HIGH DEFINITION LITHO APPLIQUE AND EMBLEMS

Abstract

The invention provides high definition litho appliqué and emblems manufactured from appropriate fabric, such as 100% polyester twill or micro fiber material, which has been sublimated with a high definition photograph-quality print. The high definition litho appliqué and emblems are cut into the desired shape and optional affixed to a garment. The invention further provides processes for producing the same.

Description

FIELD OF THE INVENTION

The present invention is generally directed to a process for making high definition appliqués and emblems for garments and other material items. More particularly, the present invention is directed to high definition litho appliqué and emblems and processes for producing the same.

BACKGROUND OF THE INVENTION

In the textile arts there are many methods and processes for decorating and/or personalizing fabric including, for example, appliqué, silk-screening, and decorative stitching.

Generally, appliqué involves placing or laminating a first fabric layer over a second fabric layer and securing the first layer in place. Various methods of adhering the first and second fabric layers are known in the art and include sewing or basting the first layer to the second layer, or the use of adhesive material.

Modified appliqués and methods of making the same are known in the art and include methods of making screen printed appliqués as disclosed in U.S. Pat. No. 6,955,124 and methods of making sublimated and screen printed appliqués as disclosed in U.S. Pat. No. 7,410,932.

This background information is provided for the purpose of making known information believed by the applicant to be of possible relevance to the present invention. No admission is necessarily intended, nor should be construed, that any of the preceding information constitutes prior art against the present invention.

SUMMARY OF THE INVENTION

An object of the present invention is to provide high definition litho appliqués and emblems and processes for producing the same. In accordance with an aspect of the present invention, there is provided a method for manufacturing high definition litho appliqué comprising digitally printing a high resolution image onto transfer paper; transferring the image to an appropriate fabric to obtain an imaged fabric; and cutting out the image from the imaged fabric to obtain a high definition litho appliqué. Optionally, the appliqué is a limited edition appliqué. The limited edition appliqué may be either a numbered or open series limited edition. In accordance with one embodiment of the invention, the method further comprises attaching the high definition litho appliqué to a garment.

In accordance with another aspect of the invention, there is provided a method for manufacturing a garment or hat with high definition litho emblem comprising digitally printing a high resolution image onto transfer paper; transferring the image to an appropriate fabric to obtain an imaged fabric; cutting out the image from the imaged fabric to obtain a cut out printed design; cutting out a felt backing for the cut out printed design; and applying the cut out printed design and felt backing to a garment or hat.

In accordance with another aspect of the invention, there is provided a high definition litho appliqué or emblem manufactured from appropriate fabric which has been sublimated with a high definition photograph-quality print. In accordance with one embodiment, the appliqué or emblem has the sheen of standard sport twill. Optionally, the appliqué or emblem is a limited edition appliqué or emblem.

In accordance with another aspect of the present invention, there is provided a method for manufacturing high definition litho appliqué comprising digitally printing a high resolution image onto an appropriate fabric to obtain an imaged fabric; and cutting out the image from the imaged fabric to obtain a high definition litho appliqué. In accordance with one embodiment of the invention, the method further comprises attaching the high definition litho appliqué to a garment.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a schematic diagram illustrating the system which makes the high definition litho appliqué in accordance with one embodiment of the invention;

FIG. 2 is a flow chart depicting one embodiment of the method of making high definition litho appliqué;

FIGS. 3A to 3F are photographic representations of the method of making high definition litho appliqué shown in FIG. 2;

FIG. 4 is a flow chart depicting one embodiment of the method of making high definition litho emblems;

FIG. 5 is a schematic diagram illustrating the system which makes the high definition litho appliqué in accordance with one embodiment of the invention;

FIG. 6 is a flow chart depicting one embodiment of the method of making high definition litho appliqué.

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides a method of producing high definition litho appliquéand emblems and includes processes for embedding a photograph or pattern onto a twill or micro fiber appliqué such that the sheen of standard sport twill is maintained. The resulting high definition litho appliqué and emblems can optionally be applied to garments or other items.

The present invention further provides high definition litho appliqué and emblems manufactured from appropriate fabric, such as 100% polyester twill or micro fiber material, which has been sublimated with a high definition photograph-quality print. The high definition litho appliqué and emblems are cut into the desired shape and optional affixed to a garment. Optionally, the high definition litho appliqué is in the shape of standard athletic sport lettering. The design can include any high resolution images including images of people, organizations, companies, teams, animals, landmarks, events including entertainment and/or sporting events, etc. Optionally, the design may incorporate a logo and/or trademark. Alternatively, a logo and/or trademark may be applied to the garment separately and optionally at a location distinct from the design. The logo and/or trademark may be representative of the people, organizations, teams, landmarks and/or events illustrated in the design's high resolution image.

In one embodiment, the logo and/or trademark is stitched into the fabric of the garment to which the high definition litho appliqué is affixed. Optionally, the stitching of the logo and/or trademark at least partial affixes the high definition litho appliqué to the garment.

In one embodiment of the invention, the high definition litho appliqués and/or emblems are produced in a limited edition with each high definition litho appliqué and/or emblem in the limited edition series assigned a unique number which is printed into the design. Optionally, the numbering is digitally integrated into the design using software capable of a variable data technique. The resulting limited edition high definition litho appliqué or emblem is optionally applied to a garment or other wearable items to form a collectable wearable or collector-targeted memorabilia article. The limited edition appliqué may be either a numbered or open series limited edition.

Optionally, the collectable wearable or collector-targeted memorabilia article is package with a authentication statement and/or other confirmation of the limited edition status.

In one embodiment, the authentication statement and/or other confirmation of limited edition status is affixed to or is integral with the collectable wearable and is optionally a component of a label.

FIG. 1 schematically illustrates a system (10) for making high definition litho appliqué in accordance with one embodiment of the invention. The system (10) comprises an appropriately programmed computer (20) for preparing the design and a plotter (15) such as a wide format ink jet plotter to digitally print the reverse image using sublimation inks onto a transfer paper (17), a heat transfer machine (30) to transfer the image to appropriate fabric, scanner (40), flatbed laser cutter (50) and optionally an embroidery machine (60).

FIGS. 2 and 3A-3F illustrate one method of producing high definition litho appliqué using the system shown in FIG. 1. As shown, high resolution images are formed into the Branding or logo design using an appropriately programmed computer. The reverse image of the final design is digitally printed using sublimation inks onto transfer paper. Appropriate printers, inks and transfer papers are known in the art and are available from various suppliers including Sawgrass Technologies amongst others. Optionally, wide format inkjet plotters can be used.

The printed transfer paper is then imaged onto white 100% polyester twill or micro fiber fabric at about 400 to about 425 degrees Fahrenheit for about 25 to about 35 sec. using a heat transfer machine. Optionally, at the same time, a high temperature backing can be applied to the back of the fabric for stability.

The imaged fabric is then scanned into the computer to create two files. The first file is the cut file to be used on a flatbed laser cutter. The second file is the digitized file used on an embroidery machine to sew the cut design on the garment. The imaged fabric is then accurately cut using the flatbed laser machine with a camera that will recognize a shape. Alternatively, the image may be cut out using a variety of other methods known in the art including die cutting, hand cutting and waterjet cutting. This procedure produces the appliqué which is now ready to be affixed to a garment. The final step is to sew the appliqué on to the garment using a commercial embroidery machine. Alternatively, the appliqué can be affixed to the garment using other means known in the art.

In one embodiment, in addition to affixing the appliqué to the garment, the stitching forms an integral part of the look and design of the final product. In such embodiments, in addition to being on the perimeter of the appliqué, stitching can be used to pick out or highlight details from the high definition image, add design elements, logos, trademarks and/or lettering. Optionally, the stitching may be in multiple colours, thickness, patterned or textured.

In one embodiment, the appliqué is sewn down strategically using zig zag stitching pattern. To create the rich look of an appliqué, the zig zag pattern is sewn on around each letter or branding to an accuracy of about 1 mm.

In one embodiment, the appliqué is sewn down strategically using a stitching pattern that is more complicated than standard zig zag stitching achieved by manual means.

FIG. 4 illustrates one method of producing high definition litho emblems. The desired design is printed using a digital ink jet printer with dye-sublimation CMYK inks on sublimation paper. The design is then transferred using a high heat; high-pressure heat press on to a 100% polyester twill or micro fiber substrate. Using a laser cutter equipped with a magic eye technology or die cut the printed polyester twill or micro fiber material is precisely cut out. A piece of felt that is 2 mm larger than the cut out printed design is cut out using a laser cutter or die cutter. The felt with the printed twill or micro fiber material is applied onto hats or other garments using an embroidery machine.

FIG. 5 schematically illustrates a system (10) for making high definition litho appliqué in accordance with one embodiment of the invention. The system (10) comprises an appropriately programmed computer (20) for preparing the design and a plotter (15) such as a wide format inkjet plotter to digitally print the image on to appropriate fabric, a scanner (40), flatbed laser cutter (50) and optionally an embroidery machine (60).

FIG. 6 illustrates one method of producing high definition litho appliqué using the system shown in FIG. 5. As shown, high resolution images are digitally printed onto white 100% polyester twill or micro fiber fabric. The imaged fabric is then scanned and cut out as described above to produce the appliqué which is now ready to be affixed to a garment.

Although the invention has been described with reference to certain specific embodiments, various modifications thereof will be apparent to those skilled in the art without departing from the spirit and scope of the invention. All such modifications as would be apparent to one skilled in the art are intended to be included within the scope of the following claims.

Claims

1. A method for manufacturing high definition litho appliqué comprising

(a) digitally printing a high resolution image onto transfer paper;

(b) transferring the image to an appropriate fabric to obtain an imaged fabric; and

(c) cutting out the image from the imaged fabric to obtain a high definition litho appliqué.

2. The method of claim 1, wherein step (a) further comprises printing a unique number into each appliqué applied of a specific design.

3. A high definition litho appliqué produced by the method of claim 1.

4. A high definition litho appliqué produced by the method of claim 2, wherein the high definition litho appliqué is a limited edition high definition litho appliqué.

5. The method of claim 1 further comprising (d) attaching the high definition litho appliqué to a garment.

6. The method of claim 5, wherein step (d) comprises affixing the high definition litho appliqué with a complex stitching pattern.

7. A garment produced by the method of claim 5.

8. The garment of claim 7, further comprising a separate trademark or logo.

9. A method for manufacturing a garment or hat with high definition litho emblem comprising

(a) digitally printing a high resolution image onto transfer paper;

(b) transferring the image to an appropriate fabric to obtain an imaged fabric;

(c) cutting out the image from the imaged fabric to obtain a cut out printed design;

(d) cutting out a felt backing for the cut out printed design; and

(e) applying the cut out printed design and felt backing to a garment or hat.

10. The method of claim 9, wherein step (e) comprises affixing the printed design and felt backing with a complex stitching pattern.

11. A garment or hat produced by the method of claim 9.

12. A high definition litho appliqué or emblem manufactured from appropriate fabric which has been sublimated with a high definition photograph-quality print.

13. A method for manufacturing high definition litho appliqué comprising

(a) digitally printing a high resolution image onto an appropriate fabric to obtain an imaged fabric; and

(b) cutting out the image from the imaged fabric to obtain a high definition litho appliqué.

14. The method of claim 13 further comprising (c) attaching the high definition litho appliqué to a garment.

15. The method of claim 14, wherein step (c) comprises affixing the high definition litho appliqué with a complex stitching pattern.