1. Field of the Invention
The present invention relates to an automated sewing device for automatically sewing the curved ends of materials together. In particular, the invention is directed to an automated sewing device capable of sewing together the curved ends of thin contractible materials which naturally tend to curl.
2. Description of Prior Art
Basically, a trim cover assembly for a vehicle or automotive seat is formed by sewing together a peripheral cover material with a central cover material, wherein the central cover material is adapted to cover a central seating region of the seat on which a seat occupant's buttocks portion rests and the peripheral cover material is adapted to cover a peripheral vertical wall of the seat surrounding that central seating region of seat. In most cases, the central seating region of seat is of a generally ellipse or circular shape, and therefore, in conformity therewith, the corresponding central cover material is also of a generally ellipse or circular shape and thus has curved end portion. Accordingly, in the process of forming the trim cover assembly, end portion of the peripheral cover material should be aligned and sewn with such curved portion of central cover material, which requires a sewing machine designed to sew those two materials together curvilinearly along their respective curved end portions.
Some automated sewing devices enabling such curvilinear sewing are known. For example, the U.S. Pat. No. 5,544,602 discloses an automated sewing device comprising a movable guide plate having some guide rollers provided on the reverse side thereof and some guide grooves formed in a table on which a sewing machine is mounted. In this prior art, the guide rollers are movably fitted in the guide grooves so that the movable guide plate can be moved along a predetermined path, thereby causing a curved end portion of central cover material placed on the guide plate to be automatically sewn by the sewing machine with and along a curved end portion of peripheral cover material being fed toward the sewing machine.
However, such prior-art automated sewing device has been found defective in that it is troublesome for a worker to securely set the central cover material in position on the guide plate, and further, it is quite annoying labor for the worker to replace the guide rollers and guide grooves by different shapes of guide rollers and grooves according to a size and contour of each different central cover material as well as to a curvature of the curved end portion of the central cover material.
In particular, some of trim cover assemblies for automotive seats use one unitary sheet of thin contractible elastic material in the central cover section thereof. A typical material used in such central cover section is a Tricot knit fabric material or the like. This sort of thin contractible material, when it is cut and trimmed into a predetermined shape of central cover material corresponding to the central cover section of trim cover assembly, naturally tends to curl at the localized end portions thereof into a generally “U” shaped cross-section, as shown in
In view of the above-stated drawbacks, it is a primary purpose of the present invention to provide an improved automated sewing device which allows two materials to be easily sewn together without requiring any movable guide members and other support elements.
In order to achieve such purpose, in accordance with the present invention, there is basically provided an automated sewing device for automatically sewing together a first material and a second material, comprising:
Preferably, the blower tube means may comprise at least one blower tube formed from a bendable or flexible metallic tube which can be bent in any desired direction.
It is another purpose of the present invention to allow a thin contractible material to be smoothly fed to the sewing machine, while preventing an end of such material from curling.
For that purpose, in the above-described automated sewing device, a stretching means is provided, which works to stretch either end of the first material and end of the second material outwardly, the stretching means comprising at least one blower tube means so arranged as to allow air to be blown therefrom in a direction transversely of a direction in which the first and second materials are to be fed to the sewing machine.
The afore-stated blower tube means and stretching means are effective in causing the first and second materials to smoothly fed to a conventional end alignment control means provided on both of the table and guide means in this sort of automated sewing device, wherein the end alignment control means is operable to automatically keep both end portions of the first and second materials in alignment with each other before they are sewn by the sewing machine
Other various features and advantages will become apparent from reading of the description hereinafter, with reference to the annexed drawings.
Referring to
At first, reference is made to
As shown in
In accordance with the automated sewing device (S), a first sloped guide member (44) is fixedly mounted on the table (T) in the proximity of the sewing machine (M), and a second sloped guide member (45) is fixedly mounted on the table (T) so as to be spaced apart from the first sloped guide member (44), as illustrated in FIG. 1. Thus, a certain transversely extending space is defined between the first and second sloped guide member (44) (45).
As best seen in
On the other hand, the second sloped guide member (45) is formed to have: a sloped flat portion (45D); an upwardly extending portion (45A) defined in one lateral side of the sloped flat portion (45D) a securing portion (45B) defined in another lateral side of the sloped flat portion (45D); and a vertical transit region (45C) between the flat portion (45D) and securing portion (45B). As seen from
As can be seen from
Designations (40) and (50) denote an upper guide roller and a lower guide roller, respectively. As in
The sensor system (41, 42, 42A), guide roller system (40, 50) and control unit (43) are provided as a known end alignment control means for automatically causing both two curved end portions (A1) (B1) respectively of those two cover materials (A) (B) to be aligned with each other constantly toward the sewing machine (M), as disclosed in the Japanese Laid-Open Patent Publication No. 2001-359540. In brief, such end alignment control system works to automatically move the central and peripheral cover materials (A) (B) responsive to the corresponding sensors (41, 42) detecting any slight dislocation therefrom in order that both two curved end portions (A1) (B1) respectively of those two cover materials (A) (B) are kept in alignment with each other and fed to the sewing machine (M) and sewn together, with a constant margin given from a seam along the curved end portions (A1) (B1). For further information and details thereof, reference should be made to the Japanese Publication No. 2001-359540.
In accordance with the present invention, a feeding roller (2) is provided, which has a length greater than a width-wise length of a sewn portion of the two end portions (A1) (B1) which has undergone sewing operation by the sewing machine (M), including a margin from a seam created along the two end portions (A1) (B1). Thus, as will be explained, such sewn portion of the two end portion (A1) (B1) is entirely pressed by the feeding roller (2) against the table (T), thereby positively preventing the sewn portion from curling. As best shown in
With the soft contractible property of central cover material (A) in view, the present invention contemplates a stretching means for stretching the central cover material end portion (A1) outwardly so as to prevent the same from natural curling. Also, the invention contemplates an auxiliary feeding means for assisting in the feeding of the central cover material (A) in a predetermined direction in conjunction with the lower guide roller (50), thereby making it smooth and easy to feed the central cover material (A) toward the sewing machine (M) without any slack and twisting occurred therein.
Thus, as the foregoing stretching means for stretching the central cover material curved end portion (A1), there may be provided a transverse blower tube (10) adapted to allow air to be blown in a direction transversely of a path through which the curved end portion (A1) is to be fed toward the sewing machine (M). Specifically, as illustrated, the transverse blower tube (10) has a vent (10A) defined in the free end portion thereof and extends on and along the table (T). Such free end portion of transverse blower tube (10) is shown to extend in and along the space between the first and second guide members (44) (45), wherein that particular space extends in a direction transversely of the two passage spaces (44H) (45H) respective of the first and second guide members (44) (45H). In other words, the transverse blower tube (10) extends transversely of a path along which the end portion (A1) of central cover material (A) is to be fed to the sewing machine (A). But, as best seen in
On the other hand, the auxiliary feeding means for assisting in the feeding of the central cover material (A) in a predetermined direction in conjunction with the lower guide roller (50) may be embodied by a blower tube arrangement which, by way of example, comprises: a first blower tube (11) disposed so as to allow air to be blown to the central cover material (A) in a forward blowing direction to the sewing machine (M), thereby causing the cover material (A) to smoothly move toward the sewing machine (M) without slack and twisted regions created therein; and a pair of second and third blower tubes (12) (13) are disposed so as to allow air to be supplied therethrough and impinged on the central cover material (A) in a backward blowing direction opposite to the afore-stated forward blowing direction of first blower tube (11).
Specifically, in the illustrated embodiment, the first blower tube (11) has a vent (11A) defined in the free end portion thereof and extends along the reverse surface (45E) of sloped flat portion (45D) of second guide member (45) in a direction to the second guide member (44) and sewing machine (M), as shown in
The second blower tube (12) extends alongside of the vertically extending portion (45A) of second guide member (45) toward a side where the first guide member (44) and sewing machine (M) are located. But, as shown, the free end portion of that second blower tube (12) is curved backwardly at a point in front of the space between the first and second guide members (45) (44), while extending downwardly to the table (T), in a direction opposite to the afore-stated side where the first guide member (44) and sewing machine (M) are located.
The third blower tube (13) extends from the sewing machine (M) and the free end portion of the third blower tube extends downwardly to the table (T) while being curved in a direction to the second blower tube (12) (i.e. in a direction opposite to the side where the first guide member (44) and sewing machine (M) are located).
With such arrangement of three blower tubes (11) (12) (13), it is seen that a forward air pressure is applied from the first blower tube (11) to one side of the central cover material (A) in a forward direction to the sewing machine (M), while a backward air pressure is applied from the second and third blower tubes (12) (13) to another opposite side of the central cover material (A) in a backward direction opposite to that forward direction, thereby causing the central cover material (A) to automatically rotate anticlockwise on the table (T) as indicated by the arrow in
It is noted that all the three blower tubes (11) (12) (13) are formed from a bendable metallic material and may be bent and/or curved and retained in any desired direction and by any desired angle, depending on the size of the central cover material (A) and the curvature of the curved end portion (A1). The transverse blower tube (10) may also be formed from such bendable metallic material. While not shown, those three blower tubes (11) (12) (13) are connected with a conventional air supply device having a computerized control system programmed to control a timing of supplying air into each of those three blower tubes (11, 12 and 13) and also adjustingly control a degree of air pressure for each of the blower tubes.
As suggested in
Additionally, as suggested in
Of course, the transverse blower tube (10) may be provided above and spaced apart from the table (T) so that the end portion (A1) of central cover material (A) may be fed therebetween. In that case, air is blown from the vent (10A) of the tube (10) to apply an appropriate degree of air pressure to the upper surface of the central cover material end portion (A1). Thus, that end portion (A1) is effectively prevented against curling. The same goes for another transverse blower tube (100).
Now, a description will be made of operation of the above-described automated sewing device (S).
As can be seen from
Upon turning on of a switch (not shown), the sewing machine (M) starts to sew together the two juxtaposed curved end portions (A1) (B1) of central and peripheral cover materials (A) (B) with a fixed margin to seam. During the sewing operation, as understandable from
Accordingly, in accordance with the present invention, there is no need to provide any guide plate on the table (T), which movably supports the central cover material (B), as with the prior art. Further, the central cover material (A) is automatically stretched flat upon the table (T) on the table (T) and positively fed towards the sewing machine (M) by air pressure being applied from the transverse blower tube (10) and three blower tubes (11, 12 and 13), without any curling, slack and twisted portions created in either of the two cover materials (A) (B). Of course, the peripheral cover material (B) may also be automatically stretched flat on the second sloped guide member (45) and positively fed towards the sewing machine (M) by air pressure applied from additional transverse blower tube (100) and additional two blower tubes (111 and 112). Thus, there is eliminated troublesome labor and skill on the part of workers to change such guide plate and manually stretch the contractible cover material as found in the prior art.
It should be understood that the present invention is not limited to the illustrated embodiments, but any modification, replacement and addition may be applied thereto without departing from the scopes of the appended claims. For example, the three blower tubes (11, 12 and 13) are not limitative, but instead thereof, only one blower tube will suffice for the purpose of the present invention, in which case, one blower tube may be provided, likewise as in one of the second and third blower tubes (12) (13), with the vent thereof being oriented in a proper direction opposite to a side where the sewing machine (M) is located.
Number | Name | Date | Kind |
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4590876 | Mencke et al. | May 1986 | A |
5544602 | Kawasaki | Aug 1996 | A |
5850792 | Adamski et al. | Dec 1998 | A |
Number | Date | Country | |
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20040226496 A1 | Nov 2004 | US |