A variety of articles are formed from textiles. As examples, articles of apparel (e.g., shirts, pants, socks, footwear, jackets and other outerwear, briefs and other undergarments, hats and other headwear), containers (e.g., backpacks, bags), and upholstery for furniture (e.g., chairs, couches, car seats) are often at least partially formed from textiles. These textiles are often formed by weaving or interlooping (e.g., knitting) a yarn or a plurality of yarns, usually through a mechanical process involving looms or knitting machines.
In some applications, the textile may be embroidered with at least one embroidery element, such as a strand, thread, yarn, or the like (herein referred to as a “strand” when referring to an embroidered element). The embroidery process may be accomplished on a mechanical device called an embroidery machine. Typically, an embroidery machine includes a needle for mechanically manipulating the strand through the base layer of the textile. Usually, the embroidery process occurs after the base layer of the textile is formed, and the embroidery machine is typically separate from the machine used to form the base textile layer (e.g., a knitting machine or a weaving loom).
While embroidery machines have been used with success for certain applications, one shortcoming of existing machines involves the limited motion of the embroidery needle. For example, existing embroidery needles are movable vertically and/or in a horizontal plane, but they cannot rotate or otherwise change the orientation of their vertical axes. This shortcoming has limited the usefulness of embroidery machines with respect to certain types of textiles, and particularly textiles with a tubular construction and/or curved areas. In particular, embroidery machines of the type described above cannot reach all areas of a tubular or curved textile without human intervention (e.g., through repositioning the textile during the embroidery process). The embodiments described below provide an improved device for overcoming this shortcoming.
The invention can be better understood with reference to the following drawings/figures and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. Moreover, in the figures, like referenced numerals designate corresponding parts throughout the different views.
Various aspects are described below with reference to the drawings in which like elements generally are identified by like numerals. The relationship and functioning of the various elements of the aspects may better be understood by reference to the following detailed description. However, aspects are not limited to those illustrated in the drawings or explicitly described below. It also should be understood that the drawings are not necessarily to scale, and in certain instances details may have been omitted that are not necessary for an understanding of aspects disclosed herein, such as conventional fabrication and assembly.
One general aspect of the present disclosure includes an assembly including: a support device having a surface for receiving a textile component; and an actuation device, the actuation device having at least one actuation surface that at least partially surrounds the support device, where the actuation surface is movable with respect to the surface of the support device such that, when the textile component is held by the support device, movement of the actuation surface with respect to the surface of the support device causes movement of the textile component with respect to the surface of the support device.
Another general aspect of the present disclosure includes an assembly, including: a actuation device, the actuation device having at least one belt defining an actuation surface that is movable with respect to an outer surface of a support device, where the actuation device has an engaged state and an open state, where the actuation surface at least partially surrounds the support device when in the engaged state, and where at least a portion of the actuation surface moves away from the support device when transitioning from the engaged state to the open state.
Another general aspect of the present disclosure includes a method, the method including: placing a textile component on a surface of a support device; placing the support device into engagement with an actuation device, the actuation device having at least one actuation surface that at least partially surrounds the support device; and moving the textile component with respect to the support device by moving the actuation surface while the actuation surface is engaged with the textile component.
Another general aspect of the present disclosure includes a textile component, including: a tubular construction forming a textile layer that defines and surrounds an inner opening; and an embroidered strand, where the embroidered strand extends at least 360 degrees around the tubular construction of the textile component.
The assembly 102 may be separate from the embroidery machine (as shown), or alternatively it may be built as a portion of the embroidery machine. The assembly 102 may generally include a support device 104 for holding a textile component 202 and an actuation device 108 for moving (e.g., rotating) the textile component 202. A housing 114 of the assembly 102 (which may be fixed to the embroidery machine) may have a connection port 116 that connects to the first end 118 of the support device 104. The connection port 116 may include a socket, a flange, a series of connection holes (e.g., for bolting or screwing), a clamp, etc. The connection port 116 may couple to the support device 104 in a permanent or non-permanent manner. In some embodiments, the support device 104 may be fixed to the embroidery machine through the port 116. Herein, “fixed to” means “rigidly attached to” in a permanent or non-permanent manner. Similarly, the actuation device 108 may be fixed to or otherwise coupled to the embroidery machine, but it is also contemplated that the actuation device 108 may simply be placed adjacent to the embroidery machine in an appropriate location for communication with the embroidery machine.
The support device 104 may be cylindrical in shape, which is particularly advantageous when the textile component 202 is tubular in shape. For example, the textile component 202 may be a circular-knit tubular configuration for use in a variety of applications (e.g., a sock, a glove, a portion of an article of footwear, a portion of an article of apparel, an industrial tubular component, a stent, etc.). Other types of textiles are also contemplated, including non-tubular textiles (e.g., flat-knit textiles, flat-woven articles, etc.). Thus, it is contemplated that the support device 104 may be flat or have another suitable shape that corresponds to textiles having a variety of shapes, curvatures, sizes, etc. For simplicity, the support device 104 will be described as being generally cylindrical in the remainder of this description.
The outer surface 122 of the support device may be configured (e.g., sized, shaped, and positioned) to receive the textile component 202, and also to contact and support an inner surface of the tubular textile component 202 upon receipt. For example, the outer surface 122 of the support device 104 may have a diameter that is about the same size as, or slightly larger than, the inner diameter of the textile component 202 when the textile component 202 is in a relaxed state. In other embodiments, the diameter of the outer surface 122 may be substantially larger than (e.g., at least 10% larger than) the inner diameter of the relaxed textile component 202 such that the textile component 202 is slightly or substantially stretched when deployed on the support device 104. This may be advantageous when a stretched orientation is desirable during embroidery.
An opening or window 126 may be present and extend through at least a portion of the outer surface 122 to provide access to a space or cavity 128, and the cavity 128 may be defined by an inner surface 130 of the support device 104. The window 126 and cavity 128 are advantageous for providing room for the embroidery needle 110 (
The actuation device 108 may include at least one actuation surface 132 (where “132” collectively represents the actuation surfaces 132a, 132b, and 132c). The actuation surfaces 132 may at least partially surround the support device 104. In the depicted embodiment, three actuation surfaces 132 are included: a first actuation surface 132a, a second actuation surface 132b, and a third actuation surface 132c. Other embodiments may have fewer (e.g., one or two) or more (e.g., four, five, or more) actuation surfaces 132. The actuation surfaces 132 may be movable with respect to the outer surface 122 of the support device 104. For example, the first actuation surface 132a may be a surface of a first belt 134a, and the first belt 134a may be capable of rotating or otherwise cycling such that the first actuation surface 132a moves with respect to the outer surface 122 of the support device 104. Similarly, the second actuation surface 132b may be a surface on a second belt 134b, and the third actuation surface 132c may be a surface on a third belt 134c. More or fewer than three belts 132 may be included (where “132” collectively represents the belts 132a, 132b, and 132c).
The actuation surfaces 132a of the first belt 134a may be located on a first face 136 of the first belt 134a, and a second face 138 of the first belt 134a (opposite the first face 136) may be mechanically coupled to at least one shaft 140 (where “140” represents the shafts 140a, 140b, 140c, and 140d). Four shafts may be included: a first shaft 140a, a second shaft 140b, a third shaft 140c, and/or a fourth shaft 140d. At least one of the shafts 140 may include idler-wheels 142 for transmitting the rotation of the shafts 140 into rotation or other cycling motion of the belts 134. To enhance these transmissions, the second face 138 of the first belt 134a may include grooves 146 that communicate with a set of projections 144 extending from the idler-wheels 142. In other words, to avoid slippage, the projections 144 of the idler-wheels 142 may be received by the grooves 146 on the second face 138 of the first belt 134a. As a result, as the first shaft 140a rotates, the first belt 134a will cycle. The second belt 134b and the third belt 134c may also, or alternatively, include grooves and thus also cycle when the shafts 140 rotate.
In the depicted embodiment, the four shafts 140 include two top shafts (e.g., the first shaft 140a and the second shaft 140b) and two bottom shafts (the third shaft 140c and the fourth shaft 140d). More particularly, the first shaft 140a and the second shaft 140b are located on in a first plane (e.g., a plane that is horizontal) and the third shaft 140c and the fourth shaft 140d are located in a lower second plane. The first shaft 140a and the third shaft 140c are located on a right side 148 of the actuation device 108 (from the perspective of
The shafts 140 may be driven (i.e., forced into rotation) through any suitable device or method. For example, at least one of the shafts 140 may be coupled to a motor. If only one motor is included, the motor may be coupled to only one of the shafts 140 or to multiple shafts 140 (e.g., through a chain or belt drive). In other embodiments, more than one motor may be included (e.g., certain shafts 140 may be associated with separate motors). Herein, a shaft 140 that is mechanically coupled to a motor (or other rotation-effecting actuator) through something other than the belts 134 themselves is referred to as a “driven shaft.” For example, in some non-limiting exemplary embodiments, at least one of the bottom shafts 140c, 140d may be a driven shaft, but the top shafts 140a, 140b may not be. As a result, rotation of the first shaft 140a and the second shaft 140b may be determined solely by motion of the belts 134. This embodiment may be advantageous for allowing the first shaft 140a and the second shaft 140b to be horizontally/vertically movable, as described in more detail below.
One embodiment for providing control of the shaft position is shown in
In the depicted embodiment, the linkage 160 is coupled to the first shaft 140a and the third shaft 140c. In other embodiments, the lower shafts (i.e., the third shaft 140c and fourth shaft 140d) may not be directly secured to the linkages 160, and therefore they may not move when the linkages 160 move. This may be advantageous when the lower shafts 140c, and 140d are drive shafts that are coupled to a motor or other actuator, since a common location among different states (e.g. open and closed states) prevents the need to also move the associated motor or other actuator with the drive shafts.
The degree of extension of the actuation arm 164 may also be variable, which may allow for one or more intermediate states between the open state and the closed state. As a result, the actuation device 108 may be capable of adapting to two or more different support devices 104 having different dimensions, and/or different belts 134. Optionally, more than one linear actuator 158 may be included. For example, a second linear actuator 159 may be included to assist with shaft positioning. While not visible in
Referring to
The ability to rotate of the textile component 202 may provide an embroidery needle with access to areas of the textile component 202 that would not otherwise be reachable if the textile component 202 was stationary. To illustrate, in current systems, embroidery needles can typically only move vertically and axially, and they cannot rotate around a tubular textile component to gain access to locations 360 degrees around the entirety of the textile surface. The present embodiments overcome this shortcoming by providing an apparatus and method that is capable of moving/rotating the textile with respect to the embroidery needle, and therefore providing 360 degree access to surfaces of the textile. Notably, this 360 degree access is provided without necessitating human intervention during the embroidery process and without additional machine-setup steps (and therefore without substantially compromising manufacturing efficiency).
Another advantage of the assembly 102 is the capability of multi-directional rotation. Referring to
The rotation direction may be switched during the embroidery process, which allows the formation of zig-zag patterns and other patterns where the embroidered strand 204 varies in its stitch direction. This may provide the capability of creating complex embroidery patterns through controlling rotation of the textile component 202 while simultaneously controlling the operation of the embroidery needle. The assembly 102 may be automatically controlled (e.g., through a programmed control system) and/or manually controlled (through an interface providing control capabilities to a human operator). If automatically controlled, the same control system may operate both the embroidery needle and the assembly 102, or separate control systems may be used.
Referring to
The present embodiments also provide the assembly 100 with the ability to efficiently switch between different support devices 104. For example, different support devices 104 may have different dimensions (e.g., diameter, length, etc.) for receiving different sized textile components. Since the support devices 104 may have an identical or similar connection adapter 123, a certain support device 104 may be quickly and efficiently selected and placed into communication with the remainder of the assembly 102 without substantially adjusting anything else.
The embodiment of
In the present disclosure, the ranges given either in absolute terms or in approximate terms are intended to encompass both, and any definitions used herein are intended to be clarifying and not limiting. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the present embodiments are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Moreover, all ranges disclosed herein are to be understood to encompass any and all subranges (including all fractional and whole values) subsumed therein.
Furthermore, the present disclosure encompasses any and all possible combinations of some or all of the various aspects described herein. It should also be understood that various changes and modifications to the aspects described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present disclosure and without diminishing its intended advantages. It is therefore intended that such changes and modifications be covered by the appended claims.
This application claims the benefit of U.S. Provisional Application No. 62/657,179, filed Apr. 13, 2018, which is hereby incorporated by reference in its entirety.
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