Sewing – Method of sewing – Stitch forming
Reexamination Certificate
1999-12-22
2001-07-24
Izaguirre, Ismael (Department: 3765)
Sewing
Method of sewing
Stitch forming
C112S439000
Reexamination Certificate
active
06263817
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates to embroidery auxiliary members that are adapted to be superimposed on a base fabric, sewn together with the base fabric using embroidery yarn, and thereafter removed. The present invention also relates to embroidery methods and embroidery products using the embroidery auxiliary members.
RELATED ART
Embroidery auxiliary members have been adapted to be superimposed on a base fabric, sewn together with the base fabric by embroidery yarn, and thereafter removed. Such embroidery auxiliary members have been used for the following two known applications:
(1) “Spacer” for forming hollow three-dimensional embroideries.
(2) “Support member” for supporting a base fabric during an embroidering operation.
The technique relating to the (1) “spacer” application will now be explained. A method of manufacturing hollow three-dimensional embroidery products using a known embroidery machine is disclosed in Japanese Laid-Open Patent Publication No. 5-195411. The principle of the manufacturing method disclosed in this publication is based on the steps of: laying a sheet-like member on a base fabric, which sheet-like member has a predetermined thickness and is also known as a “spacer” that is soluble for removal; and embroidering by sewing over the spacer. After completion of the embroidering operation, the spacer existing between embroider yarn, which have been sewn over the base fabric, and the upper surface of the base fabric is dissolved and removed. As a result, the embroidery yarn remains in a three-dimensional form, so that a hollow three-dimensional embroidery product can be obtained. In order to remove the spacer, three different methods have been utilized in the art, which methods include (A) dissolving in water, (B) melting by heat, and (C) dissolving in an organic solvent.
According to method (A), a plate made of water-soluble material, such as a starch wafer, or a non-woven fabric formed of polyvinyl alcohol fibers (PVA felt), is used as a spacer and is dissolved in a room temperature water or hot water. However, with this method, the dissolved spacer material has a paste-like consistency, so that it is difficult to completely remove the dissolved material from the embroidery product. According to method (B), as disclosed in Japanese Patent Publication Nos. 59-7824 and 60-42311, this method must be carried out with the aid of an absorbable material that is applied to the spacer material while it melts, in order to prevent the embroidery yarn from absorbing the melted spacer material. Therefore, the removal of the melted spacer material is quite difficult.
In contrast, in the case of method (C), acetate fabric, diacetate felt (non-woven fabric), an expanded polystyrene plate or the like are used as spacers and are adapted to be dissolved in an organic solvent, such as acetone or 1-2 dichloroethane. If acetone or 1-2 dichloroethane is used, the removal operation of the dissolved spacer can be performed more easily than the above methods (A) and (B).
However, acetone and 1-2 dichloroethane are highly flammable, such that the handling of these solvents is dangerous. If these solvents are used, the spacer dissolving and removing operation should be performed in an explosion-proof installation. Therefore, this spacer dissolving and removing method that uses such organic solvents can be practiced only by manufacturers who can install a large-scale explosion-proof plant. An ordinary manufacturer of embroidery products cannot practice this method.
The technique relating to the (2) “Support member” application for supporting a base fabric during an embroidering operation will now be explained. For example, Japanese Laid-Open Patent Publication No. 5-186957 teaches the use of a synthetic resin sheet made of synthetic resin as a support member, which synthetic resin sheet is soluble in solvents that are used for a dry-cleaning purposes. The solvents listed in this publication as being appropriate for dry-cleaning purposes include trichloroethane, trichloroethylene, tetrachloroethylene and petroleum solvents (mineral spirit or mineral turpentine). The synthetic resins listed in this publication as being soluble in these solvents include ethylene, vinyl acetate copolymer, polyvinyl acetate, polyethylene and polypropylene or mixtures thereof.
However, in order to practice the technique disclosed in this publication, it is necessary to heat the solvents. In fact, in the preferred embodiments disclosed in the publication, the solvents are heated to 60°-90° depending on their properties.
Thus, in order to practice the technique of this publication, heating means as well as temperature control means for maintaining the temperature of the solvents at suitable temperatures is required. In addition, in order to prevent the evaporated solvents from exploding, a pressure-resistant and explosion-proof installation is required. Therefore, the embroidering method using the support members of this publication is expensive.
Further, among the solvents listed in the publication, the production of trichloroethane and trichloroethylene has already been discontinued in Japan, because of their harmful effect on the environment or the human body. This is also a worldwide trend. Further, because petroleum solvents are flammable, an explosion-proof installation is required as discussed in connection with (1).
Although tetrachloroethylene is available, support members that are made from materials listed above may not, in practice, be dissolved in this solvent, even if the solvent has been heated.
Therefore, the actual technique that can be practiced involves dissolving and removing the support member using petroleum solvents and based on the conditions that an explosion-proof installation and heating means are incorporated in the technique.
As described above, for any of the embroidery auxiliary members as discussed in (1) and (2), a problem exists that an expensive installation is required.
SUMMARY OF THE INVENTION
One aspect of the present invention provides an embroidery auxiliary member that can be easily dissolved and removed without increasing costs.
Another aspect of the present invention provides an embroidery auxiliary member and a method of manufacturing an embroidery product by using such an embroidery auxiliary member that can be used as a spacer for forming a three-dimensional embroidery and that can be easily dissolved and removed.
Another aspect of the present invention provides an embroidery auxiliary member and a method of manufacturing an embroidery product by using such an embroidery auxiliary member that can be used as a support member for supporting a base fabric during an embroidering operation and that can be easily dissolved and removed.
Another aspect of the present invention provides a method of easily manufacturing a hollow three-dimensional embroidery product by using an embroidery auxiliary member that is utilized as a spacer for forming the hollow three-dimensional embroidery pattern, and another embroidery auxiliary member that is utilized as a support member for supporting a base fabric during an embroidering operation.
Another aspect of the present invention provides a hollow three-dimensional embroidery product that has an unique appearance.
According to the invention an embroidery auxiliary member is provided, which embroidery auxiliary member is adapted to be superimposed on a base fabric, embroidered together with the base fabric using embroidery yarn, and thereafter removed, the embroidery auxiliary member being made of material that is soluble in tetrachloroethylene.
Here, “tetrachloroethylene” is a solvent that is also known as perchloroethylene or perchlene, and broadly known according to its Japanese name of “shienka-echiren.”
Tetrachloroethylene is a non-combustible compound and is not easily flammable. Therefore, the dissolving and removing operation may not have a danger of explosion. For this reason, an explosion-proof installation is not needed to dissolve and remove the embroidery auxiliary member.
In addition, because the
Nanba Shunzo
Tajima Ikuo
Dennison, Scheiner Schultz & Wakeman
Izaguirre Ismael
Tokai Kogyo Mishin Kabushiki Kaisha
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