Classifications

• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
  • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
  • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
  • D06M15/37—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
  • D06M15/564—Polyureas, polyurethanes or other polymers having ureide or urethane links; Precondensation products forming them
• • D—TEXTILES; PAPER
  • D05—SEWING; EMBROIDERING; TUFTING
  • D05C—EMBROIDERING; TUFTING
  • D05C13/00—Auxiliary devices incorporated in embroidering machines, not otherwise provided for; Ancillary apparatus for use with embroidering machines
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
  • D06N3/12—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins
  • D06N3/14—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins with polyurethanes
• • D—TEXTILES; PAPER
  • D05—SEWING; EMBROIDERING; TUFTING
  • D05C—EMBROIDERING; TUFTING
  • D05C17/00—Embroidered or tufted products; Base fabrics specially adapted for embroidered work; Inserts for producing surface irregularities in embroidered products
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
  • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
  • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
  • D06M15/21—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
  • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
  • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
  • D06M15/37—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
  • D06M15/507—Polyesters
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
  • D06N3/0086—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique
  • D06N3/0088—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique by directly applying the resin
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
  • D06N3/04—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
  • D06N3/045—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds with polyolefin or polystyrene (co-)polymers
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
  • D06N3/12—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins
  • D06N3/121—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins with polyesters, polycarbonates, alkyds
  • D06N3/123—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins with polyesters, polycarbonates, alkyds with polyesters

Definitions

• Embroidery is the craft of decorating fabric or other materials using a needle to apply thread or yarn. Embroidery may also incorporate other materials such as pearls, beads, quills, and sequins. In modern days, embroidery is usually seen on caps, hats, coats, blankets, dress shirts, denim, dresses, stockings, and golf shirts. Embroidery is available with a wide variety of thread or yarn color and can include 3D designs which have exaggerated thicknesses.
• Embroidery often requires a stabilizer (also called a backing) to provide support for the thread so that the design does not pucker or bunch up.
• a stabilizer is often used when embroidery is performed on soft, pliable fabrics such as cotton, wool, lace, polyester, and the like.
• a sheet of stabilizer and the fabric are hooped together (e.g., using a hooping frame) while embroidery is performed to create a design (e.g., text, picture, logo, etc.) on the exterior surface of the garment.
• the portion of the stabilizer which is disposed on an interior side of the garment and not directly behind the embroidery, can be cut off.
• the stabilizer or backing material is typically made of non-woven material of varying thickness or other type of non- woven fabric which provides structural support for fabric and the corresponding embroidered design based on the type and thickness of the fabric being embroidered, the embroidery design including the number of stitches per inch required to create the embroidery and the properties of stabilizer material.
• the stabilizer comes in direct contact with the skin of the person wearing the garment it can be an irritant.
• the stabilizer itself is expensive and the excess portion must typically be removed by a human, further driving up costs of embroidery.
• removing excess stabilizer backing must be performed manually by a labor intensive and therefore expensive process.
• One embodiment described herein is an article that includes fabric, a stabilizer coating disposed on the fabric, and an embroidery design disposed on the fabric and within an area defined by the stabilizer coating.
• Another embodiment described herein is a method that includes providing an article, applying a stabilizer coating onto the article, tensioning the article, and performing embroidery on the tensioned article in an area of the stabilizer coating.
• Another embodiment described herein is a method that includes applying a stabilizer coating onto an article by changing a viscosity of the stabilizer coating and performing embroidery on the article in an area of the stabilizer coating.
• Figure 1 illustrates an embroidery process, according to one embodiment.
• Figure 2 illustrates a stabilizer coating used in an embroidery process, according to one embodiment.
• FIG. 3 is a flowchart for an embroidery process, according to one embodiment.
• Figure 4 is a flowchart for applying a stabilizer coating for an embroidery process, according to one embodiment.
• Figure 5 is a flowchart for applying a stabilizer coating for an embroidery process, according to one embodiment.
• Figure 6 is a flowchart for a 3D embroidery process, according to one embodiment.
• the embodiments herein describe using a stabilizer coating rather than a typical paper or fabric backing for an embroidery process.
• the stabilizer coating can be applied on either an exterior or interior side of the garment, unlike typical backing material that for aesthetic reasons is always disposed on an interior side of the garment.
• the stabilizer coating can be applied using a variety of different techniques such as being sprayed, rolled, printed, brushed, or melted onto the garment.
• the stabilizer coating is any coating that can provide sufficient structural backing for embroidery where a viscosity of the coating was changed during its application to the garment.
• the stabilizer coating e.g., a pre-polymer
• a thin film thermoplastic polymer material may be placed on the garment and then heated such that the polymer material melts, adheres to the garment, and then solidifies to form the stabilizer coating.
• the area or boundary of the stabilizer coating matches (or is slightly larger) than the area or boundary of the embroidery design.
• the coating may be clear, because the design covers the stabilizer coating, the coating can have a color and still be disposed on an exterior surface of the garment without being noticed (i.e., without having a negative impact on the aesthetics of the garment). Further, disposing the stabilizer coating on the exterior surface ensures the coating does not irritate the skin of the person wearing the garment due to jagged or rough edges.
• placing the coating on the same side of the garment as the embroidery can simplify the manufacturing process since backing does not need to be placed on a first side of the garment (e.g., the interior side) while the embroidery is formed on the second, opposite side of the garment (e.g., the exterior side).
• a stabilizer coating on a garment e.g., a piece of clothing
• the embodiments herein can be performed using various “articles” which can include, but are not limited to, a piece of clothing (e.g. shirts, pants, socks, shoes, shorts, coats, jackets, skirts, dresses, underwear, hats, headbands, etc.), accessories (e.g. wallet, purse, etc.), and homewares (e.g. towels, pillow cases, blankets, mats, etc.).
• a piece of clothing e.g. shirts, pants, socks, shoes, shorts, coats, jackets, skirts, dresses, underwear, hats, headbands, etc.
• accessories e.g. wallet, purse, etc.
• homewares e.g. towels, pillow cases, blankets, mats, etc.
• FIG. 1 illustrates an embroidery process 100, according to one embodiment.
• the embroidery process 100 includes an application stage 105, curing stage 110, and embroidery stage 115.
• the application stage 105 includes a stabilizer dispenser 120 that places the material of the stabilizer coating onto a designated area 130 of the garment 125.
• the stabilizer coating is applied while the garment 125 is under tension.
• the stabilizer coating is applied when the garment 125 is not tensioned.
• the garment 125 can be tensioned before embroidery is performed.
• an area 130 of the garment 125 on which the stabilizer component is to be applied may be stretched using a hoop (e.g., a hooping frame).
• the garment 125 is placed on a platen.
• the garment may be placed on, and stretched by, a surface of the platen, or the paten may be placed within the garment and then stretched.
• the stabilizer dispenser 120 is not limited to any particular technique for applying the stabilizer coating to the garment 125.
• the stabilizer coating is applied in a liquid state (with a relatively low viscosity).
• the stabilizer dispenser 120 can spray, roll, brush, or otherwise apply the material of the stabilizer coating onto the garment 125.
• the stabilizer coating may be a pre-polymer such as silicone or elastomeric polyurethane, polyester, or polyethylene.
• the stabilizer coating polymerizes into a silicone elastomer film with physical characteristics similar to that of, e.g., DOWSILTM 734 self-leveling sealant.
• the stabilizer coating may also polymerize into a foam with the help of blowing agents such as expandable hollow spheres (e.g. Nouryon Expancel®) or isocyanate and water after being applied to the garment 125.
• the stabilizer dispenser 120 may apply a hot melt polymer such as a molten fibrous material (e.g., polypropylene, polyester, or polyethylene) that is ejected at high speed onto the area 130 to form the stabilizer coating.
• the stabilizer may be 3D printed, on demand, localized to the area and shape, over printed graphics to create varying thickness layers for a high-fidelity embroidery embellishment that is capable of creating very high quality artwork that cannot be recreated using existing technology.
• the stabilizer dispenser 120 applies the material of the stabilizer coating in a solid state.
• the same design is applied to many garments (e.g., a large order of 100 or more of the same design)
• the cutout portions can then be placed at the areas 130 of the garment.
• a heating process can then be used to melt the material (and reduce its viscosity) and form the stabilizer coating on the garment 125.
• the stabilizer coating is selected according to its elasticity.
• the stabilizer coating has a Young’s modulus between 0.5 to 2000MPa to provide stability during embroidering and provide durability when the garment is worn and goes through wash cycles.
• the stabilizer coating can be stretched or elongated by more than 200% before breaking or losing its structural integrity.
• the stabilizer coating may include an adhesive that helps the stabilizer stick or adhere to the garment when in a state with low viscosity.
• the stabilizer coating can then be dried or cured to adhere to the garment.
• the material of the stabilizer coating may be selected based on the garment 125 on which it is to be applied.
• one type of stabilizer coating may be used on organic fabrics (e.g., cotton) and a different type of stabilizer coating may be used on synthetic fabrics (e.g., polyester, nylon, spandex, etc.).
• stabilizer coatings applied as a hot melt may lead to poor results when applied on organic fabrics while providing good results when applied on synthetic fabrics.
• materials that rely on reactive chemistry (e.g., polyurethane) to form the stabilizer coatings may be better for organic fabrics.
• the curing stage 110 can be used to change the phase or the viscosity and elasticity of the stabilizer coating 140 so that it adheres to the garment 125.
• a heater 135 can dry or cure the coating 140 into a solid state (or relatively low viscosity and high elasticity).
• the heater 135 can be replaced by a fan or air circulation device for curing the stabilizer coating 140.
• this change in phase or viscosity can be a physical process or a chemical reaction.
• radiation or light of a certain wavelength may be used to cure the stabilizer.
• the stabilizer is applied to the article and humidity cured at room temperature over a specific time.
• the heater 135 may melt, rather than cure, the stabilizer coating 140 so its viscosity changes and adheres to the garment 125.
• the curing stage 110 can be used as a both a heating and drying stage to melt the stabilizer coating 140 before then drying the coating 140 so it adheres to the garment 125.
• an embroidery apparatus 145 uses a head 150 (e.g., a sewing head) to form an embroidery design 155 (e.g., text, logo, image, etc.) in the area 130 on which the stabilizer coating 140 was formed.
• a head 150 e.g., a sewing head
• an embroidery design 155 e.g., text, logo, image, etc.
• the embroidery apparatus 145 can include any number of heads 150 and use any different colors of thread or yarn in order to generate the design 155.
• the garment 125 is held in a fixed position while the head 150 moves in X and Y directions to form the design 155.
• the head 150 remains stationary while the garment 125 is moved in the X and Y directions.
• both the head 150 and the garment moves.
• the garment 125 may be moved in the X direction while the head 150 moves in the Y direction when performing the embroidery.
• the design 155 is a 3D embroidery where the stabilizer coating 140 provides a defined height or height profile across the design 155.
• a 3D embroidery process may use a thicker stabilizer coating 140 to provide a desired height for the design 155 relative a 2D embroidery process where the thickness of the stabilizer coating 140 may have a de minimis effect on the thickness or height of the design 155.
• the stabilizer coating surface is non flat and renders a 3D topology. The flexibility provided by the application of the types of stabilizer coatings described herein enables the creation of more complex and previously difficult to achieve 3D embroidery designs.
• Figure 2 is a stabilizer coating 210 used in an embroidery process, according to one embodiment.
• Figure 2 illustrates a portion of a garment 200 that is stretched by a hoop 205 (e.g., a hooping frame) that tensions the garment 200 within the hoop 205. While a hoop 205 is used in Figure 2, in other embodiments the tension may be applied by a platen or some other tensioning apparatus.
• a hoop 205 e.g., a hooping frame
• Applying tension helps to ensure the stabilizer coating 210 and the design 215 are applied on a flat surface without any wrinkles or sagging.
• the coating 210 and the design 215 are applied on the same surface of the garment 200. This may help with manufacturing since the stabilizer dispenser 120 and the embroidery apparatus 145 in Figure 1 can operate on the same side of the garment 200 which avoids having to flip over the garment during the embroidery process.
• the stabilizer coating 210 has a boundary (shown by the dotted lines) that substantially matches a shape of the design 215.
• the area occupied by the design 215 may substantially match the area occupied by the stabilizer coating 210 on the garment 200.
• substantially match means the boundaries of the stabilizer coating and the design 215 may be less than a few (e.g., five) millimeters apart at corresponding locations. In one embodiment, it may be desired to ensure that the boundary or area of the stabilizer coating 210 is slightly expanded or larger (e.g., 1-7 millimeters) than the boundary or area of the design 215 which may provide extra support to the design 215.
• the stabilizer coating 210 may not be completely covered by the thread of the design 215, the coating 210 may still not be viewable (or easily viewable) on the surface of the garment 200.
• the stabilizer coating 210 is selected to have the same color as the garment 200 so it is less visible.
• the stabilizer coating 210 is selected to have a different color from the garment 200 or the thread for contrast enhancement to the garment color or the embroidery threads for rich, artistic, embroidery artworks.
• the stabilizer coating 210 may be disposed on the opposite side of the garment 200 than the design 215 so there are no restrictions on the area of the stabilizer coating 210.
• the stabilizer coating 210 can be made to size without affecting the person wearing the garment 200.
• the stabilizer coating 210 can also be applied with one or more holes (i.e. , an absence of the stabilizer material) within the boundary of the coating 210 to match the design of the embroidered art (if it does not have thread at that area of the design). With a traditional stabilizer, it’s impractical to trim or tear away stabilizer material behind unembroidered areas that are inside the perimeter of the embroidered art when there are holes in the art design.
• FIG. 3 is a flowchart of a method 300 for an embroidery process, according to one embodiment.
• a tensioning apparatus tensions the garment.
• the tensioning apparatus can be a hoop, hooping frame, platen, or wire frame. Further, the tensioning apparatus can tension the entire garment, or just a portion of the garment on which the stabilizer coating and the embroidery design are to be applied.
• a stabilizer dispenser applies a stabilizer coating onto the garment.
• a stabilizer coating onto the garment.
• various different techniques for applying the stabilizer coating are described in detail in the flowcharts in Figures 4-6.
• applying the stabilizer coating includes changing the viscosity of the material of the stabilizer coating.
• the stabilizer coating may be changed from having a low viscosity to a high viscosity, which can result in the stabilizer coating having a liquid (or molten) state to having a solid state.
• Changing the viscosity of the stabilizer coating can permit it to adhere or attach to the garment. That is, when changing from low to high viscosity, the stabilizer coating may adhere to the garment to form a solid film that provides the necessary support for performing the embroidery process.
• the stabilizer may be aerosolized and may be applied in the form of a spray.
• the stabilizer is applied on the front side garment in such conditions to allow the stabilizer material to flow, diffuse around the fibers to encapsulate the fibers, diffuse into the fabric layer, with controlled thickness, and once properly cured, structurally adheres to the fibers of the fabric(s) forming the garment without chemically bonding to the fibers.
• the stabilizer coating is applied to the garment before applying any tension to the garment. That is, the stabilizer coating is applied while the garment is not under tension. In one embodiment, the stabilizer coating is applied and cured before the garment is tensioned in preparation of the embroidery process. In another embodiment, the stabilizer coating is applied but then tensioned before being cured. However, in some embodiments such as method 300, the stabilizer coating is applied to the garment and is cured after placing the garment under some tension. In some embodiments, the amount of tension applied to the garment may be adjusted based on a variety of factors, including the fabric thickness or weight, the type of fabric, the embroidery design including the design requirements as to the number of stitches per inch, etc.
• an embroidery apparatus performs embroidery in the area of the stabilizer coating.
• block 315 is performed after the stabilizer coating has been cured or dried such that it is in a solid state (e.g., a high viscosity).
• the embodiments herein are not limited to any particular type of embroidery apparatus or type of embroidery. That is, the stabilizer coating can be used in a variety of different embroidery processes and with a variety of different embroidery apparatuses.
• the embroidery design can be 2D or 3D, where the stabilizer component can set the thickness, height, or height profile of the design.
• the application of the stabilizer coating and the embroidery may be performed on the same side of the garment or on opposite sides.
• the shape and size of the stabilizer coating may be controlled to be substantially the same (or slightly larger) than the design so the coating (which may have a shiny appearance depending on the material chosen) is not readily visible.
• the area of the stabilizer coating may be less of a concern, but a non irritant material may be selected to ensure the coating does not irritate the wearer’s skin, which may not be a concern when the coating is applied on the exterior surface of the garment.
• Figure 4 is a flowchart of a method 400 for applying a stabilizer coating for an embroidery process, according to one embodiment.
• the method 400 is one example of applying a stabilizer coating onto a garment as described at block 310 of Figure 3.
• the garment has already been tensioned, but this is not a requirement.
• the stabilizer dispenser applies the stabilizer coating onto the garment in a liquid state.
• the liquid state has a lower viscosity than a solid state obtained after the stabilizer coating has been dried or cured.
• the stabilizer coating can be applied by spraying, printing, brushing, or ejecting the coating material onto the garment. Further, the liquid may be applied as a foam or applied in a liquid and expands into a foam.
• the heater cures the stabilizer coating to convert it into a solid state. Further, curing the stabilizer can cause the material of the stabilizer coating to adhere to the garment to provide suitable support for the embroidery design. In one embodiment, curing the stabilizer changes the viscosity of the material so that the stabilizer coating is in a solid state.
• the curing can be performed by applying heat, increased airflow, light (e.g., ultraviolet light), combining two reactive components of a reactive chemistry, and the like. That is, curing can be performed by any process that changes the stabilizer coating from a liquid to a solid state. Curing can be a chemical or a physical process.
• the method 400 can proceed to block 315 where the embroidery design is applied in the same area of the stabilizer coating.
• the stabilizer may need not be cured or may be partially cured before the embroidery operation is performed
• Figure 5 is a flowchart of a method 500 for applying a stabilizer coating for an embroidery process, according to one embodiment.
• the method 500 is another example of applying a stabilizer coating onto a garment as described at block 310 of Figure 3.
• the garment has already been tensioned, but this is not a requirement
• a cutting apparatus provides a thin film having a shape of a desired embroidery design.
• the thin film may be provided in a rolled up sheet of material for the stabilizer component.
• the sheet can be unrolled so that the cutting apparatus can cutout portions from the sheet that have shapes that substantially match (or are slightly larger) than the embroidery design.
• This may be especially useful in a high-volume embroidery process where the same embroidery design (e.g., the same text, logo, or image) is being formed on a large number of garments.
• the stabilizer in high-volume embroidery operations, may be directly pre-applied and cured onto the garment to be embroidered to increase processing speed by pre-applying and pre-curing the stabilizer.
• the cutouts can have substantially the same boundary and size as the boundary and size of the text as shown in Figure 2 above. In this manner, a large sheet of stabilizer material can be cut up into smaller portions that substantially match the shape and size of the desired embroidery design.
• the stabilizer dispenser places the thin film (e.g., the cutout portions) on the garments.
• the thin film may be held on the garments by gravity (e.g., simply placed on top of the garment where the embroidery is to take place), or the stabilizer dispenser may attach the thin film using a temporary attachment technique.
• the thin film may have an adhesive on one side so that the film sticks to the garment.
• the stabilizer dispenser may use pins to hold the thin film in place on the garment.
• the material of the stabilizer component is initially placed on the garment in a solid state, rather than a liquid state.
• the heater heats the thin film to form a stabilizer coating adhered to the garment. Stated differently, the heater lowers the viscosity of the thin film so it is permanently adhered to the garment. This can include changing the thin film from a solid state to a liquid or molten state. Further, the heating process can cause a physical change or a chemical reaction in the thin film.
• the stabilizer coating is cooled so the viscosity increases again.
• the stabilizer coating may have a solid state once cooled.
• the stabilizer coating is permanently adhered to the garment and forms a suitable substrate for forming the embroidery design on the garment.
• the method 500 can proceed to block 315 where the embroidery design is applied in the same area of the stabilizer coating.
• FIG. 6 is a flowchart of a method 600 for a 3D embroidery process, according to one embodiment.
• a 3D embroidery process is performed by using a mold or substrate that is placed on the same surface on which the embroidery is performed. A backing material may still be placed on the opposite side of the surface to provide additional support.
• the embroidery design is then formed on the mold or substrate whose thickness gives the embroidery design its depth or height.
• the stabilizer coating can be used to perform both functions - i.e. , to provide thickness so the design becomes 3D, as well as provide sufficient support for the design.
• a designer determines a desired height of the 3D embroidery design. That is, in addition to selecting the color of the thread, the size of the design, etc., the designer can also indicate the thickness or height of the design on the garment (e.g., how far the design sticks out from the exterior surface of the garment).
• the stabilizer dispenser determines the appropriate thickness of the stabilizer coating to achieve the desired height of the 3D design. That is, the stabilizer dispenser determines how thick the stabilizer coating should be in order to result in a 3D design with the desired height. In some embodiments, by closely adjusting the amount of stabilizer dispensed in any given location, thereby producing a 3D height profile as the foundation for the embroidered art, complex 3D designs may be formed that are not possible with traditional 3D methods.
• the stabilizer dispenser applies a stabilizer coating with the desired thickness at the location for the 3D design.
• the stabilizer dispenser may perform multiple coats of the stabilizer coating (curing each coat) to build up a stabilizer coating with the desired thickness.
• the stabilizer dispenser applies just one, thick coat of the stabilizer material (e.g., as a foam or gel) which has a sufficient thickness.
• the method 600 can proceed to block 315 where the embroidery design is applied in the same area of the stabilizer coating.
• embodiments described herein may be embodied as a system, method or computer program product. Accordingly, embodiments may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, etc.) or an embodiment combining software and hardware aspects that may all generally be referred to herein as a “circuit,” “module” or “system.” Furthermore, embodiments described herein may take the form of a computer program product embodied in one or more computer readable medium(s) having computer readable program code embodied thereon.
• Program code embodied on a computer readable medium may be transmitted using any appropriate medium, including but not limited to wireless, wireline, optical fiber cable, RF, etc., or any suitable combination of the foregoing.
• Computer program code for carrying out operations for embodiments of the present disclosure may be written in any combination of one or more programming languages, including an object oriented programming language such as Java, Smalltalk, C++ or the like and conventional procedural programming languages, such as the "C" programming language or similar programming languages.
• the program code may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server.
• the remote computer may be connected to the user's computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider).
• LAN local area network
• WAN wide area network
• Internet Service Provider for example, AT&T, MCI, Sprint, EarthLink, MSN, GTE, etc.
• These computer program instructions may also be stored in a computer readable medium that can direct a computer, other programmable data processing apparatus, or other device to function in a particular manner, such that the instructions stored in the computer readable medium produce an article of manufacture including instructions which implement the function/act specified in the block(s) of the flowchart illustrations or block diagrams.
• the computer program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other device to cause a series of operational steps to be performed on the computer, other programmable apparatus or other device to produce a computer implemented process such that the instructions which execute on the computer, other programmable data processing apparatus, or other device provide processes for implementing the functions/acts specified in the block(s) of the flowchart illustrations or block diagrams.
• the flowchart illustrations and block diagrams in the Figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various embodiments of the present disclosure.
• each block in the flowchart illustrations or block diagrams may represent a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function(s).
• the functions noted in the block may occur out of the order noted in the Figures.
• two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order or out of order, depending upon the functionality involved.
• each block of the block diagrams or flowchart illustrations, and combinations of blocks in the block diagrams or flowchart illustrations can be implemented by special purpose hardware-based systems that perform the specified functions or acts, or combinations of special purpose hardware and computer instructions.

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• 2021
  • 2021-06-30 US US17/364,666 patent/US20230002966A1/en not_active Abandoned
• 2022
  • 2022-06-29 IL IL294396A patent/IL294396A/en unknown
  • 2022-06-29 KR KR1020220080050A patent/KR20230004332A/ko not_active Application Discontinuation
  • 2022-06-30 FR FR2206618A patent/FR3124807A1/fr not_active Withdrawn
  • 2022-06-30 CN CN202210773078.1A patent/CN115538058A/zh active Pending
  • 2022-06-30 WO PCT/US2022/073312 patent/WO2023279063A1/en unknown
  • 2022-06-30 DE DE102022002379.2A patent/DE102022002379A1/de not_active Ceased
  • 2022-06-30 JP JP2022106072A patent/JP2023008960A/ja active Pending

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