This application claims priority to Japanese Patent Application No. 2008-013443, filed Jan. 24, 2008, the disclosure of which is hereby incorporated herein by reference in its entirety.
The present disclosure relates to a sewing machine and a computer-readable medium storing a program that controls the sewing machine. More particularly, the present disclosure relates to a sewing machine that can easily determine a sewing position and a sewing angle of an embroidery pattern to sew the pattern, and a computer-readable medium storing a program that controls the sewing machine.
Conventionally, when sewing an embroidery pattern selected by a user to a predetermined position on a work cloth with a sewing machine capable of embroidery sewing, the user may have to operate an eight-directional key to thereby move an embroidery frame holding the work cloth to adjust a needle drop point coincides with the predetermined position. Also, when the user desires to change a sewing angle at which the embroidery pattern is to be sewn on the work cloth, the user may have to operate a rotation key to thereby rotate a preset angle for the embroidery pattern.
In contrast, a sewing machine disclosed in U.S. Pat. No. 5,911,182, for example, reads a sewing designation mark drawn beforehand on a work cloth that is attached to an embroidery frame, obtains at least one of a position and a direction for sewing an embroidery pattern on the work cloth on the basis of image data of the sewing designation mark, and edit embroidery data of the embroidery pattern in accordance with at least one of the obtained position and direction. In the case of position adjustment to the sewing designation mark, the center point of an outline of the embroidery pattern is used. In the case of direction adjustment to the sewing specification mark, a direction of the embroidery pattern is used. After the pattern data is edited, the sewing machine sews embroidery based on the post-edit pattern data.
Various exemplary embodiments of the general principles described herein provide a sewing machine that can appropriately and easily determine a sewing position and a sewing angle of an embroidery pattern on a work cloth and sew the embroidery pattern, and a computer-readable medium storing a program that controls the sewing machine.
Exemplary embodiments provide a sewing machine that is capable of sewing an embroidery pattern on a work cloth held by an embroidery frame. The sewing machine includes a storage device that stores embroidery data to identify a shape of the embroidery pattern and reference line data to identify a pattern position and a pattern angle. The pattern position is a position on the work cloth at which the embroidery pattern is to be sewn, and the pattern angle is an angle with respect to a predetermined direction on the work cloth at which the embroidery pattern is to be sewn. The sewing machine also includes an imaging device that captures an image of the work cloth onto which a marker that can be affixed onto the work cloth is affixed, and a detection device that detects a marker position and a marker angle based on information of the image captured by the imaging device. The marker position is a position at which the marker is affixed onto the work cloth, and the marker angle is an angle with respect to the predetermined direction on the work cloth at which the marker is affixed. The sewing machine further includes a conversion device that converts the embroidery data based on the pattern position and the pattern angle contained in the reference line data, and the marker position and the marker angle detected by the detection device. The sewing machine still further includes a sewing control device that controls sewing of the embroidery pattern based on the embroidery data obtained after conversion by the conversion device.
Exemplary embodiments also provide a computer-readable medium storing a program to control a sewing machine that is capable of sewing an embroidery pattern on a work cloth held by an embroidery frame. The program causes a controller of the sewing machine to execute the following instructions. Acquiring information of an image, captured by an imaging device, of the work cloth onto which a marker that can be affixed onto the work cloth is affixed, detecting a marker position and a marker angle based on the information of the captured image, converting predefined embroidery data to identify a predefined shape of the embroidery pattern based on a pattern position and a pattern angle contained in predefined reference line data to identify the pattern position and the pattern angle, and controlling sewing of the embroidery pattern based on the embroidery data obtained after conversion. The marker position is a position at which the marker is affixed onto the work cloth, and the marker angle is an angle with respect to a predetermined direction on the work cloth at which the marker is affixed. The pattern position is a position on the work cloth at which the embroidery pattern is to be sewn, and the pattern angle is an angle with respect to the predetermined direction on the work cloth at which the embroidery pattern is to be sewn.
Exemplary embodiments will be described below in detail with reference to the accompanying drawing in which:
The following will describe embodiments with reference to the drawings. First, the configuration of a sewing machine 1 will be described below with reference to
As shown in
Above the sewing machine bed 11, an embroidery frame 34 to hold a work cloth 100 is disposed. A region inside the embroidery frame 34 makes an embroidery region in which stitches of an embroidery pattern can be formed. An embroidery frame transfer unit 92 that transfers the embroidery frame 34 can be attached to and detached from the sewing machine bed 11. Over the embroidery frame transfer unit 92, a carriage cover 35 extends in the front-and-rear direction. The carriage cover 35 contains a Y-axis transfer mechanism (not shown) that transfers a carriage (not shown) in the Y-direction (front-and-rear direction). The embroidery frame 34 can be attached to and detached from the carriage. To the right of the carriage, a frame attachment portion (not shown) is provided, to which the embroidery frame 34 may be attached. The frame attachment portion protrudes more rightward than the right side surface of the carriage cover 35. An attachment portion 93 (see
The pillar 12 has a vertically long rectangular liquid crystal display (hereinafter referred to as LCD) 15 on its front surface. The LCD 15 may display names and illustrations of commands to execute various kinds of commands required to set or edit a variety of patterns and control sewing operations. The LCD 15 also displays various set values and messages relating to sewing.
The LCD 15 is equipped with a touch panel 26 corresponding to various display positions where names of a plurality of patterns, function names for executing various functions, set numerical values on various setting screens, etc. are displayed. By pressing a position on the touch panel 26 that corresponds to a pattern display portion or a setting portion on the screen displayed on the LCD 15 with a finger or a dedicated touch pen, the user can select a pattern to be sewn, instruct a function, set a numerical value, etc. An operation of pressing the touch panel 26 is hereinafter referred to as a “panel operation”.
Next, a configuration of the arm 13 will be described below. The arm 13 is provided with a cover 16 to be opened and closed over an upper portion of the arm 13. The cover 16 is provided along the longitudinal direction of the arm 13 and axially supported on the upper rear part of the arm 13 so that the cover 16 can be opened and closed around the right-and-left directional axis. Under the cover 16, a concaved spool housing 18 is formed in the vicinity of the midsection of the upper portion of the arm 13. The spool housing 18 houses a thread spool 20 from which a needle thread is supplied to the sewing machine 1. From the inner wall surface of the thread spool housing 18 on the pillar 12 side, a spool pin 19 protrudes toward the head 14. The thread spool 20 may be attached to the spool pin 19 when the spool pin 19 is inserted through an insertion hole (not shown) formed in the thread spool 20. A needle thread (not shown) extending from the thread spool 20 may pass through a tensioner and a thread take-up spring, which are disposed on the head 14 to adjust thread tension, and thread hooking portions, such as a thread take-up lever etc. for taking up the needle thread by reciprocating in the up-and-down direction. Then, the needle thread may be supplied to a sewing needle 7 (see
At the lower portion of the front surface of the arm 13, a sewing start-and-stop switch 21, a reverse stitch switch 22, a needle up-and-down switch 23, a presser foot elevation switch 24, an automatic threading switch 25, are provided. The sewing start-and-stop switch 21 starts and stops operations of the sewing machine 1, that is, may be used to instruct starting and stopping of sewing. The reverse stitch switch 22 may be used to input an instruction of feeding the work cloth from the rear side to the front side, which is opposite to the normal feed direction. The needle up-and-down switch 23 may be used to input an instruction of switching the position of the needle bar 6 (see
Next, the needle bar 6, the sewing needle 7, a presser bar 45, a presser foot 47, and a neighboring area will be described below with reference to
Next, the electrical configuration of the sewing machine 1 will be described below with reference to
The CPU 61 conducts main control over the sewing machine 1 and executes various kinds of computation and processing in accordance with a control program stored in a program data storage area 201 of the ROM 62, which is a read-only memory. The RAM 63, which is a random access memory, has a variety of storage areas as required for storing the results of computation and processing carried out by the CPU 61. The sewing start-and-stop switch 21 is a button-type switch. The lower-needle-position sensor 89 detects a rotation phase of the drive shaft. The lower-needle-position sensor 89 is set up to output an ON signal, if, as the drive shaft rotates, the needle bar 6 lowers from the upper needle position to permit the tip of the sewing needle 7 to reach a position lower than the upper surface of the needle plate (not shown).
Next, the storage areas arranged in the ROM 62 will be described below with reference to
The program data storage area 201 stores program data required by the CPU 61 to execute processing of recognizing a marker 120 (see
Next, the storage areas arranged in the RAM 63 will be described below with reference to
The selected pattern storage area 211 stores the pattern data of the embroidery pattern 140 selected by the user through panel operations. The pattern data may be read from among the pattern data pieces stored in the pattern data storage area 202 (see
Next, an example of the marker 120 to be affixed onto the work cloth 100 (see
Among four portions enclosed and divided by a circumference of the first circle 101, the line segment 103, and the line segment 104, the upper right portion 108 and the lower left portion 109 are filled with black, while the lower right portion 113 and the upper left portion 114 are filled with white. Among four portions enclosed and divided by a circumference of the second circle 102, the line segment 103, and the line segment 105, the upper right portion 106 and the lower left portion 107 are filled with black, while the lower right portion 115 and the upper left portion 116 are filled with white. The remaining portions of the base material sheet 94 other than the above are transparent. The colors with which to fill the divided portions are not limited to black and white, but may be a combination of any other colors as far as the contrast is clear. Further, for example, if the work cloth 100 is a fabric colored white or nearly white, a marker having divided portions only filled with black may be employed. Conversely, if the work cloth 100 is a fabric colored black or nearly black, a marker having divided portions only filled with white may be employed. In such a manner, a marker with an appropriate color(s) may be employed, corresponding to the color of the work cloth 100.
Over the back surface of the base material sheet 94, a transparent adhesive is applied. Therefore, the base material sheet 94 can be affixed onto the work cloth 100. The base material sheet 94 may usually be attached to release paper (not shown). The user may peel off the base material sheet 94 from the release paper for use.
In the present embodiment, before sewing the embroidery pattern 140 (see
Next, an example of the pattern data 146 of the embroidery pattern 140 stored in the pattern data storage area 202 (see
As shown in
In the present embodiment, the reference line data identifies the shapes of a first reference circle 141, a second reference circle 142, and reference line segments 143, 144, and 145. The embroidery data and the reference line data each contains coordinate information as position information in a three-dimensional space. Based on the coordinate information, the positions of the graphics (the embroidery pattern 140, the first reference circle 141, the second reference circle 142, and the reference line segments 143 to 145) identified by the embroidery data and the reference line data and the positional relationships among these graphics are defined in the three-dimensional space.
In the example shown in
The position of the center 150 of the first reference circle 141 is hereinafter referred to as a “reference pattern position”. The inclination of the straight line that extends from the center 150 of the first reference circle 141 to the center 151 of the second reference circle 142 is hereinafter referred to as a “reference pattern angle”. In the present embodiment, the embroidery pattern 140 may be sewn at such a position that the reference pattern position coincides with the reference marker position of the marker 120 (see
In the example of
A condition in which the marker 120 is affixed to the work cloth 100 will be described below with reference to
As described earlier, the adhesive is applied over the back surface of the base material sheet 94 of the marker 120. Therefore, if the position to which or the angle at which the marker 120 has been affixed on the work cloth 100 is different from a desired position or angle of the user, the user can peel off the marker 120 from the work cloth 100 and affix the marker 120 onto the work cloth 100 again. By thus using the marker 120 that can be affixed onto the work cloth 100, the user can adjust the position and the angle as many times as desired.
Next, a condition in which the embroidery pattern 140 has been sewn on the work cloth 100 will be described below with reference to
In such a manner, the user may affix the marker 120 onto the work cloth 100 at a desired sewing location of the embroidery pattern 140. Then, the sewing machine 1 may detect a position to which and an angle at which the marker 120 has been affixed, and identify a sewing position and a sewing angle, thereby appropriately executing sewing of the embroidery pattern 140. Thus, the need of setting a position and an angle for embroidery sewing, which is conventionally performed by the user through key operations, may be eliminated, thus facilitating sewing an embroidery pattern to a desired position and at a desired angle.
Next, processing in which the sewing machine 1 detects the marker 120 affixed on the work cloth 100 and determines a sewing position and a sewing angle of the embroidery pattern 140 will be described below with reference to
A main flowchart of sewing position determination processing will be described below with reference to
Subsequently, the embroidery frame 34 (see
A frame determination mechanism 30 provided to the carriage (not shown) will be described below with reference to
After the frame information corresponding to the identified type of the embroidery frame 34 is stored in the frame information storage area 203, the user may affix the marker 120 on the work cloth 100 held by the embroidery frame 34 at a location where the embroidery pattern 140 is to be sewn.
Subsequently, a scan operation start button is displayed on the LCD 15. The CPU 61 waits until the user selects the displayed scan operation start button through panel operations to instruct the start of processing to recognize the marker 120 affixed onto the work cloth 100 (NO at S15). If it is detected on the touch panel 26 that the user has selected the scan operation start button (YES at S15), the CPU 61 proceeds to marked region specification processing, in which the marked region is specified (S17).
Next, the marked region specification processing will be described below with reference to
As shown in
An example of the screen displayed on the LCD 15 at step S41 of the marked region specification processing shown in
It should be noted that the two-dot-and-dash lines 182 and 183 may be set in such a manner that the area of each of the divided regions formed by dividing the work cloth 100 with the two-dot-and-dash lines may be smaller than an imaging area that can be captured by the image sensor 50 at a time. Accordingly, by selectively extracting a part of the imaging information obtained by image capturing by the image sensor 50, the quantity of information for recognizing the marker 120 in the image processing can be reduced. Thus, time to recognize the marker 120 can be shortened. It should be noted that the arrangement of the two-dot-and-dash lines that divide the image 180 of the work cloth 100 displayed on the LCD 15 at step S41 of
The user may perform panel operations to select the marked region from among the four regions obtained by dividing the image 180 of the work cloth 100 by the two-dot-and-dash lines 182 and 183. The select input by the user is detected by the touch panel 26 (S43), and a scan start button is displayed on the LCD 15. The CPU 61 waits until the scan start button is selected by the user's panel operations to instruct start of scanning (NO at S45). If the selection of the scan start button is detected by the touch panel 26 (YES at S45), the information of the region of the work cloth 100 selected by the user at step S43 (hereinafter referred to as “marked region information”) is stored in the marked region storage area 213 (see
In such a manner, the information about which one of the regions on the work cloth 100 the marker 120 is affixed to is acquired from the user. Accordingly, it is possible to perform the recognition processing on the marker 120, preferentially using the image information of a specific region of the entire image information obtained by image capturing by the image sensor 50. Since a lot of computation and processing is usually required to recognize the marker 120, a certain level of time is required. In contrast, the time required to recognize the marker 120 can be shortened by thus limiting the image information. As described in detail later, there may be some cases where the marker 120 cannot be recognized because the user has selected a wrong marked region for the marker 120. In such a case, the CPU 61 may recognize the marker 120 by referring to the other remaining image information (see S68 of
Next, the scan processing (see S19 of
Subsequently, the image information that corresponds to the region identified by the marked region information read at step S61, that is, the marked region, is extracted from the entire image information obtained as a result of image capturing by the image sensor 50 at step S65, and stored into the image information storage area 215 of the RAM 63. Then, processing to recognize the marker 120 affixed to the work cloth 100 is executed, and determination is made as to whether the marker 120 affixed to the marked region has been successfully recognized (S67).
The outline of a method of recognizing the marker 120 based on the image information will be described below with reference to
Further, as shown in
The center coordinates (a, b) and radius r obtained through Hough transform and the corner coordinates (A, B) obtained through Harris Operator are compared with each other. If there are any coordinates (A, B) that coincide with any coordinates (a, b) and there are any other coordinates (A, B) that coincide with coordinates of a position at a distance of the radius r from a center coordinates (a, b), it is determined that these coordinates are respectively the coordinates of the center of the circle and the coordinates of an intersection between the circumference and the line segment on the marker 120 shown in
Subsequently, the coordinates (P, Q) and (p, q) of the extracted two points are converted into coordinates in the three-dimensional real space. The coordinates obtained as a result of the conversion are defined as center coordinates (P′, Q′, S) of the first circle 101 and center coordinates (p′, q′, s) of the second circle 102, respectively. Thus, the positions of the center of the first circle 101 and the second circle 102 can be recognized in the real space. The center coordinates (P′, Q′, S) of the first circle 101 correspond to the reference marker position and the inclination of a straight line that extends from (P′, Q′, S) to the center coordinates (p′, q′, s) of the second circle 102 corresponds to the reference marker angle.
By thus executing the image processing, the center coordinates of the first circle 101 and the center coordinates of the second circle 102 on the marker 120 affixed to the work cloth 100 are recognized, and the reference marker position and the reference marker angle (marked position and marked angle respectively) are calculated. As described in detail later, the reference marker position is taken as a reference for the sewing position of the embroidery pattern 140 and the reference marker angle is taken as a reference for the sewing angle of the embroidery pattern 140.
When the marker 120 is not recognized as a result of the image processing at step S67 in
If the marker 120 is recognized at step S67 (YES at S67) or at step S68 (YES at S68), the center coordinates (P′, Q′, S) of the first circle 101 and the center coordinates (p′, q′, s) of the second circle 102 obtained through the processing to recognize the marker 120 are stored in the marker position information storage area 214 of the RAM 63. The CPU 61 ends the scan processing and returns to the main processing (see
When the marker 120 is not recognized based on the image information stored in the image information storage area 215 of the RAM 63 (NO at S68), it is determined that the marker 120 has not been affixed in the region of which the image was captured at step S65. Therefore, the image sensor 50 captures an image of any other remaining region of the work cloth 100 of which the image was not captured at step S65, and the recognition processing on the marker 120 is performed. If there remains any region of the work cloth 100 of which the image has not been captured by the image sensor 50 and thus for which the recognition processing on the marker 120 has not been performed (NO at S71), the CPU 61 transfers the embroidery frame 34 to a position at which the image sensor 50 can capture an image of the remaining region of the work cloth 100 (S72). The CPU 61 controls the image sensor 50 to capture the image of the work cloth 100 (S73) and returns to step S68 to repeat recognition processing on the marker 120. If the marker 120 is not recognized even after capturing images of the entire region of the work cloth 100 by the image sensor 50 and performing recognition processing on the marker 120 (YES at S71), the CPU 61 determines that the marker 120 has not been affixed onto the work cloth 100 and ends the scan processing to return to the main processing (see
As shown in the main processing shown in
The embroidery pattern 140 will be sewn on the work cloth 100 in such a manner that the reference marker position of the marker 120 affixed onto the work cloth 100 may coincide with the reference pattern position in the pattern data 146, and the reference marker angle of the marker 120 may coincide with the reference pattern angle in the pattern data 146. Therefore, first a conversion quantity is calculated that is required to convert the reference pattern position and the reference pattern angle predetermined in the pattern data 146 into the reference marker position and the reference marker angle of the marker 120. Then, the position information of the embroidery pattern 140 is converted by using the calculated conversion quantity, thereby defining the sewing position and a sewing angle of the embroidery pattern 140.
At step S21, the CPU 61 calculates the conversion quantity that is required to match the reference pattern position in the pattern data 146 with the reference marker position of the marker 120. The calculated conversion quantity is hereinafter represented by ΔL. Subsequently, the CPU 61 calculates another conversion quantity that is required to match the reference pattern angle in the pattern data 146 with the reference marker angle of the marker 120. The calculated conversion quantity is hereinafter represented by ΔM. Subsequently, coordinate information that identifies the position of the embroidery pattern 140 in the pattern data 146, more specifically, coordinate information of the needle drop points of the embroidery pattern 140 contained in the embroidery data is converted using ΔL and ΔM. The obtained coordinate information is stored in the selected pattern storage area 211 of the RAM 63 (see
On the other hand, if the marker 120 was not recognized in the scan processing (S19) (NO at S20), the CPU 61 controls the LCD 15 (see
If the marker 120 was recognized in the scan processing (S19) (YES at S20), after the coordinate information that identifies the position and the angle of the embroidery pattern 140 is calculated (S21), determination is made as to whether any of the calculated coordinates exist outside the embroidery sewing-enabled region of the embroidery frame 34, that is, the sewing area 184 (see
When any of the coordinates of the embroidery pattern 140 exist outside the sewing area 184, that is, the embroidery pattern 140 goes beyond the sewing area 184 (YES at S23), the specified embroidery pattern 140 cannot be sewn at the position on the work cloth 100 specified by affixing the marker 120. Therefore, the CPU 61 controls the LCD 15 to indicate an error (an off-sewing area error) that the embroidery sewing cannot to be performed because the embroidery pattern 140 does not fit within the sewing area (S25), and prompts the user to peel off and affix the marker 120 again. The CPU 61 replaces the coordinate information that identifies the post-conversion position of the embroidery pattern 140 stored in the selected pattern storage area 211 of the RAM 63 with the pre-conversion coordinate information (S27), thereby clearing the calculated coordinate information. After the user who is notified of the error affixes the marker 120 again to such a position that the embroidery pattern 140 may fit within the sewing area 184, the process returns to step S15 and the recognition processing on the marker 120 is repeated. By thus using the marker 120 that can be affixed onto the work cloth 100, the user can adjust the position and the direction (angle) over again without the need of detaching the work cloth 100 from the embroidery frame 34 and then attaching the work cloth 100 to the embroidery frame 34 again.
On the other hand, when the embroidery pattern 140 fits within the sewing area of the embroidery frame 34 (NO at S23), the embroidery pattern 140 can be sewn at the position where the marker 120 is affixed, so that processing to sew the embroidery pattern 140 is executed (S24), and the main processing is terminated.
As described above, the user may affix the marker 120 onto the work cloth 100 at the desired location of the embroidery pattern 140. The reference marker position and the reference marker angle of the affixed marker 120 may be calculated based on the information obtained by image capturing by the image sensor 50. Based on the reference marker position and the reference marker angle, the sewing position and the sewing angle of the embroidery pattern may be identified. Specifically, the embroidery data that identifies the shape of the embroidery pattern with the coordinates of the needle drop points may be converted in such a manner that the reference marker position and the reference marker angle may respectively coincide with the reference pattern position and the reference pattern angle identified by the reference line data contained in the pattern data. By sewing the embroidery pattern 140 based on the post-conversion embroidery data, the user may not have to set the sewing position and the sewing angle through key operations. In other words, according to the sewing machine 1 of the present embodiment, it is possible for the user to sew an embroidery pattern by easily setting the sewing position and the sewing angle of the embroidery pattern with respect to the work cloth.
Since the marker 120 has a shape that enables identifying the sewing position and the sewing angle of the embroidery pattern 140, it is possible for the to sew the embroidery pattern 140 at a desired position and at a desired angle by adjusting a position to which and an angle at which the marker 120 is affixed.
Further, in the case of capturing an image of the upper surface of the work cloth 100 with the image sensor 50 in order to recognize the marker 120, the marker 120 may not be affixed in an area where the image sensor 50 can capture the image. In such a case, by transferring the embroidery frame 34 that holds the work cloth 100, it is possible to make the marker 120 exist in an area where the image sensor 50 can capture an image. Accordingly, even in a case where the area of the work cloth 100 is larger than the imaging area of the image sensor 50 and thus, an image of the entire area of the work cloth 100 cannot be captured by the image sensor 50 at a time, it is possible to capture an image including a location on the work cloth 100 where the marker 120 is affixed. Since the embroidery frame 34 is automatically transferred, the marker 120 disposed on the work cloth 100 is automatically recognized, and the sewing position and the sewing angle of the embroidery pattern may be specified. Accordingly, it is unnecessary for the user to move the marker 120 manually to a region where the image sensor 50 can capture the image of the marker 120. Moreover, by prompting the user to specify the region on the work cloth 100 where the marker 120 has been affixed by user's operations, it is possible to recognize the marker 120 by performing recognition processing only on the image information of the specified region of the entire image information obtained by image capturing by the image sensor 50. In such a case, time to recognize the marker 120 can be shortened.
It should be noted that the present disclosure is not limited to the described exemplary embodiment and can be modified variously.
The marker 120 of the above-described exemplary embodiment includes the first circle 101 and the second circle 102 as well as the line segments 103, 104, and 105. The shape is, however, not limited to the shape of the marker 120, and any other shape may be possible as far as the reference marker position and the reference marker angle can be identified.
The apparatus and method described above with reference to the various embodiments are merely examples. It goes without saying that they are not confined to the depicted embodiments. While various features have been described in conjunction with the examples outlined above, various alternatives, modifications, variations, and/or improvements of those features and/or examples may be possible. Accordingly, the examples, as set forth above, are intended to be illustrative. Various changes may be made without departing from the broad spirit and scope of the underlying principles.
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