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.

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.