U.S. patent application number 13/588914 was filed with the patent office on 2014-02-20 for stitching machine.
This patent application is currently assigned to NIKE, INC.. The applicant listed for this patent is Bryan N. Farris. Invention is credited to Bryan N. Farris.
Application Number | 20140048003 13/588914 |
Document ID | / |
Family ID | 49301594 |
Filed Date | 2014-02-20 |
United States Patent
Application |
20140048003 |
Kind Code |
A1 |
Farris; Bryan N. |
February 20, 2014 |
Stitching Machine
Abstract
A stitching machine may include a needle apparatus, a sewing
thread spool receiving device, and a bobbin thread spool receiving
device. The stitching machine may further include a bobbin thread
tensioner configured to receive bobbin thread from the bobbin
thread spool receiving device. The bobbin thread tensioner may be
further configured to supply the bobbin thread to the needle
apparatus. The bobbin thread spool receiving device is configured
to receive a bobbin spool holding approximately 700 meters or more
of bobbin thread. The bobbin thread spool receiving device may be
located above a stitching location of the stitching machine. The
stitching machine may provide improved access to a bobbin spool,
enhanced manufacturing efficiency, and enhanced manufacturing
flexibility.
Inventors: |
Farris; Bryan N.; (North
Plains, OR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Farris; Bryan N. |
North Plains |
OR |
US |
|
|
Assignee: |
NIKE, INC.
Beaverton
OR
|
Family ID: |
49301594 |
Appl. No.: |
13/588914 |
Filed: |
August 17, 2012 |
Current U.S.
Class: |
112/475.17 ;
112/229; 112/231; 112/475.08 |
Current CPC
Class: |
D05B 57/26 20130101;
D05B 57/28 20130101; D05B 43/00 20130101; D05B 63/00 20130101 |
Class at
Publication: |
112/475.17 ;
112/229; 112/231; 112/475.08 |
International
Class: |
D05B 57/26 20060101
D05B057/26; D05B 63/00 20060101 D05B063/00 |
Claims
1. A stitching machine, comprising, a needle apparatus; a sewing
thread spool receiving device; a bobbin thread spool receiving
device; and a bobbin thread tensioner configured to receive bobbin
thread from the bobbin thread spool receiving device and supply the
bobbin thread to the needle apparatus, wherein the bobbin thread
spool receiving device is configured to receive a bobbin spool
holding at least 700 meters of bobbin thread.
2. The stitching machine of claim 1, wherein the bobbin spool
receiving device is located above a stitching location.
3. The stitching machine of claim 2, wherein the bobbin spool
receiving device is located at least 0.5 meter above the stitching
location.
4. The stitching machine of claim 1, wherein the tensioner is
located above a stitching location.
5. The stitching machine of claim 1, wherein the tensioner is
located at least 0.5 meter above the stitching location.
6. The stitching machine of claim 1, wherein the tensioner is
located below the stitching location.
7. The stitching machine of claim 6, wherein a bottom surface of a
base of the stitching machine includes an aperture to receive the
bobbin thread through the base and supply the bobbin thread to the
stitching location.
8. The stitching machine of claim 1, wherein the stitching machine
is a sewing machine.
9. The stitching machine of claim 1, wherein the stitching machine
is an embroidery machine.
10. A stitching machine, comprising: a needle apparatus; a sewing
thread spool; a bobbin spool holding approximately 700 meters or
more of bobbin thread; and a bobbin thread tensioner configured to
receive bobbin thread from the bobbin thread spool receiving device
and supply the bobbin thread to the needle apparatus.
11. The stitching machine of claim 10, wherein the bobbin spool is
located approximately 0.5 meter or more above a stitching
location.
12. The stitching machine of claim 10, wherein the tensioner is
located above a stitching location.
13. The stitching machine of claim 10, wherein the tensioner is
located below the stitching location.
14. The stitching machine of claim 10, wherein the bobbin spool
holds approximately 900 to 10,000 meters of bobbin thread.
15. The stitching machine of claim 10, wherein the bobbin spool
holds approximately 1000 to 10,000 meters of bobbin thread.
16. A method of stitching an article, the method comprising:
providing a sewing thread spool holding sewing thread and supplying
the sewing thread from the sewing thread spool to a stitching
machine; providing a bobbin thread spool holding approximately 700
meters or more of bobbin thread and supplying the bobbin thread
from the bobbin thread spool to the stitching machine; laying the
sewing thread against a first surface of the article; laying a
bobbin thread against a second surface of the article, the first
surface being opposite the second surface; and stitching the sewing
thread and the bobbin thread together.
17. The method of claim 16, wherein the step of providing the
bobbin thread spool include supplying the bobbin thread from the
bobbin thread spool to a tensioner and then supplying the bobbin
thread from the tensioner to the stitching machine.
18. The method of claim 16, wherein the step of providing the
bobbin thread spool includes locating the bobbin thread spool above
the stitching machine during the step of stitching the sewing
thread and the bobbin thread together.
19. The method of claim 18, wherein the tensioner is located below
the stitching machine during the step of stitching the sewing
thread and the bobbin thread together.
20. The method of claim 16, wherein the step of stitching includes
forming a lock stitch with the sewing thread and the bobbin
thread.
21. The method of claim 16, wherein the article is an article of
footwear.
22. A method of stitching an article of footwear, the method
comprising: laying a first strand against a first surface of a
material element; providing a bobbin spool holding approximately
700 to 10,000 meters of a second strand and supplying the second
strand to a stitching machine; stitching over the first strand with
the second strand via the stitching machine to secure the second
strand to the first surface at a plurality of locations on opposite
sides of the first strand; and incorporating the material element
and first strand into the article of footwear.
23. The method of claim 22, wherein the step of providing the
bobbin spool includes supplying the second strand from the bobbin
spool to a tensioner and from the tensioner to the stitching
machine.
24. The method of claim 23, wherein the bobbin spool is located
above a stitching location during the steps of stitching.
25. The method of claim 24, wherein second strand is supplied from
the tensioner to the stitching machine through an aperture in a
base of the stitching machine.
26. The method of claim 22, wherein the first strand is a tensile
strand that resists stretch.
Description
BACKGROUND
[0001] Sewing machines, embroidery machines, and other stitching
machines may be supplied with thread from one or more spools. The
thread may be used for various purposes, such as stitching together
articles of fabric and/or stitching ornamental patterns. Stitching
may include the use of a bobbin thread, which is generally located
on an underside of an article of fabric. The thread sewn or
embroidered on a top side of the article of fabric may be pushed
through the article of fabric by a needle and secured with the
bobbin thread so that the sewing or embroidering thread is stitched
into place.
SUMMARY
[0002] A stitching machine may include a needle apparatus, a sewing
thread spool receiving device, and a bobbin thread spool receiving
device. The stitching machine may further include a bobbin thread
tensioner configured to receive bobbin thread from the bobbin
thread spool receiving device. The bobbin thread tensioner may be
further configured to supply the bobbin thread to the needle
apparatus. The bobbin thread spool receiving device is configured
to receive a bobbin spool holding approximately 700 to 10,000
meters of bobbin thread.
[0003] In another aspect, a stitching machine may include a needle
apparatus, a sewing thread spool, a bobbin spool, and a bobbin
thread tensioner. The bobbin spool may hold approximately 700 to
10,000 meters or more of bobbin thread. The bobbin thread tensioner
may be configured to receive bobbin thread from the bobbin thread
spool receiving device and supply the bobbin thread to the needle
apparatus.
[0004] In another aspect, a method of stitching an article may
include a step of providing a sewing thread spool holding sewing
thread and supplying the sewing thread from the sewing thread spool
to a stitching machine. The method may further include providing a
bobbin thread spool holding approximately 700 to 10,000 meters of
bobbin thread and supplying the bobbin thread from the bobbin
thread spool to the stitching machine. A sewing thread may further
be laid against a first surface of the article. The method may
further include laying a bobbin thread against a second surface of
the article, the first surface being opposite the second surface.
In addition, the sewing thread and the bobbin thread may be
stitched together.
[0005] In another aspect, a method of stitching an article of
footwear includes laying a first strand against a first surface of
a material element. The method may further include providing a
bobbin spool holding approximately 700 to 10,000 meters of a second
strand and supplying the second strand to a stitching machine. The
first strand may be stitched over with a second strand via the
stitching machine to secure the second strand to the first surface
at a plurality of locations on opposite sides of the first
strand.
[0006] The advantages and features of novelty characterizing
aspects of the invention are pointed out with particularity in the
appended claims. To gain an improved understanding of the
advantages and features of novelty, however, reference may be made
to the following descriptive matter and accompanying figures that
describe and illustrate various configurations and concepts related
to the invention.
FIGURE DESCRIPTIONS
[0007] The foregoing Summary and the following Detailed Description
will be better understood when read in conjunction with the
accompanying figures.
[0008] FIG. 1 is a perspective view of a sewing machine including a
conventional bobbin.
[0009] FIG. 2 is an enlarged view of the needle apparatus of the
sewing machine of FIG. 1.
[0010] FIG. 3 is a perspective view of a bobbin spool.
[0011] FIG. 4 is a perspective view of a bobbin spool with bobbin
thread wound upon the bobbin spool.
[0012] FIG. 5 is a top perspective view of a sewing machine
including a bobbin spool and a tensioner.
[0013] FIG. 6 is a bottom perspective view of the sewing machine of
FIG. 5.
[0014] FIG. 7 is a perspective view of a thread tensioner,
according to an embodiment.
[0015] FIG. 8 is a side view of a thread tensioner, according to an
embodiment.
[0016] FIG. 9 is a side view of an article after a needle with a
first thread has penetrated the article.
[0017] FIG. 10 is a side view of an article a first loop is made in
the first thread.
[0018] FIG. 11 is a side view of an article after a shuttle with a
bobbin thread has passed through the first loop.
[0019] FIG. 12 is a side view of an article after the needle has
been withdrawn from the article and the shuttle has been withdrawn
towards its initial position to make a first lock stitch.
[0020] FIG. 13 is a side view of an article after the needle and
first thread have penetrated the article a second time to create a
second loop of first thread.
[0021] FIG. 14 is a side view of an article after the shuttle with
the bobbin thread has been advanced through the second loop of the
first thread.
[0022] FIG. 15 is a side view of an article after the needle has
been withdrawn from the article and the shuttle has been withdrawn
towards its initial position to make a second lock stitch.
[0023] FIG. 16 is a side view of an article in which two lock
stitches have been made.
[0024] FIG. 17 is a side view of an article after a needle with a
first thread has penetrated the article.
[0025] FIG. 18 is a side view of an article after a rotary hook has
rotated towards the first thread held by the needle.
[0026] FIG. 19 is a side view of an article after the rotary hook
has engaged the first thread.
[0027] FIG. 20 is a side view of an article after the rotary hook
has advanced the first thread to create a loop with the first
thread.
[0028] FIG. 21 is a side view of an article after the rotary hook
has advanced the first thread further past the bobbin thread.
[0029] FIG. 22 is a side view of an article after the first thread
has begun to wrap around the bobbin thread.
[0030] FIG. 23 is a side view of an article after the first thread
has been looped around the bobbin thread.
[0031] FIG. 24 is a side view of an article after the needle has
been withdrawn from the article to make a third lock stitch.
[0032] FIG. 25 is a perspective view of an embroidery machine
including a bobbin spool and a tensioner.
[0033] FIG. 26 is an enlarged view of the needle apparatus of the
embroidery machine of FIG. 25.
[0034] FIG. 27 is a perspective view of an article including lock
stitches.
[0035] FIG. 28 is an exploded perspective view of the article of
FIG. 27.
[0036] FIG. 29 is a cross-sectional view of the article along line
29 of FIG. 27.
[0037] FIG. 30 is a cross-sectional view of the article along line
30 of FIG. 27.
[0038] FIG. 31 is a lateral side elevational view of an article of
footwear.
DETAILED DESCRIPTION
[0039] The following discussion and accompanying figures disclose
various configurations of stitching machines, such as sewing
machines or embroidery machines. The concepts described herein may
be applied to a variety of machines that sew or embroider with a
first thread and a bobbin thread. The machines may be used to sew
or embroider a variety of articles. For instance, an article may be
an article of apparel, such as a shirt, pants, jacket, or any type
of footwear. For example, a shoe may be a baseball shoe, basketball
shoe, training shoe, cycling shoe, football shoe, running shoe,
tennis shoe, soccer shoe, or hiking boot. The concepts may also be
applied to footwear types that are generally considered to be
non-athletic, including dress shoes, loafers, sandals, and work
boots. In another instance, an article may be luggage or a
backpack.
Conventional Machine and Bobbin
[0040] A conventional sewing machine 100 is shown in FIG. 1. Sewing
machine 100 includes a head 110 connected to a base 120. Head 110
may include a needle apparatus 130 and a take-up lever 140. Base
120 may include a needle plate 122 and may include feed dogs (not
shown) to engage an article being sewn and advance the article in a
sewing direction. A spool of sewing thread (not shown) may be
provided on post 190, threaded through take-up lever 140, and
supplied to needle apparatus 130. Sewing thread may be supplied to
needle apparatus 130 by reciprocation of the take-up lever 140 in a
vertical direction relative to base 120, as well as the
reciprocation of needle apparatus 130 itself. A knob 150 may be
provided to adjust tension applied by take-up lever 140 to sewing
thread passing through take-up lever 140. Sewing machine 100 may
further include (a) a width knob 160 to adjust a width of stitches
formed from the sewing thread and (b) a length knob 170 to adjust a
length of the stitches. A hand wheel 180 may also be provided to
manually adjust the position of needle apparatus 130.
[0041] Turning to FIG. 2, needle apparatus 130 may include a needle
shaft 132 to which a needle 136 is mounted via a needle clamp 135.
A sewing thread 134 may be strung from take-up lever 140 above (see
FIG. 1), down along sewing shaft 132, and through needle 136.
Needle apparatus 130 may further include a presser bar or shaft 133
and a presser foot 137 connected to presser bar 133. Presser foot
137 may engage or otherwise press down upon an article being sewn
(not shown) that is placed between presser foot 137 and needle
plate 122. Needle plate 122 may include one or more needle slots or
apertures 123 through which needle 136 may be inserted during a
sewing operation.
[0042] Besides using a sewing thread to create stitches in an
article, a bobbin thread may also be supplied to an underside of an
article. For example, a bobbin thread may be supplied to an article
to make a locking stitch with a sewing thread, as will be explained
below. As shown in FIGS. 1 and 2, sewing machine 100 may include a
bobbin spool 200 to supply a bobbin thread. As shown in FIG. 3, a
bobbin spool 200 may include a cylinder 210, a first flange 212,
and a second flange 214. FIG. 4 shows an example of a bobbin spool
200 with bobbin thread 220 wound between first flange 212 and
second flange 214. Referring back to FIG. 1, bobbin thread 220 may
be wound upon bobbin spool 200, for example, by installing bobbin
spool 200 upon bobbin winder 192, installing a bulk cone of bobbin
thread upon post 190, and activating sewing machine 100 to drive a
shaft of bobbin winder 192 so that bobbin spool 200 is rotated,
causing bobbin thread to be pulled from the bulk cone and wound
onto bobbin spool 200.
[0043] Because a bobbin thread is supplied to an underside of an
article sewn by needle apparatus 130 of sewing machine 100, bobbin
spool 200 may be located within a recess 124 located underneath
needle plate 122. As a result, bobbin spool 200 is located a
distance 10 beneath needle apparatus 130. Because the components of
needle apparatus 130 typically reciprocate up and down in a
vertical direction relative to base 120, distance 10 may be a
distance from bobbin spool 200 to an average height of needle
apparatus 130 during a sewing operation. In another example,
distance 10 may be a distance from bobbin spool 200 to a maximum
height of a tip of needle 136 nearest needle plate 122 when needle
apparatus is withdrawn vertically upwards away from needle plate
122. Distance 10 may be, for example, in the range of 2 to 15
centimeters.
[0044] Sewing machine 100 may include other devices located within
recess 124. For example, sewing machine 100 may include a device to
create a locking stitch in an article, such as a rotary hook 138 or
a shuttle. Although bobbin spool 200 may be located at any position
within recess 124, such as the position shown in FIG. 2, if sewing
machine 100 includes rotary hook 138, bobbin spool 200 may be
located within a central recess 139 of rotary hook 138.
[0045] Conventional bobbin spools are relatively small and hold a
length of bobbin thread on the order of a few hundred meters.
Therefore, during sewing or embroidery operations, in which the
amount of bobbin thread utilized is relatively large, the entire
length of bobbin thread may be consumed. Depending upon the article
being sewn or embroidered and/or the sewing or embroidery
operation, this may result in the article being discarded because
the operation cannot be completed after the bobbin thread runs out.
As a result, waste may occur in the sewing or embroidery operation
and the efficiency of the operation suffers.
[0046] In addition, bobbin spools are typically located beneath an
article being sewn or embroidered. For instance, a conventional
bobbin spool may be located underneath plate 122 within base 120 of
sewing machine 100. Embroidery machines may have similar
arrangements for a bobbin spool. Because a bobbin spool 200 is
typically located within recess 124 of base 120, the accessibility
of bobbin spool 200 is limited. In particular, a panel in base 120
is typically removed and then bobbin spool 200 is extracted from
recess 124 if work must be done on bobbin spool 200, such as
replenishing bobbin thread 220.
[0047] Further, a bobbin spool may not be easily accessible in
conventional machines. A panel covering recess 124 may obscure
viewing of bobbin spool 200 so that a user may not know how much
bobbin thread is left on bobbin spool 200. In addition, an article
being sewn or embroidered may be placed upon base 120 during a
sewing or embroidery operation, covering recess 124 and causing
bobbin spool 200 to be obscured from view. To access the bobbin
spool, a user must open the panel within the base and withdraw the
bobbin spool, limiting the accessibility of the bobbin spool.
[0048] A conventional bobbin spool 200 may have various sizes. For
example, bobbin spools typically used in domestic sewing or
embroidery machines found in homes are size L or size 15/A
(sometimes referred to as size A). A size L bobbin spool may have a
diameter (a distance across a flat side of a flange) of, for
example, 0.912 inches and a height (a distance from a flat side of
one flange, across the cylinder, to a flat side of the other
flange) of, for example, 0.359 inches. A size L bobbin spool may
hold approximately 115-125 meters of bobbin thread. A size 15/A
bobbin spool may have a diameter of, for example, 0.815 inches
(2.07 cm) and a height of, for example, 0.465 inches (1.18 cm). A
size 15/A bobbin spool may hold approximately 135-145 meters of
bobbin thread. Another size of bobbin spool is size F, which have a
diameter of 0.770 inches (1.96 cm) and a height of 0.303 inches
(0.769 cm).
[0049] Other bobbin spool sizes may be used. Commercial machines
may use, for example, a size G, size M, or size U bobbin spool. A
size G bobbin spool may have a diameter of 0.991 inches (2.52 cm)
and a height of 0.390 inches (0.991 cm). A size M bobbin spool may
have a diameter of 1.023 inches (2.598 cm) and a height of 0.435
inches (1.105 cm). A size M bobbin spool may hold approximately 270
meters of bobbin thread. A size U bobbin spool may have a diameter
of 1.161 inches (2.949 cm) and a height of 0.457 inches (1.161
cm).
[0050] The conventional bobbin spools discussed above have
relatively small sizes and therefore hold only a limited amount of
bobbin thread. Due to their relatively small sizes, conventional
bobbin spools used in a sewing machine or an embroidery machine
typically hold approximately 50 meters of bobbin thread to a
maximum of 500 meters of bobbin thread. During a sewing or
embroidery operation using bobbin thread, the length of bobbin
thread may be entirely consumed so that there is no more bobbin
thread left on a conventional bobbin spool. This may result in the
article being sewn or embroidered being discarded because the
sewing or embroidering operation cannot be completed after the
bobbin thread runs out. As a result, waste may occur in the sewing
or embroidery operation.
[0051] In view of these considerations, it is desirable to provide
sewing machines and embroidery machines that allow greater
accessibility to bobbin spools and minimize waste due to the use of
relatively small bobbin spools that hold relatively small amounts
of bobbin thread.
Stitching Machine Configuration
[0052] An example of a stitching machine having the configuration
of a sewing machine 300 is shown in FIG. 5. Sewing machine 300 may
include a head 310 connected to a base 320. Head 310 may include a
needle apparatus 330 and a take-up lever 340. Needle apparatus 330
may include the components and features of needle apparatus 130
shown in FIG. 2. Base 320 may include a needle plate 322 and may
include feed dogs (not shown) to engage an article being sewn and
advance the article in a sewing direction. A knob 350 may be
provided to adjust tension applied by take-up lever 340 to sewing
thread. A width knob 360 may be provided to adjust the width of
stitching. Sewing machine may also include a length knob 370 to
adjust the length of stitches and a hand wheel 380 to manually
adjust the position of needle apparatus 330.
[0053] Sewing machine 300 may include a sewing thread spool
receiving device, such as a post 312. Although a post 312 is shown
here, other embodiments could incorporate any other device used in
the art for receiving a sewing thread spool. Sewing thread 316 may
be unwound from spool 314, fed through take-up lever 340, and
supplied to needle apparatus 330.
[0054] As shown in FIG. 5, sewing machine 300 may include a bobbin
spool 400 to supply bobbin thread 402 to sewing machine 300. Bobbin
spool 400 may have, for example, the features and structure of
bobbin spool 200 shown in FIG. 3. In another example, bobbin spool
400 may be formed by winding bobbin thread 402 onto a shaft or
cylinder that does not include flanges. The accumulated windings of
bobbin thread 402 on the shaft or cylinder may have, for example,
the shape of a cone or a cylinder.
[0055] Bobbin spool 400 may be larger than a conventional bobbin
and thus hold more bobbin thread than a conventional bobbin. For
example, bobbin spool 400 may be configured to hold approximately
700 or more meters of bobbin thread. In another example, bobbin
spool 400 may hold approximately 700 to 10,000 meters of bobbin
thread. In another example, bobbin spool 400 may hold approximately
900 to 10,000 meters of bobbin thread. In another example, bobbin
spool 400 may hold approximately 1000 to 10,000 meters of bobbin
thread. In another example, bobbin spool 400 may hold approximately
2000 to 10,000 meters of bobbin thread. In another example, bobbin
spool 400 may hold approximately 3000 to 10,000 meters of bobbin
thread.
[0056] Due to the relatively large size of bobbin spool 400, a more
continuous feed of bobbin thread 402 may be provided to sewing
machine 300. As a result of the increased amount of bobbin thread
402 available in a single continuous feed, waste caused by
unfinished sewing operations may be minimized. Also, greater
flexibility may be provided in planning sewing operations for
different articles requiring different amounts of bobbin thread
402.
[0057] Bobbin spool 400 may be mounted, for example, onto a bobbin
spool 400 receiving device, such as a post 404 or other device used
in the art. The location of post 404 may be selected to provide
greater accessibility to bobbin spool 400 mounted upon post 404.
For instance, when bobbin spool 400 is mounted to post 404 or is
otherwise ready for use with sewing machine 300, bobbin spool 400
may be separate from and not directly attached to sewing machine
300. As shown in FIG. 5, post 404 may be located separately from
sewing machine 300 so that post 404 is not directly connected or
directly attached to sewing machine 300. In contrast with
conventional designs, bobbin spool 400 may not be located within a
recess of sewing machine 300, which may otherwise obscure the view
of bobbin spool 400 and hamper accessing bobbin spool 400, such as
when the supply of bobbin thread 402 from bobbin spool 400 has been
exhausted and bobbin spool 400 must be replaced. In general,
however, bobbin spool 400 may hold at least 700 meters of bobbin
thread.
[0058] To locate bobbin spool 400 separately from sewing machine
300, post 404 may be positioned so that when bobbin spool 400 is
mounted on post 404, bobbin spool 400 is located above sewing
machine 300. As shown in the example of FIG. 5, post 404 may be
located above sewing machine 300 so that when bobbin spool 400 is
mounted on post 404, bobbin spool 400 is located at a height 20
from base 320 of sewing machine 300 that is greater than a distance
22 from base 320 to a top of the head 310 of sewing machine 300.
Height 20 may be measured to a bottom surface of bobbin spool 400,
or bobbin spool receiving device, when bobbin spool 400 is mounted
on the bobbin spool receiving device, such as post 404. Height 20
and height 22 may also be measured from a stitching location. Such
a stitching location may be proximate to needle apparatus 330 and
needle plate 322 where stitching of an article occurs. For
instance, height 20 may be measured from a stitching location to
the bottom surface of bobbin spool 400 or bobbin spool receiving
device. Height 20 may be, for example, approximately 0.5 meters or
more. In another example, height 20 may be, for example,
approximately 0.75 meters. In another example, height 20 may be,
for example, approximately 1 meter.
[0059] Due to the relatively large size of bobbin spool 400, sewing
machine 300 may have difficulty regulating the tension applied to
bobbin thread 402 drawn from bobbin spool 400, which may affect the
quality of stitching produced by sewing machine. Further, sewing
machine 300 may even have insufficient power to spin the relatively
large and heavy bobbin spool 400 so that bobbin thread 402 cannot
be drawn. To address these issues, sewing machine 300 may include a
tensioner 410. One tensioner 410 may be provided per bobbin spool
400, as shown in FIG. 5. In another example, a plurality of
tensioners 410 may be provided for each bobbin spool 400, such as
two tensioners 410 per bobbin spool 400 or three tensioners 410 per
bobbin spool 400.
[0060] Bobbin thread 402 may be supplied from bobbin spool 400 to
tensioner 410, which in turn regulates the tension applied to
bobbin thread 402 and supplies the bobbin thread 402 to sewing
machine 300. Tensioner 410 may be configured to pull thread from a
relatively large spool, such as bobbin spool 400, so that a proper
amount of tension may be applied to bobbin thread 402. A stitching
machine, such as sewing machine 300, may not be properly configured
to pull a thread from a relatively large bobbin spool at a desired
tension. For instance, a stitching machine may not be capable of
pulling a bobbin thread from a relatively large bobbin spool with a
desired tension at a relatively constant rate or amount. Thus,
tensioner 410 may compensate for a greater amount of tension
required to pull bobbin thread 402 from bobbin spool 400 and may
regulate the tension of the bobbin thread 402 to be relatively
constant.
[0061] As shown in the example of FIG. 5, tensioner 410 may be
separate from and not directly attached to sewing machine 300,
similar to bobbin spool 400. For instance, tensioner 410 may also
be provided at height 20 above base 320 or stitching location of
sewing machine 300. Bobbin thread 402 may be supplied from
tensioner 402 to sewing machine 300 in various manners. For
instance, bobbin thread 402 may be strung from tensioner 410
located above sewing machine 300 to a bottom surface 323 of base
320 of sewing machine 300, as shown in FIG. 6, so that tensioner
402 is easily accessible above sewing machine 300. An aperture 324
may be provided in the bottom surface 323 of base 320 so that
bobbin thread 402 may be supplied to the stitching location
proximate to needle apparatus 330 and needle plate 322. Other
guides or channels (not shown) may be provided to guide bobbin
thread 402 from bobbin spool 400 to the stitching location.
[0062] In another example, tensioner 410 may be located below
sewing machine 300 instead of above sewing machine 300. For
instance, tensioner 410 may be located below bottom surface 323 of
base 320. In such an example, bobbin thread 402 may be provided
from bobbin spool 400 located above sewing machine 300 to tensioner
410 below bottom surface 323, and then from tensioner 410 through
aperture 324 to the stitching location. In the case that sewing
machine 300 is placed upon or mounted to a surface of a table (not
shown), tensioner 410 may be located underneath the surface of the
table. In some configurations, bobbin spool 400 and tensioner 410
may be located below sewing machine 300.
Tensioner Devices
[0063] Tensioner 410 may be any type of device configured to
regulate the tension applied to bobbin thread 402. Turning to FIG.
7, tensioner 410 may include a fixed drum 412 that bobbin thread is
wound onto by a rotating disc 411. For instance, bobbin thread 402
may be strung through tensioner 410 and disc 411, so that when disc
411 rotates in direction 24, bobbin thread 402 is wound onto fixed
drum 412, as shown in FIG. 7. Tensioner 410 may further include a
braking device 414. Braking device 414 may be configured to control
the tension applied to bobbin thread 402 by pressing bobbin thread
402 between braking device 414 and an end 413 of fixed drum 412 as
bobbin thread 402 is pulled from and unwinds from fixed drum 412.
Braking device 414 may have a shape corresponding to end 413 of
fixed drum 412 so that bobbin thread 402 may be pressed between
braking device 414 and end 413 in a desired manner. For example,
braking device 414 may generally have a conical or frustoconical
shape.
[0064] To urge braking device 414 towards end 413 of fixed drum
412, braking device 414 may be connected to a support 417 by one or
more connecting members 418. Connecting members 418 may be elastic
in their nature. For example, connecting members 418 may be
springs. Support 417 may have a generally annular shape, such as a
ring. The position of support 417 may be adjusted by moving support
417 along direction 26 shown in FIG. 7. Thus, the connection
created between braking device 414, connecting members 418, and
support 417 may cause braking device 414 to be urged towards end
413 of fixed drum 412 in direction 26, as shown in FIG. 7.
Therefore, when bobbin thread 402 is unwound from fixed drum 412,
bobbin thread 402 may be pressed between braking device 414 and end
413 of fixed drum 412. By adjusting the position of support 417,
the tension applied to bobbin thread 402 may be controlled.
Further, because connecting members 418 may be elastic, tension
applied to bobbin thread 402 may be relieved when the tension is
too high, due to connecting members 418 stretching and permitting
the distance between braking device 414 and end 413 to increase.
Bobbin thread 402 may exit from between braking device 414 and end
413 of fixed drum 412 by passing through a central aperture 416 of
braking device 414. Tensioner 410 may also include an annular guide
419 through which bobbin thread 402 may pass and exit from
tensioner 410, as shown in the example of FIG. 7.
[0065] Examples of the type of tensioner 410 shown in FIG. 7
include tensioners manufactured by LGL.RTM. Electronics of Gandino,
Italy. For instance, the following models manufactured by LGL.RTM.
Electronics may be used as tensioner 410: Primo, Vector, Attivo,
and Compact.
[0066] Another example of a tensioner 420 is shown in FIG. 8.
Tensioner 420 may include a drum 422 upon which bobbin thread 402
is wound. Drum 422 may be fixed and not rotate or may rotate. Drum
422 may be included to provide an accumulation of bobbin thread 402
and to control the tension applied to downstream components of
tensioner 420. Bobbin thread 402 may be unwound from drum 422 and
supplied to a first roller 424. Subsequently, bobbin thread 402 may
be strung in a serpentine manner between first roller 424, a
movable roller 428, and a second roller 426. Although first roller
424 and second roller 426 may be fixed in position, the position of
movable roller 428 may be varied. For example, movable roller 428
may be moved in direction 28 shown in FIG. 8 so that the amount of
force applied by movable roller 428 to bobbin thread 402 may be
increased or decreased to adjust and control the tension applied to
bobbin thread 402. In another example, tensioner 420 may include
first roller 424, second roller 426, and movable roller 428 but not
include drum 422.
Lock Stitching
[0067] One use of bobbin thread in a stitching or embroidering
operation is making a lock stitch. A lock stitch may be used for
various purposes. In one example, lock stitching may be used to
stitch layers of fabric together. In another example, lock
stitching may be used to stitch a cord or other element to a
surface of an article, as will be discussed below. The methods and
devices described below may be used with any of the embodiments
described herein.
[0068] Turning to FIGS. 9-15, a first method for making lock
stitches that uses a shuttle will be described. As shown in FIG. 9,
an article 500 to be stitched may be provided. Article 500 may
include one or more layers of fabric to which a cord or other
element (not shown) is stitched or article 500 may include a
plurality of layers that are stitched together by the locking
stitches. A needle 510 is provided and threaded with a sewing
thread 512 above a top side 501 of article 500. Top side 501, for
instance, may serve as an exterior surface of article 500. Needle
510 is then pierced through article 500 in direction 30 shown in
FIG. 9 to draw sewing thread 512 through article to an underside
503 of article 500. Underside 503, for instance, may serve as an
interior surface of article 500.
[0069] As shown in FIG. 10, once thread 512 has been drawn through
article 500, a first loop 514 may be formed by thread 512 on
underside 503 of article 500. Once first loop 514 has been formed,
a shuttle 520 carrying a bobbin thread 522 may be moved in
direction 32 shown in FIG. 10. This results in shuttle 520 and
bobbin thread 522 passing through first loop 514, as shown in FIG.
11. Subsequently, needle 510 and sewing thread 512 are withdrawn in
direction 34 and shuttle 520 and bobbin thread 522 are withdrawn in
direction 38, as shown in FIG. 12. Article 500 may also be advanced
in direction 36 shown in FIG. 12 to continue locking stitching. The
motions of needle 510 and shuttle 520 result in sewing thread 512
and bobbin thread 522 being pulled together to form a first lock
stitch 523.
[0070] The process described above may be repeated to produce
additional lock stitches. For instance, as shown in FIG. 13, needle
510 may again penetrate through article 500 by moving in direction
30 to pull sewing thread 512 through article 500 and to underside
503 of article 500. A second loop 516 may be formed by sewing
thread 512 and shuttle 520 may be moved in direction 32 to pull
bobbin thread 522 through second loop 516, as shown in FIG. 14.
Subsequently, needle 510 may be withdrawn in direction 34 and
shuttle 520 may move in direction 38, causing sewing thread 512 and
bobbin thread 522 to be pulled together to make a second lock
stitch 525, as shown in FIG. 15.
[0071] A second method of making lock stitches uses a rotary hook,
as shown in FIGS. 16-24. Turning to FIG. 16, article 500 may be
provided and sewing thread 512 may be strung through needle 510,
which is initially positioned on top side 501 of article 500.
Bobbin thread 532 may be wound onto a bobbin spool 530, which a
rotary hook 534 rotates around. Initially, needle 510 moves in
direction 40 to pull sewing thread 512 through article 500, as
shown in FIG. 17. During this operation, rotary hook 534 may
continuously rotate in direction 42, so that a hook end 536 of
rotary hook 534 advances towards sewing thread 512 held by needle
510 on underside 503 of article 500.
[0072] Turning to FIG. 19, once hook end 536 of rotary hook 534
reaches sewing thread 512, hook end 536 may grasp sewing thread
512. As rotary hook 534 rotates, sewing thread 512 captured by hook
end 536 is pulled downwards and away from article 500, as shown in
FIG. 20. Rotary hook 534 continues to rotate in direction 42 and
pull sewing thread 512 downward, as shown in FIG. 21.
[0073] Turning to FIG. 22, as rotary hook 534 continues to rotate,
sewing thread 512 is pulled around bobbin thread 532, creating a
loop 518 of sewing thread 512 around bobbin thread 532. Eventually,
as rotary hook 534 rotates, sewing thread 512 is released from hook
end 536 of rotary hook 534, causing loop 518 of sewing thread 512
to close about bobbin thread 532, as shown in FIG. 23. Needle 510
may also be withdrawn in direction 44 shown in FIG. 23 to pull
sewing thread 512 back through article 500. This in turn may apply
tension to loop 518 of sewing thread 512 and bobbin thread 532 to
create lock stitch 537, as shown in FIG. 24. This process may be
repeated as rotary hook 534 continues to rotate, such as by
advancing article 500 in direction 46 and repeating the steps
described above.
[0074] Lock stitches may be located on the underside of an article,
as shown in FIGS. 12, 15, and 24. However, depending on the
configuration of an article, sewing thread, bobbin thread, and
other factors, such as the location of a loop of sewing thread,
lock stitches may be provided in other locations, such as between a
top side and underside of an article, or on a top side of the
article.
Embroidery Machine
[0075] The aspects and methods described herein may also be applied
to other types of stitching machines, including an embroidery
machine. Embroidery machines may include a bobbin spool and may,
therefore, be affected by the accessibility and efficiency
considerations described above for conventional bobbin spools. In
view of this, it would be advantageous to provide an embroidery
machine that provides improved access to a bobbin spool and
enhanced manufacturing efficiency and flexibility.
[0076] An example of an embroidery machine 600 is shown in FIG. 25.
Embroidery machine 600 may include an array 610 of spool receiving
devices configured to receive spools of sewing thread. Array 610 is
provided so that embroidery machine 600 may stitch with a variety
of threads having different colors and/or sizes, according to a
desired design. Threads from spools of sewing threads provided in
array 610 may be strung through an array of guides 612 and
subsequently to a needle apparatus 614. Embroidery machine 600 may
include a table or frame 616 to hold an article to be embroidered.
In one example, needle apparatus 614 may be stationary while table
616 moves so that a pattern may be embroidered into an article held
by table 616. In another example, table 616 may be stationary and
needle apparatus 614 may move to embroider a desired pattern.
[0077] Embroidery machine 600 may be used to stitch sewing thread
supplied from array 610 onto an article in a desired pattern. In
another example, embroidery machine 600 may be used to stitch an
element to a surface of an article. For instance, as shown in FIG.
26, needle apparatus 614 may include a cording attachment 650 for
guiding a cord 642 through needle apparatus 614 so that cord 642
may be stitched to a surface of article 640 using stitch patterns
used in the art. Such a cording attachment may also be used with
sewing machine 300 of FIG. 5 to stitch a cord to a surface of an
article.
[0078] Embroidery machine 600 may further include a bobbin spool
620 placed upon a bobbin spool receiving device 621, such as a
post. Bobbin spool 620 may have the features of bobbin spool 400 of
FIG. 5, including the sizes discussed above (i.e. the lengths of
bobbin thread, in meters, held by the spool). Bobbin spool 620 may
be located at distance from a stitching location 615 of embroidery
machine 600. For instance, bobbin spool 620 may be located at a
height 50 that is measured from stitching location 615 to a bottom
surface of bobbin spool 620 when bobbin spool 620 is mounted on
bobbin spool receiving device 621. Stitching location 615 may be
proximate to needle apparatus 614 and table 616 where embroidery
stitching of an article occurs. In another example, height 50 may
be measured from table 616 to a bottom surface of bobbin spool 620.
Height 50 may be, for example, approximately 0.5 meter or more. In
another example, height 50 may be, for example, approximately 0.75
meters. In another example, height 50 may be, for example,
approximately 1 meter.
[0079] Bobbin thread 622 unwound from bobbin spool 620 may be
supplied to a tensioner 630, which in turn supplies the bobbin
thread 622 to embroidery machine 600. Tensioner 630 may have the
features of the tensioners described above, such as tensioner 410
of FIG. 7 or tensioner 420 of FIG. 8, and may be located in the
same locations relative to embroidery machine. For instance,
tensioner 630 may be located at a height above a stitching location
615 similar to height 20 in FIG. 5.
[0080] By providing embroidery machine 600 with bobbin spool 620
and tensioner 630, embroidery machine 600 may advantageously place
bobbin spool 620 in a more accessible and viewable location.
Further, the increased length of bobbin thread 622 supplied by the
relatively large bobbin spool 620 may reduce waste and enhance
manufacturing efficiency and flexibility.
Articles Manufactured
[0081] Various articles may be stitched using the machines and
methods described above. In one example, an article may be
manufactured by stitching an element to a surface of the article.
The element may be added to the article, for example, to affect the
properties of the article. For instance, the element may be added
to the article to enhance the strength of the article and resist
stretching of the article. Such an element may be stitched to the
article using sewing machine 300 of FIG. 5 or embroidery machine of
FIG. 25 by using the methods of FIGS. 9-15 and FIGS. 16-24.
[0082] Turning to FIG. 27, an article 660 is shown that includes
tensile strands 642 stitched to a foundation element 640.
Foundation element 640 may be, for example, an article of fabric,
such as a woven fabric or other type of fabric used in the art.
Tensile strands 642 form structural components in article 660 that
resist stretch. In addition to strength properties, tensile strands
642 may be included in article 660 to impart distinctive aesthetic
properties.
[0083] By being substantially parallel to the exterior surface of
foundation element 640, tensile strands 642 resist stretch in
directions that correspond with the planes of foundation element
640. Although tensile strands 642 may extend through foundation
element 640 (e.g., as a result of stitching) in some locations,
areas where tensile strands 642 extend through foundation element
640 may permit stretch, thereby reducing the overall ability of
tensile strands 642 to limit stretch. As a result, each of tensile
strands 642 generally lie adjacent to the exterior surface of
foundation element 640 and substantially parallel to the exterior
surface of foundation element 640 for distances of at least twelve
millimeters, and may lie adjacent to the exterior surface of
foundation element 640 and substantially parallel to the exterior
surface of foundation element 640 for distances of at least five
centimeters or more.
[0084] Tensile strands 642 may be stitched to foundation element
640 in various ways. For example, tensile strands 642 may be
stitched to foundation element 640 using locking stitches, such as
the methods described in FIGS. 9-24. Sewing machine 300 of FIG. 5
or embroidery machine of FIG. 25 may be used to stitch tensile
strands 642 to foundation element 640 of article 660. For instance,
tensile strands 642 may be supplied through the needle apparatus of
sewing machine 300 of FIG. 5 or the needle apparatus of embroidery
machine 600 of FIG. 25, such as by using the cording attachment 650
of FIG. 26.
[0085] FIGS. 27 and 28 show an example of a structure of a locking
stitch in which tensile strands 642 are secured to foundation
element 640 by stitching securing strands 624 to repeatedly extend
over tensile strands 642. Securing strands 624 may be secured to
foundation element 640 on opposite sides of tensile strands 642. In
this configuration, securing strands 624 are secured to foundation
element 640 at a plurality of locations on opposite sides of the
tensile strands 642 and form, for example, a zigzag pattern along
at least a portion of the lengths of tensile strands 642.
[0086] Securing strands 624 may extend through foundation element
640 and wrap around backing strands 622, such as in a locking
stitch configuration, to effectively hold securing strands 624 in
place, as shown in FIGS. 29 and 30. For instance, securing strands
624 may be provided by a sewing thread on an upper side of
foundation element 640, while backing strands 622 may be provided
by a bobbin thread on an underside of foundation element 640. For
instance, backing strands 622 may be provided from a bobbin spool
discussed above. Such a configuration secures tensile strands 642
between securing strands 624 and foundation element 640. Although
adhesives or other joining mechanisms may be used to secure tensile
strands 642 to foundation element 640 or supplement the securing of
tensile strands 642 to foundation element 640, securing strands 624
and backing strands 622 may be solely responsible for holding
tensile strands 642 to foundation element 640. According to another
example, backing strands 622 may be absent in some
configurations.
[0087] Based upon the above discussion, tensile strands 642 may
form structural components in article 660 that resist stretch,
whereas securing strands 624 and backing strands 622 are
cooperatively utilized to secure the position of tensile strands
642 upon foundation element 640. Given that tensile strands 642 are
used to resist stretch and may be subjected to substantial tensile
forces, the materials and thicknesses of tensile strands 642 may be
selected to bear the tensile forces without breaking, yielding, or
otherwise failing. Similarly, the materials and thicknesses of
securing strands 624 and backing strands 622 may be selected to
ensure that tensile strands remain properly positioned relative to
foundation element 640. In some article, the tensile forces applied
to tensile strands 642 may be significantly greater than the forces
subjected to securing strands 624 and backing strands 622. As a
result, in some cases, the diameter or thickness of tensile strands
642 may be greater than the diameters or thicknesses of securing
strands 624 and backing strands 622.
[0088] Strands 642, 624, and 622 and threads discussed herein
(including sewing and bobbin threads) may be formed from a variety
of filaments, fibers, yarns, threads, cables, or ropes that are
formed from rayon, nylon, polyester, polyacrylic, silk, cotton,
carbon, glass, aramids (e.g., para-aramid fibers and meta-aramid
fibers), ultra high molecular weight polyethylene, liquid crystal
polymer, copper, aluminum, and steel, for example. Strands and
threads may be uncoated or coated. Strands 642, 624, and 622 may be
formed from the same material, or may be formed from different
materials. For example, tensile strands 642 may be formed from
polyethylene, whereas strands 624 and 622 may be formed from nylon.
As another example, strands 642 and 624 may be formed from
polyester, whereas backing strands 622 are formed from cotton.
Similarly, some of tensile strands 642 may be formed from aramids,
whereas other tensile strands 642 may be formed from silk. The
materials utilized for strands 642, 624, and 622 may vary,
therefore, to impart different properties to different areas of
article 660.
[0089] Although strands 642, 624, and 622 and threads will often
have a cross-section where width and thickness are substantially
equal (e.g., a round or square cross-section), suitable
cross-sections may have a width that is greater than a thickness
(e.g., a rectangular, oval, or otherwise elongate cross-section).
The diameter or thicknesses of strands 642, 624, and 622 may also
vary significantly to range from 0.03 millimeters to more than 5
millimeters, for example.
[0090] Article 600 may be further processed to make a particular
article of manufacture, such as an article of apparel. For example,
article 600 may be incorporated into an upper 710 of an article of
footwear 700, as shown in FIG. 31. For instance, foundation element
640 of article 600 may provide an exterior surface of upper 710,
with tensile strands 642 being attached to the exterior surface of
upper 710, as shown in FIG. 31. Tensile strands 642 may be secured
to the exterior surface of upper 710 with various securing strands
624 and backing strands 622, as discussed above in regard to
article 600.
[0091] Besides upper 710, article of footwear 700 may include a
sole structure 720. Sole structure 720 is secured to upper 710 and
extends between the foot and the ground when footwear 10 is worn.
The primary elements of sole structure 20 are a midsole 721, an
outsole 722, and a sockliner (not shown). Upper 710 is secured to
sole structure 720 and defines a void within footwear 700 for
receiving and securing a foot relative to sole structure 20. More
particularly, an interior surface of foundation element 640 may
form at least a portion of the void within upper 710. As depicted,
foundation element 640 is shaped to accommodate the foot and
extends along the lateral side of the foot, along the medial side
of the foot, over the foot, around the heel, and under the foot. In
other configurations, foundation element 640 may only extend over
or along a portion of the foot, thereby forming only a portion of
the void within upper 710. Access to the void within upper 710 is
provided by an ankle opening 712 located in at least heel region
64. A lace 714 extends through various lace apertures 716, which
extend through foundation element 640, and permit the wearer to
modify dimensions of upper 710 to accommodate the proportions of
the foot. In addition, upper 710 may include a tongue (not
depicted) that extends under lace 714.
[0092] During walking, running, or other ambulatory activities, a
foot within the void in footwear 700 may tend to stretch upper 710.
That is, many of the material elements forming upper 710, including
foundation element 640, may stretch when placed in tension by
movements of the foot. Although tensile strands 642 may also
stretch, tensile strands 642 generally stretch to a lesser degree
than the other material elements forming upper 710 (e.g.,
foundation element 640). Each of tensile strands 642 may be
located, therefore, to form structural components in upper 710 that
resist stretching in specific directions or reinforce locations
where forces are concentrated. As an example, the various tensile
strands 642 that extend between lace apertures 716 and sole
structure 720 resist stretch in the medial-lateral direction (i.e.,
in a direction extending around upper 710). These tensile strands
642 are also positioned adjacent to and radiate outward from lace
apertures 716 to resist stretch due to tension in lace 714. As
another example, the various tensile strands 642 that extend
between forefoot region 60 and heel region 64 resist stretch in a
longitudinal direction (i.e., in a direction extending through each
of regions 60, 62, 64). Accordingly, tensile strands 642 are
located to form structural components in upper 710 that resist
stretch.
[0093] Methods for incorporating sewn or embroidered elements into
articles, including features of the articles themselves, are
discussed in U.S. application Ser. No. 12/847,860, filed on Jul.
30, 2010 to Frederick Dojan; U.S. application Ser. No. 13/404,377,
filed on Feb. 24, 2012 to Frederick Dojan et al.; and U.S.
application Ser. No. 12/546,022, filed on Aug. 24, 2009 to
Frederick Dojan et al., which are hereby incorporated by reference
in their entireties.
[0094] The invention is disclosed above and in the accompanying
figures with reference to a variety of configurations. The purpose
served by the disclosure, however, is to provide an example of the
various features and concepts related to the invention, not to
limit the scope of the invention. One skilled in the relevant art
will recognize that numerous variations and modifications may be
made to the configurations described above without departing from
the scope of the present invention, as defined by the appended
claims.
* * * * *