Abstract:
A graphic for application to a textile is disclosed. The graphic includes a front surface configured to be viewable when the graphic is applied to the textile. The graphic further includes a back surface opposite the front surface and configured to contact the textile. The graphic further includes an attachment mechanism, other than stitching, that attaches the graphic to the textile. The graphic also includes a simulated stitching pattern “etched” onto the front surface of the graphic extending around a perimeter of the graphic and includes projections simulating stitch ends.

Description:
TECHNICAL FIELD 
     The embodiments described herein are generally directed to graphics, such as numbers, letters, licensed characters, figures, and other images, that are applied to garments and other textiles. 
     BACKGROUND 
     Graphics, such as letters, numbers, licensed characters, figures, and other images are commonly applied to garments and other textiles. Many different techniques exist for applying such graphics, including screen printing, heat transfer, stitching, etc. Each available technique gives the graphic a somewhat different appearance. For example, when a graphic is stitched onto a garment or textile, the stitch marks are visible to an observer. For various applications, this “stitched” appearance is desirable. However, stitching graphics onto a textile is more costly and time consuming than other methods of applying graphics, such as adhering the graphic to the textile using a heat-activated adhesive, for example. 
     The inventors hereof have recognized a need to provide a graphic that has a “stitched” appearance, but is faster and more cost-effective to apply to a textile than actually stitching the graphic to the textile. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates an exemplary graphic having a simulated stitching pattern extending around the perimeter of the graphic. 
         FIG. 2  illustrates the back side of the graphic shown in  FIG. 1 . 
         FIG. 3  is a perspective view of the graphic shown in  FIGS. 1 and 2  relative to a textile to which the graphic is applied. 
         FIG. 4  illustrates an exemplary laser device that can be used create the graphic illustrated in  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION 
     The embodiments described herein relate to a graphic and related methods for generating and applying such graphic to a textile having a “stitched” appearance, but which does not involve actually stitching the graphic to the textile. A cutting device, such as but not limited to a laser, is used to cut the graphic from a material. The cutting device is further used to create “scallops” around the perimeter of the graphic such that a series of small projections of material extends outward from the perimeter of the graphic to emulate the appearance of the stitching thread that would normally be present outside the perimeter of the graphic if the graphic were actually stitched to the textile. The cutting device is further used to “etch” a pattern into the graphic itself, near the graphic&#39;s perimeter, to emulate the stitching thread that would normally be present on the interior of the graphic if the graphic were actually stitched to the textile. The graphic is then applied to the textile using a method other than stitching, such as adhesion using a heat-activated adhesive on the backing of the graphic. In this way, the desired “stitched” appearance is achieved at a lower cost. 
       FIG. 1  illustrates an exemplary graphic having a stitched appearance, but which is not actually stitched to a textile. Graphic  5  is shown in  FIG. 1  as a numeric “7.” Clearly, graphic  5  can be any type of letter, number, figure, character, or other image that is to be applied to a garment or other textile. Graphic  5  includes a front surface  10  and a back surface  13  (shown in  FIG. 2 ) on the opposite side of the front surface  10 . The front surface  10  of the graphic  5  is intended to face outward from the textile when the graphic  5  is applied to the textile. The back surface  13  is intended to be in contact with the textile to which the graphic  5  is applied, as shown in  FIG. 3 . The back surface of the graphic  5  includes a mechanism, other than stitching thread, for attaching the graphic to a garment or other textile. Various attachment mechanisms can be used, including various adhesives, including heat-activated adhesives. The back side  13  of the graphic is shown in  FIG. 2  having adhesive  15  thereon to act as the attachment mechanism. 
     As best shown in  FIG. 1 , the graphic  5  has a simulated stitching appearance around the perimeter of the graphic  5 . The simulated stitching appearance includes a series of projections  12  that extend outward from the perimeter of the graphic  5  to create a “scalloped” appearance on the perimeter of the graphic, effectively emulating the appearance of stitching thread attaching the graphic  5  to the textile outside of the graphic  5 . The projections  12  are created while cutting the perimeter of the graphic  5  using a “scalloped” contour as the perimeter of the graphic  5  and are integral with the graphic  5 . The graphic  5 , including the projections  12 , may be cut from a roll or piece of material using a laser cutting system. The simulated stitching appearance also includes an etched pattern  14  on the interior portion of the graphic  5 . The etched pattern  14  may be created by using a laser or other device to create “lines” on the material of the graphic  5 . Together, the projections  12  and etched pattern  14  create the appearance of stitching thread applied around the perimeter of the graphic  5  to couple the graphic  5  to a textile. However, it is the attachment mechanism on the back side of the graphic  5 , such as an adhesive, that actually attaches the graphic  5  to a textile. 
     One possible laser system that can be used to cut the graphic  5  (including the projections  12 ) and to create the etched pattern  14  in the material of the graphic  5  to simulate a stitched appearance is described below, with reference to  FIG. 4 . The laser  111  of  FIG. 4  generates a laser beam  112  in the direction of a computer numerically controlled mirror system. The mirror system includes an x-axis mirror  113 . The x-axis mirror  113  is mounted on an x-axis galvanometer  114 . The x-axis galvanometer  114  is adapted to rotate to cause rotation of the x-axis mirror  113 . Rotation of the x-axis mirror  113  causes movement of the laser beam  112  along the x-axis. A numerical control computer  115  controls the output of a power source  116  to control rotation of the x-axis galvanometer. The laser beam  112  is deflected by the x-axis mirror  113  and directed toward a y-axis mirror  117 . The y-axis mirror  117  is mounted on an y-axis galvanometer  118 . The y-axis galvanometer  118  is adapted to rotate to cause rotation of the y-axis mirror  117 . Rotation of the y-axis mirror  117  causes movement of the laser beam  112  along the y-axis. The numerical control computer  115  controls the output of the power source  116  to control rotation of the y-axis galvanometer  118 . 
     The laser beam  112  is deflected by the y-axis mirror  117  and directed through a focusing lens  119 . The lens  119  is adapted to focus the laser beam  112 . The lens  119  is a multi-element flat-field focusing lens assembly, which optically maintains the focused spot on a flat plane as the laser beam moves across the material  11  to generate the graphic  30 . The apparatus  110  further includes a working surface  120  which can be almost any solid substrate such as a table, or even a gaseous fluidized bed. The material  11  is placed on the working surface  120 . The working surface  120  can be adjusted vertically to adjust the distance from the lens  119  to the grain  16  of the material  11 . 
     The preceding description has been presented only to illustrate and describe exemplary embodiments of the methods and systems. It is not intended to be exhaustive or to limit the invention to any precise form disclosed. It will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. The invention may be practiced otherwise than is specifically explained and illustrated without departing from its spirit or scope. The scope of the invention is limited solely by the following claims.