Patent Application
20130276685
This invention is in the field of sewing machine accessories and in particular in the field of take-up rail assemblies for quilting frames.
A quilt is usually sewn from three layers, a pre-sewn and pieced top fabric, a fabric backing bottom layer, and batting in the middle of the two fabric layers. Machine quilting is traditionally accomplished using one of two methods. For the first method, a user uses a sewing machine on a table and pushes the entire quilt around to quilt the three layers, which is cumbersome and difficult to manipulate.
For the second method, a user uses a quilting frame with a sewing or quilting machine mounted on it. For this method, the quilting frame typically consists of a system of four or five separate rails to manage the three layers of fabric. At the front of the frame there are three rails. Each rail has one of the three quilt layers of fabric rolled onto it. The three rails feed the three layers of fabric sandwiched together to the take up rail, located toward the back of the frame. On some frames the fabric layers first pass under an idler rail and then up to the take up rail. The idler rail serves to position the fabric just above the bed or bottom of the throat of the sewing machine so the fabric does not drag on the bed of the machine as the machine is moved around on the quilt to create the quilted patterns on the fabric. When no idler rail is present, the take up rail must be repositioned higher in relation to the bed of the machine to prevent the fabric from dragging on the bed of the machine as the quilted fabric is gradually rolled up on the take up rail, gradually growing in diameter. The present invention requires the use of an idler rail.
The back half of the frame consists of a framework that holds the sewing machine on a wheeled plate (or the sewing machine has wheels mounted directly to it and therefore serves as the top plate itself) that rolls in an X axis which sits on a second wheeled plate that rolls on the framework in a Y axis. The sewing machine or the top plate will have a set of handles that gives the user the ability to move the sewing machine smoothly across the quilt fabric layers to stitch them together. The take up rail passes through the throat of the sewing machine and is used to roll up the fabric layers once they have been quilted together with the sewing machine.
The size of the patterns that a user can sew on the quilt at one time is limited by the length of the throat of the sewing machine and by the diameter of the quilted roll of fabric layers that is located in the throat of the sewing machine. The length of the throat of the sewing machine is equal to the distance from the back of the throat of the machine to the sewing needle. If a sewing machine has a throat size of 18 inches and the take up rail and idler rail diameters are the typical 1.5 inches, then the maximum size pattern that could be quilted would be 16.5 inches assuming the needle could sew right to the edge of the rail. Once the available area of quilt has been sewn, the sewn area of fabric is rolled onto the take up rail. Depending on the thickness of batting and the length of the quilt, the roll of quilted fabric can be as large as 6 inches or even larger. So, as the user finishes the quilt and there is approximately a six inch diameter roll of fabric passing through the machine, the effective quiltable area has become only 12 inches. This must be accounted for as a user plans their quilt from the beginning, so that they do not plan to use 14 inch patterns, which are feasible at the beginning of the quilt, but impossible at the end of the quilt when the maximum size pattern is 12 inches.
The present invention is intended to remedy this problem. With the use of a stationary idler rail and a take up rail that moves longitudinally, i.e. forward and back, as the sewing machine approaches the take up rail at the needle side or back side of the throat of the machine, the user will have the same available quilting area throughout the quilt regardless of the size of the roll of fabric passing through the throat of the machine. Having the take up rail move in relationship to the idler rail gives the user the ability to quilt the maximum area that the throat of the sewing machine will allow from the beginning of the quilt to the end of the quilt. Thus, with the same 18 inch throat sewing machine, the present invention gives the user the ability to sew 16.5 inch patterns all the way through the quilt rather than being limited to 12 inches when the finished roll of quilted material is six inches. With the present invention, the user can quilt the same size patterns with an 18 inch throat machine that would have previously required a 22.5 inch throat sewing machine.
An objective of the present invention is to provide a take-up rail assembly which will increase the usable throat length of a sewing machine, and in particular a quilting machine.
A further objective of the present invention is to provide a take-up rail assembly which will increase the usable throat length of a sewing machine and continue to provide increased throat length as sewed fabric, e.g., quilted material, is rolled onto the take-up rail and the diameter of the roll of sewed fabric increases.
In the case of a typical quilting sewing operation, the fabric layers consist of a quilt front, a quilt back, and backing material. The take-up rail assembly of the present invention includes a fixed idler rail and a longitudinally movable take-up rail. The fixed idler rail, the position of which may be longitudinally and vertically adjustable with respect to the quilting frame, is attached or attachable to a quilting frame. As the sewing machine moves from a machine full forward position to a machine full back position, and the fixed idler rail moves from an idler rail full back position to an idler rail full forward position, with respect to the sewing machine, the take-up rail, which is movably attached or attachable to the quilting frame, moves longitudinally rearward, with respect to the fixed idler rail, from a take-up rail full forward position to a take-up rail full back position. As the sewing machine moves from the machine full back position to the machine full forward position, the fixed idler rail moves, with respect to the sewing machine, from the full forward position to the full back position, and the take-up rail moves longitudinally forward, with respect to the fixed idler rail, from the take-up rail full back position to the take-up rail full forward position. The forward and rearward longitudinal movement of the take-up rail provides for full idler rail travel from the full forward position to the full back position and thus the full utilization of the throat of the sewing machine regardless of the amount of fabric which has been rolled on the take-up rail, until the take-up rail is fully loaded with fabric.
It will be noted that some of the embodiments shown in the drawings and described in this specification provide for the longitudinal movement of the take-up rail by pivoting of the take-up rail about a take-up rail pivot axis. For those embodiments, longitudinal movement of the take-up rail is accomplished by movement of the take-up rail along an arc centered on a take-up rail pivot axis. As a result, the movement of the take-up rail, for those embodiments, has a vertical component as well as the desired longitudinal component. For purposes of this application, the term “longitudinal movement”, when referring to the take-up rail, shall be defined to include movement of the take-up rail, with respect to the fixed idler rail, having a longitudinal component, whether or not the take-up rail movement also has a vertical component due to the pivoting or other movement of the take-up rail resulting from the overall structure of the take-up rail assembly.
For embodiments which provide for longitudinal movement of the take-up rail by providing for pivoting of the take-up rail, the take-up rail assembly may provide for the take-up rail to pivot about a take-up rail pivot axis centered on the axis of the fixed idler rail or displaced from axis of the fixed idler rail. By selecting a pivot radius of a displaced take-up rail pivot axis, pivoting of the take-up rail can be accomplished which will maintain a take-up force on the fabric on the take-up rail while preserving the maximum travel of the fixed idler rail. For the pivoting embodiments, the take-up rail may be pivotally attached to a quilting frame by a pair of take-up rail pivot arms. A pivot control mechanism controls the movement of the take-up rail pivot arm and the take-up rail pivoting.
For pivoting embodiments which have a pivot control mechanism, as well as other embodiments having other types of take-up rail control mechanisms, the movement and positioning of the take-up rail may be controlled based upon the position of the idler rail as it moves between the idler rail full back position and the idler rail full forward position, which may be determined by idler rail position sensors. The take-up rail pivot control mechanism or other take-up rail control mechanism may also control the movement and positioning of the take-up rail based upon contact of the fabric roll with the forward throat edge and the rearward throat edge. A pivot control mechanism or other take-up rail control mechanism may be linked to a computerized sewing machine control system which controls the movement of the sewing machine on a quilting frame or other sewing frame.
Preferred embodiments of the take-up rail assembly of the present invention may incorporate a compound fixed idler rail having a first idler rail shaft and a second idler rail shaft. The fabric is clamped between the first idler rail shaft and the second idler rail shaft, and may be coiled on the compound fixed idler rail so as to maintain a desired tension on the fabric and thereby maintain the desired positioning and tension of the fabric as sewing occurs.
Preferred embodiments of the take-up rail assembly may be attached to a typical stationary quilting frame, which provides for the longitudinal and lateral movement of the sewing machine with respect to the stationary quilting frame. A typical quilting frame may be equipped with a sewing machine carriage movably attached to the frame, to which a sewing machine may be mounted. The controlled movement of the sewing machine carriage on the quilting frame may provide for the movement of the sewing machine as required to sew a desired pattern. However, other preferred embodiments of the take-up rail assembly may be attached to a moving quilting frame which moves with respect to a stationary sewing machine as required for the sewing machine to sew a pattern in the fabric or layers of fabric being sewn.
An alternative embodiment of a take-up rail assembly of the present invention may provide for take-up rail longitudinal movement by a take-up rail axle sliding longitudinally, i.e. forward and rearward, in a slide track which is attached to the quilting frame. Other variations of a take-up rail control mechanism may provide for sliding or otherwise moving the take-up rail longitudinally between the full back position and the full forward position. Such take-up rail control mechanisms may include a piston or screw drive.
A further embodiment of the take-up rail assembly provides for longitudinal movement of the take-up rail with respect to the fixed idler rail by providing for forward and rearward movement of a pair of take-up rail support members to which the take-up rail is attached, one on each end of the take-up rail. The take-up rail support members may have a support member projection which may reduce or eliminate conflict between the idler rail and the take-up rail as the take-up rail moves between the take-up rail full back position and the take-up rail full forward position.
A preferred embodiment of a drive mechanism for this embodiment of the take-up rail assembly may provide for each of the take-up rail support members to be attached to an anchor member having a first roller and a second roller which provide for movement of the anchor member on a roll track and for movement of the take-up rail support member and the take-up rail. A take-up cam may provide for positioning of the anchor member and the support member by cam contact with a cam bar which is connected to the anchor member. Cam contact between the take-up cam and the cam bar may be maintained by a cam retainer device, such as cam spring, a pressurized gas cylinder, or other device known to persons of skill in the art. An alternative preferred embodiment of a drive mechanism for this embodiment of the take-up rail assembly may incorporate a screw drive which is rotated by a drive motor and threaded through a screw sleeve which is connected to the anchor member and the take-up rail support member, thereby providing for the desired movement of the take-up rail.
Other embodiments and variations of a take-up rail control mechanism which provide for moving the take-up rail longitudinally between the full back position and the full forward position may utilize a cam drive, a screw drive, a hydraulic ram, a solenoid, or other drive mechanisms known to persons skilled in the art.
As noted above, embodiments of the take-up rail assembly of the present invention may incorporate an idler rail which is vertically and horizontally adjustable, allowing the vertical and horizontal adjustment of the idler rail to match the sewing machine, or the fabric being sewed, or both. Accordingly, where the term “fixed” idler rail is used in this application, the term is defined to include embodiments wherein the user may vertically or horizontally adjust the position of the idler rail and “fix” the idler rail in the position desired by the user or needed for the sewing machine or fabric, or both, being used.
It must also be noted that, although preferred embodiments of the take-up rail assembly of the present invention are described as attached or attachable to a typical quilting frame, and used for quilting of multiple fabric layers, other embodiments of the take-up rail assembly of the present invention may be attached or attachable to sewing frames used for embroidery or other sewing operations involving a single fabric layer or multiple fabric layers.
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In the case of a typical quilting sewing operation, the fabric layers 9 consist of a quilt front, a quilt back, and backing material. The take-up rail assembly 2 illustrated in
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The embodiment of the take-up rail assembly shown in
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It should be noted that the preferred embodiments of the take-up rail assembly 2 illustrated in the
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Other embodiments and variations of a take-up rail control mechanism which provide for moving the take-up rail longitudinally between the full back position and the full forward position will be known to persons of ordinary skill in the art, in view of the description and drawings presented in this application. Such take-up rail control mechanisms may utilize a cam drive, a screw drive, a hydraulic ram, a solenoid, or other drive mechanisms known to persons skilled in the art.
Also, as noted above for the embodiments having a pivoting take-up rail, the take-up rail control mechanism may also control the longitudinal movement of the take-up rail based upon contact of the fabric roll 15 with the forward throat edge 5 and the rearward throat edge 7 as shown in
Embodiments of the take-up rail assembly of the present invention may incorporate an idler rail which is vertically and longitudinally adjustable, allowing the vertical and longitudinal adjustment of the idler rail to match the sewing machine, or the fabric being sewed, or both. Accordingly, where the term “fixed” idler rail is used in this application, the term is defined to include embodiments wherein the user may vertically or longitudinally adjust the position of the idler rail and “fix” the idler rail in the position desired by the user or needed for the sewing machine or fabric, or both, being used.
As noted above, although preferred embodiments of the take-up rail assembly of the present invention are described as attached or attachable to a typical quilting frame, and used for quilting of multiple fabric layers, other embodiments of the take-up rail assembly of the present invention may be attached or attachable to sewing frames used for embroidery or other sewing operations involving a single fabric layer or multiple fabric layers.
The drive mechanism used for the movement of the take-up rail, whether it incorporates a cam drive, screw drive, ratchet drive, solenoid, or other drive mechanism, may use an electric drive motor and a gear mechanism, or other electric actuator. The actuation and control of the drive motor and the gear mechanism, or other electric actuator to accomplish the desired movement of the take-up rail, may be accomplished by a take-up rail control mechanism dedicated to the quilting frame or other sewing frame, or may be accomplished by link to an external computer.
Regardless of the embodiment of the take-up rail control mechanism, it may be linked to a computerized sewing machine control system which controls the movement of the sewing machine on a quilting frame or other sewing frame. The sewing machine control system may also control the longitudinal movement of the take-up rail by the take-up rail control mechanism, based upon the position of the sewing machine with respect to the frame or with respect to the fixed idler rail. Other embodiments of the take-up rail control mechanism, for controlling the longitudinal movement of the take-up rail, will be known to persons of ordinary skill in the art in view of the description and the drawings for the present invention presented for this application.
The drawings and the foregoing description show and describe various preferred embodiments of the take-up rail assembly 2 of the present invention. The embodiments incorporate various embodiments of a take-up rail support structure 131 for movably attaching the take-up rail 13 to the sewing frame 34, for supporting the take-up rail in its various positions, and providing for longitudinal movement of the take-up rail as driven by the drive mechanism and controlled by the take-up rail control mechanism. Other embodiments of the take-up rail support structure providing for support and movement of the take-up rail as driven by the drive mechanism and controlled by the take-up rail control mechanism, will be known to persons of ordinary skill in the art, in view of the drawings and description of the present invention presented in this application.
For clarification, the term “take-up rail control mechanism” shall be defined to include the drive mechanism which provides the force for the movement of the take-up rail and positions the take up rail as directed by the take-up rail control mechanism. The take-up rail control mechanism transmits a control signal to the drive mechanism which causes to drive mechanism to position the take-up rail by interaction with the take-up rail support structure or directly with the take-up rail. The take-up rail control system may provide for input by the user, such as maximum fabric roll diameter, sewing machine make and model, or sewing machine throat length. The sewing machine control mechanism may be a dedicated control system or may depend on interface with an external computer for input of control parameters or signals.
Other embodiments and other variations and modifications of the embodiments described above will be obvious to a person skilled in the art. Therefore, the foregoing is intended to be merely illustrative of the invention and the invention is limited only by the following claims and the doctrine of equivalents.
