Pre-sewn letter and method

• US 5,149,388 A
• Filed: 02/04/1991
• Issued: 09/22/1992
• Est. Priority Date: 10/21/1988
• Status: Expired due to Term

• Current Assignee: Stahls' Inc.
• Original Assignee: Ted Stahl
• Inventors: Stahl, Ted
• Primary Examiner(s): Powell, William A.
• Assistant Examiner(s): DIXON, MERRICK L
• Application Number:
  US07/651,018
• Time in Patent Office: 596 Days
• Field of Search: 156/250, 156/256, 156/258, 428/40, 428/102, 428/104, 428/197, 428/158, 428/187, 428/906.6, 112/439, 112/266.1, 206/45.33
• US Class Current: 156/250
• CPC Class Codes: B32B 2038/008 Sewing, stitching
• CPC Class Codes: B32B 2305/18 Fabrics, textiles
• CPC Class Codes: B32B 2307/404 Multi-coloured
• CPC Class Codes: B32B 2437/00 Clothing anti-ballistic clothing B32B2571/02
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 37/025 Transfer laminating
• CPC Class Codes: B32B 37/12 characterised by using adhesives
• CPC Class Codes: B32B 37/1207 Heat-activated adhesive B32B37/04 takes precedence
• CPC Class Codes: B32B 38/0004 Cutting, tearing or severing, e.g. bursting; Cutter details cutting in general B26D; laminating combined with punching or perforating B32B38/04; removing all or part of the layers B32B38/10; cutting in combination with laying up and registration B32B38/185 takes precedence
• CPC Class Codes: D06M 17/04 by applying synthetic resins as adhesives
• CPC Class Codes: D06M 17/10 Polyurethanes polyurea
• CPC Class Codes: D06Q 1/005 Producing embroidered textiles by chemical means; Transferring embroidered products to textiles embroidered products D05C17/00
• CPC Class Codes: D06Q 1/10 by treatment with, or fixation of, a particulate material, e.g. mica, glass beads by metallising D06Q1/04; by transferring D06Q1/12
• CPC Class Codes: G09F 3/0341 having label sealing means
• CPC Class Codes: Y10T 156/1052 with cutting, punching, tearing or severing
• CPC Class Codes: Y10T 156/1062 Prior to assembly
• CPC Class Codes: Y10T 156/1064 Partial cutting [e.g., grooving or incising]
• CPC Class Codes: Y10T 156/1066 Cutting to shape joining edge surfaces only
• CPC Class Codes: Y10T 156/1074 Separate cutting of separate sheets or webs
• CPC Class Codes: Y10T 156/1075 of plural laminae from single stock and assembling to each other or to additional lamina
• CPC Class Codes: Y10T 156/1082 : Partial cutting bonded sandwich [e.g., grooving or incising]
• CPC Class Codes: Y10T 428/1424 : Halogen containing compound
• CPC Class Codes: Y10T 428/24033 : including stitching and discrete fastener[s], coating or bond
• CPC Class Codes: Y10T 428/2405 : Coating, impregnation, or bond in stitching zone only
• CPC Class Codes: Y10T 428/24736 : Ornamental design or indicia
• CPC Class Codes: Y10T 428/24752 : Laterally noncoextensive components
• CPC Class Codes: Y10T 428/2481 : including layer of mechanically interengaged strands, strand-portions or strand-like strips
• CPC Class Codes: Y10T 428/24818 : Knitted, with particular or differential bond sites or intersections
• CPC Class Codes: Y10T 428/24843 : with heat sealable or heat releasable adhesive layer
• CPC Class Codes: Y10T 428/24851 : Intermediate layer is discontinuous or differential
• CPC Class Codes: Y10T 428/2486 : with outer strippable or release layer

Abstract

An improved method for producing a multi-colored emblem which may be bonded to a fabric is disclosed which provides an emblem with an embroidered appearance. The emblem is easily heat sealable onto difficult to adhere fabrics. The method generally involves providing a first woven material blank, providing a barrier layer of thermoplastic material, laminating the barrier layer onto one side of said material blank to form an assembly, cutting said assembly to a specific configuration, sewing a thread about the periphery of the cut assembly, and laminating said assembly onto a second woven material blank having a different color. This second assembly is again cut to a complimentary larger configuration and also provided with a thread about the periphery. The two material blanks are then heat sealed together and an adhesive layer is provided to the exposed barrier layer.

Claims

1. A method of producing an embroidered emblem for application by heat to a fabric comprising the steps of:

providing a woven fabric layer;

cutting from the woven fabric layer the shape of the emblem to be formed;

sewing a thread about the periphery of the cut-out emblem to form an embroidered emblem; and

applying a thermoplastic adhesive over one surface of the emblem and the sewn thread exposed on such surface.

7. The method of claim 1 which further comprises the step of applying a barrier layer to the woven fabric layer prior to the application of the thermoplastic adhesive.

2. The method of claim 9 wherein prior to cutting the shape of the emblem from the woven fabric layer, applying a barrier layer to the woven fabric layer, and applying said adhesive over such barrier layer.

3. The method of claim 2 wherein the barrier layer is a thermoplastic resin.

4. The method of claim 3 wherein the barrier layer is selected from the group consisting of PVC, AVA, urethane, polyester and nylon.

5. The method of claims 2, 3 or 4 wherein the melting point of the adhesive is lower than the melting point of the barrier layer.

6. The method of claim 5 wherein the thermoplastic adhesive is a thermosettable film of a polyester polymer and a heat-activated curing agent.

8. A method of producing an embroidered emblem for application by heat to a fabric comprising the steps of:

applying a thermoplastic barrier layer to the woven fabric layer;

cutting from the woven fabric layer and attached barrier layer the shape of the emblem to be formed;

sewing a thread about the periphery of the cut out emblem to form an embroidered emblem; and

applying a thermoplastic adhesive over one surface of the emblem and the sewn thread exposed on such surface, wherein the thermoplastic adhesive has a melting point lower than the melting point of the barrier layer.