Methods of embroidery, and products so made

Abstract

New methods of providing embroidered indicia on patches which are mounted to articles of manufacture. After the patch is mounted to a substrate which is a functional element of the article of manufacture, the patch is embroidered to provide the embroidered indicia. Embroidering on the patch after the patch is mounted to the substrate passes the embroidering threads through both the patch and the substrate, such that the embroidery threads provide at least supplemental, optionally primary, attachment of the patch to the substrate. The substrate, thus the corresponding product, can be, without limitation, a piece of wearing apparel, namely a garment. Any product which is susceptible of receiving an embroidered patch is susceptible of benefiting from the methods of the invention, along with the corresponding resultant inventive products.

Description

BACKGROUND

This invention relates to embroidered garments and other wearing apparel. Such garments and other wearing apparel, hereinafter collectively referred to as garments, include for example and without limitation, shirts, T-shirts, sweat shirts, caps, shop shirts or work shirts (hereinafter referred to as work shirts), bowling shirts, jackets, pants, and the like.

Embroidered garments have become increasingly common, and increasingly more popular. Demand for embroidered garments has resulted in introduction of a wide variety of embroidered products. Such products include those where embroidered indicia are defined directly on the garment as well as those where the embroidered indicia are defined on a patch which is attached to or affixed to the garment.

Specifically, this invention relates to embroidered garments wherein the embroidered indicia are defined on a patch, or patches, which is/are applied to the garment.

It is known to apply embroidery indicia to a patch, and to subsequently affix the patch to the garment. The patch may be affixed by stitching about the outer perimeter of the patch, or may be attached by adhesive on a surface of the patch or garment between the patch and the garment, or both.

SUMMARY

This invention provides new methods of providing embroidered indicia on garments and other articles of manufacture where a patch is used as a carrier of the embroidered indicia. The patch is mounted to a substrate which is a functional element of the article of manufacture, and is subsequently embroidered to provide the embroidered indicia. The embroidering on the patch which occurs after the patch is mounted to the substrate passes the embroidering threads through both the patch and the substrate, such that the embroidery threads provide at least supplemental attachment, and in some embodiments primary attachment, of the patch to the substrate. In some embodiments, the substrate, and thus the corresponding product, is a piece of wearing apparel, namely a garment. In other embodiments, the substrate embodies some or all of a non-garment product, such as a decorative pillow, a cushion, a blanket, or other household product. Any product which is susceptible of receiving an embroidered patch is susceptible of benefiting from the methods of the invention, along with the corresponding resultant inventive products.

In a first family of embodiments, the invention comprehends, in combination, a patch, and a garment to which the patch is mounted. The patch comprises a first outer surface facing away from the garment, a first inner surface facing toward the garment, a perimeter which defines an outer edge of the patch, and an outer edge region disposed proximate the outer edge of the patch. The garment has a second outer surface facing away from the garment, including toward the patch, and a second inner surface facing inwardly, toward a body of a wearer of the garment. The combination of the garment and the patch comprises embroidered indicia on the outer surface of the patch. Threads defining the embroidered indicia extend through both the patch and the garment.

In some embodiments, the combination further comprises a layer of adhesive between the patch and the garment. The threads defining the embroidered indicia further extend through the layer of adhesive.

In some embodiments, the layer of adhesive comprises heat seal adhesive, bonding the patch to the garment.

In other embodiments, the layer of adhesive comprises contact adhesive bonding the patch to the garment.

In still other embodiments, the layer of adhesive comprises a first layer of heat seal adhesive and a second layer of contact adhesive.

In some embodiments, the embroidered indicia is confined inwardly of the edge region of the patch.

In other embodiments, the embroidered indicia extends into the edge region of the patch.

In some embodiments, the embroidered indicia covers the entirety of the outer surface of the patch, including in the edge region.

In some embodiments, the embroidered indicia is predominantly informational in nature, for example letters, numbers, words, or the like.

In other embodiments, the embroidered indicia is predominantly artistic in nature, for example natural or fanciful designs, objects, or the like.

In still other embodiments, the embroidered indicia is a generally balanced combination of informational and artistic elements.

In some embodiments, the combination further comprises stitching, either sewing stitches or embroidery stitches, about the outer edge of the patch, as supplemental securement of the outer edge of the patch to the garment.

In some embodiments the combination comprises a cut-out aperture in the patch material, disposed inwardly of the outer edge of the patch, and a second edge region about the cut-out aperture, wherein the embroidered indicia may or may not be displaced from the second edge region.

In some embodiments, the patch is so affixed to the garment by the embroidered indicia that the patch cannot be removed from the garment without damaging a substantial portion of the embroidered indicia on the patch.

In a second family of embodiments, the invention comprehends a method of mounting a patch to a garment. The method comprises, from a web of patch material, cutting out a patch having a desired outline, the patch having first and second opposing surfaces, and an outer perimeter defining an outer edge of the patch, and a corresponding outer edge region proximate the outer edge; subsequent to cutting out the patch, mounting the patch to the garment; after mounting the patch to the garment, embroidering indicia onto the patch, including extending embroidering threads through both the patch material and through the garment.

In some embodiments, the method further comprises, prior to mounting the patch to the garment, applying a layer of adhesive material to the patch so as to cover substantially the entirety of the first surface of the patch, and activating the adhesive as necessary in the process of mounting the patch to the garment, whereby the adhesive material facilitates the mounting of the patch to the garment.

In some embodiments wherein the layer of adhesive material comprises a layer of hot melt adhesive, the method further comprises heating the hot melt adhesive in the process of mounting the patch to the garment, so as to activate the hot melt adhesive thereby to facilitate the mounting of the patch to the garment, and wherein the extending of the embroidering threads through the patch material and through the garment further comprises extending the embroidering threads through the layer of hot melt adhesive.

In some embodiments, the method includes defining a first portion of the embroidered indicia inwardly of the edge region, and a second portion of the embroidered indicia in the edge region.

In some embodiments, the patch further comprises a cut-out aperture in the patch material, disposed inwardly of the outer edge, and a second edge region about the cut-out aperture, the method further comprising confining the embroidered indicia away from the second edge region.

In some embodiments, the patch is so affixed to the garment by the embroidered indicia thereon, with or without the use of an intervening layer of adhesive, that the patch cannot be removed from the garment without (i) damaging a substantial portion of the embroidered indicia on the patch.

In a third family of embodiments, the invention comprehends a method of creating a garment bearing an embroidered patch, the patch having first and second opposing surfaces, an outer perimeter defining an outer edge, and an edge region proximate the outer edge. The method comprises at least temporarily affixing the patch to the garment; subsequent to at least temporarily affixing the patch to the garment, passing embroidery threads through both the patch and the garment in developing embroidered indicia on the patch.

In some embodiments, the method includes, prior to passing embroidery threads through both the patch and the garment, the at least temporarily affixing of the patch to the garment comprising affixing the patch to the garment using an intervening layer of adhesive, optionally a layer of hot melt adhesive.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a pictorial view of a work shirt embodying informational embroidery indicia of the invention, in the form of a person's name embroidered on a patch, and the patch mounted on the shirt.

FIG. 2 shows an enlarged view of the patch area of the work shirt of FIG. 1, including the embroidered patch.

FIG. 3 shows an enlarged view of a patch area of a garment, including an embroidered patch, as in FIG. 2, but showing the number “8”, embroidered with fanciful graphic e.g. artistic representations.

FIG. 4 shows a cross-sectional view of an embroidered garment/patch combination of the invention and is taken at 4-4 of FIG. 3.

FIG. 5 shows a cross-sectional view of a second embodiment of an embroidered garment/patch combination of the invention.

The invention is not limited in its application to the details of construction or the arrangement of the components set forth in the following description or illustrated in the drawings, such description and drawings being by way of illustration and example only. The invention is capable of other embodiments and/or of being practiced or carried out in various other ways. Also, it is to be understood that the terminology and phraseology employed herein is for purpose of description and illustration and should not be regarded as limiting. Like reference numerals are used to indicate like components.

DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

As used herein, “embroidered indicia” and derivatives thereof mean a pattern or design, such as lettering, or numbering, or wording, or graphics, or stylized elements of lettering, or numbering, or wording or graphics, which may be informational or artistic in nature, using an embroidery machine to apply well-known embroidery stitches and/or stitching techniques, other than at, or in addition to, edge stitching which is commonly applied by a sewing machine.

As used herein, “edge stitching” means stitching at the edge of the patch, without extending such stitching to any other layer to which the patch may ultimately be affixed and which preserves the woven pattern of the patch material in the edge region of the patch by stitching techniques other than embroidery stitching.

Referring to FIG. 1, a work shirt 10 has a front 12, a back 14, and left and right arms 16. A patch 18, bearing the name “BILL” is mounted to the front of the work shirt.

Turning attention now to FIGS. 2 and 4, the patch 18 has an outer surface 20 which faces away from the shirt, and an inner surface 22 which faces toward the shirt. The shirt has a second outer surface 24 which faces away from a body of a person wearing the shirt, a portion of which faces patch 18, and a second inner surface 26 which faces inwardly of the shirt, and toward the body of a person wearing the shirt.

Patch 18 further has an outer perimeter 28 which defines the outer edge 30 of the patch, a corresponding outer edge region 32 proximate the outer edge, and an interior region 34 defined inside edge region 32. Correspondingly, the entirety of the outer surface of the patch consists of the combination of the edge region 32 and the interior region 34.

Edge region 32 includes any portion of the patch adjacent the edge which includes edge stitching 36 which may be used to consolidate or preserve the woven pattern of the patch material at or adjacent the outer edge. The interior region of the patch is the remainder of outer surface 20 which is not occupied by the edge region.

The edge stitching 36 can have a functional feature of preserving the woven pattern of the patch material. Edge stitching 36 can be merely decorative. Edge stitching 36 can be in part functional in preserving the woven pattern and in part decorative. Edge stitching 36 is commonly a simple embroidery satin stitch which progresses in a regular and consistent pattern about the edge of the patch. In the alternative, edge stitching 36 can be any embroidery stitch, or combination of embroidery stitches, in a regular or fanciful pattern, which performs any desired edge function, including consolidating, preserving and/or strengthening structure of the edge region of the patch material, enhancing the appearance of the edge of the patch, or participating in a larger pattern of embroidery indicia which extends inwardly of the edge region, conversely extends outwardly from the interior region to the edge region, including bridging the interior region and the edge region.

In the embodiment of FIGS. 1 and 2, interior region 34, is embroidered with indicia 38 in the form of the word “BILL”, a person's name.

FIG. 3 shows a second enlarged view of a patch of the invention in the form of a number “8”. FIG. 3 illustrates at least two features which are different from the embodiment of FIGS. 1 and 2. First, the embroidered indicia 38 are artistic and fanciful, rather than representing letters or numbers, which are generally considered informational. Stylized letters and numbers can be both informational and artistic. Further, graphic representations can be informational as well as artistic. Second, the configuration of patch 18 includes interior cut-out apertures 40, disposed inward of the outer region, in the interior region of the patch.

As with the edge stitching 36 at outer edge 32, the edges of apertures 40 are optionally stitched with edge stitching, which can be employed for he same reasons as the edge stitching 36 at outer edge 30.

FIG. 4 shows a cross-section of the patch 18 of FIG. 3, minus the edge stitching, and is also well illustrative of the patch of FIGS. 1 and 2. Edge stitching is not shown in FIG. 4 in order to emphasize other features of the figure, and in light of the fact that edge stitching in conventionally-embroidered patches is well known. As seen in FIG. 4, the cross-section includes a first layer 42 of the shirt material, a second layer 44 of the patch material, and an intervening layer 46 of adhesive material between the patch material and the shirt material.

The shirt material can be any shirt material which is known for use in shirts, as well as a wide variety of other materials which can be used in fabricating other types of garments and/or other embroidered products. Thus, there can be mentioned a wide variety of woven and non-woven sheet materials, reticulated and apertured materials which are sufficiently continuous in nature, and sufficiently dimensionally stable, to accept and hold the embroidery threads, and to correspondingly hold a stable representation of the indicia embroidered thereonto. The garment material can, further, be comprised of a plurality of layers, where all the layers can be the same, or can be different materials and/or different structures based on the same material. Thus, the garment material or other substrate can be a multiple layer structure. The layers can be bonded to each other, or not, depending on the properties desired for the particular garment material.

Typical patch material, also well known in the industry, is relatively stiff, and resistant to flexing, compared to typical shirt material or other garment material, and may be, for example and without limitation, a twill, a cotton, a polyester, or felt. The patch material can be, by way of further example, a polymeric film apertured, reticulated, or the like. Thus, the patch material can be a multiple layer structure. The layers can be bonded to each other, or not, depending on the properties desired for the particular patch material.

However, the patch material need not be stiff or resistant to flexing, as a wide variety of backing and other materials are well known for enhancing the stiffness of a patch where enhanced stiffness is desirable. Accordingly, a wide range of patch materials can be used, including but not limited to any material which is otherwise known as being useful in making conventional patches and conventionally-patched garments.

Adhesive 46 can be any adhesive known for use in attaching patches to garments, either temporarily or permanently. As will be seen herein, a temporary affixation is, in some embodiments, all that is required of adhesive 46. In other embodiments, the adhesive desirably is the principle functionary for permanently affixing the patch to the garment.

Adhesive 46 can be a contact adhesive, for example, a pressure-sensitive adhesive. In the alternative, adhesive 46 can be a polymeric hot melt adhesive. The adhesive can be applied in any known manner including spray application, and various other known coating process. The adhesive layer can be either continuous, e.g. a full-surface sheet-like layer, or discontinuous such as spaced dots, or a connected continuous pattern which embodies apertures and/or voids over a substantial portion of the area defined by the pattern, or may be continuous over a first part of the coated surface and discontinuous over a second part of the coated surface.

Exemplary but not limiting of pressure sensitive and/or contact adhesives are acrylic esters, silicone resins, polyurethane dispersions, ethylene vinyl acetate, and rubber solvent blends. Respective ones of the above compositions can be homopolymers or copolymers, as well known in the art.

Exemplary but not limiting of the hot melt adhesives are polyurethanes, polyamides, polyesters, polyethylenes, polyvinyl acetates, polyolefins, polyvinyl chlorides, ethylene-vinyl acetate copolymers, polypropylenes, and blends and other mixtures of the above compositions. Respective ones of the above hot melt compositions can be homopolymers or copolymers, as well known in the art.

The amount of pressure sensitive adhesive applied varies depending on the physical character of the adhesive, the adhesive characteristics of the particular material selected, and the method by which the adhesive is applied.

The amount of hot melt adhesive applied also depends on the nature of the material, and the extent to which the hot melt penetrates into the patch material. Typically, layer thickness of a hot melt adhesive layer is of the order of about 0.003 inch thick to about 0.030 inch thick, optionally about 0.005 inch thick to about 0.025 inch thick, and still further optionally about 0.015 inch thick to about 0.020 inch thick, yet further optionally about 0.012 inch thick, all measured from the outer surface of the hot melt adhesive layer, prior to bonding to the shirt material, to the interface of adhesive and fiber where multiple strands of fiber are generally in contact with each other.

Where a pressure sensitive adhesive layer is used, the pressure sensitive adhesive layer is typically applied as a coating to the patch material, and a carrier sheet is employed on the surface of the pressure sensitive layer until such time as the patch is applied to the shirt.

Still referring to FIG. 4, embroidery thread 48 passes through layer 42 of the shirt material, layer 44 of the patch material, and layer 46 of the adhesive. By passing the embroidery thread through layer 42 of the shirt material, the shirt material can be used as a hooping material for purposes of the embroidery process, whereby no auxiliary backing or hooping material need be employed in developing the embroidery indicia on patch 18.

FIG. 5 illustrates a cross-section as in FIG. 4, but with the addition of a second layer 50 of adhesive between layer 46 of adhesive and layer 42 of shirt material. In the embodiment of FIG. 5, there can be mentioned, for example, a layer 46 of hot melt adhesive in surface-to-surface contact with the patch material layer 44 and a layer 50 of contact adhesive overlying the layer 46 of hot melt adhesive and in contact with the shirt material. Prior to activation of the hot melt adhesive, the contact adhesive provides primary bonding between the patch and the shirt material, by bonding to both the hot melt adhesive and the shirt material. The hot melt adhesive is at that point bonded to the patch material.

As an alternative, the adhesive layers can be reversed, such that the hot melt adhesive is bonded to the shirt material and the contact adhesive is bonded to the patch material.

When it is desired to develop a stronger or more permanent bond between the patch and the shirt material by means of the hot melt adhesive component, heat is applied to the outer surface of the patch, alternatively to the inner surface of the shirt, or both. Sufficient heat is driven through the respective layer of material, patch material or shirt material, to activate the hot melt adhesive, whereupon the hot melt adhesive becomes effective to bond the shirt material and the patch material to each other.

FIGS. 1, 2, and 3 show the outline of the patch 18 as being a regular geometric shape. FIGS. 1 and 2 show an oval shaped patch. FIG. 3 shows the patch in the shape of the number “8”. While not further illustrated, the outline of the patch, namely the outer perimeter of the patch, can be any outline desired by the designer of such patch. In that light, the patch need not be a regular shape, or even a well-recognized shape. Indeed, the shape of the patch, as represented in its outer perimeter, and including any interior apertures 40, can take on any configuration imagined and applied by the designer of the patch. Thus, there can be mentioned, for example the outline of any known object, or unknown and fanciful object. As known objects, there might be mentioned, for example and without limitation, plants, animals, mineral objects, representations of astrological images, flames, lights, manufactured objects, vehicles, and buildings. Fanciful images are, of course, not subject to description until reduced to tangible representations of such images.

The patch can be any size which is compatible with fitting into an, or industrial embroidery bed and which is compatible with bonding the patch to the e.g. garment substrate. Thus, the patch can be e.g. small such as the name patch illustrated in FIG. 1, or can be large such as to cover a large fraction of the front 12 or back 14 of the garment/shirt. The patch can be generally centrally-defined such as in a single centralized element; or can be rather dispersed such as in an array of rays emanating from a central location, or a non-central location. Multiple patches can be used on a garment in one or more organized or non-organized arrays. Thus, the design of the configuration of the patch and/or patch array is limited only by the imagination of the designer of the patch, and the space available on the substrate to receive the patch, and is not limited spatially by the substance of the invention.

Exemplary of methods of developing garments of the invention, bearing embroidered such patches, is the following description of applying a patch to a shirt. A patch is cut from a sheet of patch material. The patch has an outer perimeter which defines an outer edge of the patch. Embroidery or other stitching can be applied in the outer edge region of the patch, if and as desired, after the patch has been cut out of the sheet of patch material to consolidate or maintain the integrity of the edge region of the patch.

In the alternative, embroidery or other stitching can be applied to the sheet of patch material before the patch is cut out, at or adjacent the prospective line of cutting. The edge of the stitching can be coincident with the edge of the cut-out patch.

In the alternative, the edge of the stitching can be e.g. slightly inward of the outer edge of the cut-out patch.

In cutting out the patch, a laser cutter or heated cutting knife or die cutter can apply heat to the edge of the cut material, e.g. twill patch material, during making the patch cut-out, sufficient to seal the patch material near the threads while the knife or laser cutter is cutting out the patch. Those skilled in the art can well develop suitable cutting processes, including cutting temperatures, with reasonably nominal effort, based on the specific parameters of the specific situation.

One or more layers of adhesive 46, 50 are applied to the patch material either before or after the patch is cut out of the patch sheet material. A single layer of adhesive can be used, either contact adhesive or hot melt adhesive; or at least one layer of each. Additional layers of adhesive can be used as desired.

A single layer of adhesive can be applied to either the patch or the patch material, or to the shirt material. If applied to the shirt material, the adhesive is optionally registered to the location where the patch will be applied. If applied to the patch, the adhesive can be applied to the entirety of the inner surface 22 of the patch, alternatively to the sheet of patch material before the patch is cut out of the sheet of patch material. In some embodiments, the adhesive is applied to the entirety of what will be, or is, the inner surface of the patch, thereby maximizing the size of the potential surface by which the patch can be bonded to the shirt material.

In some embodiments, a pressure sensitive adhesive is used which is sufficiently aggressive to permanently affix the patch to the shirt. In such instance, the patch must be carefully positioned by the time the adhesive is in contact with the shirt material.

In other embodiments, a less aggressive adhesive is used, optionally in combination with a hot melt adhesive, whereby the less aggressive contact adhesive accommodates at least limited repositioning the patch after initial contact with the shirt material, and whereby the hot melt adhesive, if present, is activated after the location of the patch has been confirmed, the contact adhesive being effective to hold the patch in place against modest forces, up to the time the hot melt adhesive is activated.

Application of the embroidered indicia in the interior of the outer surface of the patch may be partially completed before the patch is applied to the shirt material. However, at least a portion of the embroidery indicia remains uncreated at the time the patch is applied or affixed or mounted to the shirt.

After the patch has been applied to the garment, and is being held in place either with temporary strength of e.g. the contact adhesive, or with permanent strength of either contact adhesive or a hot melt adhesive, the garment is hooped in an embroidery hoop, and desired embroidery stitching is done. As illustrated in FIGS. 4 and 5, such embroidery stitching extends through the patch, through the one or more adhesive layers, and through the garment material. With the patch already in place on the shirt, the embroidery process is continued until such time as the desired amount of embroidery indicia has been added to the patch.

The embroidery indicia applied to the patch with the patch mounted to the garment, namely after-mounting embroidery, can be all of the embroidery which is applied to the patch, including edge embroidery which can be used to supplement the attachment of the patch to the garment in the edge region.

The after-mounting embroidery can be all embroidery in the interior region of the patch, excluding edge embroidery stitching.

The after-mounting embroidery can be all embroidery in the interior region, and can extend into the edge region but can embroider less than all of the edge region.

The after-mounting embroidery can cover all, or only a portion, of the interior region of the patch.

The after-mounting embroidery can cover all, or substantially, all of the outer surface of the patch, including the entirety of the edge region.

The after-mounting embroidery can essentially cover all portions of the patch which could conventionally be embroidered before the patch is mounted to the garment.

Since the garment material layer 42 can serve as the hooping material, no backing material need be used in order to secure, in the embroidery hoop or industrial embroidery bed, the material to be embroidered, though a backing material can be used as desired to provide additional stiffness or other body to the garment layer 42 and/or the patch layer where the garment material and/or the patch material are relatively lighter weight materials, e.g. outside the conventional range of garment materials and/or outside the range of patch materials. In general, though, no backing material is needed to support garment layer 42.

The embroidering on the patch after the patch has been secured to the garment material typically serves to operate as a secondary affixation of the patch to the garment material.

However, where the extent of the embroidery on the patch is such as to cover a large fraction, e.g. at least 50%, optionally at least 70%, of the outer surface of the patch, the embroidery stitching can function as the primary method of attaching the patch to the layer 42 of garment material. Accordingly, where a large fraction of the outer surface of the patch is to be embroidery stitched after the patch has been at least temporarily affixed to the garment material, a relatively less aggressive adhesive composition can be used, as compared to where the stitching is extant over a relatively smaller fraction of the outer surface of the patch.

In the alternative, and still addressing the large fraction of the surface area of the patch which is to be covered by embroidery stitching, a relatively lesser quantity of adhesive material can be used e.g. a thinner layer or a more disperse array of adhesive elements, or an intermediate quantity of an intermediately aggressive adhesive can be used.

In any event, the adhesion properties of the adhesive are matched to the need to secure the patch to the garment material until a suitable degree of attachment is developed by the embroidery stitching that a suitable level of attachment is supplied by the embroidery stitching.

Whatever the level of attachment of the patch to the garment material by embroidery stitching, upon completion of the embroidering on the patch, the level of securement of the patch to the garment material can be assessed, and additional adhesive strength activated as available in adhesive layer 46 and/or 50. Such assessment can be done globally for setting up a run of multiple shirt/patch combinations, or can be assessed individually, garment by garment.

In some embodiments, sufficient heat is applied to the patch, either directly to the patch, or through garment layer 42 to the patch, to securely bond the patch to the garment before the after-mounting embroidery is begun. Accordingly, once the desired embroidering has been completed, the garment is removed from the embroidery hoop, which completes process of the invention.

Where desired, additional heat can be applied, either to the entire patch, or to selected portions of the patch, to further enhance bonding of the patch to the garment material.

Also where desired, additional conventional non-embroidery stitching can be employed e.g. at the outer edge of the patch, through the patch, through the adhesive, and through the layer of garment material to further strengthen the attachment of the patch to the garment material at the outer edge of the patch.

As used herein “permanent strength” or “permanent securement” of the adhesive means that a level of strength has been developed whereby the patch stays in place in an environment of normal wearing use of the resulting garment. Such permanent strength can be developed by appropriately heating the hot melt adhesive in a conventional T-shirt/garment press heater for about 5 seconds to about 30 seconds, optionally about 10 seconds to about 18 seconds, optionally about 12 seconds. Such conventional T-shirt/garment press is useful for applying conventional patches to garments using conventional hot melt adhesive.

While the above description has been expressed in terms of using an adhesive layer 46 to bond the patch to the garment, other means, such as temporary stitching, pins, spaced spots of adhesive can be employed to lightly secure the patch to the garment material until such time as the embroidered indicia provide a desired level of permanent securement of the patch to the garment.

For example, where the entire outer edge region is to be embroidered through the garment material, or where the entire outer surface of the patch is to be embroidered through the garment material, only a low level of temporary securement is required when the embroidery process is started, enough securement to keep the patch from moving until the embroidery stitching secures the patch permanently against undesired amounts of movement. In such case, no adhesive need be used. Indeed, no securement material need be used which is of such nature as to be a permanent part of the finished garment. Thus, temporary pins, temporary clips, temporary basting stitching can be employed; and can be subsequently removed after application of the embroidery indicia has been completed, in which case no adhesive need be used, and no adhesive need be present in the finished garment. However, the embroidery stitching still extends through both the layer of patch material and the layer of garment is material.

Where no adhesive is used, the permanent strength of attachment is provided by the embroidered indicia which cover a large fraction of the outer surface of the patch. Where some areas of the edge region are not embroidered, or where adhesive is present but ineffective, supplemental attachment can be provided by additional stitching of the patch to the garment material in those respective areas of the edge region which are so affected.

In some embodiments, the embroidery indicia extend across the boundary of the patch and onto the outer surface of the garment such that a portion of the embroidered indicia is stitched directly to the garment material, and not through the patch. In such embodiments, part of the embroidered indicia overlie the patch, and part of the embroidered indicia directly overlie the garment material, outside the outer perimeter of the patch. Some of the embroidery threads, e.g. stitches, can bridge between the patch and the garment material. Especially outside the outer perimeter of the patch, conventional embroidery backing material can be used to support that portion of the embroidered garment material which is not overlaid by the patch material.

In any of the embodiments of the invention, it is not necessary, and in many embodiments, it is not desirable, to use any of the conventionally-used embroidery backing materials. Such embroidery backing materials may be conventionally used, for example, to mount the patch in an embroidery hoop. Such backing material may be used behind the garment material where the embroidering is applied directly to the garment substrate without intervening patch material. However, the absence of backing material in the cross-sections of FIGS. 4 and 5 is intentional and use of backing material is not necessary to implementation of the invention.

On the other hand, while use of backing material is exceptional in the invention, backing material can beneficially be used in the invention in certain instances such as where the substrate material or the patch material are especially flexible.

In any event, by extending the embroidery stitching through both the patch and the shirt or other garment material, the patch cannot be removed from the garment without damaging a substantial portion, or all, of the embroidered indicia on the patch, thus the appearance of the patch.

Those skilled in the art will now see that certain modifications can be is made to the products and methods herein disclosed with respect to the illustrated embodiments, without departing from the spirit of the instant invention. And while the invention has been described above with respect to the preferred embodiments, it will be understood that the invention is adapted to numerous rearrangements, modifications, and alterations, and all such arrangements, modifications, and alterations are intended to be within the scope of the appended claims.

To the extent the following claims use means plus function language, it is not meant to include there, or in the instant specification, anything not structurally equivalent to what is shown in the embodiments disclosed in the specification.

Claims

1. In combination, a patch, and a garment to which said patch is mounted,

said patch comprising a first outer surface facing away from said garment, a first inner surface facing toward said garment, a perimeter which defines an outer edge of said patch, and an outer edge region disposed proximate the outer edge of said patch,

said garment having a second outer surface facing away from said garment, including toward said patch, and a second inner surface facing inwardly, toward a body of a wearer of said garment,

said combination of said garment and said patch comprising embroidered indicia on the outer surface of said patch, threads defining said embroidered indicia extending through both said patch and said garment.

2. A combination as in claim 1, further comprising a layer of adhesive between said patch and said garment, said threads defining said embroidered indicia further extending through said layer of adhesive.

3. A combination as in claim 2 wherein said layer of adhesive comprises heat seal adhesive, bonding said patch to said garment.

4. A combination as in claim 2 wherein said layer of adhesive comprises contact adhesive bonding said patch to said garment.

5. A combination as in claim 2 wherein said layer of adhesive comprises a first layer of heat seal adhesive and a second layer of contact adhesive.

6. A combination as in claim 1 wherein the embroidered indicia is confined inwardly of the edge region.

7. A combination as in claim 1 wherein the embroidered indicia extends into the edge region.

8. A combination as in claim 1 wherein the embroidered indicia covers an entirety of the outer surface of said patch, including in the edge region.

9. A combination as in claim 1 wherein the embroidered indicia is defined in part inwardly of the edge region, and in part in the edge region.

10. A combination as in claim 1 wherein the embroidered indicia is predominantly informational in nature.

11. A combination as in claim 1 wherein the embroidered indicia is predominantly artistic in nature.

12. A combination as in claim 1, further comprising stitching about the outer edge of said patch, as supplemental securement of the outer edge of said patch to said garment.

13. A combination as in claim 1, further comprising a cut-out aperture in said patch material, disposed inwardly of the outer edge, and a second edge region about said cut-out aperture, wherein the embroidered indicia is displaced from the second edge region.

14. A combination as in claim 1 wherein said patch is affixed to said garment that said patch cannot be removed from said garment without damaging a substantial portion of the embroidered indicia on said patch.

15. In combination, a patch, and a garment to which said patch is mounted,

said patch comprising a first outer surface facing away from said garment, a first inner surface facing toward said garment, a perimeter which defines an outer edge of said patch, and an outer edge region disposed proximate the outer edge of said patch,

said garment having a second outer surface facing away from said garment, including toward said patch, and a second inner surface facing inwardly, toward a body of a wearer of said garment,

said combination of said garment and said patch comprising embroidered indicia on the outer surface of said patch, the embroidered indicia being configured in cooperation with said patch and said garment such that said patch cannot be removed from said garment without damaging a substantial portion of the embroidered indicia.

16. A method of mounting a patch to a garment, the method comprising:

(a) from a web of patch material, cutting out a patch having a desired outline, the patch having first and second opposing surfaces, and an outer perimeter defining an outer edge of the patch, and a corresponding outer edge region proximate the outer edge;

(b) subsequent to cutting out the patch, mounting the patch to the garment; (c) after mounting the patch to the garment, embroidering indicia onto the patch, including extending embroidering threads through the patch material and through the garment.

17. A method as in claim 16, further comprising, prior to mounting the patch to the garment, applying a layer of adhesive material to the patch so as to cover substantially the entirety of the first surface of the patch, and activating the adhesive as necessary in the process of mounting the patch to the garment, whereby the adhesive material facilitates the mounting of the patch to the garment.

18. A method as in claim 17 wherein the layer of adhesive material comprises a layer of hot melt adhesive, the method further comprising heating the hot melt adhesive in the process of mounting the patch to the garment, so as to activate the hot melt adhesive thereby to facilitate the mounting of the patch to the garment, and wherein the extending of the embroidering threads through the patch material and through the garment further comprises extending the embroidering threads through the layer of hot melt adhesive.

19. A method as in claim 16, further comprising confining the embroidered indicia inwardly of the edge region.

20. A method as in claim 16, including defining a first portion of the embroidered indicia inwardly of the edge region, and a second portion of the embroidered indicia in the edge region.

21. A method as in claim 16, including defining the embroidered indicia over substantially the entirety of the outer surface of the patch, including in the edge region.

22. A method as in claim 16 wherein the embroidered indicia is predominantly informational in nature.

23. A method as in claim 16 wherein the embroidered indicia is predominantly artistic in nature.

24. A method as in claim 19, the patch further comprising a cut-out aperture in the patch material, disposed inwardly of the outer edge, and a second edge region about the cut-out aperture, the method further comprising confining the embroidered indicia away from the second edge region.

25. A method as in claim 16 wherein the patch is so affixed to the garment by the embroidered indicia thereon that the patch cannot be removed from the garment without damaging a substantial portion of the embroidered indicia on the patch, thus the appearance of the patch.

26. A method of creating a garment bearing an embroidered patch, the patch having first and second opposing surfaces, an outer perimeter defining an outer edge, and an edge region proximate the outer edge, the method comprising:

(a) at least temporarily affixing the patch to the garment;

(b) subsequent to at least temporarily affixing the patch to the garment, passing embroidery threads through both the patch and the garment in developing embroidered indicia on the patch.

27. A method as in claim 26 including, prior to passing embroidery threads through both the patch and the garment, the at least temporarily affixing of the patch to the garment comprising affixing the patch to the garment using an intervening layer of adhesive.

28. A method as in claim 26 including, prior to passing embroidery threads through both the patch and the garment, the at least temporarily affixing of the patch to the garment comprising affixing the patch to the garment using an intervening layer of hot melt adhesive.

29. A method as in claim 26, further comprising confining the embroidered indicia inwardly of the edge region.

30. A method as in claim 26, including defining a first portion of the embroidered indicia inwardly of the edge region, and a second portion of the embroidered indicia in the edge region.

31. A method as in claim 26, including defining the embroidered indicia over substantially the entirety of the outer surface of the patch, including in the edge region.

32. A method as in claim 26, comprising defining embroidered indicia which is predominantly informational in nature.

33. A method as in claim 26, comprising defining embroidered indicia which is predominantly artistic in nature.

34. A method as in claim 26 wherein the patch is so secured to the garment that the patch cannot be removed from the garment without damaging a substantial portion of the embroidered indicia on the patch.