordinary.

[0013] The detailed contents and other characteristics of the present invention can be better understood by way of reading the following detailed descriptions with reference to the accompanied drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] FIG. 1 shows step (a) according to the invention.

[0015] FIG. 2 shows step (b) according to the invention.

[0016] FIG. 3 shows step (c) according to the invention.

[0017] FIG. 4 shows step (d) according to the invention.

[0018] FIG. 5 is a schematic view showing the accomplished brush-type embroidery processed according to the invention.

[0019] FIG. 6 shows step (c) according to the second embodiment process of the invention.

[0020] FIG. 7 shows step (c) according to the third embodiment process of the invention.

[0021] FIG. 8a is a cut-away view of the embroidery accomplished in step (a) according to the invention.

[0022] FIG. 8b is a cut-away view of the embroidery accomplished in step (b) according to the invention.

[0023] FIG. 8c is a cut-away view of the embroidery accomplished in step (c) according to the invention.

[0024] FIG. 8d is a cut-away view of the embroidery accomplished in step (d) according to the invention.

DETAILED DESCRIPTION OF THE EMBODIMENT

[0025] As shown in the drawings, the invention includes the following steps:

[0026] (a) placing a first layer of raised filler 20 and a second layer of raised filler 21 on a base fabric 10 with the first layer of raised filler 20 on the top of the second layer of raised filler 21, the fillers cover an area greater than that of the integral pattern to be embroidered (as shown in FIG. 1);

[0027] The first layer of raised filler 20 and second layer of raised filler 21 can be made of EVA or foam sheet materials or the like, and be selected from a variety range of thicknesses of 1.5, 2.0, 2.5, 3.0, 3.5, 4.0 mm and/or other thicknesses within these measurements, depending on the need in process, while the density of the fillers is adapted to be stitched through by an embroidering needle. To prevent the embroidering threads from sinking too deep inside of the fillers, a lining material such as a non-woven fabric 22 may be additionally placed on the surface of the first layer of raised filler (as shown in FIG. 8a) or the like having a sustaining function to make the threads sink in a proper depth.

[0028] (b) embroidering by threaded needle(s) 30 of a computerized embroidering machine through the first layer of raised filler 20 and second layer of raised filler 21 to the base fabric 10 to present a specifically designed pattern 40 (as shown in FIG. 2);

[0029] In the preferred embodiment according to the invention, the material of the upper embroidering threads used in step (b) may be rayon or polyester, while the lower threads may be any kind of threads. By way of stitching of the pre-determined pattern area, the threads pass through the fillers to the basic fabric in the corresponding area. To obtain a better tie up effect for the threads, a paper underlayer 11 can be further provided beneath the base fabric 10.

[0030] (c) after the embroidery pattern 40 has been accomplished, cutting off the threads in the crevice A in-between the first layer of raised filler 20 and second layer of raised filler 21 (i.e. the underside of the first layer of raised filler 20) by a knife 31 (as shown in FIG. 3); and

[0031] After the embroidery pattern has been accomplished, the threads beneath the base fabric 10 can be tied up firmly by way of the following actions:

[0032] 1. applying suitable resin or glue (such as polyvinyl white resin) to the threads beneath the base fabric 10 and drying up said applicable resin;

[0033] 2. adhering a self-adhesive lining fabric to the undersurface of the threads beneath the base fabric.

[0034] (d) as the first layer of filler 20 has been removed by way of the previous step, now taking away the remaining second layer of raised filler 21 such that the surface stub threads will form a brush-type embroidery due to the second layer's being removed by force and the stub threads' being combed by the second layer of raised filler 21 to appear a brush-type embroidery 50 of the effect as a brush (as shown in FIG. 5).

[0035] Note that during step (c), when cutting off the threads in the crevice A in-between the first layer of raised filler 20 and second layer of raised filler 21 (i.e. the underside of the first layer of raised filler 20) by a knife 31 to form surface stub threads 41, besides the knife 31 shown in FIG. 3, scissors 32 (as shown in FIG. 6) may be applied in this step as a cutter. Alternatively, electric cutters such as electric knife, electric scissors, electric sanders 33 or the like may be used to cut or grind off the threads on the surface of the first layer of raised filler 20 to obtain an embroidery artwork of the same effect.

[0036] As shown in FIG. 8a, being a sectional view of the embroidery accomplished in step (a) according to the invention, the first layer of raised filler 20 and the second layer of raised filler 21 are piled up on the base fabric 10. To prevent the embroidering threads from sinking too deep inside of the first layer of raised filler 20, a non-woven fabric may be added onto the surface of the first layer of raised filler 21. Besides, a paper underlayer 11 may be provided beneath the base fabric 10 to make the threads tied up firmly without loosing from the base fabric. Furthermore, in a preferred embodiment according to the invention, each of the first layer of raised filler 21 and second layer of raised filler 22 may be an inclined or curved board having an uneven height. For example, if the second layer of raised filler 22 is an inclined or curved plane board having an uneven height, the surface stub threads of the brush-type embroidery may have uneven height to present a product with a vivid effect according to the invention.

[0037] As shown in FIG. 8b, being a sectional view of the embroidery accomplished in step (b) according to the invention, an embroidery pattern 40 appears on the layers after stitching by threaded needle(s) 30.

[0038] As shown in FIG. 8c, being a sectional view of the embroidery accomplished in step (c) according to the invention, the first layer of raised filler 20 has been removed due to cutting off of the threads 41, while the second layer of raised filler 21 is still connected with the base fabric 10.

[0039] As shown in FIG. 8d, being a sectional view of the embroidery accomplished in step (d) according to the invention, the second layer of raised filler 21 has been removed by force with the remaining surface stub threads 41 combed thereby, while the surface stub threads will form a brush-type embroidery 50 and have the appearance of brush bristles.

[0040] Concluded above, the present invention discloses a novel brush-type embroidery process, which may provide a totally different visual effect from the plane and extruding embroideries processed according to the prior art. While the threads emerge erectly from the base fabric as brush bristles, they provide a comfortable feeling in touch and present a 3-dimensional aesthetic feeling visually. In addition, as the process according to the invention is simple and neat, it is particularly applicable to mass production and would greatly reduce the cost in manufacture.

[0041] While certain novel features of this invention have been shown and described and are pointed out in the annexed claims, it is not intended to be limited to the details above, since it will be understood that various omissions, modifications, substitutions and changes in the forms and details of the device illustrated and in its operation can be made by those skilled in the art without departing in any way from the spirit of the present invention.