U.S. patent application number 14/585973 was filed with the patent office on 2015-07-02 for machine and method for sewing, embroidering, quilting and/or the like.
The applicant listed for this patent is Alberto Landoni. Invention is credited to Alberto Landoni.
Application Number | 20150184320 14/585973 |
Document ID | / |
Family ID | 43334492 |
Filed Date | 2015-07-02 |
United States Patent
Application |
20150184320 |
Kind Code |
A1 |
Landoni; Alberto |
July 2, 2015 |
MACHINE AND METHOD FOR SEWING, EMBROIDERING, QUILTING AND/OR THE
LIKE
Abstract
One embodiment of the present invention relates to a machine for
sewing, embroidering, quilting and/or the like. Another embodiment
of the present invention relates to a method for sewing,
embroidering, quilting and/or the like. In one example, the present
invention may be applied (e.g., as a machine and/or method) to a
multi-needle machine or method. In another example, the present
invention may provide for automatic lower (or bottom) thread
cutting. In another example, the present invention may provide for
automatic lower (or bottom) thread cutting by utilizing the phase
(that is, movement phase) of a return of a looper (or hook) to cut
the lower (or bottom) thread.
Inventors: |
Landoni; Alberto; (Fagnano
Olona, IT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Landoni; Alberto |
Fagnano Olona |
|
IT |
|
|
Family ID: |
43334492 |
Appl. No.: |
14/585973 |
Filed: |
December 30, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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12826926 |
Jun 30, 2010 |
8925474 |
|
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14585973 |
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61222365 |
Jul 1, 2009 |
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Current U.S.
Class: |
112/475.17 ;
112/166 |
Current CPC
Class: |
D05B 55/14 20130101;
D05B 55/08 20130101; D05B 1/24 20130101; D05B 1/10 20130101; D05B
57/02 20130101; D05B 65/00 20130101 |
International
Class: |
D05B 1/10 20060101
D05B001/10; D05B 57/02 20060101 D05B057/02; D05B 65/00 20060101
D05B065/00; D05B 55/14 20060101 D05B055/14 |
Claims
1. A machine for making double chain stitches in a material, the
double chain stitches being made using at least one upper thread
and at least one lower thread, the machine comprising: at least one
needle bar a plurality of needles, wherein the needle bar has
attached thereto the plurality of needles and wherein each needle
brings the at least one upper thread from above the material to
below the material; and at least one arm wherein the arm having a
first end and a second end, the first end of the arm being
connected to a drive train and the second end of the arm having
attached thereto the needle bar; wherein the arm is sufficiently
designed such that the second end of the arm moves along a path
forming an arc; and wherein each of the plurality of needles is
elongated along a long axis and wherein each of the plurality of
needles is curved along the long axis.
2. The machine of claim 1, wherein each needle oscillate as each
needle brings the upper thread from above the material to below the
material.
3. The machine of claim 1 further comprising: a plurality of
loopers disposed below the material sufficiently designed to
manipulate the lower thread to form double chain stitches in
combination with the upper thread; wherein each looper sufficiently
designed to cut the lower thread with at least one cutting element
associated with each looper; and wherein each looper oscillates as
the looper manipulates the lower thread to form double chain
stitches in combination with the upper thread.
4. The machine of claim 1, wherein the cutting element comprises a
knife edge.
5. The machine of claim 1, wherein the looper comprises a leading
end extending from a neck portion, and wherein the cutting element
of the looper is disposed in a direction extending from the neck
away from the leading end.
6. The machine of claim 5, wherein the cutting element of the
looper is disposed in a direction extending approximately 180
degrees away from the leading end.
7. The machine of claim 1, wherein the cutting element is attached
to the looper.
8. The machine of claim 1, wherein the cutting element is integral
with the looper.
9. The machine of claim 1 further including at least a first and
second needle bar, wherein each needle bar is independently
moved.
10. A method for making double chain stitches in a material, the
double chain stitches being made using a plurality of upper threads
and a plurality of lower threads, the method comprising: providing
the material to receive the double chain stitches; utilizing a
plurality of needles, each needle bringing one of the upper threads
from above the material to below the material; utilizing a
plurality of loopers disposed below the material, wherein each
looper is used to manipulate one of the lower threads to form
double chain stitches in combination with a respective one of the
upper threads; and utilizing the plurality of loopers to cut each
respective lower thread with at least one cutting element
associated with each of the loopers.
Description
RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application Ser. No. 61/222,365, filed Jul. 1, 2009. The
aforementioned application is incorporated herein by reference in
its entirety.
FIELD OF THE INVENTION
[0002] One embodiment of the present invention relates to a machine
for sewing, embroidering, quilting and/or the like.
[0003] Another embodiment of the present invention relates to a
method for sewing, embroidering, quilting and/or the like. In one
example, the present invention may be applied (e.g., as a machine
and/or method) to a multi-needle machine or method.
[0004] In another example, the present invention may provide for
automatic lower (or bottom) thread cutting.
[0005] In another example, the present invention may provide for
automatic lower (or bottom) thread cutting by utilizing the phase
(that is, movement phase) of a return of a looper (or hook) to cut
the lower (or bottom) thread.
[0006] For the purposes of describing and claiming the present
invention, the term "looper" (or "hook") is intended to refer to a
mechanism of the type disclosed herein and is intended to be
different from a known "rotary hook" (or "rotary hook
assembly").
[0007] Of note, while various embodiments of the present invention
are described herein, it is to be understood that the present
invention may be applied to any desired type of machine and/or
method (for example, the machine or method does not necessarily
need to utilize curved needles (although such curved needles may,
of course, be utilized); further the machine or method does not
necessarily need to utilize independent needle bars (although such
independent needle bars may, of course, be utilized)). In one
example, the present invention may be applied to any desired type
of quilting machine and/or method. In another example, the present
invention may be applied to any desired type of machine and/or
method using double chain stitch. In another example, the present
invention may be applied to any desired type of quilting machine
and/or method using double chain stitch.
BACKGROUND OF THE INVENTION
[0008] Various machines for quilting, stitching and the like have
been disclosed in various patent-related documents. Examples
include the following: U.S. Pat. No. 3,680,507, issued Aug. 1, 1972
to Landoni (entitled "MULTINEEDLE QUILTING MACHINE"); U.S. Pat. No.
4,089,281, issued May 16, 1978 to Landoni (entitled "CONTROL DEVICE
OF A NEEDLE-BEARING IN A QUILTING MACHINE"); U.S. Pat. No.
4,106,417, issued Aug. 15, 1978 to Landoni (entitled "APPARATUS FOR
CONTROLLING THE MOVEMENT OF A FABRIC-SUPPORTING CARRIAGE IN A
QUILTING MACHINE"); U.S. Pat. No. 4,262,613, issued Apr. 21, 1981
to Landoni (entitled "APPARATUS FOR CONTROLLING THE TRANSVERSE
MOVEMENT OF A FABRIC SUPPORTING CARRIAGE IN A QUILTING MACHINE");
U.S. Pat. No. 4,501,208, issued Feb. 26, 1985 to Landoni (entitled
"PROCESS FOR THE BIDIRECTIONAL FEEDING OF FABRICS IN QUILTING
MACHINES, AND A MACHINE UTILIZING THIS PROCESS"); U.S. Pat. No.
5,005,499, issued Apr. 9, 1991 to Landoni (entitled "DEVICE FOR
DISABLING AND ENABLING STITCHING NEEDLES IN A QUILTING MACHINE OR A
MULTI-NEEDLE EMBROIDERY MACHINE"); U.S. Pat. No. 5,269,238, issued
Dec. 14, 1993 to Landoni (entitled "QUILTING MACHINE LOOPERS WITH
LINKAGE/PISTON DRIVEN THREAD CUTTERS"); U.S. Pat. No. 5,676,077,
issued Oct. 14, 1997 to Landoni (entitled "MULTI-NEEDLE CHAIN
STITCH SEWING MACHINE WITH THREAD SEVERING SYSTEM"); U.S. Pat. No.
5,967,068, issued Oct. 19, 1999 to Landoni (entitled "MULTI-NEEDLE
KNOTTED-STITCH QUILTING MACHINE WITH LOWER STITCHING ELEMENTS
HAVING ROTATING HOOKS"); U.S. Pat. No. 6,957,615, issued Oct. 25,
2005 to Landoni (entitled "METHOD AND DEVICE TO APPLY CORD THREAD
OR RIBBONS ONTO FABRICS IN A QUILTING MACHINE"); U.S. Patent
Publication 2008/0245283, published Oct. 9, 2008 in the name of
Landoni (entitled "AUTOMATIC MULTI-FUNCTION MULTI-NEEDLE SEWING
MACHINE, AND RELATIVE SEWING METHOD"); and U.S. Pat. No. 7,591,227,
issued Sep. 22, 2009 to Landoni (entitled "SYSTEMS AND METHODS FOR
THREAD HANDLING AND/OR CUTTING").
SUMMARY OF THE INVENTION
[0009] In one embodiment, the present invention relates to a
machine for making double chain stitches in a material, the double
chain stitches being made using at least one upper thread and at
least one lower thread, the machine comprising: at least one needle
bar; a plurality of needles, wherein the needle bar has attached
thereto the plurality of needles and wherein each needle brings the
at least one upper thread from above the material to below the
material; and at least one arm wherein the arm having a first end
and a second end, the first end of the arm being connected to a
drive train and the second end of the arm having attached thereto
the needle bar; wherein the arm is sufficiently designed such that
the second end of the arm moves along a path forming an arc; and
wherein each of the plurality of needles is elongated along a long
axis and wherein each of the plurality of needles is curved along
the long axis.
[0010] In another embodiment, the present invention further
includes a machine wherein each needle oscillate as each needle
brings the upper thread from above the material to below the
material.
[0011] In another embodiment, the present invention further
includes a machine comprising a plurality of loopers disposed below
the material sufficiently designed to manipulate the lower thread
to form double chain stitches in combination with the upper thread;
wherein each looper sufficiently designed to cut the lower thread
with at least one cutting element associated with each looper; and
wherein each looper oscillates as the looper manipulates the lower
thread to form double chain stitches in combination with the upper
thread.
[0012] In another embodiment, the present invention further
includes a machine wherein the cutting element comprises a knife
edge.
[0013] In another embodiment, the present invention further
includes a machine wherein the looper comprises a leading end
extending from a neck portion, and wherein the cutting element of
the looper is disposed in a direction extending from the neck away
from the leading end.
[0014] In another embodiment, the present invention further
includes a machine wherein the cutting element of the looper is
disposed in a direction extending approximately 180 degrees away
from the leading end.
[0015] In another embodiment, the present invention further
includes a machine wherein the cutting element is attached to the
looper.
[0016] In another embodiment, the present invention further
includes a machine wherein the cutting element is integral with the
looper.
[0017] In another embodiment, the present invention further
includes a machine having at least a first and second needle bar,
wherein each needle bar is independently moved.
[0018] In yet another embodiment, the present invention relates to
a method for making double chain stitches in a material, the double
chain stitches being made using a plurality of upper threads and a
plurality of lower threads, the method comprising: providing the
material to receive the double chain stitches; utilizing a
plurality of needles, each needle bringing one of the upper threads
from above the material to below the material; utilizing a
plurality of loopers disposed below the material, wherein each
looper is used to manipulate one of the lower threads to form
double chain stitches in combination with a respective one of the
upper threads; and utilizing the plurality of loopers to cut each
respective lower thread with at least one cutting element
associated with each of the loopers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1A shows a cross-sectional side view of a machine
according to an embodiment of the present invention.
[0020] FIG. 1B shows various details associated with a portion of
the machine as shown in FIG. 1A.
[0021] FIG. 2A shows a cross-sectional side view of the machine of
FIG. 1A (this cross-sectional side view is taken at position
different from the cross-sectional side view of FIG. 1A).
[0022] FIG. 2B shows various details associated with a portion of
the machine as shown in FIG. 2A.
[0023] FIG. 3 shows a plan view of a portion of the machine of
FIGS. 1A, 1B, 2A and 2C.
[0024] FIG. 4 shows a front view of a portion of the machine of
FIGS. 1A, 1B, 2A and 2C.
[0025] FIG. 5 shows various details associated with a portion of
the machine as shown in FIG. 3.
[0026] FIG. 6 shows various details associated with a portion of
the machine as shown in FIGS. 2A and 2B.
[0027] FIG. 7A shows a perspective view of a portion of the machine
of FIGS. 1A, 1B, 2A and 2B.
[0028] FIG. 7B shows various details associated with a portion of
the machine as shown in FIG. 7A.
[0029] FIG. 8A shows another perspective view of a portion of the
machine of FIGS. 1A, 1B, 2A and 2B.
[0030] FIG. 8B shows another perspective view of a portion of the
machine of FIGS. 1A, 1B, 2A and 2B (this view is similar to the
view of FIG. 8A, but with certain parts removed to show other
parts).
[0031] FIG. 9 shows another perspective view of a portion of the
machine of FIGS. 1A, 1B, 2A and 2B.
[0032] FIG. 10 shows a plan view of a portion of a machine with
independent needle bars according to another embodiment of the
present invention.
[0033] FIGS. 11-13 show various views of a portion of a machine
according to another embodiment of the present invention (FIGS. 11
and 12 show loopers (or hooks) at two different phases of movement
and FIG. 13 shows certain details of a looper (or hook) of FIGS. 11
and 12).
[0034] FIGS. 14A-14F show various views of a looper (or hook) at
various phases of movement according to an embodiment of the
present invention (in one example, the looper (or hook), as well as
the various phases, shown in these FIGS. 14A-14F may be utilized in
connection with the machine shown in FIGS. 11-13).
[0035] FIG. 15 shows a view of a looper (or hook) according to an
embodiment of the present invention (in one example, the looper (or
hook), as well as the phase, shown in this FIG. 15 may be utilized
in connection with the machine shown in FIGS. 11-13).
[0036] FIGS. 16-18 show various views of a looper (or hook) at
various phases of movement according to an embodiment of the
present invention (in one example, the looper (or hook), as well as
the various phases, shown in these FIGS. 16-18 may be utilized in
connection with the machine shown in FIGS. 11-13).
[0037] FIGS. 19A-19F show various side and top views of a looper
(or hook) according to an embodiment of the present invention (in
one example, the looper (or hook) shown in these FIGS. 19A-19F may
be utilized in connection with the machine shown in FIGS.
11-13).
[0038] FIGS. 20-27 show views of various example patterns that may
be produced using various embodiments of the present invention.
[0039] FIGS. 28-31 show views of additional various example
patterns that may be produced using various embodiments of the
present invention (each of these FIGS. shows an example pattern on
a mattress, along with a detail view of a portion of the associated
pattern).
[0040] FIGS. 32-38 show views of additional various example
patterns that may be produced using various embodiments of the
present invention.
[0041] FIGS. 39-41 show views of additional various example
patterns that may be produced using various embodiments of the
present invention (each of these FIGS. shows an example pattern on
a mattress, along with a detail view of a portion of the associated
pattern).
[0042] FIG. 42 shows an example configuration using three needle
bars according to an embodiment of the present invention.
[0043] FIG. 43 shows an example configuration (in table format)
using three needle bars according to an embodiment of the present
invention.
[0044] FIGS. 44A-44H show views of various example independent
needle bar movement available using various embodiments of the
present invention (each needle bar is shown end-on in these FIGS.
44A-44H, with each associated row of needles pointing
downward).
[0045] Among those benefits and improvements that have been
disclosed, other objects and advantages of this invention will
become apparent from the following description taken in conjunction
with the accompanying figures. The figures constitute a part of
this specification and include illustrative embodiments of the
present invention and illustrate various objects and features
thereof.
DETAILED DESCRIPTION OF THE INVENTION
[0046] Detailed embodiments of the present invention are disclosed
herein; however, it is to be understood that the disclosed
embodiments are merely illustrative of the invention that may be
embodied in various forms. In addition, each of the examples given
in connection with the various embodiments of the invention is
intended to be illustrative, and not restrictive. Further, the
figures are not necessarily to scale, some features may be
exaggerated to show details of particular components (and any data,
size, material and similar details shown in the figures are, of
course, intended to be illustrative and not restrictive).
Therefore, specific structural and functional details disclosed
herein are not to be interpreted as limiting, but merely as a
representative basis for teaching one skilled in the art to
variously employ the present invention. Of note, the application
contains material that is subject to copyright protection. The
copyright owner has no objection to the facsimile reproduction by
anyone of the copyrighted material, as it appears in the Patent and
Trademark Office file or records, but otherwise reserves all
copyright rights whatsoever.
[0047] As described herein, in one embodiment the present invention
may provide a multi-needle machine utilizing curved needles and/or
independent movement of the needle bars.
[0048] Further, as described herein, in one example the present
invention may be distinguished from certain conventional systems
that, due to considerable inertia of the moving parts (and their
complexity) present in such conventional systems, have various
shortcomings, including (but not limited to):
[0049] Relatively limited sewing speed
[0050] Relatively high wear associated with sliding parts
[0051] Impossible to control independently a plurality of needle
bars
[0052] Relatively high cost due to quantity and complexity of
components
[0053] Further, as described herein, in another embodiment the
present invention may provide a multi-needle double chain stitch
quilting machine in which the sewing needles are curved to fit a
semicircular, oscillating-alternating movement of the needle
bars.
[0054] Further, as described herein, in another embodiment the
present invention may provide a machine that allows for higher
sewing speed due (at least in part) to the lower inertia of the
moving parts.
[0055] Further, as described herein, in another embodiment the
present invention may provide a machine that allows independent
control of two, three (or more) needle bars such that certain
patterns (e.g., sewing patterns) that are typically impossible (or
very difficult) to accomplish on certain conventional machines
(e.g., without independently movable needle bars such that all
needle bars are in movement) may be produced (e.g., produced
relatively easily using an embodiment of the present
invention).
[0056] Further, as described herein, in another embodiment the
present invention may provide a machine that has reduced
manufacturing costs.
[0057] Reference will now be made to the FIGS.
[0058] FIG. 1A shows a cross-sectional side view of a machine
according to an embodiment of the present invention. Further, FIG.
1B shows various details associated with a portion of the machine
as shown in FIG. 1A.
[0059] As seen in these FIGS. 1A and 1B, a free end of each of arms
9, 10, 11 is driven in this embodiment in a reciprocating manner in
an arc (see arrows A,B,C of FIG. 1B which indicate the arcs along
which the free ends of each of arms 9, 10, 11 is driven (the drive
mechanism is discussed in more detail below). Of course, as the
free ends of each of arms 9, 10, 11 is driven in an arc, each of
needle bars 3,4,5 (which are attached, respectively, to arms 9, 10,
11) is also driven in an arc. Moreover, of course, as each of
needle bars 3,4,5 is driven in an arc, each needle 1 is also driven
in an arc (any desired number of needles may be attached to each
needle bar).
[0060] In one example, one or more of the needles may be curved. In
another example, all of the needles may be curved. In another
example, at least one needle may have different radius of curvature
than at least one other needle. In another example, all of the
needles may have the same radius of curvature. In one specific
example, a radius of curvature of a needle may be 200 mm.
[0061] Of note, in one embodiment, use of curved needles may
provide for a lighter assembly that runs at a higher speed with a
lower parts count.
[0062] Still referring to FIGS. 1A and 1B, it is seen that presser
feet 100A,100B,100C may be reciprocated (e.g., by a motor) up and
down by the components generally identified in FIG. 1A as Portion
100.
[0063] Still referring to FIGS. 1A and 1B, it is seen that hooks 2
may be reciprocated (e.g., by a motor) by the components generally
identified in FIG. 1A as Portion 200 (see arrows G,H,I of FIGS. 1A
and 1B showing the movement of hooks 2 around their respective
pivot points).
[0064] Thus, as seen, each of needles 1 may be driven in an arc to
cooperate with hooks 2 and presser feet 100A,100B,100C to perform
any desired sewing, embroidering, quilting and/or the like.
[0065] Of course, the various components may be driven (e.g.,
reciprocated) by one or more motor(s). In one example, a first
motor may drive (e.g., reciprocate) arms 9, 10, 11; a second motor
may drive (e.g., reciprocate) presser feet 100A,100B,100C; and a
third motor may drive (e.g., reciprocate) hooks 2. In another
example, a single motor may drive (e.g., reciprocate) arms 9, 10,
11 and/or presser feet 100A,100B,100C and/or hooks 2.
[0066] Still referring to FIGS. 1A and 1B, it is seen that arms 9,
10, 11 may be reciprocated up and down in their respective arcs
(e.g., circular arcs) by rotating rods 6,7,8 (the drive mechanism
for rotating rods 6,7,8 is discussed in more detail below). More
particularly, rotating rods 6,7,8 (which may be reciprocally
rotated as shown by arrows D,E,F of FIG. 1B) may drive arms 9, 10,
11 due to each of arms 9,10,11 being attached to one of rotating
rods 6,7,8.
[0067] Referring now to FIGS. 2A, 2B and 6, certain details
regarding how rotating rods 6,7,8 are rotated back and forth as
discussed above will be provided. More particularly, it is seen
that each of rotating rods 6,7,8 has mounted thereto a respective
connector element 12,13,14 (in one example, each of connector
elements 12, 13,14 may comprise a clamp of the type discussed in
more detail below). In addition, each of connector elements
12,13,14 is connected to tie bar 15 (such that the connector
elements move together (see, e.g., FIGS. 2A and 6 where is seen
that as tie bar 15 reciprocates along arrow J (in an essentially
linear movement), each of rotating rods 6,7,8 is driven (by one of
connector elements 12,13,14 when the respective clamp is engaged)
to rotate back and forth (e.g., in a circular arc) as seen by
arrows K,L,M).
[0068] Further, it is seen that tie bar 15 is driven to reciprocate
along arrow J by the action of drive bar 16 (operatively connected
at one end to connector element 12 and at the other end to
eccentric 17). Of course, eccentric 17 converts the rotary motion
shown by arrow N into the motion shown by arrow O associated with
drive bar 16 (in one example, the rotation associated with
eccentric 17 may be a back-and-forth rotation; in another example,
the rotation associated with eccentric 17 may be a rotation in a
single direction).
[0069] Again, various components may be driven by one or more
motors (e.g., eccentric 17 may be driven by a motor to cause the
various movements described above).
[0070] In one example, each of connector elements 12,13,14 may be
clamped to each rotating rod 6,7,8 such that each clamp may be
engaged (thus engaging the respective rotating rod 6,7,8, to cause
the respective rotating rod 6,7,8 to reciprocate along with the
respective connector element 12,13,14) or disengaged (thus
disengaging the respective rotating rod 6,7,8 to allow the
respective rotating rod 6,7,8 to not reciprocate along with the
respective connector element 12,13,14). In another example, each
clamp may be hydraulically and/or pneumatically activated (that is,
engaged/disengaged). In another example, each clamp may be
activated (that is, engaged/disengaged) under computer control.
[0071] In another example, each clamp may be activated (that is,
engaged/disengaged) together (that is, all of the arms may be
driven to reciprocate at one time). In another example, each clamp
may be activated (that is, engaged/disengaged) independently (that
is, one or more of the arms may be driven to reciprocate at one
time while one or more other arms may not be driven to reciprocate
at that time).
[0072] Referring now to FIG. 5, certain additional details
regarding a clamp of the type discussed above is shown (see, e.g.,
line 200 (which may carry hydraulic and/or pneumatic material
(e.g., fluid, air, gas) and contact element 201 (comprising, for
example, a clutch element or the like)).
[0073] Referring now to FIG. 3, it is seen that various bearings
may be utilized as desired (see, e.g., the example bearings
300A-300F of FIG. 3). Further, it is seen that, for example,
connectors 400A-400F may be utilized to permit quick replacement of
a component without removing an entire rotating rod (for example,
connector element 12 may be removed and replaced by disconnecting
elements 400C and 400F from rotating rod 6).
[0074] Referring now to FIG. 4, this FIG. shows a front view of a
portion of the machine of FIGS. 1A, 1B, 2A and 2B.
[0075] Referring now to FIG. 7A, this FIG. shows a perspective view
of a portion of the machine of FIGS. 1A, 1B, 2A and 2B.
[0076] Referring now to FIG. 7B, this FIG. shows various details
associated with a portion of the machine as shown in FIG. 7A.
[0077] Referring now to FIG. 8A, this FIG. shows another
perspective view of a portion of the machine of FIGS. 1A, 1B, 2A
and 2B.
[0078] Referring now to FIG. 8B, this FIG. shows another
perspective view of a portion of the machine of FIGS. 1A, 1B, 2A
and 2B (this view is similar to the view of FIG. 8A, but with
certain parts removed to show other parts).
[0079] Referring now to FIG. 9, this FIG. shows another perspective
view of a portion of the machine of FIGS. 1A, 1B, 2A and 2B.
[0080] Referring now to FIG. 10, this FIG. shows a plan view of a
portion of a machine with independent needle bars according to
another embodiment of the present invention.
[0081] As described herein, various embodiments of the present
invention may provide for the conversion of rotating motion (see,
e.g., eccentric 17 and arrow N of FIG. 2A) to angular motion (see,
e.g., arms 9,10,11 and arrows A,B,C of FIG. 1B).
[0082] In one example, all of the needle bars may be moved together
(that is, at the same time in a manner such that movement of one
needle bar is not independent from movement of the other needle
bars). In another example, movement of one or more needle bars may
be independent from movement of one or more other needle bars (this
may be accomplished, for example, by engaging/disengaging one or
more clamps as discussed herein). In another example, independently
movable needle bars may be provided in a multiple needle bar
machine (and/or method).
[0083] Of note, independently movable needle bars provided in a
multiple needle bar machine (and/or method) may provide certain
distinguishing feature(s) over an independent needle configuration.
For example, an independent needle configuration may be very
complicated (as compared, for example, to the above-mentioned
independently movable needle bars configuration). In addition, an
independent needle configuration may have problems with thread
coming out of the needle when a given needle is raised above the
work surface (this problem may be reduced or eliminated through use
of the independently movable needle bars configuration described
herein with reference to various embodiments of the present
invention because a non-used needle bar may simply be left at
rest). Further, in practice, independent needles may typically only
be implementable on the first needle bar (due, for example, to the
size of the implementing pistons and the limited space available in
the vicinity of the needle bars (e.g., the limited space available
between adjacent needle bars)).
[0084] In another embodiment, an independently movable needle bars
configuration may be provided via a mechanism that permits one or
more needle bars to be lifted up (such that the associated needles
would not sew the work surface). In one example of this
configuration, all of the needle bars may be moved together, but,
as just mentioned, one or more of the needle bars may be raised as
desired such that the needles associated with the raised needle
bar(s) would not sew the work surface. Of course, the raised needle
bar(s) could also be lowered when it was desired that the needles
associated with such needle bar(s) would sew the work surface. In
one specific example, needle bar(s) of this configuration could be
raised/lowered using a rack and pinion gear system. In another
example, each needle bar may be electrically, hydraulically and/or
pneumatically raised/lowered. In another example, each needle bar
may be raised/lowered under computer control. In another example,
each needle bar may be raised/lowered together. In another example,
each needle bar may be raised/lowered independently (that is, one
or more of the needle bars may be raised at one time (such that the
needles associated with the raised needle bar(s) would not sew the
work surface) while one or more other needle bars may be left in
the lowered position (such that the needles associated with the
lower needle bar(s) would sew the work surface).
[0085] In another example, the machine may be a
computer-implemented machine (e.g., implemented using one or more
programmed processors).
[0086] In another example, the machine may operate at least in part
in an automated manner.
[0087] In another example, the method may be a computer-implemented
method (e.g., implemented using one or more programmed
processors).
[0088] In another example, the method may be carried out at least
in part in an automated manner.
[0089] In one example (which example is intended to be illustrative
and not restrictive), a lock stitch may be carried out.
[0090] In another example (which example is intended to be
illustrative and not restrictive), lock stitch cording may be
carried out.
[0091] In another example (which example is intended to be
illustrative and not restrictive), a moss stitch/chain chenille
stitch may be carried out.
[0092] In another embodiment, a machine for making stitches with
thread may be provided, comprising: at least one needle bar (see,
e.g., needle bars 3, 4, 5 in FIGS. 1A and 1B), wherein the needle
bar has attached thereto a plurality of needles (see, e.g., needles
1 in FIGS. 1A, 1B, 2A and 2B); a drive train (see, e.g., elements
17, 16, 15, 14, 13, 12, 8, 7 and 6 in FIG. 2B--of note, as
described above, one or more motors (e.g., electric motors) may
drive element 17); and at least one arm (see, e.g., arms 9, 10 and
11 in FIGS. 1A and 1B), the arm having a first end and a second
end, the first end of the arm being connected to the drive train
and the second end of the arm having attached thereto the needle
bar; wherein the arm is moved by the drive train such that the
second end of the arm moves along a path forming an arc; and
wherein each of the plurality of needles is elongated along a long
axis and wherein each of the plurality of needles is curved along
the long axis.
[0093] In one example, the machine may perform one (or more) of:
(a) sewing; (b) embroidering; and/or (c) quilting.
[0094] In another example, the machine may stitch a double-needle
chain stitch.
[0095] In another example, the arc may be a semi-circular arc.
[0096] In another example, each of the arm(s) may be moved by the
drive train such that the second end of each arm reciprocates back
and forth along the path forming the arc.
[0097] In another example, at least a plurality of the needles may
have the same radius of curvature along the long axis of each of
the needles.
[0098] In another example, all of the needles may have the same
radius of curvature along the long axis of each of the needles.
[0099] In another example, the radius of curvature of at least a
first one of the plurality of the needles may be different along
the long axis of the first one of the plurality of needles than the
radius of curvature of at least a second one of the plurality of
the needles along the long axis of the second one of the plurality
of needles.
[0100] In another example, the machine may further comprise a
programmed computer.
[0101] In another example, the drive train may comprise at least
one motor.
[0102] In another example, the motor may comprise an electric
motor.
[0103] In another embodiment, a machine for making stitches with
thread is provided, comprising: a first needle bar (see, e.g.,
needle bars 3, 4, 5 in FIGS. 1A and 1B) having attached thereto a
plurality of needles (see, e.g., needles 1 in FIGS. 1A, 1B, 2A and
2B); a second needle bar (see, e.g., needle bars 3, 4, 5 in FIGS.
1A and 1B) having attached thereto a plurality of needles (see,
e.g., needles 1 in FIGS. 1A, 1B, 2A and 2B); a drive train (see,
e.g., elements 17, 16, 15, 14, 13, 12, 8, 7 and 6 in FIG. 2B--of
note, as described above, one or more motors (e.g., electric
motors) may drive element 17); a first arm (see, e.g., arms 9, 10
and 11 in FIGS. 1A and 1B), the first arm having a first and a
second end, the first end of the first arm being selectively driven
by the drive train and the second end of the first arm having
attached thereto the first needle bar; and a second arm (see, e.g.,
arms 9, 10 and 11 in FIGS. 1A and 1B), the second arm having a
first and a second end, the first end of the second arm being
selectively driven by the drive train and the second end of the
second arm having attached thereto the second needle bar; wherein,
when the first end of the first arm is driven by the drive train,
the first arm is moved by the drive train such that the second end
of the first arm moves along a path forming a first arc; wherein,
when the first end of the second arm is driven by the drive train,
the second arm is moved by the drive train such that the second end
of the second arm moves along a path forming a second arc; and
wherein the driving of the first end of the first arm by the drive
train is independent of the driving of the first end of the second
arm by the drive train.
[0104] In one example, the machine may perform one (or more) of:
(a) sewing; (b) embroidering; and/or (c) quilting.
[0105] In another example, the machine may stitch a double-needle
chain stitch.
[0106] In another example: the drive train may comprise a first
connector element (see, e.g., connector elements 12, 13, 14 in
FIGS. 2A and 2B), a second connector element (see, e.g., connector
elements 12, 13, 14 in FIGS. 2A and 2B), a first rod (see, e.g.,
rods 6, 7, 8 in FIGS. 2A and 2B) and a second rod (see, e.g., rods
6, 7, 8 in FIGS. 2A and 2B); wherein the first end of the first arm
may be fixed to the first rod and the first rod may be selectively
rotated by engagement with the first connector element; and wherein
the first end of the second arm may be fixed to the second rod and
the second rod may be selectively rotated by engagement with the
second connector element.
[0107] In another example: the first end of the first arm may be
fixed to the first rod and the first rod may be selectively
reciprocally rotated back and forth by engagement with the first
connector element; and the first end of the second arm may be fixed
to the second rod and the second rod may be selectively
reciprocally rotated back and forth by engagement with the second
connector element.
[0108] In another example, the first connector element may comprise
a first clamp and the second connector element may comprise a
second clamp.
[0109] In another example, each of the first clamp and the second
clamp may comprise at least one of: (a) an electromagnet clamping
element; (b) a hydraulic clamping element; and/or (c) a pneumatic
clamping element.
[0110] In another example, the drive train may comprise at least
one motor.
[0111] In another example, the motor may comprise an electric
motor.
[0112] In another example, the drive train may comprise at least
one motor operatively connected to reciprocally rotate the first
connector element back and forth and to reciprocally rotate the
second connector element back and forth.
[0113] In another example: the first arm may be moved by the drive
train such that the second end of the first arm reciprocates back
and forth along the path forming the first arc; and the second arm
may be moved by the drive train such that the second end of the
second arm reciprocates back and forth along the path forming the
second arc.
[0114] In another example: when the first end of the first arm is
not driven by the drive train the first arm may be essentially
stationary; and when the first end of the second arm is not driven
by the drive train the second arm may be essentially
stationary.
[0115] In another example, the first arc and the second arc may
have the same radius of curvature.
[0116] In another example, a radius of curvature of the first arc
may be different from a radius of curvature of the second arc.
[0117] In another example: the first arc may be a semi-circular
arc; and the second arc may be a semi-circular arc.
[0118] In another example, each of the plurality of needles may be
elongated along a long axis and each of the plurality of needles
may be curved along the long axis.
[0119] In another example, at least a plurality of the needles may
have the same radius of curvature along the long axis of each of
the needles.
[0120] In another example, all of the needles may have the same
radius of curvature along the long axis of each of the needles.
[0121] In another example, a radius of curvature of at least a
first one of the plurality of the needles may be different along
the long axis of the first one of the plurality of needles than a
radius of curvature of at least a second one of the plurality of
the needles along the long axis of the second one of the plurality
of needles.
[0122] In another example, the machine may further comprise a
programmed computer.
[0123] In another example, the machine may further comprise a
programmed computer, wherein the programmed computer may be
operatively connected to the first clamp and the second clamp to
provide independent control over the movement of the first arm and
the second arm.
[0124] In another embodiment, a machine for making stitches with
thread is provided, comprising: x number of needle bars (see, e.g.,
needle bars 3, 4, 5 in FIGS. 1A and 1B), each of the needle bars
having attached thereto a plurality of needles (see, e.g., needles
1 in FIGS. 1A, 1B, 2A and 2B); a drive train (see, e.g., elements
17, 16, 15, 14, 13, 12, 8, 7 and 6 in FIG. 2B--of note, as
described above, one or more motors (e.g., electric motors) may
drive element 17); y number of arms (see, e.g., arms 9, 10 and 11
in FIGS. 1A and 1B), each of the arms having a first and a second
end, the first end of each of the arms being selectively driven by
the drive train and the second end of each of the arms having
attached thereto one of the needle bars; wherein, when the first
end of each of the arms is driven by the drive train, each of the
arms is moved by the drive train such that the second end of each
of the arms moves along a path forming an arc; wherein the driving
of the first end of at least one of the arms by the drive train is
independent of the driving of the first end of each of the other
arms by the drive train; wherein x is an integer between 2 and 20;
and wherein y is an integer between 2 and 20.
[0125] In one example, the driving of the first end of each of the
arms by the drive train may be independent of the driving of the
first end of each of the other arms by the drive train.
[0126] Referring now to FIGS. 11-13, another embodiment of the
present invention related to an electronically controlled
multi-needle quilting machine is shown (in one example, the machine
may include a linking cylinder arranged between an eccentric
integral with a rotating spindle and a lever to drive in an
oscillating motion a number of loopers which, in combination with a
number of corresponding needles, perform stitching operations by
double chain stitches on a layered material interposed between said
members, said linking cylinder comprising, e.g., a pneumatic
cylinder controlled to change the extension of its rod during the
various operational steps, whereby the link length is changed and
the loopers may reach a position in which, by being provided with a
blade they perform a cutting operation on thread of a respective
needle).
[0127] In another example, the invention may provide a multi-needle
quilting machine adapted to produce an array of closed pattern
designs which are completely isolated from each other already at
the end of an automatic manufacturing operation.
[0128] In another example, an electronically controlled
multi-needle quilting machine may be provided (e.g., including link
means arranged between an eccentric mounted on a rotating spindle
and a lever to drive, in an oscillatory motion, a plurality of
loopers which, in combination with a plurality of corresponding
needles, perform a double chain stitching on a layered material
interposed between said members, wherein said link means may
comprise a pneumatic cylinder controlled in such a way that the
piston rod thereof projects outside in a variable extent during the
various manufacturing steps whereby the length of the link is
changed and the loopers reach a position in which, being provided
with a blade, they cut the thread of a respective needle).
[0129] Referring now to FIG. 11, the quilting machine according to
this embodiment is shown to include a main spindle 1101 which
drives a secondary spindle 1102 parallel thereto, by means of a
belt 1103 mounted on suitable pulleys. On spindle 1102 there is
mounted an eccentric 1104 integral with a pneumatic cylinder 1105
whose rod 1106 is connected to an end of a substantially
triangularly shaped lever 1107. Said lever is pivoted on a shaft
1108 carrying fastened thereon supports of a first row of loopers
1110 parallel to each other, only the first of which loopers of
this row is visible in this figure. A second and a third row, for
example, of loopers 1110', 1110'' are located on the front and rear
side of said first row and pivoted around shafts 1108', 1108''
parallel to said first shaft 1108, while at the ends of said shafts
there are fastened respective levers 1111, 1111', 1111'', hingedly
connected by a transverse bar 1112. Of note, there may be any
desired number of looper(s) in each row and any desired number of
row(s) of looper(s).
[0130] Above the three rows of loopers of this example, suitable
dragging rollers (not shown) cause a sliding motion of the layered
material 1114 (which in the following, for sake of simplicity, is
called fabric) which is operated upon by means of three rows of
needles 1113, 1113' and 1113'', each of which is positioned at a
respective looper 1110, 1110', 1110''. During the stitching step
shown in FIG. 11, rod 1106 of pneumatic cylinder 1105 is kept in a
position of maximum extension, while said cylinder is actuated in a
substantially reciprocating motion by means of eccentric 1104
mounted on spindle 1102. Therefore, cylinder 1105 behaves like a
link.
[0131] According to what has been said above, lever 1107 is driven
in an oscillating motion and it subjects to an alternating rotary
motion both shaft 1108 integral therewith and shafts 1108' and
1108'' through bar 1112 and levers 1111, 1111' and 1111''.
[0132] Therefore, in this example, all the loopers of the machine
are subjected to an oscillating motion and, in combination with the
motion of the corresponding needles, they perform the double chain
stitching used for quilting fabric 1114. It should be noted that
each double chain stitch is made by two threads only one of which,
shown at 1116, 1116', 1116'' passes through a respective needle
1113, 1113', 1113''. It should further be noted that in this step
of this example each looper cooperates to working on the fabric
with its upper portion only.
[0133] When a machine operating cycle is over, i.e., when each
needle has finished its stitching, the quilting machine control
unit stops needles 1113, 1113', 1113'' in a raised position
relative to fabric 1114, and with respective threads 1116, 1116',
1116'' loaded on corresponding loopers 1110, 1110', 1110'', while
also main spindle is stopped. Said threads, that during the
stitching operations were substantially braked, are left free, and
fabric 1114 is moved forward through a span whose length may be
programmed in order to control the length of the portion of thread
inserted through the needle, with which the operation will have to
be resumed next.
[0134] At this point, after threads 1116, 1116', 1116'' have been
locked again, pneumatic cylinder 1105 is biased in such a way as to
bring rod 6 thereof in the minimum extension position, whereby the
lever is rotated and, according to what has been said above, the
same thing takes place for loopers 1110, 1110', 1110''. In
particular, the central row of loopers driven directly by lever
1107, transmits an identical motion to the front and back row of
loopers through bar 1112 and levers 1111, 1111', 1111'', whereby
all the loopers result to be located in the position shown in the
drawing (see, e.g., FIG. 12), corresponding to a substantially
larger rotation compared to the one performed during a regular
oscillating motion during the stitching step.
[0135] The figure (e.g., FIG. 12) shows that, following the above
described motion, each thread 1116, 1116', 1116'' slides all the
way to the neck of a respective looper 1110, 1110', 1110'' and it
is in this point that the thread gets cut.
[0136] In fact, FIG. 13 shows that, at the neck of each looper 1110
there is mounted a blade 1115 for cutting the thread and, once said
operation has been performed, the machine is brought back to the
FIG. 11 condition, and the normal stitching cycle is resumed.
[0137] It should be noted that, when using a quilting machine
according to this embodiment, in addition to doing completely away
with the manual thread cutting step, it is possible to program the
automatic cutting of said thread in such a way that the final look
is improved. In fact, by dragging fabric 1114 along a suitable span
in the step ahead of thread cutting, "thread tails" are obtained
(i.e., lengths of thread going from the cutting point to the
needles eye) long enough to make it possible to resume normally the
stitching operation after the cutting operation, but short enough
to prevent the cut end of the thread to be left outside the surface
of the fabric once the stitching has been resumed. It should
eventually be noted that the machine in various embodiments can go
through the sequence of operations necessary for the thread cutting
cycle within few a seconds, therefore without any substantial
influence on the production times.
[0138] It is understood that pneumatic cylinder 1105 may be
replaced by any desired device, suitable for moving rod 1106
according to the ways described herein above, while loopers 1110,
blades 15 mounted thereon, and all the mechanical components
mentioned above may be of any other type suitable for their
purpose.
[0139] Reference will now be made to FIGS. 14A-14F, showing various
phases (movement phases) of a looper (or hook) used in connection
with applying, e.g., double chain stitch sewing (in one example,
the phases move from FIG. 14A to 14B to 14C to 14D to 14E to 14F
and back to 14A (e.g., in a repeating cycle). As seen, these FIGS.
include needle 1401, looper (or hook) 1403, spreader 1406, upper
thread 1402, lower thread 1404, work surface 1410 and material 1412
(similar elements are also shown in FIGS. 15-19).
[0140] With reference now to FIG. 15, the upper thread may be cut
by blade 1407 with an extra hook stroke as described above (in one
example, the movement phase shown in this FIG. 15 may follow the
movement phase shown in FIG. 14A).
[0141] With reference now to FIG. 16, the lower thread may be cut
by blade 1408 applied to the looper (or hook) in such a position
that in the extra stroke phase it is located in the triangle of the
lower thread ready to cut the lower thread when the looper (or
hook) returns to its position to start sewing (see, e.g., FIG. 18)
(in one example, the movement phase shown in this FIG. 16 may
follow the movement phase shown in FIG. 15).
[0142] With reference now to FIG. 17, an intermediate phase of
lower thread cutting preparation is shown (that is, a phase of
movement between what is shown in FIG. 16 and what is shown in FIG.
18).
[0143] With reference now to FIG. 18, the phase of lower thread
cutting is shown (in one example, the movement phase shown in this
FIG. 18 may follow the movement phase shown in FIG. 17). This phase
of FIG. 18 shows the tail of the lower cut thread cutting which may
be important to start again further sewing. In one example, in the
sequences of the multineedles for the quilting of isolated patterns
(panel quilt), many or just a few loopers (or hooks) are engaged in
the automatic cut of the superior (top or upper) and inferior
(bottom or lower) thread and the tail of the inferior thread is not
unthreaded during the not-working phase since it is retained by the
small brake (thread tensioner or thread tensor) 1409.
[0144] With reference now to FIG. 19, various views of the assembly
of a looper (or hook) with applied blade 1408 are shown (brake or
thread tensor or thread tensioner 1409 is also shown).
[0145] In another embodiment a machine for making double chain
stitches in a material (e.g., a fabric), the double chain stitches
being made using at least one upper thread and at least one lower
thread, is provided, comprising: at least one needle (see, e.g.,
needle 1401 of FIGS. 14A-14F and FIGS. 15-18) bringing the at least
one upper thread (see, e.g., upper thread 1402 of FIGS. 14A-14F and
FIGS. 15-18) from above the material to below the material (see,
e.g., material 1412 of FIGS. 14A-14F and FIGS. 15-18); and at least
one looper (see, e.g., looper 1403 of FIGS. 14A-14F and FIGS.
15-18) disposed below the material; wherein the looper manipulates
the lower thread (see, e.g., lower thread 1404 of FIGS. 14A-14F and
FIGS. 15-18) to form double chain stitches in combination with the
upper thread; and wherein the looper comprises at least one cutting
element (see, e.g., cutting element 1408 of FIGS. 16-18) configured
to cut the lower thread.
[0146] In one example, the material may be disposed adjacent a work
surface (see, e.g., work surface 1410 of FIGS. 14A-14F and FIGS.
15-18). In one specific example, the material may be disposed above
a work surface. In another specific example, the material may be
disposed below a work surface.
[0147] In another example, the needle may oscillate (e.g., up and
down and/or in an arc) as the needle brings the upper thread from
above the material to below the material.
[0148] In another example, the looper may oscillate (e.g., in an
arc) as the looper manipulates the lower thread to form double
chain stitches in combination with the upper thread.
[0149] In another example, the cutting element may comprise a knife
edge.
[0150] In another example, the cutting element may comprise a blunt
edge.
[0151] In another example, the looper may comprise a leading end
(see, e.g., leading end 1403A of FIGS. 14A-14F and FIGS. 15-18)
extending from a neck portion (see, e.g., neck portion 1403B of
FIGS. 14A-14F and FIGS. 15-18), and the cutting element of the
looper may be disposed in a direction extending from the neck away
from the leading end.
[0152] In another example, the cutting element of the looper may be
disposed in a direction extending approximately 180 degrees away
from the leading end.
[0153] In another example, the cutting element may be attached to
the looper.
[0154] In another example, the cutting element may be integral with
the looper.
[0155] In another embodiment a method for making double chain
stitches in a material (e.g., a fabric), the double chain stitches
being made using at least one upper thread and at least one lower
thread, is provided, comprising: providing the material (see, e.g.,
material 1412 of FIGS. 14A-14F and FIGS. 15-18) to receive the
double chain stitches; utilizing at least one needle (see, e.g.,
needle 1401 of FIGS. 14A-14F and FIGS. 15-18) to bring the upper
thread (see, e.g., upper thread 1402 of FIGS. 14A-14F and FIGS.
15-18) from above the material to below the material; utilizing at
least one looper (see, e.g., looper 1403 of FIGS. 14A-14F and FIGS.
15-18) disposed below the material to manipulate the lower thread
(see, e.g., lower thread 1404 of FIGS. 14A-14F and FIGS. 15-18) to
form double chain stitches in combination with the upper thread;
and utilizing the at least one looper to cut the lower thread with
at least one cutting element (see, e.g., cutting element 1408 of
FIGS. 16-18) associated with the at least one looper.
[0156] In one example, the material may be disposed adjacent a work
surface (see, e.g., work surface 1410 of FIGS. 14A-14F and FIGS.
15-18). In one specific example, the material may be disposed above
a work surface. In another specific example, the material may be
disposed below a work surface.
[0157] In another example, the needle may oscillate (e.g., up and
down and/or in an arc) as the needle brings the upper thread from
above the material to below the material.
[0158] In another example, the looper may oscillate (e.g., in an
arc) as the looper manipulates the lower thread to form double
chain stitches in combination with the upper thread.
[0159] In another example, the cutting element may comprise a knife
edge.
[0160] In another example, the cutting element may comprise a blunt
edge.
[0161] In another example, the looper may comprise a leading end
(see, e.g., leading end 1403A of FIGS. 14A-14F and FIGS. 15-18)
extending from a neck portion (see, e.g., neck portion 1403B of
FIGS. 14A-14F and FIGS. 15-18), and the cutting element of the
looper may be disposed in a direction extending from the neck away
from the leading end.
[0162] In another example, the cutting element of the looper may be
disposed in a direction extending approximately 180 degrees away
from the leading end.
[0163] In another example, the cutting element may be attached to
the looper.
[0164] In another example, the cutting element may be integral with
the looper.
[0165] In another embodiment a machine for making double chain
stitches in a material (e.g., a fabric), the double chain stitches
being made using a plurality of upper threads and a plurality of
lower threads, is provided, comprising: a plurality of needles
(see, e.g., needle 1401 of FIGS. 14A-14F and FIGS. 15-18), each
needle bringing one of the upper threads (see, e.g., upper thread
1402 of FIGS. 14A-14F and FIGS. 15-18) from above the material to
below the material; and a plurality of loopers (see, e.g., looper
1403 of FIGS. 14A-14F and FIGS. 15-18) disposed below the material;
wherein each looper manipulates one of the lower threads (see,
e.g., lower thread 1404 of FIGS. 14A-14F and FIGS. 15-18) to form
double chain stitches in combination with a respective one of the
upper threads; and wherein each looper comprises at least one
cutting element (see, e.g., cutting element 1408 of FIGS. 16-18)
configured to cut the respective lower thread.
[0166] In one example, the material may be disposed adjacent a work
surface (see, e.g., work surface 1410 of FIGS. 14A-14F and FIGS.
15-18). In one specific example, the material may be disposed above
a work surface. In another specific example, the material may be
disposed below a work surface.
[0167] In another example, each of the needles may oscillate (e.g.,
up and down and/or in an arc) as each of the needles brings the
respective upper thread from above the material to below the
material.
[0168] In another example, each of the loopers may oscillate (e.g.,
in an arc) as each of the loopers manipulates the respective lower
thread to form double chain stitches in combination with the
respective upper thread.
[0169] In another example, each cutting element may comprise a
knife edge.
[0170] In another example, each cutting element may comprise a
blunt edge.
[0171] In another example, each of the loopers may comprises a
leading end (see, e.g., leading end 1403A of FIGS. 14A-14F and
FIGS. 15-18) extending from a neck portion (see, e.g., neck portion
1403B of FIGS. 14A-14F and FIGS. 15-18), and the cutting element of
each of the loopers may be disposed in a direction extending from
the neck away from the leading end.
[0172] In another example, the cutting element of each of the
loopers may be disposed in a direction extending approximately 180
degrees away from the leading end.
[0173] In another example, the cutting element of each of the
loppers may be attached to each of the loopers.
[0174] In another example, the cutting element of each of the
loopers may be integral with each of the loopers.
[0175] In another embodiment a method for making double chain
stitches in a material (e.g., a fabric), the double chain stitches
being made using a plurality of upper threads and a plurality of
lower threads, is provided, comprising: providing the material
(see, e.g., material 1412 of FIGS. 14A-14F and FIGS. 15-18) to
receive the double chain stitches; utilizing a plurality of needles
(see, e.g., needle 1403A of FIGS. 14A-14F and FIGS. 15-18), each
needle bringing one of the upper threads (see, e.g., upper thread
1402 of FIGS. 14A-14F and FIGS. 15-18) from above the material to
below the material; utilizing a plurality of loopers (see, e.g.,
looper 1403 of FIGS. 14A-14F and FIGS. 15-18) disposed below the
material, wherein each looper is used to manipulate one of the
lower threads (see, e.g., lower thread 1404 of FIGS. 14A-14F and
FIGS. 15-18) to form double chain stitches in combination with a
respective one of the upper threads; and utilizing the plurality of
loopers to cut each respective lower thread with at least one
cutting element (see, e.g., cutting element 1408 of FIGS. 16-18)
associated with each of the loopers.
[0176] In one example, the material may be disposed adjacent a work
surface (see, e.g., work surface 1410 of FIGS. 14A-14F and FIGS.
15-18). In one specific example, the material may be disposed above
a work surface. In another specific example, the material may be
disposed below a work surface.
[0177] In another example, each of the needles may oscillate (e.g.,
up and down and/or in an arc) as each of the needles brings the
respective upper thread from above the material to below the
material.
[0178] In another example, each of the loopers may oscillate (e.g.,
in an arc) as each of the loopers manipulates the respective lower
thread to form double chain stitches in combination with the
respective upper thread.
[0179] In another example, each cutting element may comprise a
knife edge.
[0180] In another example, each cutting element may comprise a
blunt edge.
[0181] In another example, each of the loopers may comprises a
leading end (see, e.g., leading end 1403A of FIGS. 14A-14F and
FIGS. 15-18) extending from a neck portion (see, e.g., neck portion
1403B of FIGS. 14A-14F and FIGS. 15-18), and the cutting element of
each of the loopers may be disposed in a direction extending from
the neck away from the leading end.
[0182] In another example, the cutting element of each of the
loopers may be disposed in a direction extending approximately 180
degrees away from the leading end.
[0183] In another example, the cutting element of each of the
loppers may be attached to each of the loopers.
[0184] In another example, the cutting element of each of the
loopers may be integral with each of the loopers.
[0185] As described herein, various embodiments of the present
invention may provide for a double chain stitch automatic quilting
machine for cutting the superior (top or upper) and/or inferior
(bottom or lower) thread. Various embodiments of the present
invention may solve the problem of a floating lower thread (which,
left uncut such as in the case of pattern link drawings, may
conventionally create trouble).
[0186] In one specific example, a disclosed mechanism for automatic
cutting of thread (e.g., lower thread and/or upper thread) may be
combined with a disclosed mechanism for independent needle bar
movement (e.g., three independent needle bars)--e.g., to permit the
making of various desired patterns.
[0187] In another example, the present invention may be applied
(e.g., as a machine and/or method) to a single needle machine or
method.
[0188] As described herein, various embodiments of the present
invention relate to a double chain stitch quilting machine.
[0189] In one example, the double chain stitch quilting machine may
be capable of working up to 1,400 s.p.m.
[0190] In another example, movement is simplified and the number of
mechanical parts needed are reduced.
[0191] In another example, a pretension system may be provided.
[0192] In another example, various 360 degree continuous pattern(s)
may be stitched (e.g., at very high productivity) using various
embodiments of the present invention.
[0193] In another example, production (e.g., stitching) of panel
quilt pattern(s) that may be essentially impossible to produce in
an essentially continuous manner by other means may be
provided.
[0194] In another example, various pattern-link drawings may be
stitched using various embodiments of the present invention.
[0195] In another example, various embodiments of the present
invention may be used to operate on elastic knitted materials.
[0196] In another example, various embodiments of the present
invention may provide for one or more of the following: independent
presser feet (e.g., instead of a traditional presser plate);
independent needle bars (e.g., with oscillating movements); dynamic
and constant pretension of the materials; and/or real-time control
of the yarn's tension (and/or of the thread's tension).
[0197] In another example, three independent needle bars may be
utilized.
[0198] In another example, various embodiments of the present
invention may be used to operate on one or more of the following:
mattress; bed cover; and/or bed spread.
[0199] In another example, various standard quilting, 360 degree
decorative patterns, and/or pattern-link movement may be produced
using a single highly productive, flexible and efficient sewing
system using various embodiments of the present invention.
[0200] In another example, a fully integrated computerized control
system may be provided. In another example, material of any desired
thickness may be operated on (e.g., up to 2'' foam plus 200 gr
wadding).
[0201] In another example, various embodiments of the present
invention may provide for any desired type of sewing, quilting,
embroidery and/or the like.
[0202] In another example, high precision control of carriage and
rolls may provide for one or more of the following: precision in
360 degree patterns; no skipped stitches in any direction; use of
thin needles (e.g., 130/160); and or quilting of extra heavy or
very thin filling materials.
[0203] In another example, a number of fixed looper positions
(e.g., 100 fixed looper positions) may be provided (e.g., to accept
any desired needle set and avoid a long down time to move and set
the loopers at new positions).
[0204] In another example, independent positive presser feet (e.g.,
instead of a traditional presser plate) may provide for one or more
of the following: presser feet only correspond to position of
needles; very tight stitches; and/or more quilting thickness and
puff effect.
[0205] In another example, a 90 degree looper bars reversing system
may be provided (e.g., which may allow easy and fast looper
threading operation).
[0206] In another example, bartack and jump (e.g., with an
automatic top thread cutting system essentially assuring zero tail
on top surface) may be provided.
[0207] In another example, an upper thread feeder with yo-yo action
may be provided (e.g., such upper thread feeder with yo-yo action
may, thanks to its progressive pulling action, allow a stronger
closing of stitches without stressing the top threads (as compared,
for example, to a traditional butterfly system)--thus avoiding
thread breaks.
[0208] In another example, stop motion action may be provided for
needles and/or loopers (this may allow, for example, visual control
of the tension of every thread). In another example, the stop
motion action may be integrated into software.
[0209] In another example, a working speed may be up to 1,400
s.p.m.
[0210] In another example, a pattern range may be 360 degrees.
[0211] In another example, a carriage stroke may be 12'' (305
mm).
[0212] In another example, there may be no theoretical limit in
back sewing.
[0213] In another example, equalized stitch length in all
directions may be provided.
[0214] In another example, there may be a three needle bar
configuration as follows: 1''.times.3''.times.6''.
[0215] In another example, a multi-roll material handing system may
be provided.
[0216] In another example, stitch length may be 1/6 mm.
[0217] For the purposes of this disclosure, a computer readable
medium is a medium that stores computer data in machine readable
form. By way of example, and not limitation, a computer readable
medium can comprise computer storage media as well as communication
media, methods or signals. Computer storage media includes volatile
and non-volatile, removable and non-removable media implemented in
any method or technology for storage of information such as
computer-readable instructions, data structures, program modules or
other data. Computer storage media includes, but is not limited to,
RAM, ROM, EPROM, EEPROM, flash memory or other solid state memory
technology; CD-ROM, DVD, or other optical storage; cassettes, tape,
disk, or other magnetic storage devices; or any other medium which
can be used to tangibly store the desired information and which can
be accessed by the computer.
[0218] Further, the present invention may, of course, be
implemented using any appropriate computer readable medium,
computer hardware and/or computer software.
[0219] As mentioned, the techniques described herein may, of
course, be computer implemented and may utilize any appropriate
computer hardware and/or computer software. In this regard, those
of ordinary skill in the art are well versed in the type of
computer hardware that may be used (e.g., a personal computer
("PC"), a network (e.g., an intranet and/or the Internet)), the
type of computer programming techniques that may be used, and the
type of computer programming languages that may be used. The
aforementioned examples are, of course, illustrative and not
restrictive.
[0220] Of course, any embodiment/example described herein (or any
feature or features of any embodiment/example described herein) may
be combined with any other embodiment/example described herein (or
any feature or features of any such other embodiment/example
described herein).
[0221] While a number of embodiments of the present invention have
been described, it is understood that these embodiments are
illustrative only, and not restrictive, and that many modifications
may become apparent to those of ordinary skill in the art. For
example, any desired number and/or type of motors(s) may be
utilized (e.g., electric AC motor(s); electric DC motors(s);
electric stepper motor(s); electric induction motor(s); electric
linear motor(s); electric actuators (e.g., linear actuator(s));
piston(s) (hydraulic and/or pneumatic)). Further still, any desired
number of needle(s) may be used on any desired number of needle
bar(s). Further still, any desired number of arm(s) may be used on
any given needle bar (e.g., multiple arms for each needle bar).
Further still, any desired number of arm(s) may be used on any
given rotating rod (e.g., multiple arms for each rotating rod).
Further still, any desired number of rotating rod(s) may be
utilized. Further still, any desired number of hooks(s) may be
utilized. Further still, any desired number of presser feet may be
utilized. Further still, any reciprocation described herein may be,
for example, a back-and-forth oscillation. Further still, any
rotation described herein may be, for example, a back-and-forth
rotation or a rotation in one direction only. Further still, the
various steps may be carried out in any desired order (and any
desired steps may be added and/or any desired steps may be
eliminated).
* * * * *