JP7315971B2 - Embroidered button and its manufacturing method - Google Patents

Description

The present invention relates to an embroidered button and its manufacturing method, and in particular, it is formed by sewing thread, has desired strength, durability, hardness, etc. as a button, has various design variations, and can be manufactured in small lots. A possible embroidered button and its manufacturing method.

Patent Literature 1 discloses resin buttons such as polyester buttons, ABS resin buttons, and nylon buttons as conventional buttons attached to clothes. Polyester buttons can be mass-produced by a rod tube method, centrifugal molding method, or the like, and ABS resin buttons can be mass-produced by, for example, injection molding using an injection method.

In addition, Patent Literature 2 discloses a metal button as a conventional button attached to clothing or the like. Metal buttons can be mass-produced by pressing or cutting.

The resin buttons and metal buttons described above are fixed to the plackets and sleeves of clothing such as shirts, blouses, jackets, coats, and pants with threads. Then, the user can put on or take off the clothing by engaging the button with the buttonhole portion of the clothing or by releasing the button from the buttonhole portion of the clothing. . The buttons are used not only on clothes but also on various items such as bags and other small items.

Utility Model Registration No. 3127654 Japanese Patent No. 6785004

When the user puts on or takes off the clothes, the button is engaged with the buttonhole or released from the buttonhole. Also, used clothes are washed at home or at a dry cleaning shop. For this reason, the buttons are required to have desired strength, durability, hardness, and the like. As conventional buttons, resin buttons and metal buttons, which easily satisfy the strength and the like, are often used. In addition, resin buttons and metal buttons can be mass-produced, which is advantageous in terms of manufacturing costs.

However, especially with resin buttons, although it is possible to reduce costs through mass production, it is difficult to create unique designs that match individual clothing designs, such as variations in the color of the buttons, and they lack fashion sense. I have a problem. On the other hand, there is a problem that it is difficult to reduce the cost when resin buttons are produced in a small lot according to the design of each garment. Metal buttons, like the resin buttons, also have the problem of unique designs such as color variations.

Due to the above problems and the like, there is a demand in the fashion industry these days for new buttons that can be matched with individual clothing designs. Further, as described above, there is a demand for a button that maintains the desired strength, durability, hardness, etc. as a button, and that can be adapted to small-lot production while suppressing a significant increase in cost.

In addition, for elderly people and those with weak finger strength, resin buttons and metal buttons are too hard and slippery. There is a problem that the work of separating from the buttonhole portion is difficult.

In addition, when resin buttons or metal buttons are attached to a soft shirt such as a blouse, the placket to which the buttons are attached hangs forward due to the weight of the buttons, and the silhouette of the shirt tends to collapse. I have a problem.

The present invention has been made in view of the above circumstances, and is formed by sewing threads, has the desired strength, durability, hardness, etc. as a button, has a variety of design variations, and can be used in small lots. To provide a producible embroidery button and a method for manufacturing the same.

The embroidered button of the present invention has a plurality of holes formed therein, a base portion made of sewn thread , and a sewn thread formed along an end portion of the base portion so as to overlap a portion of the base portion . and a wall made of the thread , wherein the hole is an opening surrounded by the thread.

Further, in the embroidery button of the present invention, the hole is formed so as to penetrate the base on the inner side of the wall, and the wall extends in a penetrating direction of the hole from the base. characterized by being formed so as to protrude from the

Further, in the embroidery button of the present invention, a base body is formed inside the base portion.

Further, in the embroidery button of the present invention, the base portion and the wall portion are formed only from the thread.

Further, in the method of manufacturing an embroidery button of the present invention, a base material for sewing is prepared, a thread is sewn to the base material for sewing, a base portion having a desired thickness is formed, and a plurality of holes are formed in the base portion. forming a portion; forming a wall portion along an edge of the base portion by sewing the thread so as to overlap a portion of the base portion; and forming a wall portion along at least a portion of the sewing base material. and forming an embroidery button having the base portion and the wall portion.

Further, the embroidery button manufacturing method of the present invention further comprises a step of sewing the thread to the sewing base material to form a base body having a plurality of opening regions that are to form the holes, In the step of forming the base portion and the hole portion, the thread is overlapped and sewn on the base body, and the thread is sewn while pulling the thread radially outward from the center side of the opening region. Characterized by

Further, in the method of manufacturing an embroidery button according to the present invention, in the step of forming the base body, the thread is formed by running stitch so as to surround the opening region.

Further, in the embroidery button manufacturing method of the present invention, the base portion and the wall portion are formed only from the thread.

The embroidered button of the present invention is formed by sewing threads. With this structure, it is possible to manufacture embroidered buttons of various designs in small lots by appropriately changing the thread type, thread color, etc. according to the design of the clothing or the like to which the embroidered button is to be attached. In particular, since there are several hundred kinds of color variations of threads, embroidery buttons with various color variations can be easily manufactured by installing threads on a mechanical sewing machine.

Further, the embroidery button of the present invention is formed by sewing thread, and has a base portion in which a plurality of holes are formed, and a wall portion formed along an end portion of the base portion. Most of the wall portion is formed so as to overlap the base portion and has a desired thickness, and the threads are intricately entangled and densely packed. With this structure, the embroidered button, which is made of thread, has the desired strength, durability, hardness, etc., is resistant to unraveling even after repeated washing, and can be fixed to clothes, etc., and can be used repeatedly.

Further, in the embroidery button of the present invention, a base body is formed inside the base. Further, the base body is a member with low stretchability, and even if it is pulled in various directions during the sewing process, it does not easily lose its shape. With this structure, the embroidery button is prevented from losing its shape during the sewing operation by having the base body.

Also, in the embroidered button of the present invention, the base and wall are formed only from threads. With this structure, if the thread is made of a biodegradable material based on a natural material other than a synthetic thread, it becomes a non-plastic product and an environmentally friendly embroidery button.

In the method of manufacturing an embroidery button of the present invention, the steps of forming the base and the hole while entangling the thread around the base material for sewing, forming the wall portion while overlapping the base and part thereof, and forming the base for sewing. and removing at least a portion of the. With this manufacturing method, a plurality of embroidery buttons can be continuously formed on the sewing base material, and mass production of embroidery buttons can be realized.

The embroidery button manufacturing method of the present invention further includes the step of forming the base body on the sewing base material, and in the step of forming the hole, the opening area of the base body is formed from the center side thereof. Sewing is performed while pulling the thread radially outward. By this manufacturing method, a plurality of holes are formed in desired regions around the center of the base, and are formed as openings through which fixing threads for fixing to clothing or the like can be inserted.

Further, in the method of manufacturing an embroidery button of the present invention, in the step of forming the base body, the thread is formed by running stitches so as to surround the opening region. With this manufacturing method, the base body becomes a member with low stretchability, and even if it is pulled in various directions, its shape does not easily collapse.

Further, in the embroidery button manufacturing method of the present invention, the base portion and the wall portion are formed only from thread. According to this manufacturing method, embroidered buttons of various designs can be manufactured in small lots by appropriately changing the thread type, thread color, etc., according to the design of clothing or the like to which the embroidered button is to be attached.

1 is a top view illustrating an embroidery button that is an embodiment of the present invention; FIG. 1 is a cross-sectional view illustrating an embroidery button that is an embodiment of the present invention; FIG. (A) Top view, (B) Top view, (C) Top view, (D) Top view, (E) Top view, (F) Top view for explaining a modification of the embroidery button that is one embodiment of the present invention It is a diagram. FIG. 5 is a flow diagram illustrating a method of manufacturing an embroidery button that is another embodiment of the present invention; FIG. 5 is a flow diagram illustrating a method of manufacturing an embroidery button that is another embodiment of the present invention; It is (A) schematic drawing explaining the manufacturing method of the embroidery button which is other embodiment of this invention, (B) schematic drawing. It is (A) schematic drawing explaining the manufacturing method of the embroidery button which is other embodiment of this invention, (B) schematic drawing.

An embroidery button 10 according to an embodiment of the present invention will now be described in detail with reference to the drawings. In the following description of the present embodiment, in principle, the same reference numerals are used for the same members, and repeated descriptions are omitted. Also, the thickness direction of the embroidery button 10 is the penetration direction of the hole portion 13 formed in the base portion 11 .

FIG. 1 is a top view for explaining an embroidery button 10 of this embodiment, which is an actually manufactured embroidery button 10. FIG. FIG. 2 is a cross-sectional view for explaining the embroidery button 10 of the present embodiment, and schematically shows a cross section of the embroidery button 10 shown in FIG. 1 taken along line AA. FIGS. 3A to 3F are top views illustrating modifications of the embroidery button 10 of this embodiment.

As shown in FIG. 1, the embroidered button 10 is formed by sewing thread using a mechanical sewing machine (not shown). It has a portion 12 and a hole portion 13 formed in a central region of the base portion 11 . Then, the embroidered button 10 is sewn and fixed to the base collar portion, placket portion, sleeve portion, or the like of clothing such as a shirt, blouse, jacket, or coat with thread. When the user puts on the garment, the embroidery button 10 is engaged with the buttonhole of the opposite garment, and when the user takes off the garment, the user removes the embroidery button 10 from the buttonhole. In addition, the user may wash and dry the clothes at home, or wash and dry the clothes at a cleaning shop, and iron the clothes as necessary.

By the above-mentioned method of use, the embroidery button 10 is repeatedly put on and taken off from the buttonhole, repeatedly rubbed against other clothes when worn in layers, and exposed to water such as detergent water during washing. , exposed to high temperatures in a dryer. Therefore, the embroidered button 10 is required to have a certain level of durability, strength, and hardness. Conventionally, there has been no embroidered button 10 manufactured by sewing threads as in the present embodiment. The embroidery button 10 of this embodiment satisfies a certain level of durability, strength, and hardness, like resin buttons and the like. In addition, the embroidered button 10 is used not only for clothing but also for various items such as bags and other small articles, like conventional resin buttons and metal buttons.

Here, the mechanical sewing machine of the present embodiment is a concept including domestic sewing machines and industrial sewing machines. The thread is a thread that can be sewn by the machine sewing machine, and is made of natural fibers such as cotton, linen, silk, cashmere, and wool. Yarns, yarns made from recycled fibers such as rayon and cupra, yarns made from chemical fibers such as polyester, nylon, acrylic, and polyurethane, and inorganic materials made from metals such as gold and silver, ceramics such as silica and alumina, carbon fibers, etc. Known yarns, such as yarns made of fibers and fibers coated or composited with inorganic materials or the like, are applicable to the present invention.

As shown in FIG. 2 , the base portion 11 is a base portion that extends over substantially the entire surface of the embroidery button 10 . Although the details will be described later, the embroidery button 10 is formed by sewing a thread to a sewing base material 22 (see FIG. 5) such as a water-soluble nonwoven fabric used for embroidery. According to this manufacturing method, the base body 21 formed on the front and back surfaces of the base material 22 for sewing is present substantially at the center of the base portion 11 in the thickness direction. The base body 21 is formed by running stitches and is a member with low stretchability, so that its top view shape is substantially the same as that of the base portion 11 .

Note that the base body 21 is not limited to being formed using running stitches, but may be formed using cross stitches, houndstooth stitches, zigzag stitches, back stitches, satin stitches, or combinations of the above stitches. It may be formed by

The base portion 11 has a desired thickness by sewing the base body 21 with threads superimposed thereon in its thickness direction. Specifically, the base portion 11 is formed using a mechanical sewing machine, so that the top surface of the base body 21 is sewn with the needle thread closely superimposed thereon, while the bottom side of the base body 21 is sewn with the bobbin thread. Closely overlapped and sewn. The base portion 11 is formed to have substantially the same thickness and substantially the same shape as the front and rear surfaces of the base body 21 with the base body 21 substantially at the center.

The method of sewing the base portion 11 will be described later, but in order to realize the thickness of the base portion 11 by sewing threads, various sewing patterns are combined, the threads are sewn in various directions, and the threads are entangled in a complicated manner. The density of the threads is increased, the threads are integrated as the embroidery button 10, the hardness, strength and durability are realized, and a structure that is difficult to unravel is realized.

The wall portion 12 is formed along the edge portion 11A of the base portion 11 . Most of the walls 12 are overlapped in the radial direction of the base 11 so as to sandwich the base 11 therebetween. Similarly to the base portion 11, the wall portion 12 is also formed by using a machine sewing machine, so that the upper surface of the base portion 11 is closely superimposed and sewn with a bobbin thread. are closely overlapped and sewn. The wall portion 12 is formed to have substantially the same thickness and substantially the same shape on the front and rear surfaces of the base body 21 with the base body 21 substantially at the center.

The method of sewing the wall portion 12 will be described later, but in order to realize the thickness of the wall portion 12 by sewing threads, various sewing patterns are combined, the threads are sewn in various directions, and the threads are entangled in a complicated manner. Thus, the density of the thread is increased, and the thread is integrated as the embroidery button 10, and its hardness, strength and durability are realized, and a structure that is difficult to unravel is realized.

In particular, most of the wall portions 12 are overlapped so as to sandwich the base portion 11 therebetween, so that the region where the wall portions 12 are formed becomes the thickest region in the embroidery button 10 and has the highest hardness. area. The wall portion 12 is formed in an annular shape along the end portion 11A of the base portion 11, and the wall portion 12 is formed to protrude in the thickness direction from the central region of the base portion 11 that does not overlap with the wall portion 12. . With this structure, in the embroidery button 10, the region where the wall portion 12 is formed has high hardness, and the wall portion 12 is formed continuously along the end portion 11A, so that the embroidery button 10 is less likely to bend in its thickness direction.

As described above, the embroidered button 10 fixed to clothing or the like is subjected to repeated bending stress by the user in the thickness direction when the buttonhole is repeatedly attached and detached. At this time, since the wall portion 12 exists along the end portion 11A of the base portion 11, the embroidery button 10 maintains a substantially flat plate shape and is reliably locked to the buttonhole portion.

Further, the end portion 12A of the wall portion 12 is formed by covering the end portion 11A of the base portion 11 from the outside. In FIG. 2, a gap is provided between the ends 11A and 12A for convenience of explanation. is in contact with the base 11 . In addition, when the water-soluble nonwoven fabric is used as the base material 22 for sewing, the thread shrinks during the drying process when it is washed together with the clothes, etc., and the wall portion 12 contacts the base portion 11 and is closely attached. state.

Further, as shown in FIG. 1, the thread forming the skin layer of the wall portion 12 is sewn with a constant width in the radial direction of the embroidery button 10, and is sewn three times in the circumferential direction of the embroidery button 10, for example. It is sewn continuously. By this sewing method, the threads of the wall portion 12 are closely formed, and the ends 11A of the base portion 11 are also closely formed as described above. As a result, even if the embroidery button 10 is used repeatedly, the edge 12A of the wall 12 is in close contact with the edge 11A, so that it is difficult to unravel. And the durability of the embroidery button 10 is improved.

Here, as test samples, an embroidered button 10 sewn with rayon and an embroidered button 10 sewn with cupra were prepared, and the following tests were conducted. Embroidered button 10 was subjected to a light resistance test (class 4 test, JIS-L-0842, ultraviolet carbon arc lamp light), a home washing test (according to JIS-L-1930 C4M, using a detergent manufactured by Kao Corporation), and a washing test. (According to JIS-L-0844 A-2 (30 minutes at 50 ° C.), using synthetic detergent No. 1), dry cleaning test (perchlorethylene JIS-L-0860: 2008 A-1 method (30 30 minutes at ° C.)), dry cleaning test (petroleum-based dry solvent JIS-L-0860: 2008 B-1 method (30 minutes at 30 ° C.)), hot pressing test (according to JIS-L-0850, A -1 method (110°C for 15 seconds), wet test/strong test (wet type)), steam press test (3 times of 4 seconds of steam and 4 seconds of vacuum, steam pressure is about 4.5 kg/cm ² ), friction Test (applying JIS-L-0849, using type I crockmeter, dry and wet 10 times each, test with two layers of white cotton cloth for friction), jungle test (using low temperature constant temperature humidity, temperature 70 ° C, humidity 90 % for 96 hours) was performed. In the above home washing test, the test method is a step of putting the detergent and the object to be washed in water at 40 ° C. and washing and dehydrating, then putting the object to be washed in water, rinsing and dehydrating, Next, the article to be washed is rinsed in water, dehydrated, and finally dried in a clothes dryer (at a temperature of about 60° C.) for 1 hour.

The above test is a test performed on conventional resin buttons and the like, and as a result of the above test, the embroidered button 10 sewn with rayon and the embroidered button 10 sewn with cupra all cleared the passing value and are practically usable. In addition, a result comparable to that of a resin button was obtained.

As shown in FIG. 1, for example, four holes 13 are formed around the center CL of the base 11, and are used as locking holes for fixing thread when fixing the embroidery button 10 to clothing or the like. . As shown in FIG. 2, the hole portion 13 is formed through the base portion 11 in its thickness direction (vertical direction on the paper surface), and its inner peripheral surface is formed of threads extending in the thickness direction. That is, the hole 13 becomes an opening surrounded by the thread.

Although the details will be described later, the holes 13 are formed together when the base 11 is formed. It is formed by sewing while pulling substantially radially. By this sewing method, a reinforcing portion 14 is formed between the four holes 13 at the center CL and the peripheral region of the base portion 11, where the thread is densely packed and thickened. In other words, the hole 13 is formed in the region where the opening regions 41 to 44 are formed, and the opening regions 41 to 44 are the regions from which the hole 13 is formed.

Specifically, as shown in FIG. 1, the four holes 13 are partitioned by partitions 15 of the base 11 which are substantially cross-shaped when viewed from above. The partition part 15 is a part of the base part 11 and is formed by sewing a thread. The reinforcing portion 14 is formed at the center of the dividing portion 15, and a substantially cross-shaped reinforcing core portion 45 (see FIG. 5) of the base body 21 is formed substantially at the center of the dividing portion 15 in the thickness direction. is formed.

With this structure, the embroidered button 10 is repeatedly pulled by the fixing thread for fixing to the clothing when the clothing such as a shirt is put on and taken off, and the fixing thread bites into the partition portion 15 and the reinforcing portion 14, but the reinforcing portion is not removed. Threads extending in the thickness direction of 14 are closely entwined and thickly formed to achieve a desired tensile strength. Moreover, since the reinforcing core portion 45 of the base body 21 with low stretchability exists in the core portion of the partition portion 15, the partition portion 15 is resistant to shear failure, and a desired tensile strength is achieved.

Here, in the same manner as in the above test, an embroidered button 10 sewn with rayon and an embroidered button 10 sewn with cupra were prepared as test samples, and TGE-5kN manufactured by MinebeaMitsumi Co., Ltd. was used as a testing machine to perform a tensile strength test. did A piano wire was inserted through the hole 13 of the embroidered button 10, and the embroidered button 10 was pulled at a tensile speed of 50 mm/min while being fixed to the sample fixing jig of the tester. As a result of the test, the average breaking value was 5.90 kgf for the embroidered button 10 sewn with rayon and 5.54 kgf for the embroidered button 10 sewn with cupra. The passing value in this tensile test was 4.00 kgf, which was a sufficiently practical value. The embroidered button 10 as the test sample has a diameter of 11 mm to 13 mm, and a thickness of the base portion 11 in the area where the hole 13 is formed is 2 mm to 3 mm.

Next, as shown in FIGS. 3A to 3F, the shape of the embroidery button 10 is not limited to the substantially circular shape shown in FIG. 1 when viewed from the top. Various shapes of embroidery buttons 10 can be formed as long as they are designs that can be sewn using a machine sewing machine. The embroidery button 10 shown in FIGS. 3(A) to 3(F) similarly satisfies the desired durability, strength and hardness.

For example, FIG. 3A shows a shape in which a pattern portion 31 is formed by scallop embroidery around the circular wall portion 12 shown in FIG. FIG. 3B shows a shape in which a petal pattern portion 32 is formed around the circular wall portion 12 shown in FIG. FIG. 3C shows a shape in which a petal stalk portion 33 having a wall portion 12 is formed around a circular base portion 11 . Also, in FIG. 3D, the shape of the embroidery button 10 is a football shape. Also, in FIG. 3E, the embroidery button 10 has an octagonal shape. Also, in FIG. 3F, the embroidery button 10 has a rectangular shape. As shown in FIGS. 3(E) and 3(F), the shape of the embroidery button 10 may be other polygonal shapes.

Next, a method for manufacturing the embroidery button 10 according to another embodiment of the present invention will be described in detail with reference to FIGS. 4 to 7. FIG. In describing the method of manufacturing the embroidery button 10, reference will be made to the description of the embroidery button 10 described with reference to FIGS. , and repeated explanations are omitted.

FIG. 4 is a flowchart for explaining the method of manufacturing the embroidery button 10 of this embodiment. FIG. 5 is a flowchart for explaining the sewing process of the method for manufacturing the embroidery button 10 of this embodiment. 6A and 6B are schematic diagrams for explaining a sewing method for the base portion 11 and the hole portion 13 of the embroidery button 10 according to the present embodiment. FIGS. 7A and 7B are schematic diagrams for explaining a sewing method for the wall portion 12 of the embroidery button 10 of this embodiment.

As shown in FIG. 4, in step S1, the operator operates, for example, a personal computer to generate design data for sewing the embroidery button 10. As shown in FIG. Design data is data in which processing conditions for a mechanical sewing machine are set. When the base body 21, the base portion 11, the wall portion 12 and the hole portion 13 are formed, the design data is applied to the sewing base material 22 (see FIG. 5) placed on the work table of the mechanical sewing machine. It has the necessary conditions for manufacturing the embroidery button 10, such as the coordinate pattern for driving the stitches, the sewing speed, the type of stitches to be used, and the length of thread to be sent out. In the above coordinate pattern, the needle reciprocates in the vertical direction at the same position, but this is realized by moving the frame fixing the sewing base material 22 on the work table. In the following description, for the sake of convenience, the description will be made assuming that the needle moves during the sewing operation.

In step S2, the operator stores the design data in a control unit that controls the sewing operation by the mechanical sewing machine, such as a personal computer connected to the mechanical sewing machine. The control unit includes, for example, a CPU (Central Processing Unit), a ROM (Read Only Memory), a RAM (Random Access Memory), etc., and executes various calculations and the like for controlling the mechanical sewing machine. The design data may be generated by a personal computer connected to a mechanical sewing machine.

In step S3, the operator installs the sewing thread, the sewing base material 22 fixed to the frame, and the like on the mechanical sewing machine, and then operates the operating section of the personal computer to start the sewing work. The mechanical sewing machine is controlled by the above-described control unit, drives a needle into the sewing base material 22, and performs sewing while entwining the upper thread and the bobbin thread on the back side of the sewing base material 22 via a rotary hook. , base body 21, base portion 11, wall portion 12 and hole portion 13. Embroidery button 10 is fabricated. In this embodiment, for example, 20 embroidery buttons 10 are continuously formed on one sewing base material 22 in the frame.

In step S4, after finishing the sewing operation with the mechanical sewing machine, the operator takes out the sewing base material 22 on which the plurality of embroidery buttons 10 are formed from the frame body on the work table, and separates the sewing base material 22 from the sewing base material 22 into individual pieces. The embroidery button 10 is taken out.

Here, as the base material 22 for sewing, a water-soluble nonwoven fabric or a heat release film is used. As the water-soluble non-woven fabric, for example, Shinwa Co., Ltd.'s water-soluble non-woven fabric new type, Mitsubishi Chemical Holdings Group's Hi-Selon (product name), and the like are used. Thermal release films include thermal release films for embroidery, films for agricultural use, and the like.

When a water-soluble non-woven fabric is used as the sewing base material 22, the operator soaks the water-soluble non-woven fabric on which the plurality of embroidery buttons 10 are formed in lukewarm water or water, and removes the portion to be arranged inside the embroidery buttons 10. to dissolve the water-soluble nonwoven fabric. Thereafter, the operator removes the embroidery button 10 from the lukewarm water and dehydrates the embroidery button 10 by, for example, wiping off water adhering to the embroidery button 10 . After that, the worker performs a drying process for the embroidery button 10 using natural drying or a dryer. This drying operation removes moisture from the embroidered button 10 and shrinks the embroidered button 10 as a whole. Since the threads forming the embroidery button 10 are in close contact with each other, the embroidery button 10 has a certain level of durability and is difficult to unravel even after repeated use. In this process, the embroidery button 10 is subjected to a water-repellent treatment according to its intended use, thereby preventing the embroidery button 10 from being soiled and further improving its durability.

On the other hand, when a heat peeling film is used as the sewing base material 22, the operator places the heat peeling film on which a plurality of embroidery buttons 10 are formed on an iron plate heated to about 180° C. to 200° C., for example. to melt the heat release film except for the area where the embroidery button 10 is to be formed. After that, the operator removes the embroidery buttons 10 from the iron plate, which are separated from each other by the melting of the heat release film, and removes the heat release film remaining on the outer surface of the embroidery buttons 10 . When the heat peeling film is used, the heat peeling film remains inside the embroidery button 10, which contributes to the strength of the embroidery button 10 and prevents the thread of the embroidery button 10 from being unraveled. contribute.

In step S5, the appearance of each embroidery button 10 taken out is inspected, and after the result of the inspection, the embroidery button 10 is finished. The embroidery button 10 is then delivered to the customer.

As shown in FIG. 5, in the sewing process of the embroidery button 10, the base body 21 is formed on the front and rear surfaces of the base material 22 for sewing in step S11. The base body 21 is a base portion of the embroidery button 10, and has substantially the same size and circular shape as the base portion 11 when viewed from above. The base body 21 is formed by running stitches, so that the base body 21 becomes a member with low stretchability.

Further, as shown in the figure, four opening areas 41 to 44 are formed in the central area of the base body 21, and the opening areas 41 to 44 are defined by substantially cross-shaped reinforcing core portions 45, respectively. Then, the reinforcing core portion 45 is formed by thread adjoining to the sewing base material 22 in two rows by running stitches. In addition, as described above, the reinforcing core portion 45 is a member for preventing shear failure in the partition portion 15 (see FIG. 1), and the number of the adjacent threads is arbitrary according to the desired tensile strength. design change is possible.

In step S12, holes are formed in the base body 21 using various stitches such as cross stitch, houndstooth stitch, zigzag stitch, back stitch, and satin stitch, or various sewing patterns combining various stitches. Further, in the same process, the hole 13 is formed by sewing while pulling the thread from the center side of the opening regions 41 to 44 to the outside in multiple directions such as eight directions. The thickness of the base portion 11 is, for example, about 1 mm to 3 mm on each of the front and back sides of the base body 21, and about 2 mm to 6 mm in total.

As described above, the base body 21 on the front and back sides of the base material 22 for sewing is formed by running stitches, so that its stretchability is low, and the shape of the base part 11 and the wall part 12 is changed during the sewing process. is maintained. Then, the base 11 and the base body 21 are formed without misalignment when viewed from the top by driving the needles into the desired locations of the base body 21 according to the coordinate data of the design data. In addition, the base 11 is formed in substantially the same shape as the base 21 without losing the shape of the base 11 by disposing the base 21 substantially at the center in the thickness direction of the base 11 .

Here, as shown in FIGS. 6A and 6B, the hole portion 13 is formed at the same time as the base portion 11 is formed. In this embodiment, the needle driven into each of the open areas 41-44 is then driven near the end 11A of the base 11 outside the open areas 41-44. Alternatively, the needle driven into each open area 41-44 is driven into the other open area 41-44. In other words, in the sewing operation of the hole 13, for example, the length of the thread to be sent out is adjusted, and the thread is pulled radially from the center side of the opening regions 41 to 44 to the outside of the opening regions 41 to 44. Move the needle to spread ~44 outward. In the description of FIGS. 6A and 6B, the case where the needle of the mechanical sewing machine advances in the counterclockwise direction will be explained, but the present invention is not limited to this case. may proceed in the clockwise direction.

FIG. 6A shows, for example, one sewing pattern in which the opening regions 41 to 44 are widened to the outside of the base body 21. As shown in FIG. In the open area 41 the needles are P1, P2, P3, P4, P2, P5, P6, P2, P7, P8, P2, P9, P10, P2, P11, P12, P2, P13, P14, P2, P15, Proceed counterclockwise in the order of P16 and P2.

The distance between P1 and P3, the distance between P4 and P5, the distance between P6 and P7, the distance between P8 and P9, the distance between P10 and P11, the distance between P12 and P13, The separation distance between P14 and P15 is such that the needle driving positions do not overlap, for example, the thickness of one needle. On the other hand, the distance between P3 and P4, the distance between P5 and P6, the distance between P7 and P8, the distance between P9 and P10, the distance between P11 and P12, the distance between P13 and P14 , P15 and P16 is, for example, the thickness of five needles.

Note that P2 is the approximate center of the opening region 41 . The positions of P1 and P16 are just such that the lines connecting to P2 are slightly caught in the adjacent opening regions 42 and 44 . Also, the setting of the pitches P1 to P16 described above can be arbitrarily changed in design depending on the size and shape of the embroidery button 10 and the like.

Next, after finishing the sewing work in the opening region 41 , the sewing work of the hole portion 13 is similarly performed in the opening region 42 . As shown, the needle moves from P2 to P21, then P21, P22, P23, P24, P22, P25, P26, P22, P27, P28, P22, P29, P30, P22, P31, P32, P22. , P33, P34, P22, P35, P36, P22 counterclockwise. The positional relationship of P21 to P36 is the same as the positional relationship of P1 to P16 described above, and the description thereof will be omitted here.

Next, after finishing the sewing work in the opening region 42, the same sewing work is sequentially repeated in the opening regions 43 and 44 as well. Depending on the shape and thickness of the embroidery button 10, after completing one cycle of the opening regions 41 to 44, this cycle may be repeated multiple times. It is also possible to shift to another sewing pattern.

As described above, in the sewing process of the hole 13, when the needle is moved from the center side to the outside of the opening regions 41 to 44, the thread feeding amount is set as the linear distance between P2 and P3, for example. However, since the base portion 11 has a thickness, the thread between P2 and P3 is curved in the thickness direction by the thickness, and is required to be longer than the above set amount. As a result, since the base body 21 does not exist, the thread dropped at the coordinate position P2 is pulled to the outside of the opening region 41, causing the sewing base material 22 to break or the sewing base material 22 to break. It is brought to the outside of the opening area 41 . As the needle traces the path from P1 to P16, an opening as the hole 13 is formed in the opening area 41 formed only by the sewing base material 22 . Similarly, openings as the holes 13 are formed in the other opening regions 42 to 43 as well. As in P2 and P22, the sewing work for the hole 13 may be performed while slightly shifting the positions of the needles that are driven into the opening regions 41-44.

FIG. 6B shows, for example, one sewing pattern in which the opening regions 41 to 44 are widened inside the base body 21. As shown in FIG. The needle advances in the order P41, P42, P43, P44, P45, P46, P47, P48, P49, P50, P51, P52, P53, P54, P55, P56, P57, P58, P59, P60, P61. Then, inside the opening regions 41 to 44, sewing is performed while gradually moving from the outside to the inside of the opening regions 41 to 44 so that the needle driving positions do not overlap.

As illustrated, for example, the needle moves counterclockwise two rounds between the opening regions 41 to 44, and then repeats diagonal movement so as to pass through approximately the center of the opening regions 41 to 44, thereby opening the opening. Also inside the regions 41 to 44, the threads are sewn substantially radially.

After one cycle from P41 to P61 is completed, this cycle is repeated multiple times while bringing the needle driving position closer to the center side of the opening regions 41 to 44 . After that, the sewing pattern described with reference to FIG. 6A may be performed. Alternatively, in addition to the sewing patterns shown in FIGS. 6(A) and 6(B), in order to realize the thickness of the base portion 11 around the hole portion 13, zigzag stitches or zigzag stitches are performed several times in the circumferential direction. By interweaving the sewing pattern and other sewing patterns, the threads are intricately entwined in various directions, so that the base body 21 and the base portion 11 are integrated, and the base portion 11 itself is also integrated.

By the above-described sewing method, the base portion 11 has a desired thickness and a highly dense state of threads, and the threads of the embroidery button 10 are less likely to fray, maintain the desired shape of the embroidery button 10, and function as a button. Hardness, durability and strength to satisfy

On the other hand, the hole 13 is formed as an opening by sewing while pulling the thread from the center side of the opening regions 41 to 44 to the outside in a substantially radial pattern. When the needle is driven inside the opening regions 41 to 44, the needle thread and the bobbin thread extend in the penetrating direction of the hole 13, and the inner surface of the hole 13 extends in the penetrating direction of the hole 13. It is formed by an elongated thread. As described above, the base body 21 is a member with low elasticity, and the positions of the opening regions 41 to 44 are maintained without being greatly displaced, so that the position of the hole portion 13 is around the center CL of the base portion 11. Formed without large deviations.

In step S13, the wall portion 12 is formed on the base portion 11 by using various sewing patterns and entangling threads in various directions. In the process of sewing the wall portion 12, the needle of the mechanical sewing machine passes through the base portion 11 and repeats the work of entangling the upper thread and the bobbin thread on the back side of the base portion 11 via the rotary hook. The wall portion 12 is formed in a ring along the end portion 11A of the base portion 11 while overlapping with the base portion 11, and the four hole portions 13 are formed in the base portion 11 inside the wall portion 12. Become.

FIG. 7A shows one sewing pattern for increasing the thickness of the wall portion 12. FIG. A region between the dashed-dotted lines 51 is a forming region of the wall portion 12 . Then, the needle advances counterclockwise in the order of P71, P72, P73, P74, P75, P76, P77, and P78 in the region where the wall portion 12 is formed. At this time, between P71 and P72, for example, five backstitches are performed so that the threads extending in the circumferential direction are adjacent to each other in the radial direction. Next, between P72 and P73, five backstitches are similarly performed so that the threads extending in the circumferential direction are adjacent to each other in the radial direction. Then, the same sewing work is repeated between P77 and P78 to complete one cycle. After that, while shifting the initial position of P71 in the counterclockwise direction so that the needle driving positions do not overlap, this cycle is repeated, for example, three times within the forming area of the wall portion 12, thereby increasing the thickness of the threads. direction, and the thickness of the wall portion 12 increases.

FIG. 7B shows one of the alternative sewing patterns for increasing the thickness of the wall portion 12. FIG. In the region where the wall portion 12 is formed indicated by the dashed line 51 , zigzag stitches are performed counterclockwise at a constant pitch so as to overlap with the base portion 11 . One cycle is a sewing operation in which the zigzag stitches are circulated counterclockwise. For example, repeat 3 times. This sewing pattern differs from the sewing pattern shown in FIG. , and the thickness of the wall portion 12 increases. In the explanation of FIGS. 7A and 7B, the case where the needle of the mechanical sewing machine advances in the counterclockwise direction will be explained, but the present invention is not limited to this case. may proceed in the clockwise direction.

Thereafter, as shown in FIG. 1, on the wall portion 12, the thread is formed with a constant width in the radial direction of the base portion 11 so as to cover the thread sewn as shown in FIGS. 7(A) and 7(B). , sewing is performed along the end portion 11A of the base portion 11 in a circular manner. At this time, the threads are sewn without gaps so that parts of the threads adjacent to each other in the circumferential direction overlap or contact each other. One cycle is a sewing operation that rotates counterclockwise once, and this cycle is repeated three times, for example, within the formation area of the wall portion 12, thereby forming a wall in which the threads are closely superimposed in the circumferential direction and the thickness direction. A portion 12 is formed.

As described above, the base portion 11 and the wall portion 12 having predetermined hardness, strength, and durability are formed by increasing the density of the threads while setting the sewing directions of the threads in various directions and entangling the threads in a complicated manner. be. In particular, most of the wall portion 12 is overlapped with the base portion 11 so that the base portion 11 is sandwiched therebetween, so that the embroidery button 10 may break when the embroidery button 10 is attached to clothing or the like and used repeatedly. It becomes difficult to bend.

Further, as described above, the embroidery button 10 is formed by sewing thread, so that the weight of the button is reduced to about one-third, for example, when it has the same shape as the resin button. With this structure, even when the embroidered button 10 is attached to the front part of a soft shirt such as a blouse, the front part does not easily droop forward, and the silhouette of the shirt can be maintained.

Further, the embroidery button 10 has predetermined hardness and strength for functioning as a button, but has flexibility compared to a resin button or the like. With this structure, even an elderly person or a person with weak fingers can easily engage the embroidered button 10 in the buttonhole of the clothing or remove the embroidered button 10 from the buttonhole of the clothing.

Also, the embroidery button 10 can be formed in various designs by appropriately changing the type and color of thread installed in the mechanical sewing machine and selecting design data. By changing the thread, the remaining thread can be used by resetting it to the machine sewing machine at the next opportunity of sewing. On the other hand, in the case of a resin button, when changing the design, it takes time and labor to change the design, such as cleaning the mold, mixing the resin material, and setting the injection conditions. Furthermore, if the shapes of the designs are different, a dedicated mold is required for each design, which greatly increases the manufacturing cost. As described above, the embroidered button 10 can easily be made small in size by appropriately changing the thread type, thread color, etc., according to the design of the clothing, etc., compared to resin buttons or the like. It becomes possible to manufacture in lot units.

In addition, in the method of manufacturing the embroidery button 10, it is possible to set a plurality of threads on a mechanical sewing machine and select threads appropriately. For example, when preparing rayon threads of different thicknesses and using thicker rayon threads in places where strength and thickness of the base 11 and wall 12 are required, and forming a pattern on the design surface of the embroidery button 10, By using thin rayon thread, it is also possible to manufacture a unique embroidery button 10. - 特許庁In addition, embroidery thread such as rayon thread has hundreds of color variations, and embroidery buttons 10 with various color variations can be easily manufactured by attaching threads to a mechanical sewing machine.

In this embodiment, the case where the base body 21 is formed on the front and back surfaces of the base material 22 for sewing using running stitch or the like, and the embroidery button 10 is formed using the base body 21 as the base material has been described. is not limited to For example, a base material such as fabric, fabric, felt, or film may be used as a substitute material for the base body 21, and the base 11, the wall 12, and the hole 13 may be formed on the front and back surfaces of the base material to form the embroidery button 10. . As the base material, the opening regions 41 to 44 may be formed in advance, such as cloth, or the opening regions 41 may be formed in advance in the case of a material that can be torn in the sewing process, such as a film. .about.44 may not be formed. As described above, by forming the base material on the surface of the base material 22 for sewing and forming the embroidery button 10 so as to cover the base material, the outer shape of the embroidery button 10 does not easily deteriorate, and desired strength and durability can be obtained. Equipped with properties such as toughness and hardness.

Further, in the embroidery button 10, the case where the four holes 13 are formed in the base portion 11 has been described, but the present invention is not limited to this case. The holes 13 are locking holes for fixing the embroidered button 10 to clothing or the like, and the number of holes 13 may be two or three, for example, and the design can be changed arbitrarily according to the design of the clothing or the like.

Also, although the embroidery button 10 has been described as being formed by sewing thread, the present invention is not limited to this case. For example, by impregnating the embroidery button 10 with resin using a known resin impregnation technique, the hardness of the embroidery button 10 can be increased and the threads can be made difficult to unravel. As a result, the resin-impregnated embroidery button 10 is enhanced in strength and durability. In addition, various modifications are possible without departing from the gist of the present invention.

REFERENCE SIGNS LIST 10 embroidery button 11 base 11A end 12 wall 13 hole 14 reinforcement 15 partition 21 base 22 base material for sewing 41, 42, 43, 44 opening area 45 reinforcing core

Claims (8)

an embroidery button,
a base formed with a plurality of holes and made of sewn thread ;
a wall formed along an edge of the base and made of the sewn thread so as to overlap a portion of the base;
The embroidery button, wherein the hole is an opening surrounded by the thread. The hole is formed to penetrate the base with respect to the base inside the wall,
2. The embroidery button according to claim 1, wherein the wall protrudes from the base in a penetrating direction of the hole. 3. The embroidery button according to claim 1, wherein a base body is formed inside the base. The embroidery button according to any one of claims 1 to 3, wherein the base portion and the wall portion are formed only from the thread. preparing a base material for sewing, sewing a thread to the base material for sewing to form a base having a desired thickness, and forming a plurality of holes in the base;
forming a wall along the edge of the base by overlapping and sewing the thread so as to overlap a portion of the base;
and removing at least part of the sewing base material to form an embroidery button having the base portion and the wall portion. forming a base body having a plurality of opening regions that serve as sources of the holes by sewing the thread to the sewing base material,
In the step of forming the base portion and the hole portion, the thread is overlapped and sewn on the base body, and the thread is sewn while pulling the thread radially outward from the center side of the opening region. 6. The method of manufacturing an embroidery button according to claim 5. 7. The method of manufacturing an embroidery button according to claim 6, wherein in the step of forming the base body, the thread is formed by running stitches so as to surround the opening region. 8. The embroidery button manufacturing method according to any one of claims 5 to 7, wherein the base portion and the wall portion are formed only from the thread.