This disclosure addresses a problem in relation to the environmental destruction that excessive apparel production can produce. In various embodiments, existing textile products are deconstructed into pieces of fabric and then reassembled into apparel in a manner that creates minimal or zero waste. In some embodiments, the fabric pieces will be positioned inside of one or more pattern pieces so as to completely cover each one without overlapping its border. The positioned pieces will be treated with an adhesive and then have a paper layer adhered to it to hold the positioned fabric pieces in place while they are stitched together. Then, the resulting sandwich will be soaked to remove the paper and dissolve the adhesive. The resulting unified fabric component will then be available to be stitched together with other similarly formed fabric components to form a garment.

A fabric made of yarns interlooping with each other or passing through an inner layer at looping intervals. The fabric is embossed with a micro-pattern extending into the yarns or into a layer underneath the fabric. The micro-pattern contains a pre-defined pattern of a plurality of binding points attaching the yarns to the inner layer or to the added underlayer. This micro-pattern has an inter-point spacing between adjacent binding points that is less than the interlooping intervals. The fabric can also be embossed with a macro-pattern separate from and coarser than the micro-pattern. The macro-pattern establishes a desired aesthetic in the fabric, and the micro-pattern does not interfere with the desired aesthetic.

The invention comprises a method. The method comprises applying to a primary backing and loop backs of a tufted synthetic turf a plurality of solid polymer particles having a particle size less than or equal to 1,000 microns such that a layer of solid polymer particles is formed across the width and length of the primary backing, wherein the polymer particles are applied to the primary backing at a rate of approximately 5 to approximately 18 ounces of polymer per square yard and wherein the solid polymer particles are thermoplastic polymer particles or a mixture of thermoplastic polymer particles and thermosetting polymer particles. The method also comprises heating the polymer particles on the primary backing and loop backs to a temperature at or above the melting temperature of the polymer particles and allowing the heated polymer particles to cool below their melting temperature wherein the tufted synthetic turf has bundle lock of at least 6.8 pounds and the tufted synthetic turf has a water permeability of at least 10 inches of water per hour.

A fabric made of yarns interlooping with each other or passing through an inner layer at looping intervals. The fabric is embossed with a micro-pattern extending into the yarns or into a layer underneath the fabric. The micro-pattern contains a pre-defined pattern of a plurality of binding points attaching the yarns to the inner layer or to the added underlayer. This micro-pattern has an inter-point spacing between adjacent binding points that is less than the interlooping intervals. The fabric can also be embossed with a macro-pattern separate from and coarser than the micro-pattern. The macro-pattern establishes a desired aesthetic in the fabric, and the micro-pattern does not interfere with the desired aesthetic.

The present invention is directed to exemplary embroidered patches, and more particularly to a method of manufacture of embroidered patches using thermoplastic sheets having heat activated adhesives and embroidered patches containing such thermoplastic sheets. In accordance with an aspect of the present invention an embroidered patch is provided that may include an embroidered design having a two dimensional shape, a front side and a supporting side, and a sheet material positioned between the front side and the supporting side of the embroidered design. In accordance with this aspect of the present invention, the sheet material may have substantially the same two dimensional shape as the embroidered design.

This disclosure addresses a problem in relation to the environmental destruction that excessive apparel production can produce. In various embodiments, existing textile products are deconstructed into pieces of fabric and then reassembled into apparel in a manner that creates minimal or zero waste. In some embodiments, the fabric pieces will be positioned inside of one or more pattern pieces so as to completely cover each one without overlapping its border. The positioned pieces will be treated with an adhesive and then have a paper layer adhered to it to hold the positioned fabric pieces in place while they are stitched together. Then, the resulting sandwich will be soaked to remove the paper and dissolve the adhesive. The resulting unified fabric component will then be available to be stitched together with other similarly formed fabric components to form a garment.