Patent Application
20110041741
Not applicable
Not applicable.
1. Field of the Invention
The present invention relates to embroidered artworks and, more particularly, to an improved method for making an embroidered fabric having a sublimated dye thereon.
2. Description of Related Art
Embroidery is the art of decorating material, usually a textile fabric, by means of a needle and thread. Embroidered patterns are usually multi-colored such that different-colored threads must be stitched in the embroidered pattern. This means that for one embroidered pattern, the embroidery thread must be changed multiple times.
Dudek, II, U.S. Pat. No. 6,312,672 described a method for producing polychromatic embroidery that requires the use of only a single colored (or white) thread for embroidering the pattern on the fabric. Dudek '672 states that by using a multi-color process for sublimation printing, subtle color blends and photorealism were realized that could not otherwise be achieved employing prior art embroidery methods. Yet, with such techniques, there is often difficulty in aligning the sublimation paper with the embroidered image on the fabric. In some instances, part or all of the periphery of the embroidered design remains monochromatic (e.g., white around the edges). In other instances, the excess sublimation dyes undesirably bleed onto the underlying fabric. While templates may be useful to attempt to block the sublimation dyes from sublimating into the underlying fabric, such templates cannot be used to create finer details, such as flowers, letters, hair, sharp angles, etc. Thus, an improved process for sublimation embroidery is desired.
The present invention is directed to an improved method for making fabrics having a color embroidered pattern thereon in which the color is formed using sublimation. The sublimation method results in an embroidered pattern having distinctive and unique color qualities.
In general, a stabilizer is applied on a first top surface of the fabric. Next, an embroidered pattern is embroidered onto the top surface of the fabric. The embroidery thread or yarn is substantially light in color and is capable of binding sublimating dyes. The embroidered pattern is positioned over the stabilizer so that the stabilizer extends beyond at least a portion of the embroidered pattern. Preferably, the stabilizer extends beyond the entire periphery of the embroidered pattern and/or in the internal openings of the pattern. The embroidered pattern (which is substantially light in color) is then sublimated with one or more sublimating dyes (preferably four) to form a colored embroidered pattern. Excess stabilizer is then removed, typically by washing away or cutting away the stabilizer.
In one aspect, the present invention is well suited for sublimating one or more dyes onto an embroidered pattern having very fine details, such leaves, branches, flower petals, or individual hairs on a head.
In another aspect, the present invention is directed to an intermediate product in the overall sublimation embroidery process described herein. More specifically, the present invention is directed to a decorative embroidered fabric comprising a fabric having a first face and a second face, wherein the first face of the fabric has a first stabilizer thereon, and wherein an embroidered pattern is formed on the first face of said fabric such that said first stabilizer extends beyond at least a portion of the embroidered pattern.
In another aspect, the present invention is directed to an embroidery kit comprising a fabric; embroidery thread or yard; a stabilizer; and a paper having a pattern of one or more sublimating dyes thereon. Instructions are provided to the user such that the stabilizer is applied to the top face of the fabric followed by embroidery on the top face of the fabric followed by sublimating the embroidered pattern with one or more sublimating dyes.
Additional aspects of the invention, together with the advantages and novel features appurtenant thereto, will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following, or may be learned from the practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
The present invention is directed to a method for forming a colored embroidered pattern on a fabric. In general, a stabilizer is applied on a first top surface of the fabric. An embroidered pattern is embroidered onto the top surface of the fabric. The embroidery thread or yarn is substantially light in color and is capable of binding sublimating dyes. Typically, the embroidery thread has a high polyester content, e.g., greater than 50%, 60%, 70%, 80%, or 90%, and is most preferably 100% polyester. The embroidered pattern is positioned over most of the stabilizer so that the stabilizer extends beyond at least a portion of the embroidered pattern. The embroidered pattern (which is substantially light in color) is then sublimated with one or more sublimating dyes to form a colored embroidered pattern. Excess stabilizer is then removed, typically by washing away or cutting away the stabilizer. The overall process is depicted in
In the present invention, the fabric 10 comprises any suitable fabric for embroidery purposes and is non-limiting. The fabric includes any material comprising a network of natural or artificial fibers, including wool, linen, hemp, cotton, polyester, or other material. The fabric may be formed, for example, by weaving, knitting, crocheting, knotting, or pressing the fibers together. The fabric may be heavy-duty, for example in the case of canvas, or relatively lightweight.
The fabric 10 includes both a first surface (in which the embroidery will be applied) and an opposing second surface. In the present invention, the stabilizer 20 is positioned on the first surface as shown in
As shown in
The thread or yarn used to form the embroidered pattern 30 is one that is suitable for sublimation. As such, the thread or yard preferably has two properties. First, the thread or yarn forms an embroidered pattern which is substantially light in color. That is, the embroidered pattern is one which comprises white, clear, or light colors suitable for further sublimation printing thereon. Exemplary light colors include pastels, which are generally defined as any pale shade having relatively low color saturation. Preferably, the embroidered pattern is monochromatic, which includes pure white patterns. Second, the thread or yarn comprises a material capable of binding the sublimating dyes. Typically, the thread or yarn has a high polyester content, e.g., greater than 50%, 60%, 70%, 80%, or 90%, and most preferably 100% polyester. In general, sublimation transfer generally produce brighter colors retain more dye when the polyester content is high. Thus, the yard or thread may need to be soaked or sprayed with a polyester-based prepping liquid in order to facilitate sublimation transfer.
The embroidered pattern 30 is preferably positioned so that the stabilizer 20 extends beyond at least a portion of the embroidered pattern. Typically, the stabilizer 20 is positioned on the fabric 10 so the stabilizer extends beyond the entire periphery of the embroidered pattern 30. As illustrated in
As shown in
During the sublimation step of the present invention, one or more sublimating dyes are applied to the embroidered pattern 30, for example, a four-color process such as one involving cyan, magenta, yellow, and black. In general, the sublimation process creates a color image on the embroidery thread or yard comprising the embroidered pattern 30 by actually dyeing the thread or yarn. When a sublimation transfer is heat applied, the heat and pressure cause the sublimation dye (typically on a sublimation paper) to change from a solid directly into a gas and enter the fibrous substrate. While in its gaseous form, the sublimation dye enters the fibers of the embroidered pattern, thereby dyeing it. Because the sublimation dye penetrates the fibers of the embroidery, the colored embroidered pattern 40 created is essentially permanent and substantially non-destructible. Importantly, in the present invention, the excess dyes sublimate onto the surrounding stabilizer 20 and not onto the surrounding fabric 10.
The colored embroidered pattern may comprise any sort of monochromatic or polychromatic design. For example, the colored embroidered pattern may comprise colored geometric objects (e.g., a pattern of squares, circles, stars, peace signs, rainbows, and the like), lettering, numbering, landscapes, human, animals, commercial logos, or combinations thereof. In one aspect, the colored embroidered pattern has a photo-real quality. In another, the patterns have a “tie-dye” effect with one or more of the colors.
During the sublimation process, the stabilizer 20 prevents the sublimating dye from penetrating into the underlying fabric 10 at the boundary between fabric 10 and the colored embroidered pattern 30. The stabilizer 20 is especially useful for preventing the sublimating dye from penetrating into the fabric 10 in areas where the embroidered pattern has internal openings 32. Thus, by using the stabilizer 20, the dye is capable of forming a colored embroidered pattern 40 having unique and desirable patterns, especially those involving small or fine features, such as a single hair, leaf, branch, etc.
As shown in
In another aspect of the present invention, as discussed above, it has been found that combinations of stabilizers may optimize the sublimation process. For example, when sublimating onto a fabric which is generally light in color, a plurality of stabilizers may be used. The stabilizers may be on the same or different materials. For example, a combination of a wash-away stabilizer and a tear-away stabilizer ensures that the dye does not penetrate through the stabilizer to the underlying fabric. In a preferred aspect, two tear-away stabilizers are used on conjunction with one wash-away stabilizer. When sublimating onto a dark fabric, it is generally sufficient to use a single stabilizer.
In this example, the present invention was used to form a colored embroidered pattern comprising a generally horse-shoe like embroidered pattern having a plurality of geometric designs sublimated thereon. As shown in
From the foregoing, it will be seen that this invention is one well adapted to attain all ends and objectives herein-above set forth, together with the other advantages which are obvious and which are inherent to the invention. Since many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matters herein set forth or shown in the accompanying drawings are to be interpreted as illustrative, and not in a limiting sense. While specific embodiments have been shown and discussed, various modifications may of course be made, and the invention is not limited to the specific forms or arrangement of parts and steps described herein, except insofar as such limitations are included in the following claims. Further, it will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims.
