US3582440A - Simulated hand-embroidered material and method of making same - Google Patents

Abstract

THE PRESENT INVENTION RELATES TO A FABRIC WHICH HAS DISPOSED THEREON INDEPENDENT DESIGN AREAS. EACH DESIGN AREA, WHICH MAY TAKE ANY DESIRED SHAPE, GIVES THE GENERAL APPEARANCE AND SENSORY IMPRESSION OF A DESIGN HAVING RAISED BORDER THEREAROUND IMITATING THE HAND EMBROIDERY IMPRESSION. THE METHOD GENERALLY, OF OBTAINING THIS HAND EMBROIDERY LOOK REQUIRES THAT A BASIC DESIGN BE APPLIED USUALLY COLORED THROUGH AN APPLICATION MEANS OR OTHER APPROPRIATE DESIGN APPLICATOR USING A THINNED POLYVINYL CHLORIDE COMPOSITION. A SECOND SILK SCREEN IS USED TO APPLY A THICK LAYER OF POLYVINYL CHLORIDE AT THE BORDER OF THE BASIC DESIGN OR WITHIN SAID DESIGN AND THEREAFTER THE COMBINATION IS SUBJECTED TO A HEATING PROCESS THEREBY CREATING A DESIGN HAVING A RAISED BORDER EFFECT IN THE STYLE AND APPEARANCE OF A HAND-EMBROIDERED DESIGN.

Description

June 1, 1971 M, KUKQFF 3,582,440.

SIMULATED HAND-EMBROIDERED MATERIAL AND METHOD OF' MAKING SAME Filed May 20. 1968 I MILTON KuKol-F BY l l MORA/Ex@i United States Patent Oflee Patented June 1, 1971 3,582,440 SIMULATED HAND-EMBROIDERED MATERIAL AND METHOD OF MAKING SAME Milton Kukol, 30 Irma Drive, Oceanside, N.Y. 11572 Filed May 20, 1968, Ser. No. 730,388 Int. 'CL B44f 7 00 U.S. Cl. 161-19 4 Claims ABSTRACT OF THE DISCLOSURE The present invention relates to a fabric which has dis.

apply a thick layer of polyvinyl chloride at the border of the basic design or within said design and thereafter the combination is subjected to a heating process thereby creating a design having a raised border effect in the style and appearance of a hand-embroidered design.

Heretofore, it has been well known that hand-embroidered garments are most expensive and in general more beautiful than mere prints. The expense of making hand embroideries, whether in garments or related areas of decorative fabrics, have resulted in extremely high costs to the buying public, thereby limiting the marketability of these garments or fabrics.

Machine-embroidered fabrics and garments have met with a large measure of success. Varying types of machine embroideries have been made, some using a back ground material, such as nylon, and others merely in an openwork pattern. The machine embroidery has a raised effect, as in the hand-embroidered work, however great detail of designs cannot be obtained because of the natural limitations of the machinery itself.

Further machine embroidery does not and cannot, in the present state of the art use more than one color. That is, multicolored machine embroidered designs are not possible with the present machinery.

Attempts have been made to first print a colored design on a fabric and thereafter embroider a border or edge around the`printed design. These attempts have not been successful because of the inability to properly register the embroidery machinery with the printed design. This results primarily because of the slight irregular shrinkage of the fabric after printing as well as the normal give of the material when large areas are subjected to the machine for the application of the embroidery. Obviously the outlining of printed multicolored designs by hand embroidery, is again, extremely costly.

Therefore the schifli and Bonnaz machine embroidg public acceptance, because of the failuredescribed-above.

Numerous patents have been filed relating to raised designs for garments, few have been used and those used have not been deemed practical enough to satisfy the general public. For example one manufacturer attempted to print a design on a fabric and thereafter attempted to apply shelf edging of plastic material using at least one plastic applying roller. The object was simulated appliqud material.

Another and more recent attempt to obtain the raised design elfect was initiated by merely applying a heavy coating of resinous composition by means of a roller and thereafter using another roller to obtain depressions in the heavy first coating of resinous material. Thereafter heat was applied to set the material. This allegedly more sophisticated attempt at the raised look merely resulted in a fabric being almost rigid on its surface where the design was applied. Here again the general public found this completely non-usable.

Intermediate the above mentioned attempts, a so called breathable striped upholstery fabric was invented in which a woven fabric would be provided with raised plastic stripes of one color and valleys therebetween of a different color. A woven cotton fabric was provided with a thin vinyl coating without rendering the fabric impervious to air then the vinyl coating was thereafter heated, pressed and intermittently cooled. Thereafter, another coat of vinyl resin is applied through notched blades giving a bas-relief eect. Various ingenious vacuum tub arrangements are used to clean undesirable vinyl deposits from the fabric and the entire fully coated fabric is again heated.

In each of the aforementioned examples, the processes for making the final products, generally relates to materials which were too rigid and non-exible. The desired raised effect of embroidery was not obtained suiciently to satisfy the purchasing public, and the materials were too stiff and inflexible to be worn.

ICertainly it is recognized that it is impossible to obtain a raised look on printed fabrics. The very nature of the printing process prohibits the raised or bas-relief effect. This is further found to be true in roller printing, which although resulting in varying designs Aand multicolor effects cannot produce the bas-relief effect so frequently sought to be simulated.

However, attempts have been made in printing of designs to create a raised border (simulating embroidery). The attempt. centered about the use of viscous material for printing at the edges of the design and to print continuously until the border has been built. This has resulted in the cracking of the design and therefore has not been found practical.

Many attempts at hand printing and painting with thick and thin paints have resulted in` abject failures because of the cracking and flecking of the dried paints.

Other forms of obtaining these raised or bas-relief effects, have been tried, all with similar results. None of these varied methods and processes have been able to produce a fabric of multicolor, which is washable and dry cleanable and which provides a raised or bas-relief design which simulates embroideries.

It is the general object of the present invention to avoid and overcome the objections to prior art fabrics, and the method of making the same and yet provide an inexpensive fabric which appears to be embroidered.

Another object of the present invention is to provide a fabric which gives the impression of emfbroidery thereon.

A further object of the present invention is to provide a material with colorful designs thereon, in bas-relief, which is washable and dry cleanable.- n f- Yet another object of the present invention is to provide a washable and dry cleanable fabric which has a multiplicity of designs thereon, in bas-relief, which resembles hand-embroidered fabrics.

Still a further object of the present invention is to provide a method of making a highly decorative fabric which is washable and dry cleanable which resembles a fabric which is hand embroidered.

Still another object of the present invention is to provide a method of making a highly decorative fabric which is washable and dry cleanable and which simulates hand embroidered material, at a low manufacturing cost.

The objects of the present invention enumerated above, and other objects which Will become more apparent as the description proceeds are achieved by providing a decorative fabric which simulates a hand-embroidered fabric having a fabric base and a thinned layer of polyvinyl chloride resin applied thereto through a design application member. A second layer of thickened polyvinyl chloride resin is selectively and contiguously applied to the thinned layer of polyvinyl chloride resin thereby selectively creating a raised design effect. The fabric is then passed through a heat field in which the polyvinyl chloride layers are made integral with each other, resulting in a highly designed fabric which is washable, dry cleanable and fiexible and one which closely resembles a handembroidered fabric.

For a better understanding of the present invention reference should be had to the accompanying drawings wherein like numerals of reference indicate similar parts throughout the respective views and wherein FIG. 1 is a plan view of a bas-relief design on a fabric.

FIG. 2 is a cross-sectional view of the design of FIG. 1 taken along lines 2-2 of FIG. 1.

FIG. 3 is a cross-section view of the alternative embodiment of FIG. 2, and

FIG. 4 is pictorial representation of the apparatus used in the preparation of fabric.

Although the principles of the present invention are broadly applicable to the application of designs having an appearance of hand embroidery on various materials it should be understood that the present invention is particularly well adapted to the application of a printed design to wearable fabrics and hence it is shown and will be described as such. Referring now to FIG. 1, a fabric having a printed design thereon, simulating hand embroidery, is shown and may be designated by the reference numeral 10. A fabric base material 12 or other material suitable for wearing is provided to which a design 14 may be applied.

As shown in FIG. 2 and FIG. 4, a first application or layer 16 of polyvinyl chloride may be applied to the base material 12, in a predetermined design by means of a design application member 18. The design application member 18 may take the form of a silk screen or the like member through which a thinned composition of polyvinyl chloride resin 20 may be used. It may be seen that a myriad of varying designs may be applied in this manner. The first layer 16 of resinous material 20 will generally provide the basic design which is to be embellished soon thereafter, and generally contains the basic color theme of the design 14.

Immediately after the application of the first layer 16 has been made, to the base material 12, a second design application member 22 may be placed over the basic design 14, and in registry therewith, such that a second layer 24 of thick polyvinyl chloride may be selectively applied thereon. Generally, the second design application member 22 is used to apply the resin 20 to places on or adjacent the basic design 14 where a raised, or bas-relief effect is desired. It is contemplated that the second design application member 22 will take the form of a screen 26. However, other means may be utilized which will lend itself to this selective design application.

The simulated hand-embroidered effect of the fabric 10 is characterized in that a partial design which is applied to a base material by the first application member 18 is a relatively flat design 28 whereas the second application or layer 24 applied to selective areas bordering or on the relatively flat design 28 may be raised as much as one sixteenth (T1/i6) of an inch. The design 14 itself is completely flexible and bendable in all directions and is washable and dry cleanable. Further the back 30 of the base material 12, which may come into contact with the skin of the wearer, does not present any rough or irritating surface. The design 14 may be permanently integrated with the base material 12 so that cracking and peeling of the resinous material or polyvinyl chloride, is impossible.

In order to more fully describe the composition of the decorated fabric 10, reference is made to FIG. 4, which discloses the pictorial step by step procedure followed in the manufacture of the fabric 10. Procedurally, a base material 12, may have an open work fiat design 28 applied thereto on either selected areas of the base material 12 or covering the entire fabric. The designs 28 may be applied through a first design application member 18 which may take the form of a silk screen or stencil arrangement. A thinned polyvinyl chloride is applied to the base material -12 through the first design application member 18 which results in a generally flat appearing design 28. A second design application member 22 is thereafter placed over the firstly applied design and the openings in the screen or stencil, which are to be used to selectively flow a thickened polyvinyl chloride border (for example) around the fiat design 28, is placed in proper registry. The more viscous second design is used through the second design application member or screen 26 in order to form the second or raised design, leaving a raised formation in the predetermined pattern.

It should be recognized that although a screen is referred to as the second design application member 22, this may be applied by hand or through a sieve or screen or other type of pattern forming device to produce the desired raised pattern or design.

In order to permanently adhere the first layer 116 to the base material 12 and to integrally join the first and second layer one to the other, the base material 12 'with the partially covering design thereon or entirely covering design, is passed into a heated environment 32 such that the two layers may slightly ow together without losing the highly raised border or design created by the second layer 24 of the polyvinyl chloride. The first layer 16 achieves its flat appearance by flowing or penetrating into the pores of the base material 12 becoming integral with the base material 12 thereby being permanently bonded thereto.

The resulting fabric 10 is one which is partially or wholly covered with a bas-relief plurality of designs `14 giving the appearance of an expensive hand embroidered look which is completely washable and dry cleanable.

Basically the plastic resins applied to the base material 12 are composed of vinyl chloride resin particles dispersed in a plasticizer to which may be added stabilizers, pigments, gelling agents, mineral spirits (for thinning) and similar modifying additives. The formulation for plastisols usable with the present invention is quite wide. For example, based upon 100 parts by weight of vinyl chloride resin, the amount of plasticizer may vary from 50 parts to 200 parts and the amount of pigment, stabilizers and/ or other modifying components may vary between 0 and 10 parts.

Typical examples of plastisols which may be used with the present invention are as follows:

Pounds Polyvinyl chloride resin (QYNV) 100 Di iso octyl phthalate Dibutyl tin maleate 1 Pounds Polyvinyl chloride resin (Geon 121) 100 Di octyl phthalate 80 Barium-cadmium laurate 1 Polyvinyl chloride resin (Exon 654) 100 Tri cresyl phosphate 80 Tri basic lead stearate 2 Plastisols made according to the above formulations I have found, have the characteristics of pliability, flexibility and softness rather than the stiffness and hardness of other types of adhesives. They may be readily cut or sewn and they can withstand repeated washing or dry cleaning and have good, long lasting wearing characteristics. If desired these plastisols may contain pigmentation and may be thinned by mineral spirits. In this manner the polyvinyl chloride may be made free fiowing for the fiat design (first layer) or thick and viscous (second layer) to give the high raised appearance where desired.

Although the second layer 24, which comprises the raised portion of the overall design 14 may have been previously described as being applied on top of the first layer 16 (generally flat portion of the design) it may be seen that the second layer 24 may be applied around or bordering the first layer 16 and in direct communication with base material 12. In this instance the heated environment 32 through which the base material 12 is passed will cause the thicker (second layer 24) to partially flow and thereby penetrate the pores of the base material 12 forming a permanent bond therebetween as previously described in relation to the lirst layer 16 (thinned PVC). In this latter instance, the second layer 24 may be applied to the base material 12 through the second design application member 22 which may take the form of a hand applicator, sieve, screen or other means. In this latter case, a metal screen member is preferred from the point of view of speed and accurate registry of the second layer around the first layer (the printed design).

Further, the thickness of the second design application member 22 is of utmost importance since the height of the second layer is a function of the thickness of the screen through which it is applied. Experimentation has shown that 1/16 of an inch is an optimum figure and higher raised portions may be obtained because of the thickness of the metal screen and the viscosity of the PVC.

'I'he step of heating or passing through a heated environment may be accomplished by placing the base material 12 in a heating means 34 such as one heated plate or by placing it in an oven, or by using infra-red heating lamps, or by using any other convenient heating means. All of the plastisols described above have a heat curing temperature in the range of 300 degrees F. to 400 degrees F. and all will adhere firmly to a fabric or other porous material by becoming firmly set in the pores, as shown in FIGS. 2 and 3. As described these plastisols have a suitable degree of lflexibility which allow a piece of fabric on which they are coated to be rolled, bent, shaped or sewn.

Highly stylized simulated machine and hand-embroidered material have been made according to the process of FIG. 4 using fabrics or other fibrous material as the base material. These fabrics which may have the raised bas-relief design as much as one sixteenth (1/16) of an inch above the base material have many desirable characteristics including long wearing life, ability to withstand repeated washing, ability to withstand dry cleaning, excellent draping appearance, and softness and exibility of the plastisol.

lIn carrying out the method of the invention disclosed above, it may be seen that the pigmentation of the first layer x16 will generally provide the basic color theme of the design 14, although more than one application to the basic design may be made. The second layer 24 may be of any color which is desired to either blend with or contrast with color of the first layer 16.

Although the invention has been described as utilizing polyvinyl chloride as the basic material for the layers which make up the design, acetates of varying natures may also be used. The acetates or PVA may be treated in the same manner as the PVCs and thereby create the hand-embroidered look previously described. However, it has been found generally that the PVC are not compatible with PVA so that when selecting a material to be used to make up the design 14, the choice of the resinous material must be consistent.

In summary, I have invented a new material which closely resembles a hand-embroidered fabric as well as the method of making the same. It may be recognized by those skilled in the art that my invention has completely solved the simulation of hand embroidery problems, by providing a bas-relief design either partially or wholly covering a fabric, The design being Washable, dry cleanable and flexible in substantially all directions, as well as being soft to the touch of the wearer.

Although a preferred embodiment and alternatives thereof have been described in detail, in accordance with the patent statutes, it should be particularly understood that the invention is not limited thereto or thereby.

I claim:

1. A simulated hand-embroidered material comprising a base material, a first layer of thinned polyvinyl chloride applied to said base material in an open work design, a second layer of thickened polyvinyl chloride laid contiguously to said first layer, said second layer being disposed on said first layer and being raised above said first layer, said first layer being fused to said base material by means of heat, and said second layer being fused to said first material thereby integrating the two layers, said simulated hand embroidery material being washable and dry-cleanable.

2. A simulated hand-embroidered material according to claim 1 wherein said first layer is permanently bonded to said base material.

3. A simulated hand-embroidered material according to claim 2 wherein said first and second layers are flexible and are bendable in all directions.

4. A method of making simulated hand embroidery material comprising the steps of applying a first layer of thinned polyvinyl chloride on a base material in an open work design, applying a second layer of thickened polyvinyl chloride through a design applicator on to said first layer of thinned polyvinyl chloride forming a raised design on said first layer, heating said base material and said first and second layers of polyvinyl chloride, fusing said first layer of thinned polyvinyl chloride to said base material, and fusing said second thickened layer of the polyvinyl chloride to said first thin layer of polyvinyl chloride for permanently bonding each layer together and to said base material,

References Cited UNITED STATES PATENTS 3,323,976 6/ 1967 Salcer 117-37X 2,798,820 7/ 1957 Nelson 117-45X 3,432,328 3/1969 Vaurio 117-38 3,338,731 y8/1967 Sommer 1l7-45X 2,889,651 -6/1959 Baldanza 264-92 2,810,673 10/1957 Wooldrik 161-97X 3,259,515 7/ 1966 Pecker 117-38X PHILIP DIER, Primary Examiner UJS. Cl. X.R.

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