Abstract:
A process for the production of a textile product includes placing a flat motif template on a textile substrate, sewing the motif template onto the textile substrate in such a way that a perforation defining a desired motif in the motif template is produced, removing the part of the motif template, that is outside the motif defined by the perforation, and permanently fixing the remaining part, having the motif, of the motif template to the textile substrate.

Description:
This application is a Continuation application of U.S. Ser. No. 13/576,419, filed on Aug. 3, 2012, which is a U.S. national stage application of PCT international application PCT/EP2011/050539 filed on 17 Jan. 2011, and claims priority of both U.S. provisional patent application 61/300,494 filed on 2 Feb. 2010 and German patent document 10 2010 001 511.3 filed on 2 Feb. 2010, the entireties of which are incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     Field of the Invention 
     The invention concerns a process for the production of a textile product, in particular a textile product provided with a motif having reflecting properties. 
     State of the Art 
     DE 1 446 828 A1 discloses a reflecting transfer film and a process for the production of reflex-reflecting articles, for example for marking articles of clothing. The transfer film has a transfer layer comprising an adhesive layer and a rubber-like binding agent layer disposed thereon with incorporated microballs projecting partially therefrom, and a protective layer which is disposed on the adhesive side of the transfer layer and which can be pulled off. On its front side the transfer layer has a dimensionally stable carrier substrate which can be pulled off dry after the gluing-on operation. To transfer it onto an article of clothing a hot iron is firmly pressed onto the carrier substrate of the assembly and then the carrier substrate is pulled off the reflex-reflecting transfer film. To apply markings of different kinds of shapes the motifs in question firstly have to be cut out and then applied to the subjacent article of clothing or fabric. 
     It is further known in the state of the art for reflecting motifs which are transferred onto a textile product such as for example an article of clothing, in particular individual or free-standing letters, to be provided with a peripherally extending seam after the transfer operation, which admittedly in consideration of the resulting combination of reflecting and non-reflecting reproduction of the motif, leads to attractive effects, but that makes the process overall in consideration of the multiplicity of process steps required and in particular the cutting operation which is complex depending on the respective motif involved complicated and also expensive (as a consequence of the costly laser apparatuses generally used for the cutting operation). 
     SUMMARY OF THE INVENTION 
     The object of the present invention is to provide a process for the production of a textile product, which in a particularly economical fashion permits the production of an attractive textile product at a comparatively low level of complication and expenditure. 
     A process according to the invention for the production of a textile product comprises the following steps:
         placing a flat motif template on a textile substrate,   sewing the motif template onto the textile substrate in such a way that a perforation defining a desired motif in the motif template is produced,   removing the part of the motif template, that is outside the motif defined by the perforation, and   permanently fixing the remaining part, having the motif, of the motif template to the textile substrate.       

     In that respect here and hereinafter the term “sewing on” in conformity with the usual terminology is used to denote any operation in which one or more sewing threads or yarns are passed through a material to be sewn, wherein the threads are entwined together or to the material being sewn. As perforation of the motif template is produced principally by the step according to the invention of sewing the motif template onto the textile substrate and as the connection produced in that way between the motif template and the textile substrate becomes a permanent fixing (for example preferably being wash-resistant) only in the fixing step (being the concluding step in the sequence of the foregoing process steps), the corresponding seam can also be produced with an embroidery machine. Insofar as and because, after the part of the motif template disposed outside the motif defined by the perforation is pulled off, substantially the seam surrounding the desired motif remains and subsequent permanent fixing is only then effected for example by means of heat or pressure), the step of sewing or applying the motif template to the textile substrate can so-to-speak also be referred as “stitching on”. 
     The invention is based on the concept, when sewing on a motif template which in particular as explained hereinafter can involve a reflection transfer of a suitable configuration, of producing a perforation at the same time (that is to say so-to-speak in one and the same working step), which perforation permits subsequent removal of the part disposed beyond the perforation or outside a desired motif. 
     In that respect either the motif can already be present in the motif template from the outset or it can first be defined by the perforation or the seam producing the perforation. The motif can be for example any image motif (including multi-part), alphanumeric characters (that is to say for example also a sequence of letters or digits), or simply an area (depicted in one or more colors, including white or black and transparent) which can represent a part of the motif template. 
     According to the invention therefore with just a few process steps it is possible to produce an attractive textile product which for example shows any lettering on the one hand with a seam forming an outer boundary line and on the other hand in the region within that boundary line with special properties (that is to say for example reflecting), according to the motif template used. 
     The process according to the invention considerably simplifies in particular the conventionally usual processing of a reflection transfer in which a reflection transfer is firstly cut in the outer region in a complicated and expensive operation (generally manually or using a laser device). The process makes it possible in particular to produce short-run series very inexpensively, for example forgery-proof and high-value individual manufactures for fan clubs, by a procedure whereby for example for a sports organization a film already provided with reflecting logos is produced, to which then individual fan club names can be sewn on according to the invention. That affords a considerable saving in time and cost as for example the operation of sewing on or stitching on the logo is no longer required. If a typical number of stitches of for example between 20,000 and 30,000 stitches per motif is considered, the time saving achieved can be of the order of magnitude for example of about 20 minutes. 
     In an embodiment the motif template is provided with reflecting properties. For that purpose preferably a reflection transfer with the following layer structure is used as the motif template: base medium, transfer adhesive, optional intermediate color layer, and reflection color, wherein the reflection color contains a multiplicity of reflection particles and wherein the reflection particles are raised above the surface of the hardened reflection color. The base medium (for example an adhesive-repellent, silicone-based protective paper) is removed prior to placement on the textile substrate. 
     In that respect the invention is based on the realization that a reflection transfer of suitable structure, more specifically formed from a transfer adhesive layer and a color layer comprising a reflection color with a multiplicity of reflection particles, permits such delimitation of the total thickness of the reflection transfer with at the same time good reflection particles that the operation according to the invention of sewing it onto a textile substrate can be implemented with simultaneous production of a sufficiently clean perforation in the reflection transfer. 
     In that respect it is to be noted that in the state of the art conventional reflection transfers have a comparatively “closed” or sealed layer which does not at all permit sewing to be effected therethrough, or allow a clean perforation effect which that entails. In particular, as already explained in the opening part of this specification, such reflection transfers generally require a kind of “transfer tape” which is required during the production process as a base layer for application of reflection particles—such application operation being in side-reversed relationship—and which after transfer onto the textile substrate closes off the layer structure upwardly, and are consequently not free towards the top side (permitting sewing through the entire reflection transfer). 
     In an embodiment the motif template on the side towards the textile substrate has a fixing layer. That fixing layer can be both a fixing layer for provisional or temporary fixing on the textile substrate (prior to the subsequent operation of sewing it on) and also a fixing layer which permits concluding permanent fixing, for example under the effect of heat and/or pressure). 
     In an embodiment the step of placing the motif template on the textile substrate includes at least temporary fixing of the motif template on the textile substrate, preferably using a spray adhesive. 
     In an embodiment the motif template has a film made from a thermoplastic material (for example polyurethane or polyamide). The motif template can further have a suitable screen printing adhesive (for example as described in EP 1 137 546 B1). 
     In an embodiment a motif template with a total thickness in the range of between 15 μm and 100 μm, in particular in the range of between 25 μm and 85 μm, is used. 
     In an embodiment the desired motif is represented in the correct side relationship in plan view by the reflection color in the reflection transfer. Such a representation in correct side relationship is implemented precisely by the above-described reflection transfer of suitable structure, it avoids the use, which is usual in the state of the art, of a “transfer tape”, as is required during the production procedure as a base layer for applying reflection particles in side-reversed relationship, and it thus makes it possible to sew through the entire reflection transfer in accordance with the invention. 
     The invention further concerns a textile product produced by a process according to the invention. 
     Further configurations of the invention are to be found in the description and the appendant claims. 
     The invention is described in greater detail hereinafter by means of embodiments by way of example illustrated in the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  shows a flow chart to describe a process according to the invention in a preferred embodiment, 
         FIGS. 2 a - f    show diagrammatic views to illustrate the process according to the invention, and 
         FIG. 3  is a diagrammatic view of a reflection transfer used in the process of  FIGS. 1 and 2 . 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     A preferred embodiment of the process according to the invention will now be described with reference to the flow chart shown in  FIG. 1  and the diagrammatic views serving for illustrative purposes in  FIGS. 2 a    through  2   f.    
     Referring to  FIG. 2 a   , firstly a motif template  10  in the form of a reflection transfer, the structure of which will be described in greater detail with reference to  FIG. 3 , is provided with an adhesive layer  20  in the form of a spray adhesive for provisional fixing, and is then placed on a textile substrate  30  (for example a T-shirt) (step S 10 ), in which case also a stitching non-woven fabric or embroidery backing  40  is placed under the textile substrate  30 . 
     The motif template  10  or the reflection transfer has a motif (wherein that motif can already be present in the motif template from the outset or can first be defined by the perforation described hereinafter or the seam producing the perforation). That motif can be for example any image motif, alphanumeric characters (that is to say for example a succession of letters or digits) or also simply a surface (which is of one or more colors, including white or black and transparent). In the case of a sequence of letters or digits the seam can also extend around each individual one of the characters (that is to say for example each individual, free-standing letter). In that way, it is possible to achieve in the finished textile product an improved feel in the material, in comparison with sewing on a larger motif over a full area. 
     In step S 20  the motif template  10  or the reflection transfer  10  (after pulling the base medium off the layer structure shown in  FIG. 3 ) is sewn onto the assembly consisting of the textile substrate  30 , the adhesive layer  20  and the stitching non-woven material or backing  40 , in such a way that at least one perforation is produced in the motif template  10 , to define the motif which is desired on the textile product to be produced. That operation of sewing on the motif template  10  firstly includes producing a first seam  50  in the form of a tacking stitch, as shown in  FIG. 2 c   , preferably with a stitch length in the range of between 2 mm and 2.5 mm, followed by the production of a second seam  60  in the form of a satin stitch, preferably of a stitch length in the range of between 2 mm and 3 mm in length, as shown in  FIG. 2 d   . It will be appreciated however that the invention is not limited to those stitching or sewing stitches which are stated only by way of example, but can also be implemented with any other kinds of stitch with which the motif template  10  or film is perforated. 
     Then as shown in  FIG. 2 e    in step S 30  that portion  10   b  of the motif template  10 , that does not belong to the motif desired on the textile product to be produced or that is disposed beyond the perforation, is removed for example manually, in which respect use is made of the fact that the motif template  10  is well perforated by the seams  50 ,  60  previously produced in step S 20 . 
     Thereupon in step S 40  as shown in  FIG. 2 f    the textile product together with the remaining part of the motif template  10  or the reflection transfer is laid under a transfer press  70  for permanent fixing and is permanently fixed by means of heat and/or pressure, being pressed for example for a period of between 5 and 20 seconds at a temperature of between 120 and 180° C. 
     The reflection transfer used as the motif template  10  is preferably of the structure diagrammatically shown in  FIG. 3 , that is to say it includes in that sequence a base medium  11 , a transfer adhesive  12 , an optional intermediate color layer  15  and reflection color  13 , wherein that reflection color  13  contains a multiplicity of reflection particles  14  (for example of a maximum size of 45 .mu.m) and wherein the reflection particles  14  are raised above the surface of the hardened reflection color  13 . Suitable processes for the production of such a reflection transfer are described in EP 1 137 546 B1. The base medium  11  can be an adhesive-repellent, for example silicone-based, protection paper which is pulled off prior to placement of the reflection transfer on the textile substrate. The transfer adhesive  12  used within the reflection transfer  10  can be applied to the base medium  11  by means of any suitable process, for example an extrusion process, a screen printing process (as described in EP 1 137 546 B1), a suitable coating process or in some other fashion. 
     A suitable transfer adhesive  12  is for example a thermoplastic co-polyester hot melt adhesive film. The film or the transfer adhesive  12  should be of a strength sufficient for the sewing-on operation and in particular on the one hand should not be too soft in order to prevent it from sticking to the needle which is used during the sewing-on operation and which heats up the adhesive in the upward and downward movement. Optionally for that purpose the transfer adhesive  12  can be provided with reinforcing particles. On the other hand the film or the transfer adhesive  12  should not be too hard in order still to permit the needle to pass therethrough without any problem and to allow it to be subsequently torn off along the perforation line produced. 
     In a further embodiment a laser unit can also be additionally integrated in the apparatus used for the sewing-on operation according to the invention in order to provide for laser processing in accurate relationship during or after the above-described steps on the respective arrangement which is sewn on and secured in place. Although the motif template or film is already sufficiently perforated by the described process steps to permit removal (for example by being torn off) of unwanted film portions, it is additionally possible to use the laser unit to pass over the reflection transfer or the film in order to hatch for example the surface thereof, to “destroy” the reflection at the surface in region-wise fashion in specifically targeted manner and to achieve attractive effects (“reflection/non-reflection”). In that respect use is made of the fact that, in the case of the above-described reflection transfer used in accordance with the invention, the surface with the reflection particles is open upwardly and is not covered with a transfer tape. In addition, non-reflecting elements  16  such as for example flock strips, non-reflecting colors and so forth can also be applied by printing to the reflecting regions. 
     Even if the invention has been described by reference to specific embodiments numerous variations and alternative embodiments will be apparent to the man skilled in the art, for example by combination and/or exchange of features of individual embodiments. Accordingly it will be appreciated by the man skilled in the art that such variations and alternative embodiments are also embraced by the present invention and the scope of the invention is limited only in the sense of the accompanying claims and equivalents thereof.