Stabilizer coating for machine embroidering

Abstract

Embodiments provide for an embroidery process where a stabilizer coating (rather than a paper or fabric backing) is used to provide support for an embroidery design. In one embodiment, when applying the stabilizer coating, its viscosity is changed in order to adhere the stabilizer coating to a garment and provide sufficient support for the embroidery design.

1 - 6 . (canceled) 
     
     
         7 . A method comprising:
 providing an article;   applying a stabilizer coating onto an area of the article corresponding to a size and shape of an embroidered pattern to be applied to the area, wherein the area of the article corresponding to the size and shape of the embroidered pattern is less than an entire area of the article;   tensioning the article; and   performing embroidery on the stabilizer coating of the tensioned article to create the embroidered pattern, wherein the stabilizer coating provides sufficient structural support to the area of the article corresponding to the size and shape of the embroidered pattern such that a backing material is not used during the embroidery.   
     
     
         8 . The method of  claim 7 , wherein applying the stabilizer coating onto the area of the article corresponding to the size and shape of the embroidered pattern to be applied to the area comprises:
 applying the stabilizer coating in a liquid state or as a foam,   the method further comprising:
 curing the stabilizer coating to convert it into a solid state before performing the embroidery. 
   
     
     
         9 . The method of  claim 8 , wherein the stabilizer coating is a polymer applied in the liquid state to the article. 
     
     
         10 . The method of  claim 9 , wherein the stabilizer coating comprises at least one of polyurethane, polyester, or polyethylene. 
     
     
         11 . The method of  claim 8 , wherein the liquid state of the stabilizer coating is a hot melt of fibrous material. 
     
     
         12 . The method of  claim 7 , wherein applying the stabilizer coating onto the area of the article corresponding to the size and shape of the embroidered pattern to be applied to the area comprises:
 providing a thin film having a shape and a size that substantially matches a size and shape of the embroidered pattern, wherein the stabilizer coating comprises the thin film;   placing the thin film on the article; and   heating the thin film to melt and bond the thin film to the article, wherein the stabilizer coating comprises the bonded thin film.   
     
     
         13 . The method of  claim 7 , wherein applying the stabilizer coating onto the area of the article corresponding to the size and shape of the embroidered pattern to be applied to the area comprises:
 determining a desired height of a 3D design corresponding to the embroidered pattern;   determining a thickness of the stabilizer coating to achieve the desired height;   applying the stabilizer coating onto the area of the article at a first thickness; and   applying the stabilizer coating with the determined thickness at a location of the 3D design, wherein the first thickness is less than the determined thickness.   
     
     
         14 . The method of  claim 7 , wherein the area of the article corresponding to the size and shape of the embroidered pattern is larger than an area occupied by the embroidered pattern. 
     
     
         15 . The method of  claim 14 , wherein a boundary of the area of the article corresponding to the size and shape of the embroidered pattern is less than 7 millimeters from a boundary of the area of the embroidered pattern. 
     
     
         16 . The method of  claim 7 , wherein the stabilizer coating is disposed on an exterior surface of the article. 
     
     
         17 . The method of  claim 7 , wherein the article is tensioned before the stabilizer coating is applied to the area of the article. 
     
     
         18 . The method of  claim 7 , wherein the article is tensioned after the stabilizer coating is applied to the area of the article. 
     
     
         19 . A method of providing an embroidered article, the method comprising:
 providing an article, the article comprising a substrate layer;   applying a liquid polymer stabilizer coating onto an area of the substrate layer corresponding to a size and shape of an embroidered pattern to be applied to the area, wherein:
 the area of the substrate layer corresponding to the size and shape of the embroidered pattern is less than an entire area of the article; and 
 a viscosity of the stabilizer coating increases after the stabilizer coating is applied; and 
   performing embroidery on the stabilizer coating to produce the embroidered article, wherein
 the stabilizer coating provides sufficient structural support such that a backing material is not used during the embroidery. 
   
     
     
         20 . The method of  claim 19 , wherein applying the liquid polymer stabilizer coating comprises:
 applying the stabilizer coating in a liquid state with a first viscosity,   the method further comprising:
 curing the stabilizer coating to increase the viscosity of the stabilizer coating to a second viscosity before performing the embroidery. 
   
     
     
         21 . The method of  claim 19 , wherein applying the liquid polymer stabilizer coating comprises:
 providing a thin film with a first viscosity and having a shape that substantially matches or is slightly larger than a size and shape of the embroidered pattern;   placing the thin film on the substrate layer; and   heating the thin film to lower its viscosity to a second viscosity to bond the thin film to the substrate layer, wherein the stabilizer coating comprises the thin film.   
     
     
         22 . The method of  claim 21 , further comprising curing the stabilizer coating to increase the viscosity of the stabilizer coating to a third viscosity before performing the embroidery. 
     
     
         23 . (canceled) 
     
     
         24 . The method of  claim 13 , wherein applying the stabilizer coating with the determined thickness at a location of the 3D design comprises:
 (a) applying a layer of the stabilizer coating;   (b) curing the layer of the stabilizer coating; and   (c) repeating (a) and (b) until the stabilizer coating is at the determined thickness.   
     
     
         25 . The method of  claim 19 , wherein the stabilizer coating remains a separate layer from the substrate layer after performing embroidery on the stabilizer coating.