Embossed Crest, Badge and the Like Wearing Ornament and Method of Making the Same

The present invention relates to a crest, badge and the like wearing ornament and to a method of making the same and, more particularly, to such an ornament which is embossed.

It is known to provide a wearing ornament of the character described which is made by an embroidery process. However, such a process is expensive and time-consuming. U.S. Pat. No. 3,256,131, issued June 14, 1966 to A. G. Koch et al, describes an embossed laminated fabric for use, for instance, on the inner surface of automobile doors, on automobile seats and the like. This fabric comprises a cover layer, an intermediate continuous layer of urethane foam and a continuous backing layer of nylon or similar woven material, with all the layers adhered by a liquid layer of anhydrous polyurethane, which is applied against the inside surface of the cover layer and backing layer, and then the laminated material is pressed and heated in accordance with a definite pattern to cause foaming of the liquid polyurethane and adhesion of the different layers.

The invention in accordance with this U.S. Patent is not designed to make wearing ornaments bearing an image on its exposed face and, moreover, it involves applying a liquid polyurethane in pre-polymer form which involves a complicated operation and expensive equipment.

It is the general object of the present invention to provide a wearing ornament, such as badge, crest or the like, which is embossed and is of simple and inexpensive manufacture.

Another object of the invention is to provide a method of making the embossed wearing ornament in accordance with the invention.

Another object of the invention is to provide a wearing ornament of the character described, in which the embossed portion varies in thickness across the central portion of the ornament, said embossed portion having the size and contour of the central portion of image printed on the cover layer, thereby resulting in a very effective and decorative wearing ornament.

The wearing ornament of the invention is a laminated fabric which comprises a first cover layer made of a woven fabric which is stretchable in two perpendicular directions, said cover layer having an image printed on its exposed surface, said image including a central portion, a second layer of flexible and compressible foamed synthetic resin, which is die-cut to the contour and size of the central portion of the image; a third layer of adhesive and a fourth backing layer which is flexible but somewhat stiff, the first, third, and fourth layers being substantially co-extensive, the second layer having smaller dimensions than the remaining layers, all of the layers being superposed and said first and fourth layers being adhered by said third layer all around the second layer and in registry with one another, said first layer being stretched by said second layer and compressing the marginal portion of said second layer to a higher degree than the central portion of said second layer, so as to define an embossed ornament of a substantially uniform thickness in the area surrounding the second layer and of a varying thickness in the area across said second layer.

In the drawings:

FIG. 1 is an exploded perspective view of the various layers composing the laminated fabric and of the male and female die-press for making the ornament of the invention;

FIG. 2 is a top plan view of the ornament when totally assembled; and

FIG. 3 is a section taken along line 3--3 of FIG. 2.

The wearing ornament of the invention is generally indicated at 1 and consists of a laminated fabric formed of a first cover layer 2; a second layer 3, of flexible and compressible foamed synthetic resin, such as foamed polyurethane; an adhesive layer 4 and a backing layer 5. The cover layer 2 is made of a woven fabric, which is stretchable in two perpendicular directions and has an exposed face which is printed with an image 6 defining a main central portion 7. The second layer 3, of foam material, has a contour and shape corresponding to the contour and shape of the central portion 7 of the printed image 6. The adhesive layer 4 preferably consists of a heat-seal film, that is a thermoplastic film such as polyethylene, polyvinyl or the like. The backing layer 5 is relatively stiff, although flexible, and preferably consists of a felt-like material of non-woven fibers; first cover layer 2, third adhesive layer 4 and fourth backing layer 5 have substantially the same dimensions which are greater than the dimensions of the second layer 3 when all of the layers are superposed and made in registry with the second layer 3 in registry with the central portion 7 of the image 6. When placed in a press, the cover layer 2 is adhered to the backing layer 5 all around the second foam layer and, at the same time, the cover layer 2 is stretched over the foam layer 3 and the latter is adhered to the backing layer. This lamination is preferably carried out in a laminating press including a heated male die-plate 8 and heated female die-plate 9 which has a central cavity 10, of a contour and size to receive the foam layer 3 and which has a flat marginal surface 11 surrounding the central cavity 10 and co-acting with the flat male die-plate 8. When all the layers have been inserted into the press and the latter actuated and heated, the heat-sealing film 4 will melt and cause adherence of the cover layer 2 to the backing layer 5 and will also cause adherence to a certain extent of the foam layer 3 to the backing 5. During the pressing movement, elasticity of the foam layer 3 will cause stretching of the cover layer 2 and, consequently, in the finished product, the embossed central portion carrying the central portion 7 of the image 6 will have a cross-section of a thickness which varies in proportion to its width and cover layer l3 remains wrinkle-free. The image will preferably be a color image and the resulting ornament will be very effective. Obviously, as shown, the central image area may consist of more than one embossed areas separated by flat areas.

The press may be provided with means to die-cut the three layers 2, 4, and 5 at the beginning of the heat-sealing and pressing operation. The heat-sealing thermoplastic adhesive film 4 could be replaced by a layer of liquid glue which may dry up by evaporation. However, such a system will take a much longer time to cure and a press will nevertheless be needed to press the various layers together and stretch the cover layer 2.

In the drawings, adhesive layer 4 is shown much thicker than necessary; actually, it is much thinner than backing layer 5.

The peripheral edge of ornament 1 could be finished with overlock stitching, if desired. This is not shown, as it forms no part of the invention.