LASER ALIGNMENT DEVICE FOR SEWING MACHINE

A laser alignment device for a sewing machine and a sewing machine equipped with a laser alignment device. The laser alignment device projects an illuminated alignment guide for aligning a fabric material in a feed path for sewing by a sewing machine needle. The laser alignment device includes a laser, an optical lens to provide a linear laser projection along the feed path, and a power supply to activate the laser alignment device. The laser alignment device is mounted to the head of the sewing machine to permit multi-axial adjustment for alignment of the linear light projection with a desired feed path of the sewing machine.

BACKGROUND OF THE INVENTION

The present invention relates to sewing machines, and more particularly to alignment devices for aligning a fabric to be sewn with a feed path to the sewing needle.

Conventional alignment devices for sewing machines typically rely on an etched alignment grid on a feed path to the sewing needle or mechanical attachments to the sewing machine, such as binding attachments, and the like. While these mechanical devices may be suitable for the particular purpose to which they are adapted, they are ineffective for freehand sewing operations. In freehand operations, such as quilting, alignment grids are ineffective since the quilt will overly and completely obscure the alignment grid.

As can be seen, there is a need for improved alignment devices for sewing machines

SUMMARY OF THE INVENTION

In one aspect of the present invention, a laser alignment device for a sewing machine is disclosed. The laser alignment device includes a laser assembly having a laser configured to produce a linear light projection when operably coupled with a power source. A mounting assembly adjustably couples the laser assembly with a body of the sewing machine to orient the linear light projection along a desired feed path of the sewing machine.

In some embodiments, the laser assembly may include a ball element containing the laser; and a conductor adapted to couple the laser with the power source. The mounting assembly may include a socket having an interior cavity dimensioned to receive the ball element. A protrusion extends into the interior cavity. The protrusion is adapted to support the ball element within the mount assembly. The protrusion may be an annular rim extending into a lower portion of the interior cavity.

In some embodiments, an alignment lock is adapted to retain the laser assembly at a desired orientation within the mount assembly.

In some embodiments, the laser assembly is adjustably coupled with the mounting assembly for a multi-axial adjustment of the laser assembly.

In other aspects of the invention, a sewing machine is disclosed. The sewing machine includes a housing containing a sewing mechanism for applying a stitch to a fabric material via a reciprocating needle carrying a thread to form the stitch. A feed path supports the fabric material for engagement with the reciprocating needle. A laser alignment device is adjustably coupled with the housing. The laser alignment device includes a laser adapted to produce a linear light projection along the feed path.

In some embodiments, the laser alignment device includes a laser assembly containing the laser and a mounting assembly for adjustably coupling the laser assembly with the housing to orient the linear light projection along a desired feed path of the sewing machine.

In some embodiments, laser assembly includes a ball element containing the laser. The mounting assembly includes a socket having an interior cavity dimensioned to receive the ball element. A protrusion extends into the interior cavity. The protrusion is adapted to support the ball element within the interior cavity.

In some embodiments, an alignment lock is adapted to retain the laser assembly at a desired orientation within the mount assembly.

In some embodiments, the laser assembly is adjustably coupled with the mounting assembly for a multi-axial adjustment of the laser assembly.

In some embodiments, an alignment tool for alignment of the linear light projection with the desired feed path is included. The alignment tool is formed as a flat plate having a proximal end and a distal end. At least one longitudinal alignment line oriented along a feed direction of the sewing machine is defined on a top surface of the alignment tool. At least one transverse line, oriented orthogonal with the at least one longitudinal alignment line, is defined on the top surface.

In other aspects of the invention, a method of aligning a fabric material in a feed path of a sewing machine is disclosed. The method includes coupling a laser alignment device with the sewing machine. The laser alignment device is adapted to emit a linear light projection. The linear light projection is projected on a desired feed path of the sewing machine.

In some embodiments, the method includes placing the fabric material on the feed path of the sewing machine and aligning the fabric material with the linear light projection.

In some embodiments, the method includes feeding the fabric material into a reciprocating needle of the sewing machine to apply a stitch to the fabric material while maintaining an alignment of the fabric material with the linear light projection.

In some embodiments, the method includes adjusting the laser alignment device so that the linear light projection is aligned with the desired feed path.

In some embodiments, the method includes locking the laser alignment device with the linear light projection in an alignment with the desired feed path.

DETAILED DESCRIPTION OF THE INVENTION

As seen in reference to the drawings ofFIGS.1-4, a laser alignment device10for a sewing machine40according to aspects of the invention includes a laser assembly12and a mounting assembly14. The drawings also illustrate another aspect of the invention, a sewing machine40with a projection alignment tool44to provide a linear projection of the laser light46in a desired alignment with the feed path42of the sewing machine40.

In a non-limiting embodiment, the laser assembly12includes a laser module16, containing a laser or light emitting diode (LED) light source with optics to produce a beam of coherent light aligned to project a straight line along a linear path. In a non-limiting example, the laser module16may be contained in a 9 mm×21 mm package containing a light emitter in the 650 nm wavelength. Preferably the laser module16is a low power module of about 5 mW and utilizes a 3-5V power source. Preferably, the laser module16produces emitted light with a fixed focus at a working distance of 150 mm.

The laser module16may be provisioned with optics18, such as a lens18, configured to project a linear light projection46on a feed path42aligned with a needle46of the sewing machine40. By way of non-limiting example, the laser module16may be arranged to project the linear light projection line46from an elevation of six inches off the mounted surface of the sewing machine40. Alternatively, the linear light projection46on the feed path42may be achieved with a rapid oscillation of a beam of laser light. The laser assembly12may include a ball element20to contain the laser module16, optics18, when equipped, the conductor, and in some instances, a power source.

The laser mount14permits the laser module16to be adjustably mounted with the sewing machine40. The laser module16may also be integrally mounted with the sewing machine40. Preferably, the laser mount14provides for a multi-axis alignment of the linear light projection46.

In the embodiments shown, the laser mount14may include a mount socket22dimensioned to receive the ball element20, with the laser module16, and optics18, carried within the ball element20. The mount socket22has an upper opening of an interior cavity that is dimensioned to receive the ball element20. A protrusion26, such as an annular rim26, extends into the interior cavity at a lower portion of the interior cavity. The protrusion26supports the ball element20within the interior cavity. The ball element20may have an outer diameter to be rotationally and pivotally carried within a cylindrical opening of the laser mount. The inner diameter of the mount14has an inner diameter dimensioned to receive the laser module16with a close interference fit. Alternatively, an adhesive can be applied, or the ball element20may be molded with the laser module16.

The laser mount14may also include an alignment lock24, such as a thumb screw26carried through a sidewall of the mount socket22to impinge against an outer surface of the ball element20. The alignment lock24retains the ball element20such that the linear light projection46may be set at the desired orientation along the feed path42.

To align the linear light projection46at the desired orientation on the feed path42, the ball element20may be rotated within the socket22about a vertical, or Z-axis, for a radial adjustment of the linear projection of the laser light46on the feed path42. The ball element20may also be rotated about a transverse, or Y-axis, for a lateral adjustment of the linear projection of the laser light46on the feed path42. Likewise, the ball element20may also be rotated about a longitudinal, or X-axis, for a fore-aft adjustment of the linear light projection46along the feed path42.

The projection alignment tool44may be placed on the feed path42to facilitate alignment of the linear light projection46along the feed path42. A notch45, preferably a V-shaped notch, is disposed at a proximal end of the projection alignment tool44which can be positioned in abutment with the needle of the sewing machine40(when oriented in the downward position) for centering of the proximal end of the alignment tool44. The alignment tool44includes one or more longitudinal lines48extending along a feed path42. A first longitudinal line48may extend from the notch45to align with the needle46of the sewing machine40. The one or more secondary longitudinal lines48may be spaced apart from the first longitudinal line by a predefined lateral spacing.

One or more transverse lines50are disposed at a distal end of the alignment tool46orthogonal to the one or more longitudinal lines48. The one or more transverse lines50provide an a reference for positioning of the alignment tool with a forward edge of the feed path42such that the one or more longitudinal lines48are aligned with the feed path42. The linear light projection46may be adjusted, as previously described, for alignment with a selected one of the one or more longitudinal lines48for a desired offset from the feed path42.

A conductor28connects the laser module16with a power source, such as a battery contained within a battery compartment30. The laser module16may be controlled by a switch32. The power source may also include a USB34power source connection or connection to an electrical utility service via an adapter36. Preferably, the external power source may be integrated with the electronics and power for the sewing machine40. In the embodiments shown, the power source may be a9vbattery, or a 5-volt USB cable connection34. The laser assembly12may also include a switch32for selectively activating the laser module16.

The mount assembly14may include an adhesive or may be integrally molded with a case of the sewing machine40. Preferably, base14is coupled with the sewing machine40via an adhesive, such as a double-sided tape.

The mount assembly14is configured to project a laser light line46along a feed path42of the sewing machine40, such that a material fabric may be fed into the reciprocating needle46of the sewing machine40so that the fabric may be sewn by a thread carried by the needle46and a bobbin (not shown, subjacent to the feed path42.

In a preferred embodiment, the mount assembly14includes a base15having a cylindrical opening through the body of the base15. The cylindrical opening is dimensioned to couple with the ball element20, rotatably and pivotally carried within the cylindrical opening. The base15has an outer sidewall having a surface of varying radii along each face of the body. The radius of each face may be selected for adaptation of the base15to couple with a surface of the head of the of the sewing machine40proximal to the needle46. One or more base elements may be included in a kit to adapt the laser module16for a universal or near universal adaptation of the laser to the sewing machine.

The base15may also include an adapter17for adaption to particular irregular surfaces of the sewing machine40. The adapter17may include a slotted connection19with the mount assembly14.

In use, the mount assembly14is connected with the housing of the sewing machine40. The laser assembly12is connected with a desired power supply and activated with the switch32. The ball element20is adjusted within the mount assembly14so that the linear light projection46is projected along a desired alignment of the feed path42. As previously described, the alignment tool44may be utilized for alignment of the linear light projection46. Once a desired alignment is obtained, the ball element20is secured in the mount14via the alignment lock24.

With the laser module16secured on the sewing machine40, the user may then utilize the sewing machine40to sew their articles. Unlike conventional sewing machines, that may be equipped with alignment marks on the feed tray42that become obscured when the fabrics to be sewn are fed into the sewing machine, the linear light projection46of the present invention provides the user an alignment reference that is projected on a top surface of the materials as they are fed into sewing machine40to be joined. With the laser alignment device10of the present invention, the user can more reliably maintain a straight line while sewing fabric materials. Advantageously, the multi-axial adjustment of the laser module16allows the user to set a desired offset for the linear light projection46, to permit sewing hems, bindings, and the like, while the needle path is positioned at the desired placement to join the respective fabric materials.