GB2569308A

GB2569308A - Leather Embroidery

Info

Publication number: GB2569308A
Application number: GB1720697.0A
Authority: GB
Inventors: Randell Stephanie
Original assignee: Bayerische Motoren Werke AG
Current assignee: Bayerische Motoren Werke AG
Priority date: 2017-12-12
Filing date: 2017-12-12
Publication date: 2019-06-19
Anticipated expiration: 2037-12-12
Also published as: GB201720697D0; GB2569308B

Abstract

A method for shaping a two dimensional piece of embroidered leather into a non-planar three dimensional form comprises, forming an embroidered design in the leather by passing a filament through a multiplicity of pre-perforated holes through the leather; and shaping the embroidered two dimensional leather to have a non-planar three dimensional form. The shaping process comprises stretching or bending the embroidered leather in one or more dimensions, preferably around a three-dimensional object. Lines of the array of perforations may follow the contours or edges of the object. The object may be the waterfall portion of an automobile seat or seat piping, and the piping may be prevented from unravelling by using an end cap. By passing the thread through a pre-perforated hole forces used to shape the leather are distributed more evenly. The embroidery is preferably done by hand.

Description

Leather Embroidery

Field of the Invention

The present invention relates to methods for shaping an embroidered piece of leather by bending and/or stretching it into a three-dimensional (3D) form without significantly distorting the proportions of the embroidered design. The present invention also relates to manufacture of products according to these methods.

Background to the Invention

Leather has been decorated by embroidering with thread since prehistoric times. Usually, embroidery is carried out by passing a filament, normally a thread, from back to front through the piece of leather being embroidered and then from the front to the back leaving a length of thread (a stitch) displayed on the front surface of the leather wherein the stitch is held in place by friction from the passage of the thread through the leather at either end of the stitch. A multiplicity of stitches can be built up into a decorative design and this design can be enhanced by the use of different coloured filaments or threads to yield different coloured stitches and thus multicoloured designs.

It is most convenient to embroider leather while the leather is two dimensional (2D) because this yields simple access to both phases of the leather piece and thus to the entire length of the thread as it transits from one side of the leather to the other forming the design. In addition it is convenient to prepare and transfer a two dimensional embroidery design to a two dimensional workpiece while reliably maintaining the proportions and appearance of the design.

Many three-dimensional objects are made from leather or covered with leather and may benefit from decoration by way of embroidery. Embroidering on a threedimensional object is significantly more difficult than on a two-dimensional piece of leather because access to the “back” of the leather being embroidered is generally more restricted when the object is three-dimensional. Indeed access to the “back” of the leather may be impossible when the embroidered leather is used to cover an object, e.g. a seat upholstered with leather.

-2This disadvantage might be ameliorated by first embroidering a design on a two dimensional piece of leather and then either shaping the two dimensional piece of leather and the design thereon into the three dimensional form desired or mounting the embroidered two dimensional piece of leather on the three dimensional object that it is intended to decorate. However, shaping leather that has been embroidered in two dimensions into a three-dimensional form will distort the embroidered design because the transition from two-dimensional to three-dimensional form means that the tensions in the threads of the embroidery are changed unevenly during the shaping process thus warping or distorting the overall proportions of the design.

This is a particular problem in fields where decoration is desirable and leather work is necessarily three-dimensional such as in automotive seat coverings and interior decoration.

Hence, there is a need for an alternative means of shaping or mounting decorative embroidered leather work to conform to or with specific three dimensional shapes without distortion of the decorative embroidery, in particular for interior decoration in automobiles.

Object of the Invention

An object of the present invention is to provide methods for making three dimensional embroidered leatherwork from pieces of two dimensional embroidered leatherwork without distorting the decorative embroidery applied thereto in the transition from the two dimensional to the three dimensional form. A specific object of the invention is to provide products for interior decoration in automobiles, preferably cars, and methods for producing these products.

Summary of the Invention

Accordingly, the invention provides a method for shaping a substantially two dimensional piece of embroidered leather into a non-planar three dimensional form, wherein the leather has front and rear sides and wherein the leather is preperforated by an array of regularly spaced holes through the leather from the front to the rear side; wherein the method comprises the steps of:

-3forming an embroidered design in the pre-perforated leather by passing a filament through a multiplicity of the holes in the leather; and shaping the embroidered two dimensional leather to have a non-planar three dimensional form wherein the shaping process comprises stretching and/or bending the embroidered leather in one or more dimensions.

The object of the invention is achieved during the shaping process when the preperforated array of regularly spaced holes in the leather causes the forces used to shape the leather to be distributed more evenly throughout the piece of embroidery. This more even distribution of the shaping forces preserves the overall proportions of an embroidery design when it is shaped to cover a three-dimensional object.

The invention further provides products having a non-planar three-dimensional form produced according to the methods of the invention.

The invention also provides an embroidered leather product mounted in a vehicle and having a non-planar three-dimensional form, wherein the leather has front and rear sides and wherein the leather is preperforated by an array of regularly spaced holes through the leather from the front to the rear side;

wherein the leather has been embroidered by the passage of a filament through a multiplicity of the holes in the leather; and wherein the embroidered leather is bent or is under tension.

The two dimensional embroidered leather may be applied to or shaped around a three dimensional object.

The lines of the pre-perforated array of regularly spaced holes of the embroidered leather applied to or shaped around the three dimensional object may follow the contours or edges of the object.

The array of pre-perforated holes comprises three or more lines of holes in the embroidered leather. Preferably the array comprises at least: four lines of holes; five lines of holes; six lines of holes; seven lines of holes; eight lines of holes; nine lines

-4of holes; or ten lines of holes. Thus the array is two dimensional and is distinct from a one dimensional line of holes or two parallel lines of holes.

The regularly spaced holes may define the vertices of an array of polygons. This array may define the vertices of an array of rectangles and/or an array of triangles. Further the regularly spaced holes may define the vertices of an array of regular polygons and this array might define the vertices of an array of squares or equilateral triangles.

Preferably the holes in the perforated leather sit 5mm apart in a square grid.

The holes in the perforated leather may be of any radius suitable for allowing passage of the filament through them and allowing the intervening leather to transmit and spread the forces exerted on the leather when the filaments are under tension.

Advantageously, use of an array of polygons means that the forces applied during the stretching or bending of the leather material is can be distributed evenly during the mounting process thus one or more dimensional proportions of the embroidered design can be maintained and can be better and more evenly adapted to follow the contours and/or edges of the intended three-dimensional form.

Thus the proportions of the embroidery design need not be significantly altered in the transition from two dimensional creation to three dimensional presentation. This significantly simplifies the design process for the embroidery as it is simpler to produce a design in two dimensions for two dimensional presentation which can now be more conveniently adapted for three-dimensional presentation. Furthermore, a single embroidery design can be more simply applied to a greater number of threedimensional objects without distortion and maintaining the overall appearance of the design by using a single overarching two-dimensional design that is adapted to being presented on multiple objects.

Shaping the embroidered two dimensional leather to have a three dimensional form may comprise stretching the leather in at least one dimension and may comprise stretching the leather in two dimensions.

-5At least two dimensional proportions of the embroidered design on the two dimensional embroidered leather may be maintained following shaping the embroidered two dimensional leather to have a non-planar three dimensional form. Preferably these proportions may be considered with reference to are x and y (Cartesian) axes but might also be considered with respect to radial axes (rand Θ).

All known types of perforated leather that are suitable to hand sew through may be used in the context of the present invention. The present invention has the advantage of not being limited to using leathers that can be machine sewn. Preferably upholstery leather from bulls is used as this has the advantage of being the type of leather most commonly used in the automobile upholstery. Accordingly, this type of leather is readily available and use of this type of leather minimises the adaptations required to use the present invention in the context of producing vehicle upholstery. Saddle leather can also be hand sewn through when perforated and thus can be used in the context of the present invention. Leathers from other sources may also be used: in particular, goat, ox, elk, kangaroo and deer leathers are suitable.

Preferably, the pre-perforated leather is that produced by HEWA with the preperforated holes in the leather located 5mm apart in a square grid.

The filament may be a thread. Alternatively the thread may be a flexible wire or leather lace. Preferably the thread is sewing thread, more preferably the thread is made of any of the following materials: cotton, a cotton/polyester mix (polycotton), linen, nylon, polyester, rayon, silk or wool. The filament may be coloured. The filament may be of a single colour or multiple colours.

Preferably the threads are made of nylon, polyester, polyamide or a combination thereof. Polycotton (a combination of polyester and cotton), cotton and silk threads can also both be used in the context of the invention.

The embroidered design may be partially or completely sewn by hand.

-6Hand embroidery is advantageous in the context of the present invention because producing an embroidery in pre-perforated leather by machine requires exceedingly tight and consistent mechanical tolerances to stich through the pre-made holes without puncturing the leather elsewhere. A single failure would produce an extra hole and thus alter the mechanical properties of the embroidered leather piece and might compromise the usefulness of the pieces of embroidery in the methods of the invention. Thus hand embroidery according to the invention is advantageous over machine embroidery as there is less likelihood of damage to the embroidery piece during creation. Furthermore, hand embroidery has the advantage of being able to employ a range of functional and decorative sewing stitches that cannot be formed by a sewing machine.

The present invention is particularly suited to the use of single stitches or seed stitches. Hand sewing is advantageous in this context because these stitches are characterised by being single stitches placed randomly or uniformly over the fabric or leather and it is difficult to recreate this form of stitching with a sewing machine. In general sewing machines are set up to produce a row of ‘starting stitches’ underneath a shape because a few stitches need to be formed before the bobbin thread has been caught in by the top sewing thread. Consequently, these first few stitches of a machine-made embroidery design cannot be seen. Accordingly, it is extremely difficult to embroider individual stitches with a sewing machine.

Other hand-sewn stitches that can be employed in the context of the invention are running stitch, stem stitch, couching, chain stitch, herringbone, French knots, blanket stitch, wheat ear stitch, bullion knots and feather stitch.

Furthermore, the hand-sewn stitches described above can be used to produce a multitude of designs and can be layered or patterned to create further stitch types.

In this way stitches can be made through the perforated leather and can then be hand embroidered through these existing stitches so no threads appear on the back side of the embroidered leather. An example of a more complicated stitch of this type is the herringbone ladder stitch.

The three dimensional object may be an automotive part and may be within the cabin of an automobile.

In particular, the three dimensional object may be a seat, preferably the waterfall area of the seat of an automobile.

The waterfall area of the seat of the automobile is the area between the two rear seats. It often has the shape of a waterfall and is thus so named. This is an area of the automobile upholstery that is normally subject to low wear. Consequently, it is an area that is particularly suitable for hand embroidery, which might be more delicate and less hard wearing than other forms of embroidery.

The automotive part may be a panel in the interior of the cabin of an automobile. Similarly to the waterfall area of the upholstery, some internal panels are low wear areas and thus are particularly suitable for embellishment with hand embroidery.

The three dimensional object may be a core for forming seat piping. Thus shaping the embroidered two dimensional leather into a three dimensional form may comprise forming the leather into a roll.

In addition, at least one end of the rolled embroidered leather may be secured from unravelling by applying a cap on or over the end, preferably both ends may be secured in this or an equivalent manner. Securing the piping in this way has the advantage of preventing damage to the more delicate ends of the piping. The cap can be on the end of the piping and or extend around the end of the piping. In addition, caps can have eyes, clips or other means for fixing the piping to seats or other areas of the car interior.

Examples and Description of the Drawings

The invention is now illustrated in the following specific embodiments with reference to the accompanying drawings showing:-8Fig. 1 Photographs of the process of hand embroidering pre-perforated leather with views from the front and back of the leather showing: (A) stitches applied by hand; (B)-(E) examples of embroidery.

Fig. 2 Detail of the front and back of the embroidered perforated leather rolled into the form of piping. (A) and (B) show different examples of stitching in the rolled leather.

Fig. 3 Embroidered leather piping. (A) and (B) show different examples of stitching in the leather piping. (C) shows a further different stitching example and a cap covering the end of the piping.

Fig. 4 Embroidered leather used to upholster the “waterfall” area of a car seat and arrangement of the embroidery thereon. (A) shows an example of the whole waterfall seating component. (B) and (C) show detail of the stitching on the waterfall component.

Example 1

Leather piping for application to seat upholstery in automobiles is made by hand embroidering leather pre-perforated with an array of regularly spaced perforations (holes) wherein the regularly spaced holes define the vertices of an array of squares. The pre-perforated leather used is obtained from HEWA with the pre-perforated holes in the leather located 5mm apart in a square grid. The leather for the piping is cut to size prior to being embroidered. The first embroidery process is illustrated in Fig. 1.

The embroidered leather is then rolled (as illustrated in Fig. 2) to form a piece of piping. During the rolling process the embroidery stitches on the front of the piece of embroidery are placed under tension transverse to the direction of rolling. The outer surface of the leather is similarly placed under tension during the rolling process. These tension forces are distributed more evenly by the regularly spaced array of holes in the leather so as to maintain the overall proportions of the array of regularly spaced holes and thus the overall proportions of the embroidery design that has been produced by the passage of thread travelling through the holes of the array.

-9The rolled form of the piping is secured by the stitching along the length of the scene of the piping. Examples of the completed rolled form of the piping are shown in Figs 3A and 3B.

The completed piping is further secured by covering the ends of the piping with caps. This is shown in Fig. 3C.

Example 2

Embroidered leather for mounting on, and thereby upholstering, the waterfall area of an automobile seat is made by hand embroidering leather pre-perforated with an array of regularly spaced perforations (holes) wherein the regularly spaced holes define the vertices of an array of squares. This first embroidery process is illustrated in Fig. 1.

The embroidered leather is mounted waterfall component of the automobile seat in order to upholster it. This is done by draping the leather embroidery piece over the waterfall component, placing the leather embroidery piece under tension as necessary to ensure a correct fit without wrinkles, and securing the embroidery piece in place by attaching it to the rear of the waterfall component (not shown in Fig. 4) using metal staples.

During the process of upholstering the waterfall seat component, the leather and the embroidery stitches of the piece of leather embroidery are placed under tension. These tension forces are distributed more evenly by the regularly spaced array of holes in the leather. Thus the piece of leather embroidery can be tensioned so that the lines of the array of regularly spaced holes are arranged to follow the contours of the seat component while also maintaining the overall proportions of the array of holes and thus the overall proportions of the embroidery design that has been produced by the passage of thread travelling through the holes of the array.

Fig. 4 shows a completed automobile waterfall component upholstered with a piece of leather embroidery as described above and mounted on the waterfall component wherein the design and regularly spaced array of holes, and thus the embroidery design, follows the contours of the waterfall component.

- 10The invention thus provides improved methods for producing embroidered leather products and the products made according to these methods.

Claims

1. A method for shaping a substantially two dimensional piece of embroidered leather into a non-planar three dimensional form, wherein the leather has front and rear sides and wherein the leather is preperforated by an array of regularly spaced holes through the leather from the front to the rear side; and wherein the method comprises the steps of:

forming an embroidered design in the pre-perforated leather by passing a filament through a multiplicity of the holes in the leather; and shaping the embroidered two dimensional leather to have a non-planar three dimensional form wherein the shaping process comprises stretching and/or bending the embroidered leather in one or more dimensions.

2. A method according to claim 1, wherein the two dimensional embroidered leather is applied to or shaped around a three dimensional object.

3. A method according to claim 2, wherein the lines of the pre-perforated array of regularly spaced holes of the embroidered leather applied to or shaped around the three dimensional object follow the contours or edges of the object.

4. A method according to any preceding claim, wherein the regularly spaced holes define the vertices of an array of polygons.

5. A method according to any preceding claim, wherein the regularly spaced holes define the vertices of an array of rectangles.

6. A method according to any of claims 1—4, wherein the regularly spaced holes define the vertices of an array of triangles.

7. A method according to any preceding claim, wherein the regularly spaced holes define the vertices of an array of regular polygons.

8. A method according to claim 7, wherein the regularly spaced holes define the vertices of an array of squares.

9. A method according to claim 7, wherein the regularly spaced holes define the vertices of an array of equilateral triangles.

10. A method according to any preceding claim, wherein the filament is a thread.

11. A method according to any preceding claim, wherein the embroidered design is partially or completely sewn by hand.

12. A method according to any preceding claim, wherein at least one dimensional proportion of the embroidered design on the two dimensional embroidered leather is maintained following shaping the embroidered two dimensional leather to have a non-planar three dimensional form.

13. A method according to any preceding claim wherein shaping the embroidered two dimensional leather to have a three dimensional form comprises stretching the leather in at least one dimension.

14. A method according to any preceding claim wherein shaping the embroidered two dimensional leather to have a three dimensional form comprises stretching the leather in two dimensions.

15. A method according to any preceding claim, wherein at least two dimensional proportions of the embroidered design on the two dimensional embroidered leather are maintained following shaping the embroidered two dimensional leather to have a non-planar three dimensional form.

16. A method according to any of claims 2 to 15, wherein the three dimensional object is an automotive part.

17. A method according to any of claims 2 to 16, wherein the three dimensional object is a structure within the cabin of an automobile.

18. A method according to any of claims 2 to 17, wherein the three dimensional object is a seat.

19. A method according to any of claims 2 to 18, wherein the three dimensional object is the waterfall area of the seat of an automobile.

20. A method according to any of claims 2 to 16, wherein the three dimensional object is a panel in the interior of the cabin of an automobile.

21. A method according to any of claims 2 to 18, wherein the three dimensional object is a core for forming seat piping.

22. A method according to claim 21, wherein shaping the embroidered two dimensional leather into a three dimensional form comprises forming the leather into a roll.

23. A method according to claim 22, wherein the at least one end of the rolled embroidered leather is secured from unravelling by applying a cap on or over the end, preferably both ends are so secured.

24. An embroidered leather product having a non-planar three-dimensional form produced according to the method of any preceding claim.

25. An embroidered leather product mounted in a vehicle having a non-planar threedimensional form, wherein the leather has front and rear sides and wherein the leather is preperforated by an array of regularly spaced holes through the leather from the front to the rear side;

26. An embroidered leather product according to claim 25, wherein the lines of the pre-perforated array of regularly spaced holes of the embroidered leather follow the contours or edges of the vehicle component the embroidered leather is mounted on.

27. An embroidered leather product according to either of claims 25 or 26, wherein the regularly spaced holes define the vertices of an array of polygons.

28. An embroidered leather product according to any of claims 25-27, wherein the regularly spaced holes define the vertices of an array of rectangles.

29. An embroidered leather product according to any of claims 25-27, wherein the regularly spaced holes define the vertices of an array of triangles.

30. An embroidered leather product according to any of claims 25-29, wherein the regularly spaced holes define the vertices of an array of regular polygons.

31. An embroidered leather product according to claim 30, wherein the regularly spaced holes define the vertices of an array of squares.

32. An embroidered leather product according to claim 30, wherein the regularly spaced holes define the vertices of an array of equilateral triangles.

33. An embroidered leather product according to any of claims 25-32, wherein the filament is a thread.

34. An embroidered leather product according to any of claims 25-32, wherein the embroidered leather is bent into a roll.

35. An embroidered leather product according to claim 34, wherein at least one end of the roll are secured from unravelling by a cap, preferably both ends are so secured.

36. An embroidered leather product according to any of claims 25-35, wherein the embroidered leather is under tension in two-dimensions.

37. An embroidered leather product according to any of claims 25-36, wherein the three-dimensional form of the embroidered leather product is provided by being mounted on or to a three-dimensional object.

38. An embroidered leather product according to claim 37, wherein the three dimensional object is a structure within the cabin of the vehicle.

39. An embroidered leather product according to either of claims 37 or 38, wherein the three dimensional object is a seat.

40. An embroidered leather product according to claim 39, wherein the three dimensional object is the waterfall area of the seat of an automobile.

41. An embroidered leather product according to either of claims 37 or 38, wherein the three dimensional object is a panel in the interior of the cabin of the vehicle.

42. An embroidered leather product according to any of claims 25-41, wherein the vehicle is an automobile.