U.S. patent application number 10/599459 was filed with the patent office on 2008-10-30 for sequin feeder apparatus.
This patent application is currently assigned to TOKAI KOGYO MISHIN KABUSHIKI KAISHA. Invention is credited to Kenji Suzuki, Satoru Suzuki, Ikuo Tajima.
Application Number | 20080264316 10/599459 |
Document ID | / |
Family ID | 35056236 |
Filed Date | 2008-10-30 |
United States Patent
Application |
20080264316 |
Kind Code |
A1 |
Tajima; Ikuo ; et
al. |
October 30, 2008 |
Sequin Feeder Apparatus
Abstract
Sequin strip (60), let out from a reel and then placed on the
upper surface of a supporting plate (8), is fed at a predetermined
pitch corresponding to a size of a sequin (S') of the strip. After
a sewing needle (31) fits into a hole (61) of a leading sequin (S')
as a needle bar (31) descends in accordance with sewing operation,
a movable cutter blade cuts off the leading sequin (S') by being
driven downward by abutment against the needle bar (31) or a member
(32) movable with the needle bar (31). Sequin-cutting portion (27a)
of the movable cutter blade (27) has a thickness smaller than a
thickness of an abutting portion (27b) that abuts against the
needle bar (31) or the member (32) movable with the needle bar
(31), to secure an appropriate strength. For example, the movable
cutter blade (27) is shaped such that the thickness of a particular
region, corresponding to a needle drop position, of the movable
cutter blade (27) is reduced, and that, when the movable cutter
blade (27) is in a posture before abutting against the needle bar
(31) or the member (32) movable with the needle bar, an upper
region (u) of the thickness-reduced sequin-cutting portion (27a) is
located below an uppermost region (T) of the abutting portion (27b)
not reduced in thickness.
Inventors: |
Tajima; Ikuo; (Nagoya-shi,
JP) ; Suzuki; Satoru; (Komaki-shi, JP) ;
Suzuki; Kenji; (Niwa-gun, JP) |
Correspondence
Address: |
ROSSI, KIMMS & McDOWELL LLP.
20609 Gordon Park Square, Suite 150
Ashburn
VA
20147
US
|
Assignee: |
TOKAI KOGYO MISHIN KABUSHIKI
KAISHA
Kasugai-shi, Aichi
JP
|
Family ID: |
35056236 |
Appl. No.: |
10/599459 |
Filed: |
March 8, 2005 |
PCT Filed: |
March 8, 2005 |
PCT NO: |
PCT/JP2005/003988 |
371 Date: |
September 28, 2006 |
Current U.S.
Class: |
112/113 |
Current CPC
Class: |
D05C 7/08 20130101; D05B
3/12 20130101; D05D 2303/18 20130101 |
Class at
Publication: |
112/113 |
International
Class: |
D05B 3/22 20060101
D05B003/22 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 29, 2004 |
JP |
2004-095411 |
Claims
1. A sequin feeder apparatus comprising a feed mechanism for
feeding a strip of a multiplicity of continuously-connected
sequins, let out from a reel and then placed on an upper surface of
a supporting plate, at a predetermined pitch corresponding to a
size of a sequin of the strip, and a movable cutter blade that cuts
off a sequin by being driven downward, by abutment against a needle
bar or a member movable with the needle bar, after a sewing needle
fits into a hole of a sequin fed out by said feed mechanism as the
needle bar descends in accordance with sewing operation of a sewing
machine, characterized in that a sequin-cutting portion of said
movable cutter blade has a thickness smaller than a thickness of an
abutting portion thereof that abuts against the needle bar or the
member movable with the needle bar.
2. A sequin feeder apparatus as claimed in claim 1 wherein said
sequin-cutting portion is formed by reducing a thickness of a
particular region, corresponding to a needle drop position, of said
movable cutter blade, and wherein, when said movable cutter blade
is in a posture before abutting against the needle bar or the
member movable with the needle bar, an upper region of the
sequin-cutting portion, formed by reducing the thickness of said
movable cutter blade, is located below an uppermost region of the
abutting portion not reduced in thickness.
3. A sequin feeder apparatus as claimed in claim 1 wherein, in said
movable cutter blade, the sequin-cutting portion reduced in
thickness is formed below the abutting portion not reduced in
thickness.
4. A sequin feeder apparatus as claimed in claim 1 wherein said
feed mechanism is arranged to feed out a sequin by advancing and
retracting movement of a feed lever, said feed mechanism performing
feeding operation by causing a distal end of the feed lever to
engage the hole of at least one sequin of the strip on the
supporting plate and then advancing the feed lever, and wherein a
position of the hole where the distal end is to engage when the
feed lever is to be advanced is variable in accordance with a size
of the sequin.
Description
TECHNICAL FIELD
[0001] The present invention relates to sequin feeder apparatus for
use in sewing machines which sew a sequin onto a sewing fabric or
workpiece while severing the sequin from a ribbon or strip of
continuously-connected sequins (continuous sequin strip), and more
particularly, it relates to an improved sequin feeder apparatus
which can also be appropriately applied to a continuous strip of
extremely-small sequins.
BACKGROUND ART
[0002] Example of the conventional sequin feeder apparatus is known
from German Utility Model Registration No. G9209764.2, U.S. Pat.
No. 5,755,168 or German Patent No. DE19538084 (corresponding to
U.S. Pat. No. 5,755,168). Such a sequin feeder apparatus includes a
feed mechanism, which causes a strip of a multiplicity of
continuously-connected sequins (spangles) to be played out or let
out from a reel, having the continuous sequin strip wound thereon,
onto a supporting plate and then, through predetermined forward and
rearward (i.e., advancing and retracting) movement of a feed lever,
feeds the continuous sequin strip at a predetermined pitch
corresponding to the size of each sequin of the strip. One sequin
is sewn at a time onto a sewing workpiece while being severed from
the continuous sequin strip having been fed in interlocked relation
to a sewing operation by a needle bar of the sewing machine.
[0003] In the sequin feeder apparatus, a feed lever feeds the
continuous sequin strip by causing its distal end to engage a
center hole of a sequin and moving forward or advancing the distal
end engaging the center hole, and it then causes the distal end to
engage the center hole of a succeeding sequin by moving rearward or
retracting the distal end. The supporting plate has a slit that
allows the distal of the feed lever to bite into a predetermined
sequin in order to more reliably permit engagement between the
distal of the feed lever and the sequin. Sequins are severed, one
at a time, from the continuous sequin strip by cooperative
operation of a movable cutter blade pivotably provided in proximity
to an end of the supporting plate and a fixed cutter blade fixedly
provided at the end edge of the supporting plate. After the sewing
needle fits in the center hole of the fed-out sequin as the needle
bar descends, the movable cutter blade is caused to pivot by being
depressed by a needle clamp provided at the lower end of the needle
bar.
[0004] FIG. 12 shows a conventionally-known sequin feeder
apparatus, where (a) is a side view of the sequin feeder apparatus
and (b) is a plan view of the sequin feeder apparatus. Reference
numeral 100 indicates the supporting plate, 100a the slit, 100b the
fixed cutter blade, 101 the feed lever, 102 the movable cutter
blade, 103 the needle bar, 104 the sewing needle, 105 the needle
clamp, 106 continuous sequin strip, S the sequin, 106a the center
hole of the sequin S, and S1 a connecting portion between the
sequins S. With this conventional sequin feeder apparatus, it is
not possible to sew a sequin of an extremely small size (e.g., 3 mm
diameter). The sequin feeder apparatus is shown in FIG. 12 as used
to sew extremely-small sequins of a 3 mm diameter, and the
following paragraphs set forth reasons why such extremely-small
sequins can not be sewn. As seen in (b) of FIG. 12, the feed-out of
the sequin S is performed in such a manner that the connecting
portion between the leading or first and second sequins S is
located in vertical registry with the cutting edge of the fixed
cutter blade 100b and that the sewing needle 104 fits into the
center hole 106a of the fed-out sequin S. Thus, with the 3 mm
diameter sequin, a distance from the cutting edge of the fixed
cutter blade 100b to a needle drop position of the sewing needle
104 (indicated by A in (a) of FIG. 12) measures 1.5 mm. Thus, if
the needle bar descends from the position shown in (a) of FIG. 12,
the tip of the sewing needle 104 will undesirably hit the movable
cutter blade 102. As a consequence, it is practically impossible to
sew such an extremely-small sequin S.
[0005] Also, the conventional sequin feeder apparatus has the
following inconvenience from the viewpoint of the feed mechanism.
Namely, in the conventional sequin feeder apparatus, the distal end
of the feed lever 101 engages the center hole 106a of the second
sequin S from the leading end of the continuous sequin strip 106
when the leading sequin S is to be fed out by advancing movement of
the feed lever 101. Thus, in order to feed out a 3 mm diameter
sequin S, there is a need to extend the slit 100a toward the
movable cutter blade 102. In fact, however, the slit 100a can not
be extended because the hard fixed cutter blade 100 is fixed to an
end of the supporting plate 100 adjacent to the movable cutter
blade. Thus, for this reason as well, the conventional sequin
feeder apparatus can not feed out and sew an extremely-small sequin
S.
DISCLOSURE OF THE INVENTION
[0006] It is therefore an object of the present invention to
provide a sequin feeder apparatus which permits sewing of a
continuous sequin strip of extremely-small sequins.
[0007] In order to accomplish the above-mentioned object, the
present invention provides a sequin feeder apparatus which
comprises: a feed mechanism for feeding a strip of a multiplicity
of continuously-connected sequins, let out from a reel and then
placed on an upper surface of a supporting plate, at a
predetermined pitch corresponding to a size of a sequin of the
strip; and a movable cutter blade that cuts off a sequin by being
driven downward, by abutment against a needle bar or a member
movable with the needle bar, after a sewing needle fits into a hole
of a sequin fed out by the feed mechanism as the needle bar
descends in accordance with sewing operation of a sewing machine,
and which is characterized in that a sequin-cutting portion of the
movable cutter blade has a thickness smaller than a thickness of an
abutting portion thereof that abuts against the needle bar or the
member movable with the needle bar.
[0008] For example, the sequin-cutting portion of the movable
cutter blade may be formed by reducing the thickness of a region,
corresponding to a needle drop position, of the movable cutter
blade, and arrangements may be made such that, when the movable
cutter blade is in a posture before abutting against the needle bar
or the member movable with the needle bar, an upper region of the
sequin-cutting portion is located below an uppermost region of the
abutting portion not reduced in thickness.
[0009] With the region, corresponding to the needle drop position,
of the movable cutter blade having a smaller thickness than the
needle bar or the member movable with the needle bar as noted
above, the sewing needle can be prevented from hitting the movable
cutter blade even where the position of the sewing needle (i.e.,
position of the needle bar) is set to be closer to the movable
cutter blade than in the prior art. Thus, the sewing needle can be
prevented from hitting the movable cutter blade even in sewing of
an extremely-small sequin, so that the present invention can sew an
extremely-small sequin much smaller in size than those sewn by the
prior art. Further, because only the sequin-cutting portion of the
movable cutter blade has to be formed into a reduced thickness and
the remaining portions of the movable cutter blade may have similar
thicknesses to those in the prior art apparatus, a section for
mounting the movable cutter blade can be formed into a thickness
capable of readily securing a sufficient mounting strength. Namely,
the abutting portion of the movable cutter blade, which abuts
against the needle bar or the member fixed to the needle bar, may
be of the same thickness as the conventional counterpart. Thus,
although the needle bar or the member fixed to the needle bar abuts
against the abutting portion of the movable cutter blade as the
needle bar is driven to descend per stitching, the abutting portion
of the movable cutter blade, not reduced in thickness, can easily
withstand an abutting impact and thereby prevent breakage of the
movable cutter blade.
[0010] Further, in the present invention, the feed mechanism is
arranged to feed out a sequin by advancing and retracting movement
of a feed lever, and the feed mechanism performs feeding operation
by causing the distal end of the feed lever to engage the hole of
at least one sequin of the strip on the supporting plate and then
advancing the feed lever. Position of the hole where the distal end
is to engage when the feed lever is to be advanced is variable in
accordance with a size of the sequin.
[0011] With the arrangement that allows the position of the hole,
where the distal end is to engage when the feed lever is to be
advanced, to be varied depending on the size of the sequin, the
feed lever in the present invention can be caused to engage the
hole of, for example, a second sequin or third sequin from the
leading end of the sequin strip to thereby feed out the sequin.
Thus, in sewing an extremely-small sequin, the extremely-small
sequin can be fed out by the feed lever being caused to engage the
hole of the third sequin from the leading end of the sequin strip,
without the slit of the supporting plate having to be extended and
without being interfered with by the fixed cutter blade.
[0012] Namely, according to the present invention, only the
necessary portion of the movable cutter blade is reduced in
thickness so as to retain the necessary mechanical strength of the
movable cutter blade, and the movable cutter blade is shaped in a
particular manner so that the thickness-reduced portion of the
movable cutter blade is located below the non-thickness-reduced
abutting portion of the movable cutter blade. Thus, with the
thickness-reduced portion of the movable cutter blade, the present
invention can achieve the superior benefit that it can
appropriately sew a continuous sequin strip of extremely-small
sequins as compared to the prior art apparatus.
BRIEF DESCRIPTION OF DRAWINGS
[0013] FIG. 1 is a perspective view showing an outer appearance of
an embroidery sewing machine employing a sequin feeder apparatus in
accordance with en embodiment of the present invention;
[0014] FIG. 2 is a side view showing in an enlarged scale a part of
one of sequin sewing units in the embodiment;
[0015] FIG. 3 is a side view showing in a further enlarged scale a
part of the sequin feeder apparatus employed in the sequin sewing
unit in the embodiment;
[0016] FIG. 4 is an enlarged perspective view showing, with parts
taken away, relevant components of the sequin feeder apparatus of
FIG. 3;
[0017] FIG. 5 is a partly-sectional side view and schematic plan
view of the relevant components of the sequin feeder apparatus,
which particularly shows a state of the apparatus when one feeding
cycle has been completed with a feed lever moved to its forwardmost
position;
[0018] FIG. 6 is a partly-sectional side view and schematic plan
view of the relevant components of the sequin feeder apparatus,
which particularly shows a state of the apparatus immediately after
an engaging portion of the feed lever has disengaged from a center
hole of a sequin during retracting movement of the feed lever;
[0019] FIG. 7 is a partly-sectional side view and schematic plan
view of the relevant components of the sequin feeder apparatus,
which particularly shows a state of the apparatus when the feed
lever has retracted to its rearwardmost position;
[0020] FIG. 8 is a partly-sectional side view and schematic plan
view of the relevant components of the sequin feeder apparatus,
which particularly shows a state of the apparatus when the engaging
portion of the feed lever has engaged the center hole of a sequin
during advancing movement of the feed lever;
[0021] FIG. 9 is a partly-sectional side view and schematic plan
view of the relevant components of the sequin feeder apparatus,
which particularly shows a state of the apparatus at a time point
when an edge of a through-hole of the feed lever disengages from a
lock lever during the forward movement of the feed lever;
[0022] FIG. 10 is explanatory of an example operation for feeding
an extremely-small sequin and shows relevant components of the
sequin feeder apparatus when feed-out of one extremely-small sequin
has been completed with the feed lever moved to the forwardmost
position, of which (a) is a partly-sectional side view of the
relevant components of the sequin feeder apparatus, (b) is a
schematic plan view of the relevant components and (c) is a
perspective view, with parts taken away, of the relevant
components;
[0023] FIG. 11 is a partly-sectional side view showing a state of
the sequin feeder apparatus immediately before a needle clamp at
the lower end of a descending needle bar abuts against a movable
cutter blade upon completion of the feeding operation of FIG. 10;
and
[0024] FIG. 12 is a side view and plan view showing problems
presented by a conventionally-known sequin feeder apparatus.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0025] FIG. 1 shows a four-head embroidery sewing machine equipped
with four sewing machine heads and employing a sequin feeder
apparatus in accordance with an embodiment of the present
invention. Needle bar cases 2 are provided in corresponding
relation to the sewing machine heads, and a throat plate 50 is
disposed under the needle bars of each of the machine head. Sequin
sewing unit 1 is attached to the left side and/or right side of
each of the needle bar cases 2; in the instant embodiment, the
sequin sewing unit 1 is attached to only the left side of the
associated needle bar case 2. Each of the needle bar cases 2
comprises a multi-needle structure, and, in the case where the
sequin sewing unit 1 is attached to only the left side of the
associated needle bar case 2 as in the instant embodiment, the
leftmost needle in the needle bar case 2 is used as a sequin sewing
needle. As conventionally known in the art, an embroidery frame 51
is driven in left-right (X) and front-rear (Y) directions in
accordance with sewing data.
[0026] FIG. 2 is a side view showing in an enlarged scale a part of
one of the sequin sewing units 1. FIG. 3 is a side view showing in
a further enlarged scale a part of a sequin feeder apparatus 6
employed in the sequin sewing unit 1, and FIG. 4 is a perspective
view showing, with parts taken away, primary or relevant components
of the sequin feeder apparatus 6.
[0027] As illustrated in FIG. 2, the sequin sewing unit 1 also
includes a mounting base 4, on which are supported a reel 5, having
a continuous sequin strip 3 wound thereon and the sequin feeder
apparatus 6. The mounting base 4 is mounted, via a not-shown link
mechanism, in such a manner that it can ascend and descend relative
to the needle bar case 2. In FIGS. 2 and 3, the mounting base 4 is
shown as being in a descended position and in a posture ready for
sewing of sequins. When sewing of sequins is not to be performed,
the mounting base 4 is evacuated to an ascended position so as not
to hinder the normal embroidering operation. In the individual
machine heads, the mounting bases 4 are driven to ascend or descend
concurrently via not-shown air cylinders. Where the embroidery
sewing machine has a smaller number of the machine heads like a
single-head embroidery sewing machine, the mounting base (or bases)
4 may be caused to ascend or descend manually.
[0028] The reel 5 having the continuous sequin strip 3 wound
thereon is rotatably and removably attached to an upper end portion
of an arm section 4a formed on an upper portion of the mounting
base 4. The continuous sequin strip 3 is formed by die-cutting a
synthetic resin film of a given width into a configuration having a
multiplicity of circular sequins S continuously connected via
connecting portions S1. In the instant embodiment, the continuous
sequin strip 3 is a strip of continuously-connected sequins S each
having a needle-passing hole (hereinafter referred to as "center
hole") 3a (see FIG. 4).
[0029] Next, an example structure of the sequin feeder apparatus 6
will be explained in detail. The sequin feeder apparatus 6 is
secured to a support plate 7 that is in turn attached to a lower
end portion of the mounting base 4. The support plate 7 has a
horizontal supporting plate 8 formed on its lower end for
supporting thereon sequins. Portion of the continuous sequin strip
3, let out from the reel 5, is directed downward along the mounting
base 4 via a tension roller 45 and orientation roller 46, led onto
the supporting plate 8 by way of a guide section 12 provided on a
rear surface of a bracket 11 and then delivered rearward as viewed
from the front of the embroidery sewing machine. Note that, in the
following description about the sequin sewing unit 1, the terms
"forward" and "reward" are used to refer to directions opposite to
the forward and rearward directions of the embroidery sewing
machine. Namely, the direction in which sequins are fed out (i.e.,
in a rearward direction as viewed from the front of the embroidery
sewing machine) will hereinafter referred to as "forward
direction".
[0030] The supporting plate 8 has a slit 8a of a suitable width and
predetermined length extending in the front-rear (Y) direction from
its front position to its middle position (see (a) of FIG. 5).
Through positional adjustment in the left-right (X) direction of
the guide section 12, the center hole 3a of each sequin S of the
continuous sequin strip 3 can be appropriately positioned in
vertical registry with the slit 8a. Namely, the guide section 12
provided on the rear surface of the bracket 11 functions to
position the center hole 3a of each sequin S of the continuous
sequin strip 3 in vertical registry with the slit 8a; the guide
section 12 is never intended to position the continuous sequin
strip 3 on a predetermined region of the supporting plate 8. More
specifically, the slit 8a of the supporting plate 8 is provided to
allow a distal end engaging portion 18a of a feed lever 18 and
engaging claw 33a of a lock lever 33 to bite into predetermined
sequins S when the distal end engaging portion 18a and engaging
claw 33a have engaged the center holes 3a of the sequins S.
[0031] As illustrated in FIG. 3, a pivot shaft 15 is pivotally
supported on a middle portion of the support plate 7 with the axial
centerline of the pivot shaft 15 extending in the left-right
direction (i.e., X direction). Pivot arm or lever 16 is fixed via a
screw 17 to the pivot shaft 15, and the feed lever 18 is pivotably
supported, via a shaft 19, on a free end portion of the pivot lever
16. Further, a follower lever 20 is fixed via a screw 21 to the
pivot shaft 15 adjacent to the pivot lever 16. Consequently, the
follower lever 20 and pivot lever 16 are connected together to
provide a "bellcrank-like" structure.
[0032] Torsion spring 22 fitted around the pivot shaft 15 has one
end secured to the support plate 7 and the other end held on the
follower lever 20. The pivot lever 16 is normally biased in a
counterclockwise direction of FIG. 3 by the biasing force of the
torsion spring 22. Further, a torsion spring 23 fitted around the
shaft 19 has one end secured to the pivot art 16 and the other end
held on the feed lever 18, via which the feed lever 18 is normally
biased in a clockwise direction. Thus, the engaging portion 18a of
the feed lever 18 is normally biased toward the supporting plate
8.
[0033] The feed lever 18 functions to incrementally or sequentially
feed the continuous sequin strip 3 in the forward direction at a
predetermined pitch, by being moved forward with the engaging
portion 18a engaging the center hole 3a of a predetermined sequin S
of the strip 3 placed on the supporting plate 8. As will be later
detailed, the feed lever 18 is moved forward and rearward in
response to pivotal movement of the pivot lever 16, so as to
sequentially feed the continuous sequin strip 3 forward at the
predetermined pitch. The pivot lever 16 and mechanism for pivoting
the pivot lever 16 together constitute a feed mechanism for moving
the feed lever 18 forward and rearward. The follower lever 20
integrally connected with the pivot lever 16 has a free end
connected to a free end of a driving lever 38 via a connection link
37. The driving lever 38 is fixedly connected to an output shaft 40
of a motor 36 that is in turn secured to a left side surface of the
mounting base 4. By the motor 36 driving the driving lever 38 to
reciprocatively pivot through a predetermined angular range, the
continuous sequin strip 3 can be fed forward in a predetermined
manner.
[0034] The pivot art 16 normally biased in the counterclockwise
direction is held in a posture as illustrated in FIGS. 3, 4 and 5
by abutting against a stopper 25 provided on the support plate 7.
The illustrated posture is taken when the feeding of the continuous
sequin strip 3 has been completed. (a) of FIG. 5 is a
partly-sectional side view showing in an enlarged scale relevant
components of the sequin feeder apparatus 6 when one feeding cycle
of the continuous sequin strip 3 has been completed, and (b) of
FIG. 5 is a schematic plan view of the relevant components of the
sequin feeder. Namely, when one feeing cycle of the continuous
sequin strip 3 has been completed, the engaging portion 18a of the
feed lever 18 has fitted in the center hole 3a of the second sequin
S from the leading end of the sequin strip 3, and the connecting
portion S1 between the leading and second sequins S has been
positioned immediately above (i.e., in vertical alignment with) the
cutting edge of a fixed cutter blade 8b. The stopper 25 is in the
form of a threaded rod screwed to a bracket 26 that is in turn
secured to the support plate 7, and the pivot lever 16 abuts
against the rear end of the stopper 25. The threaded rod can be
locked by screwing up of a nut.
[0035] As clearly seen from FIGS. 3 and 4, a movable cutter blade
27 is pivotably supported via a pin 28 on a lower end portion of
the support plate 7 and is normally held, via a torsion spring 30,
in a retracted or evacuated position spaced upward from the fixed
cutter blade 8b. The movable cutter blade 27 has a small-thickness
distal end portion 27a as a sequin-cutting portion, and this
sequin-cutting portion 27a has a smaller thickness than an abutment
portion 27b that abuts against the needle clamp 32 descending with
the needle bar 31. Namely, an upper region u of the end portion 27a
of the movable cutter blade 27 is recessed obliquely downward so
that a region of the large-thickness body portion 27b of the blade
27 forms an uppermost portion T of the blade 17 when the movable
cutter blade 27 is in its retracted position. The movable cutter
blade 27 is depressed by the needle clamp 32, provided at the lower
end of the needle bar 31, as the needle bar 31 descends. The
depression by the needle clamp 32 causes the movable cutter blade
27 to pivot against the resilient biasing force of the torsion
sprint 30, so that the movable cutter blade 27 can cut the strip 3
across the connecting portion S1 of a predetermined sequin S in
conjunction with the fixed cutter blade 8b. At that time, the
descending needle clamp 32 will come into abutting contact with the
large-thickness body portion 27b because the upper region u of the
end portion 27a of the movable cutter blade 27 is recessed
obliquely downward to allow the large-thickness body portion 27b to
become the uppermost portion T. Thus, it is possible to prevent the
inconvenience that the descending needle clamp 32 abuts against and
damages the small-thickness end portion 27a of a relatively small
mechanical strength. As the needle clamp 32 ascends along with the
needle bar 31, the movable cutter blade 27 returns to its retraced
position by the restoring or resilient force of the torsion spring
30.
[0036] The above-mentioned guide section 12 for directing the
continuous sequin strip 3 onto the supporting plate 8 comprises two
guide members 12a, each of which may be made by bending a plate
into a channel-like sectional shape. The guide section 12 is
replaceable with another one depending on the width of a continuous
sequin strip 3 set on the feeder apparatus. Distance between
opposed side walls of each of the guide members 12a is set slightly
greater than the width of each sequin S of the set strip 3. Holding
member 44 is disposed in front of the bracket 11 having the guide
section 12 attached thereto. The holding member 44 is in the form
of a resilient plate, such as a spring steel plate, which has a
width equal to or slightly greater than the width of the sequin S
and has a predetermined length. The holding member 44 has one end
portion secured to the bracket 11 and the other end portion
resiliently abutted against the upper surface of the supporting
plate 8, with an intermediate portion of the holding member 44
being bent arcuately. The holding member 44 is recessed in its end
portion adjacent to the slit 8a of the supporting plate 8 so as not
to close the slit 8a (see FIG. 4). The continuous sequin strip 3,
delivered via the guide section 12, is passed between the
supporting plate 8 and the holding member 44 resiliently abutted
against the upper surface of the supporting plate 8.
[0037] Next, a description will be given about the lock lever 33
disposed above the feed lever 18 and a mechanism for driving the
lock lever 33.
[0038] As seen in FIG. 4, the lock lever 33 has an engaging claw
33a at the tip of its one end and a stopper portion 33b at its
other end. Intermediate portion of the lock lever 33 is pivotably
supported, via a pin 39, by a support block 35 that is in turn
fixed to the support plate 7. In FIG. 4, the support block 35 is
shown with its front portion taken away to allow the lock lever 33
to be visible more easily. The engaging claw 33a of the lock lever
33 extends through a through-hole 18b formed in the feed lever 18,
and a torsion spring (not shown) is provided on the pin 39 fixed to
the support block 35. The lock lever 33 is normally biased, by that
torsion spring, against the support block 35 in the
counterclockwise direction of the figure and the stopper portion
33b of the thus-biased lock lever 33 abuts against a stopper
portion 35a of the support block 35, so that the lock lever 33 in
its free state is held in a posture or position where the end edge
of the engaging claw 33a confronts the slit 8a of the supporting
plate 8. In this state, the end edge of the engaging claw 33a of
the lock lever 33 engages the center hole 3a of a predetermined one
of the sequins S, to thereby immovably lock the continuous sequin
strip 3. As will be later described in detail, the edge of the
through-hole 18b in the feed lever 18 abuts against the lock lever
33, during rearward or retracting movement of the feed lever 18, to
pivot the lock lever 33 in the clockwise direction against the
counterclockwise biasing force of the torsion spring acting on the
lock lever 33. In this way, the engaging claw 33a is moved upwardly
to disengage the center hole 3a of the sequin S.
[0039] The support block 35 supporting the lock lever 33 is
adjustable in its position, in the front-rear direction (i.e.,
feeding direction of the continuous sequin strip 3 on the
supporting plate 8), relative to the support plate 7. Thus, the
position at which the engaging claw 33a of the lock lever 33
engages the sequin S can be adjusted in accordance with the size of
the sequin S. Note that the support plate 7 too is adjustable in
its position, in the front-rear direction (i.e., feeding direction
of the continuous sequin strip 3 on the supporting plate 8),
relative to the mounting base 4.
[0040] In the instant embodiment of the embroidery sewing machine,
the needle bar cases 2 of each of the machine heads includes nine
needle bars 31, and the sequin sewing unit 1 is attached to the
left side of each of the needle bar cases 2 as noted above. In
sewing sequins, the leftmost needle bar 31 is selected, and the
sequin sewing unit 1 descends into an operating state so that it
sews sequins in conjunction with the needle bar 31.
[0041] The following paragraphs describe the sequin feeding
operation performed in the embodiment of the present invention,
with primary reference to FIGS. 5-9 showing an example sequence of
the sequin feeding operation.
[0042] FIG. 5 shows a state when one sequin feeding operation cycle
has been completed. At this phase, the leading sequin S projects
forward beyond the supporting plate 8, and the connecting portion
S1 between the leading sequin S and the second sequin S is
positioned immediately above (i.e., in alignment with) the cutting
edge of the fixed cutter blade 8b. Also, at this phase, the
engaging portion 18a of the feed lever 18 engages the
above-mentioned second sequin S, and the engaging claw 33a of the
lock lever 33 abuts against the center hole 3a of the third sequin
S from the second sequin S, as noted above.
[0043] The feeder apparatus behaves as follows in response to
descending movement of the needle bar 31.
[0044] First, as the needle bar 31 descends, a sewing needle 41
provided at the lower end of the needle bar 31 (see FIG. 3) fits
into the center hole 3a of the leading sequin S. Then, the movable
cutter blade 27 is depressed by the descending movement of the
needle clamp 32, so that the sequin strip 3 is cut in the
connecting portion S1 of the leading sequin S and thus the leading
sequin S is severed from the sequin strip 3. Then, the severed
sequin S falls onto an embroidering fabric W (FIG. 3) with the
sewing needle 41 still kept fit in the center hole 3a, after which
the sequin S is sewn onto the fabric W through controlled movement
of the embroidery frame holding the embroidering fabric W and
vertical movement of the needle bar 31.
[0045] Then, the pivot lever 16 is pivoted in the clockwise
direction via the motor 36, so that the feed lever 18 moves
rearward as shown in FIGS. 6 and 7. FIG. 6 shows a state
immediately after disengagement, from the center hole 3a, of the
engaging portion 18a of the feed lever 18, where (a) is a
partly-sectional side view and (b) is a schematic plan view. During
the disengagement, from the center hole 3a, of the engaging portion
18a, the engaging claw 33a of the lock lever 33 is kept fit in the
center hole 3a, and thus, it is possible to reliably prevent the
continuous sequin strip 3 from being undesirably displaced as the
engaging portion 18a of the feed lever 18 disengages from the
center hole 3a. Further, in the state shown in FIG. 6, the edge of
the through-hole 18b of the feed lever 18 abuts against the lock
lever 33. As the lock lever 18 further moves rearward in such a
state, the lock lever 33 pivots in the clockwise direction against
the biasing force of the torsion spring due to the engagement with
the edge of the through-hole 18b of the feed lever 18 so that the
engaging claw 33a of the lock lever 33 moves upwardly away from the
sequin S and thereby disengages from the sequin's center hole
3a.
[0046] FIG. 7 the feed lever 18 having retracted to its
rearwardmost position, where (a) is a partly-sectional side view
and (b) is a schematic plan view. Immediately before reaching the
state of FIG. 7, the engaging portion 18a of the feed lever 18
temporarily fits into the center hole 3a of the sequin S and then
gets out of the center hole 3a. During a shift from the state of
FIG. 6 to the state of FIG. 7, the continuous sequin strip 3,
having been disengaged from the engaging claw 33a of the lock lever
33, can be prevented from being undesirably displaced rearward
together with the retracting feed lever 18; this is by virtue of
the springy resilient force of the holding member 44.
[0047] After that, the pivot lever 16 is driven, by the reverse
rotation of the motor 36, to pivot in the counterclockwise
direction, so that the feed lever 18 moves forward up to the
position shown in FIG. 5. FIGS. 8 and 9 show variation in state of
the feed lever 18 during such forward or advancing movement. FIG. 8
shows the feed lever 18 at a time point when the engaging portion
18a has engaged the center hole 3a, where (a) is a partly-sectional
side view and (b) is a schematic plan view. Feeding of the
continuous sequin strip 3 is carried out by forward movement of the
engaging portion 18a engaging the center hole 3a as the feed lever
18 advances from that time point onward. FIG. 9 shows a time point
when the edge of the through-hole 18b of the advancing feed lever
18 disengages the lock lever 33, where (a) is a partly-sectional
side view and (b) is a schematic plan view. The lock lever 33,
having been disengaged from the edge of the through-hole 18b of the
feed lever 18, is caused to pivot in the counterclockwise direction
by the resilient force of the torsion spring provided on the pin
39, upon which the engaging claw 33a of the lock lever 33 are
brought into resilient contact with the upper surface of sequins S,
as shown in FIG. 9. While the feed lever 18 is advancing further,
the engaging claw 33a of the lock lever 33 slides on and relative
to the upper surfaces of the sequins S. Once the feed lever 18 has
reached the feed completion position as shown in FIG. 5, the
engaging claw 33a of the lock lever 33 engages the center hole 3a
of the sequin S.
[0048] When the motor 36 is in the non-energized or OFF state, such
as when the power supply to the embroidery sewing machine is OFF,
the pivot lever 16 is held in the feed completion position shown in
FIG. 5, by virtue of the resilient force of the torsion spring 22
secured to the pivot lever 16, so that the lever 16 is held in
abutment against the stopper 25. The motor 36 is a pulse motor that
operates under open control, so that it will lose appropriate
synchronization if an excessive force acts on the motor 36 during
the feed control. For that reason, the motor 36 employed in the
instant embodiment is temporarily deenergized when the feed lever
18 has reached the forwardmost position, i.e. when the pivot lever
16 has abutted against the stopper 25 upon completion of the
feeding cycle. Thus, the motor 36 can be restored to the zero point
without fail even when it has lost synchronization; in this way, it
is possible to prevent accumulation of positional displacement
caused by the synchronization loss.
[0049] The following paragraphs describe an example manner in which
the various components of the feeder apparatus are adjusted when
the reel 5 has been replaced with another one so that the sequins S
to be sewn onto the fabric are replaced with those of a different
size. The adjustments of the components, as set forth in items
(1)-(4) below, may be performed concurrently, or sequentially in
any appropriate order.
[0050] (1) Adjustment of Feed Pitch:
[0051] In order to adjust the feed pitch, the screw 17 fastening
the pivot lever 16 is loosened (see FIG. 3) so that the pivot lever
16 can be readily turned with a hand relative to the pivot shaft
15. Further, the stopper 25 is unlocked, and the continuous sequin
strip 3 is let out from the reel onto the supporting plate 8 so
that the leading sequin S of the strip 3 projects beyond the front
end edge of the supporting plate 8 as indicated by the "feed
completion position" as shown in (b) of FIG. 5. Then, the pivot
lever 16 and feed lever 18 are moved with a hand to cause the
engaging portion 18a of the feed lever 18 to engage the center hole
3a of the second sequin S from the leading end of the strip 3.
Then, the stopper 25 is again locked and the screw 17 is tightened
with the feed mechanism, including the pivot lever 16 and feed
lever 18, adjusted into the "feed completion position" in
accordance with the size of the sequins S.
[0052] (2) Adjustment of Lock Lever:
[0053] In order to adjust the lock lever 33, the support block 35
is unlocked. Position, in the front-rear direction, of the support
block 35 is adjusted manually to adjust the inclination of the lock
lever 33 so that the engaging claw 33a of the lock lever 33 engages
the center hole 3a of a predetermined sequin S (third one from the
sequin S engaged by the engaging portion 18a), as illustrated in
FIG. 5, with the stopper portion 33b provided at the upper end of
the lock lever 33 abutted against the stopper portion 35a of the
support block 35. Thus, the support block 35 is again locked with
the lock lever 33 positionally adjusted so that the engaging claw
33a of the lock lever 33 engages the center hone 3a of the
predetermined sequin S as indicated by the "feed completion
position" shown in (b) of FIG. 5.
[0054] (3) Positional Adjustment of Sequin's Center Hole Relative
to Sewing
Needle Position:
[0055] Positional adjustment between the sewing needle 41 and the
center hole 3a of the sequin S is carried out by adjusting the
position of the support plate 7 relative to the mounting base 4.
Because the support plate 7 is mounted to the mounting base 4 via
the forward/rearward guide members, each lock (not shown) provided
in connection with the guide members is brought into an unlocking
position so as to allow the support plate 7 to be manually moved in
the front-rear direction relative to the mounting base 4. Then, the
support plate 7 is adjusted so that the center of the center hole
3a of the sequin S, having been delivered from the supporting plate
8 to a position where the connecting portion S1 aligns with the
cutting edge of the fixed cutter blade 8b, aligns with the center
of the sewing needle 41. Upon completion of the adjustment, the
support plate 7 is locked and fixed to the mounting base 4.
[0056] (4) Replacement of Guide Section:
[0057] As necessary, the guide section 12, mounted on the bracket
11, may be replaced with another one that corresponds to the width
of sequins of a continuous sequin strip newly set on the apparatus
in place of the previous continuous sequin strip.
[0058] Lastly, a description will be given about an example manner
in which the sequin S to be sewn has been changed to another sequin
S' having an extremely small size. FIGS. 10 and 11 show an example
where extremely-small sequin S' of a 3 mm diameter are to be sewn,
in which reference numeral 60 indicates a continuous sequin strip
where extremely-small sequins S' are connected together (continuous
extremely-small-sequin strip). In sewing such extremely-small
sequin S' too, adjustments as set forth in items (1')-(4') below
are carried out.
[0059] (1') Adjustment of Feed Pitch:
[0060] Feed pitch adjustment to be performed for sewing of
extremely-small sequins S' is generally similar to the one to be
performed when the sequins S to be sewn have been changed to
sequins of an ordinary size as set forth above in item (1). In this
case, however, if the engaging portion 18a of the feed lever 18 is
caused to engage the center hole 61 of the second sequin S' from
the leading end of the sequin strip 60 as with the sequin of the
ordinary size, the engaging portion 18a of the feed lever 18 would
interfere with the front edge of the slit 8a before it completely
feeds out the leading sequin S', so that the connecting portion S'1
between the leading sequin S' and the second sequin S' can not be
positioned in appropriate vertical alignment with the cutting edge
of the fixed cutter blade 8b. Therefore, in sewing such
extremely-small sequins S', the engaging portion 18a of the feed
lever 18 is caused to engage the third sequin S' from the leading
end of the sequin strip 60, but also the feed pitch is
adjusted.
[0061] (2') Adjustment of Lock Lever:
[0062] Lock lever adjustment to be performed for sewing of
extremely-small sequins S' is generally similar to the one to be
performed when the sequins S to be sewn have been changed to
sequins of an ordinary size as set forth above in item (2).
However, because of the extremely small size, the engaging claw 33a
of the lock lever 33 is caused to engage the center hole 61 of the
fifth sequin S' from the sequin S' engaged by the engaging portion
18a of the feed lever 18.
[0063] (3') Positional Adjustment of Sequin's Center Hole Relative
to Sewing Needle Position:
[0064] Positional adjustment of the center hole of the sequin
relative to the sewing needle, performed for sewing of
extremely-small sequins S', is generally similar to the one to be
performed when the sequins S to be sewn have been changed to
sequins of an ordinary size as set forth above in item (3). With
each sequin S' having the 3 mm diameter, the center of the center
hole 61 of the leading sequin S' of the sequin strip 60 is located
1.5 mm from the cutting edge of the fixed cutter blade 8b, and the
sewing needle 41 drops to this location. FIG. 11 shows a state
immediately before the needle clamp 32 at the lower end of the
needle bar 31 abuts against the movable cutter blade 27 after the
needle bar 31 descends to fit into the center hole 61 of the
leading sequin S'. As clear from FIG. 11, even when the sewing
needle 41 has descended to a position 1.5 mm short of the cutting
edge of the fixed cutter blade 8b, the small-thickness end portion
27a of the movable cutter blade 27 can prevent the sewing needle 41
from hitting the cutter blade 27.
[0065] (4') Replacement of Guide Section:
[0066] For sewing of extremely-small sequins S', the guide section
12 provided on the bracket 11 is replaced with another one
corresponding to the width of the changed extremely-small sequins
S' in the same manner as stated in item (4) above.
[0067] According to the instant embodiment, as set forth above, the
center hole 61 of the sequin S' to be engaged by the engaging
portion 18a of the feed lever 18 can be changed. Namely, the
engaging portion 18a of the feed lever 18 can be adjusted to engage
the center hole 61 of the third sequin S from the leading end of
the sequin strip 60. Further, with the small-thickness end portion
27a formed on the movable cutter blade 27, the sewing needle 41 can
be reliably prevented from hitting the cutter blade 27 even where
the sewing needle 41 operates to sew the extremely-small sequin S'
in proximity to the cutting edge of the fixed cutter blade 8b. In
this way, the extremely-small sequin S' can be sewn appropriately.
In the above-described embodiment, the motor 36 is located in an
upper area of the sewing apparatus, and the pivot lever 16 is
driven by the motor 36 via a link. Alternatively, the pivot lever
16 may be driven directly by the output shaft 40 of the motor 36.
Namely, the pivot shaft 15 and follower lever 20 may be dispensed
with, and the motor 36 may be fixedly provided on the support plate
7 with the pivot lever 16 fixed to the output shaft 40.
[0068] Further, as described above, the preferred embodiment of the
present invention is arranged to cause the locking by the lock
lever 33 to be canceled during retracting movement of the feed
lever 18 after the operational timing of FIG. 6. However, the
present invention is not so limited, and the locking by the lock
lever 33 may be canceled at least by the timing of FIG. 7 (i.e.,
until the feed lever 18 resumes its forward movement). In the case
where the locking by the lock lever 33 is kept till the timing of
FIG. 7, the particular holding member 44 can be dispensed with
because the continuous sequin strip 3 can be held by the lock lever
33 during the rearward movement of the feed lever 18.
[0069] In the above-described embodiment, the mechanism for driving
the lock lever 33 is arranged in such a manner that the
counterclockwise pivoting of the lock lever 33 is effected via the
torsion spring provided on the pin 39 of the support block 35 and
the clockwise pivoting of the lock lever 33 is effected via the
engagement between the edge of the through-hole 18b of the
retracting feed lever 18 and the lock lever 33. However, the
present invention is not so limited, and the driving mechanism may
be constructed in any desired manner. For example, the spring used
as the biasing means may be other than the torsion spring, and the
biasing means may include electrical or electronic or mechanical
drive means other than a spring.
[0070] Further, according to the instant embodiment, the engaging
claw 33a of the lock lever 33 has engaged the center hole 3a or 61
of the predetermined sequin S or S' when feeding-out of one sequin
is completed. Thus, even when an unexpected pulling force acts on
the predetermined sequin S or S' after the sewing needle 41 fits in
the center hole 3a or 61 of the predetermined sequin S or S' to be
sewn and before the predetermined sequin S or S' is cut off, the
sequin strip 3 or 60 will not be let out, so that the sequin S or
S' can be cut off without fail at the connecting portion S1 or S'1,
so that the sequin S or S' can be reliably prevented from being cut
off into an awkward shape.
[0071] Further, because the engaging portion 18a of the feed lever
18 and the engaging claw 33a of the lock lever 33 have engaged the
center holes 3a or 61 of the predetermined sequins S or S' when
feeding-out of one sequin is completed, the sequin strip 3 or 60
can be positionally controlled at two positions in its longitudinal
direction (i.e., in the feeding direction). Thus, the sequins S or
S' can be positionally adjusted in their width direction at least
upon completion of each sequin feeding cycle. Therefore, no
particular guide member has to be provided on the supporting plate
8 for positionally controlling the sequin strip 3 or 60.
[0072] Further, whereas, in the above-described embodiment, the
needle clamp 32 is arranged to abut against the movable cutter
blade 27 during the descending movement of the needle bar 31.
However, the present invention is not so limited, and another
suitable portion of the needle bar 31 or another suitable member
movable in interlocked relation to the descending movement of the
needle bar 31 may abut against and depress the movable cutter blade
27. Further, the movable cutter blade 27 is not limited to the
illustrated construction or shape where the sequin-cutting portion
(27a) has a smaller thickness than the abutment portion (27b), and
the movable cutter blade 27 may be of any other desired
construction or shape as long as it can attain the object of the
present invention.
[0073] Note that the ordinary-size sequins S and extremely-small
sequins S' to be handled in the present invention are not limited
to the type where the needle-passing hole 3a or 61 is provided at
the center (i.e., provided as a center hole of the sequin); that
is, the needle-passing hole 3a or 61 may be an eccentric hole
provided off the center of the sequin S or S'. In such a case, if a
minimum-radius portion of each sequin S or S' in a sequin strip 3
or 60 is positioned so as to lie from the offset hole 3a or 61 to
the front (i.e., forward in the sequin feeding direction) edge of
the sequin, then a maximum-radius portion of the sequin S or S'
lies from the offset hole 3a or 61 to the rear (i.e., rearward in
the sequin feeding direction) edge of the sequin, so that the
maximum-radius portion of the sequin S or S' can be positioned in
accurate vertical alignment with the width of cut of the movable
cutter blade 27. In this way, the instant embodiment can sew a
sequin of an even smaller size by appropriately changing the degree
of eccentricity of the offset hole 3a or 61 in the sequin S or S'
(while taking an appearance of the finished sequin into account)
without changing the width of cut of the movable cutter blade 27
(i.e., thickness of the small-thickness distal end portion 27a). If
the minimum diameter of an extremely-small sequin S' with the
center hole 61 is 3 mm with the small-thickness distal end portion
27a of the movable cutter blade 27 having a predetermined
thickness, a portion, corresponding to the width of cut, of the
movable cutter blade 27 (i.e., rear portion, in the feeding
direction, of the movable cutter blade 27) only has to have a 1.5
mm diameter. Thus, if 1.5 mm is secured as the maximum-radius
portion to be located adjacent to the rear end in the feeding
direction and the minimum-radius portion to be located adjacent to
the front end in the feeding direction is set, for example, to 1.0
mm, it is possible to sew an even smaller sequin of a 2.5 mm
diameter. Note that even where the movable cutter blade 27 does not
have a thinned distal end portion, the instant embodiment can sew
sequins S of much smaller sizes than those handled by the
conventional sewing apparatus, by offsetting the needle-passing
hole 3a of the sequins S in the aforementioned manner and
positioning the maximum radius portion at a location corresponding
to the width of cut of the movable cutter blade 27.
* * * * *