Methods and apparatus for applying appliques

Abstract

Methods and apparatus for creating decorative multi-layer applique patterns for garments or other items are disclosed. In some aspects, the invention includes cutting a first pattern out of a first material to form a bottom layer, cutting a composite of the first pattern and a second pattern out of a second material to form a top layer, and affixing the layers to an item. Numerous other aspects are included.

1 . A method comprising the steps of: 
 (a) cutting a first pattern out of a first material to form a bottom layer;    (b) cutting a composite of the first pattern and a second pattern out of a second material to form a top layer; and    (c) affixing the bottom layer and top layer to an item.    
   
   
       2 . The method of  claim 1  wherein cutting a composite of the first pattern and the second pattern includes cutting an intersection of the first pattern and the second pattern.  
   
   
       3 . The method of  claim 1  wherein cutting a composite of the first pattern and the second pattern includes cutting an intersection of the first pattern and a complement of the second pattern.  
   
   
       4 . The method of  claim 1  wherein the bottom layer and top layer are different colors.  
   
   
       5 . The method of  claim 1  wherein the first material and second material are different.  
   
   
       6 . The method of  claim 1  wherein the first pattern includes letters.  
   
   
       7 . The method of  claim 1  wherein step (b) includes cutting a composite of the second pattern and a smaller version of the first pattern used in step (a).  
   
   
       8 . The method of  claim 1  wherein step (b) includes cutting a composite of the second pattern and a same sized version of the first pattern used in step (a).  
   
   
       9 . The method of  claim 1  wherein the second pattern includes a graphic image.  
   
   
       10 . The method of  claim 1  wherein the second pattern includes a negative cutout of a graphic image.  
   
   
       11 . The method of  claim 1  wherein the first pattern includes a plurality of discrete elements and the second pattern includes a design contained in one of the discrete elements.  
   
   
       12 . The method of  claim 1  wherein the first pattern includes a plurality of discrete elements and the second pattern includes a design that spans more than one of the discrete elements.  
   
   
       13 . The method of  claim 1  wherein the first pattern includes a plurality of discrete letters and the second pattern includes a negative cutout of a graphic image that spans more than one of the discrete letters.  
   
   
       14 . The method of  claim 1  further comprising the steps of: 
 cutting a composite of the top layer and a third pattern out of a third material to form a third layer; and    affixing the third layer to the top and bottom layers.    
   
   
       15 . The method of  claim 14  wherein the third material is different than the first and second materials.  
   
   
       16 . A method comprising: 
 affixing a bottom layer of material to a garment wherein the bottom layer is shaped in a first pattern; and    affixing a top layer of material to the bottom layer wherein the top layer is shaped in a second pattern,    wherein the top layer of material covers a smaller area than the bottom layer of material and the second pattern has a different shape than the first pattern.    
   
   
       17 . The method of  claim 16  wherein the second pattern has a shape such that when superimposed upon the first pattern, a third pattern is visible.  
   
   
       18 . The method of  claim 17  wherein the shape of the second pattern is the negative image of the third pattern.  
   
   
       19 . The method of  claim 16  wherein the first pattern includes a plurality of letters.  
   
   
       20 . The method of  claim 19  wherein the second pattern includes a graphic symbol.  
   
   
       21 . The method of  claim 20  wherein the graphic symbol spans more than one of the plurality of letters of the first pattern when the top layer of material is affixed to the bottom layer of material.  
   
   
       22 . A product comprising: 
 a garment having an outer facing surface;    a bottom layer of applique attached to the outer facing surface of the garment; and    a top layer of applique attached to the bottom layer,    wherein the bottom layer is shaped as a set of letters at least two of which are spaced apart from each other, and    wherein the top layer is an image extending only across at least a portion of the set of letters, following the contours of such portion, and leaving the outer facing layer free of the top layer.    
   
   
       23 . A computer readable medium adapted to store instructions operable to direct an automated garment manufacturing system controller to: 
 (a) cut a first pattern out of a first material to form a bottom layer; and    (b) cut a composite of the first pattern and a second pattern out of a second material to form a top layer.    
   
   
       24 . An apparatus comprising: 
 a controller;    a material cutter coupled to and operable by the controller; and    a memory coupled to the controller and adapted to store instructions to: 
 (a) cut a first pattern out of a first material to form a bottom layer, and  
 (b) cut a composite of the first pattern and a second pattern out of a second material to form a top layer.  
   
   
   
       25 . A method of operating a machine comprising: 
 placing a first layer of material onto a support surface;    cutting a first pattern in the first layer;    placing a second layer of material over the first layer including the portions that have been cut and uncut;    cutting a second pattern, within the boundaries of the first pattern, out of the second layer;    removing material of the layers that is outside of the cut patterns; and    removing the first and second layers from the support surface.    
   
   
       26 . The method of  claim 25  further comprising: 
 affixing the layers to an item.    
   
   
       27 . The method of  claim 25  further comprising: 
 placing a third layer of material over the second layer including the portions that have been cut and uncut; and    cutting a third pattern, within the boundaries of the first and second patterns, out of the third layer.    
   
   
       28 . The method of  claim 25  further comprising: 
 placing a third layer of material over the second layer including the portions that have been cut and uncut; and    cutting a third pattern, within the boundaries of the first pattern, out of the third layer.    
   
   
       29 . The product of  claim 22  wherein the bottom layer and top layer are different colors.  
   
   
       30 . The product of  claim 22  wherein the bottom layer of the applique is made of a first material  
   
   
       31 . The product of  claim 22 , wherein the top layer of the applique is made of a second material.  
   
   
       32 . The product of  claim 22 , further comprising a third layer of the applique.  
   
   
       33 . The product of  claim 32 , wherein the third layer of the applique is made of a third material.