Button setting apparatus with optical position indicator

An apparatus for attaching a pair of fastener elements of a garment fastener to a garment fabric, comprises an optical indicator for designating a position of the garment fabric where the two fastener elements are to be attached. The indicator includes a light projector having a light source for projecting a beam of light, a reflector for reflecting the light beam downwardly, and means defining an aperture for the passage therethrough of the reflected light beam. An actuator is operatively connected to the light projector for reciprocating the same toward and away from a position where the aperture is in registry with a common vertical axis of the two fastener elements. The indicator is structurally and functionally separated from a pusher mechanism for supplying one fastener element to an upper unit of the apparatus. The indicator may include means for changing the color of the light beam projected from the light source so that a clear and distinctive light spot is produced on the garment fabric even when the latter has a color the same as or confusingly similar to the color of the light beam.

BACKGROUND OF THE INVENTION 
1. Field of the Invention 
The present invention relates generally to an apparatus for setting a 
garment fastener, such as a snap fastener, a button or an ornament, to a 
garment fabric, and more particularly to such a button setting machine 
having a device for indicating a correct location in alignment between a 
punch and a die of the button setting machine. 
2. Prior Art 
Various button setting device are known in which a pair of fastener 
elements is supported on a lower or die unit and an upper or a punch unit, 
respectively; a garment fabric is positioned between the upper and lower 
units with the aid of an indictor; and a punch of the upper unit moves 
toward a die of the lower unit to join the two fastener elements together 
in clinched condition with the garment fabric sandwiched between the two 
fastener elements. 
U.S. Pat. No. 3,964,661, issued June 22, 1976 discloses one such button 
setting machine which includes an optical indicator constructed to produce 
a light spot on a garment fabric at a position where a pair of fastener 
elements is to be attached. The indicator comprises a light source fixed 
to a machine frame for projecting a horizontal light beam, and a mirror 
unit or reflector supported on the forward end of a slide bar so as to 
reflect the light beam downwardly at a 90.degree. angle, the slide bar 
being reciprocably movable to advance one of the fastener elements below a 
punch of an upper unit. When the slide bar is fully advanced with the one 
fastener element carried on a forward step of the slide bar, the reflected 
light beam passes along a common vertical axis of the two fastener 
elements and hence the punch and a die. Since the mirror unit reciprocates 
in unison with the slide bar for a relatively long distance, the indicator 
as a whole requires a relatively large area for installation. 
Consequently, the button setting machine becomes large as a whole. Another 
disadvantage is that the mirror unit has a downwardly directed projection 
or pointer defining a channel for the passage of the reflected light. The 
projection is likely to interfere with the garment fabric while being set 
between the punch and the die with the result that positioning operation 
would be rendered tedious and time consuming. The prior indicator has 
another disadvantage in that correct positioning of the garment fabric is 
difficult to achieve when the garment fabric has the same or similar color 
as the light beam. 
SUMMARY OF THE INVENTION 
It is therefore an object of the present invention to provide a button 
setting apparatus having an optical indicator which can be assembled 
without increasing the whole size of the button setting apparatus, and 
which incorporates structural features to enable speedy and accurate 
positioning of a garment fabric with respect to a pair of fastener 
elements to be attached even when the color of the garment fabric is 
substantially the same as or confusingly similar to the color of a light 
beam projected from a light source. 
According to the invention, an apparatus for attaching a pair of fastener 
elements of a garment fastener to a garment fabric, comprises an optical 
indicator for designating a position of the garment fabric where the two 
fastener elements are to be attached. The indicator includes a light 
projector having a light source for projecting a beam of light, a 
reflector for reflecting the light beam downwardly, and means defining an 
aperture for the passage therethrough of the reflected light beam. An 
actuator is operatively connected to the light projector for reciprocating 
at least the reflector and the aperture-defining means toward and away 
from a position where the aperture is in registry with a common vertical 
axis of a punch and a die of the apparatus. The indicator is structurally 
and functionally separated from a pusher mechanism for supplying one 
fastener element to the upper unit. The indicator may include means for 
changing the color of a light beam projected from the light source so that 
a clear and distinctive light spot is produced on the garment fabric even 
when the latter has a color which is the same as or confusingly similar to 
the color of the light beam. 
Many other advantages and features of the present invention will become 
manifest to those versed in the art upon making reference to the detailed 
description and the accompanying sheets of drawings in which preferred 
structural embodiments incorporating the principles of the present 
invention are shown by way of illustrative example.

DETAILED DESCRIPTION 
FIG. 1 shows an apparatus for assembling a pair of first and second 
fastener elements A, B (illustrated in broken lines) in clinched condition 
with a garment (not shown) sandwiched therebetween. In the illustrated 
embodiment, the first and second fastener elements A, B comprise a button 
body and a tack, respectively, of a button. As best shown in FIG. 9, the 
button body A includes a button back 11 which has an annular rim 12 
covered by a cap 13 with a circular back plate 14 disposed between the 
button back 11 and the cap 13. The button back 11 also has a hollow shank 
15 in the form of a double tube projecting centrally from an inner edge of 
the annular rim 12. The tack B has a disc-like head 16 and a spike 17 
projecting centrally therefrom for being forced through the garment fabric 
into the hollow shank 15 of the button back 11. 
The apparatus comprises an upper or punch unit 20, a first drive mechanism 
21 for vertically moving a punch 22 of the upper unit 20, a first pusher 
mechanism 23 (FIG. 3) for receiving a button body A at a time from a first 
parts feeder 24 and for supplying the button body A to the upper unit 20, 
a lower or die unit 25, a second drive mechanism 26 for vertically moving 
a die 27 of the lower unit 25, and a second pusher mechanism 28 for 
receiving a tack B at a time from a second parts feeder 29 and for 
supplying the tack B to the lower unit 25. The apparatus also comprises a 
third drive mechanism 30 operatively connected to the first and second 
pusher mechanisms 23, 28 for driving them in timed relation to each other, 
and an indicator 31 to facilitate correct positioning of the garment with 
respect to the button body A and the tack B for attachment thereof. 
The upper unit 20 as shown in FIG. 2, includes a tubular head 32 secured to 
a frame 33 of the apparatus and having a vertical bore 34 and an upper 
plunger 35 reciprocable vertically within the vertical bore 34 in the head 
32. The punch 22 is fixed to the lower end of the plunger 35. The upper 
unit 20 also includes a pair of clamp fingers 36, 36 for holding a button 
body A below the punch 22 when the button body A is supplied from the 
first pusher mechanism 23 to the clamp fingers 36, 36. The clamp fingers 
36, 36 are pivoted at their upper ends on to a support block 37 by means 
of a pair of pins 38, 38, respectively. The support block 37 is movably 
mounted on the head 32 and is operatively connected to the plunger 35 for 
limited vertical movement therewith. A torsion spring 39 is supported on 
the support block 37 by a pin 40 and acts on the clamp fingers 36, 36 to 
normaly urge them toward each other for clamping the button body A. 
The first drive mechanism 21, as shown in FIG. 1, includes a first fluid 
actuator such as an air cylinder 41 and a toggle joint 42 composed of a 
pair of first and second levers 43, 44, the first air cylinder 41 being 
pivotably supported on the frame 33. The first lever 43 is pivotably 
connected at its one end to the head 32 and is pivotably connected at the 
other end to a piston rod 45 of the air cylinder 41, while the second 
lever 44 is pivotably connected at opposite ends to the first lever 43 and 
the upper end of the plunger 35. For connection, the levers 43, 44 extend 
into the vertical bore 34 through a vertical slot 46 in the head 32. 
The first pusher mechanism 23, as shown in FIG. 3, includes a horizontal 
support block 47 secured to the frame 33, an elongated guide block 48 
secured to the underside of the support block 47, and a pair of parallel 
spaced guides 49, 49 secured to the underside of the guide block 48. The 
guide block 48 and the two guides 49, 49 jointly define therebetween a 
longitudinal guide channel 50 of a T-shaped cross-section, in which a 
first elongated pusher bar 51 of a T-shaped cross-section is slidably 
received. The two guides 49, 49 have in their inner surfaces a pair of 
elongated recesses or grooves 52, 52 for guiding the head portion of a 
button body A. The pusher bar 51 is fully advanced while the punch 22 is 
fully retracted and, in response to descending movement of the punch 22, 
it moves to a retracted position along the guide channel 50. 
A first chute 53 is connected at its upper end with the first parts feeder 
24 and, as shown in FIG. 3, it has a lower end extending through the left 
guide 49 and communicating with the groove 52 in the left guide 49 for 
delivering successive button bodies A from the first parts feeder 24 to 
the grooves 52. While the pusher bar 51 is in the advanced position, a 
leading one of the successive button bodies A is prevented from entering 
the groove 52. When the forward end of the pusher bar 51 is disposed 
behind the lower end of the chute 53 as the pusher bar 51 is fully 
retracted, the leading button body A slides into the grooves 52, 52 with 
its shank directed downwardly. As the pusher bar 51 is moved forwardly, 
the leading button body A is pushed along the grooves 52, 52 by the pusher 
bar 51 and then is gripped by the clamp fingers 36, 36 under the bias of 
the torsion spring 39 (FIG. 2). During that time, entering of the 
succeeding button body A into the grooves 52, 52 is prevented by the 
pusher bar 51. Thus the successive button bodies A are supplied one at a 
time to the first pusher mechanism 23. 
As shown in FIGS. 1 and 4, the lower unit 25 includes a base 54 fixedly 
supported on the frame 33, and a support block 55 fixed to the base 54, 
the base 54 and the support block 55 jointly defining therebetween a 
vertical bore 56 within which a lower plunger 57 is vertically movable. 
The die 27 is fixed to the upper end of the lower plunger 57. The lower 
plunger 57 is operatively connected to the second drive mechanism 26. 
The second drive mechanism 26, as shown in FIG. 1, includes a third lever 
58 pivotably supported on the frame 33 by means of a pin 59, and a second 
fluid actuator such as an air cylinder 60 fixed to the frame 33. The third 
lever 58 is pivotably connected at one end thereof to a piston rod 61 of 
the air cylinder 60. The other end of the third lever 58 is connected to 
the lower end of the lower plunger 57 via a link 62. The piston rod 61 is 
normally held in its retracted position. When the air cylinder 60 is 
actuated to extend its piston rod 61, the third lever 58 is pivotally 
moved counterclockwise to raise the lower plunger and the die 27. 
As shown in FIGS. 1, 4 and 5, the second pusher mechanism 28 includes a 
second elongated guide base 63 fixedly supported by the frame 33, a pair 
of parallel guide plates 64, 64 secured to the upper side of the guide 
base so as to define therebetween a longitudinal guide channel 65 of an 
inverted T-shaped cross-section, and a second elongated pusher bar 66 of 
an inverted T-shaped cross-section slidably received in the guide channel 
65. The two guide plates 64, 64 have in their inner surfaces a pair of 
guide groove 67, 67 for guiding the disc-like head portion of the tack B. 
The pusher bar 66 is mounted on a guide ridge 68 on the upper surface of 
the guide base 63 and has an upper pushing fin 69 received in a narrow 
upper portion of the inverted T-shaped guide channel 65, the fin extending 
across the guide grooves 67, 67. 
A second chute 70 is connected at its upper end to the second parts feeder 
29 and, as shown in FIG. 5, it has a lower end extending through the left 
guide plate 64 and communicating with the groove 67 in the left guide 
plate 64 for delivering successive tacks B from the second parts feeder 29 
to the grooves 67, 67. While the pusher bar 66 is in its fully advanced 
position, a leading one of the successive tacks B is prevented from 
entering the groove 67 by means of the pushing fin 69. When the forward 
end of the pusher bar 66 is disposed behind the lower end portion of the 
chute 70 as the pusher bar 66 is fully retracted, the leading tack B 
slides into the grooves 67 with its spike directed upwardly. As the pusher 
bar 66 is moved forwardly, the leading tack B is pushed along the grooves 
67, 67 by the pushing fin 69 and then is placed on the die 27. During that 
time, entering of the succeeding tack B into the grooves 67 is prevented 
by the pushing fin 69 of the pusher bar 66 so that the successive tacks B 
are supplied one at a time to the second pusher mechanism 28. 
The first pusher mechanism 23 and the second pusher mechanism 28 are driven 
in timed relation to each other by the third drive mechanism 30. As shown 
in FIG. 1, the third drive mechanism 30 includes a fourth lever 71 having 
an upper end pivotably supported on the frame 33 by means of a pin 72, a 
third fluid actuator or an air cylinder 73 fixed to the support block 47 
for actuating the fourth lever 71 to pivot about the pin 72, a tension 
spring 74 acting between the support block 47 and the fourth lever 71 to 
normally urge the latter toward the third air cylinder 73, and a pushing 
block 75 connected to a lower end of the fourth lever 71 via a link 76. 
The first pusher bar 51 of the first pusher mechanism 23 is connected to 
the pushing block 75 by a connector 77, while the second pusher bar 66 of 
the second pusher mechanism 28 is connected directly to the pushing block 
75. 
The piston rod 78 of the third air cylinder 73 is normally retracted so 
that the first and second pusher bars 51, 66 normally assume their 
advanced positions under the bias of the tension spring 74. Then, as the 
piston rod 78 of the air cylinder 73 projects, the fourth lever 71 pivots 
clockwise in FIG. 1 about the pin 72 to cause the first and second pusher 
bars 51, 66 to be moved to their retracted positions, thus allowing a 
successive button body A and a successive tack B to be delivered into the 
guide grooves 52, 67 in front of the first and second pusher bars 51, 66, 
respectively. When the air cylinder 73 is actuated to retract the piston 
rod 78, the fourth lever 71 pivots counterclockwise in FIG. 1 about the 
pin 72 under the bias of the tension spring 74 to cause the first and 
second pusher bars 51, 66 to be moved to their advanced positions for 
placing the successive button body A and the successive tack B, 
respectively, under the punch 22 and on the die 27. 
The indicator 31 is of the optical type and comprises a light projector 79, 
and an actuator 80 operatively connected to the light projector 79 is for 
reciprocating the latter to an advanced position where the light projector 
79 disposed below the upper unit 20, and a retracted position remote from 
the upper unit 20. The light projector 79, as shown in FIG. 6, includes a 
tubular housing 81, a light source such as a lamp 82 disposed in the 
housing 81 at one end thereof, a plug 83 fitted to the other end of the 
housing 81 to close the same, and a mirror or reflector 84 supported on 
the plug 83 in alignment with the light source 82, the reflector 84 being 
tilted toward the light source 82 substantially at an angle of 45 degrees 
to reflect a light beam from the light source 82 downwardly at a 
45.degree. angle. The housing 81 has in its circumferential wall an 
apperture 85 for the passage of the reflected light beam. 
The actuator 80, as illustrated in FIGS. 1 and 6, comprises an air cylinder 
having a piston rod 86 connected to an L-shaped support 87 on which the 
light projection 79 is supported. The air cylinder 80 is fixedly supported 
on the underside of the guides 49 of the first pusher mechanism 23 by 
means of a pair of support blocks 88, 88. The air cylinder 80 operates in 
timed relation to the reciprocating movement of the punch 22 of the upper 
unit 20. Namely, when the punch 22 is fully retracted, the air cylinder 80 
extends its piston rod 86 to move the light projector 79 from the 
retracted position to the advanced position of FIG. 6 where the reflected 
light beam projected from the hole 85 passes along a common vertical axis 
89 of the button body A on the upper unit 20 and the tack B on the lower 
unit 25. Thus, a light spot is produced on a garment fabric C when the 
latter is disposed between the button body A and the tack B. Immediately 
before the descending movement of the punch 22, the air cylinder 80 
retracts its piston rod 86 to move the projector 79 away from the upper 
unit 20. 
The apparatus thus constructed operates as follows: For the purposes of 
illustration, operation of the apparatus begins from a condition shown in 
FIG. 1 where the piston rods 45, 61, 78 of the first, second and third air 
cylinders 41, 60, 73 are retracted, while the piston rod 86 (FIG. 6) of 
the air cylinder 80 is extended. Thus, the punch 22 and the die 27 are 
fully retracted, while the first and second pusher bars,, 51, 66 are fully 
advanced so that a button body A is hedld by the clamp fingers 36, 36 
below the punch 22 and a tack B is placed on the die 27. The light 
projector 79 of the indicator 31 assumes its advanced position and the 
light beam projected from the hole 85 passes along the common vertical 
axis 89 of the button body A and the tack B. The light beam produces a 
light spot on a garment fabric when the latter is disposed between the 
upper and lower units 20, 25. 
After a position on the garment fabric where the button body A and the tack 
B are to be attached has been set in registry with the light spot, the air 
cylinder 80 is actuated to retract its piston rod 86 and hence the light 
projector 79 connected thereto, away from the upper unit 20. Then the 
third air cylinder 73 is actuated to extend its piston rod 78 whereupon 
the fourth lever 71 pivots clockwise (FIG. 1) to cause the first and 
second pusher arms 51, 66 to be moved to their retracted position. 
Thereafter, the first air cylinder 41 is actuated to extend its piston rod 
45 whereupon the toggle link 42 extends its levers to thereby lower the 
punch 22 and the clamp fingers 36 toward the die 27 with the button body A 
held by the clamp fingers 36. Immediately after the activation of the 
first cylinder 41, the second cylinder 60 is actuated to extend its piston 
rod 61. This movement of the piston rod 61 causes the third lever 68 to 
pivot counterclockwise (FIG. 1) whereby the die 27 moves upwardly toward 
the punch 22 while supporting the tack B thereon. Thus, the button body A 
and the tack B are attached to the garment fabric C accurately at the 
desired position. 
Then the first, second and third air cylinders 41, 60, 73 are actuated to 
retract their piston rods 45, 61, 78, while the air cylinder 80 is 
actuated to extend its piston rod 86, whereby the components 22, 25, 51, 
66, 79 return to their position of FIG. 1. 
FIG. 7 shows a modified indicator 90 according to the invention. The 
indicator 90 includes a light generating unit 91, a light reflecting unit 
92, an actuator 93 for reciprocating the light reflecting unit 92, and an 
optical fiber 94 optically interconnecting the light generating unit 91 
and the light reflecting unit 92, the two units 91, 92 jointly 
constituting a light projector. 
The light generating unit 91 includes a tubular housing 95 and a light 
source such as a lamp 96 disposed in the housing 95 at one end of the 
same. The other end of the housing 95 is closed by a plug 97 to which one 
end of the optical fiber 94 is fitted with the one end facing toward the 
light source 96. The housing 95 is mounted on a support block 98 secured 
to the frame 33 of the button setting apparatus. 
The light reflecting unit 92 includes a tubular housing 99 having one end 
closed by a plug or cover 100, and a mirror or reflector 101 disposed in 
the housing 99 and supported on the plug 100. The other end portion of the 
optical fiber 94 is fitted with the other end of the housing 99 and 
extends therethrough toward the reflector 101 in alignment with the latter 
so as to transmit a beam of light projected from the light source 96 to 
the reflector 101. The reflector 101 is tilted toward the other end of the 
optical fiber 94 substantially at an angle of 45 degrees to reflect the 
light beam from the optical fiber 94 downwardly at a 45.degree. angle. The 
housing 99 has in its circumferential wall an aperture or hole 102 for the 
passage of the reflected light beam. 
The actuator 93 comprises an air cylinder having a piston rod 103 connected 
to an L-shaped support 104 on which the housing 99 of the light reflecting 
unit 92 is supported. The air cylinder 93 operates in timed relation to 
the reciprocating movement of the punch 22 of the upper unit 20. Namely, 
when the punch 22 is fully retracted, the air cylinder 93 extends its 
piston rod 103 to move the light reflecting unit 92 from a retracted 
position remote from the upper unit 20, to an advanced position of FIG. 7 
where the reflected light projected from the hole 102 passes along a 
common vertical axis 109 of a button body A and a tack B supported 
respectively on the upper and lower units 20, 25. Thus, a light spot is 
produced on a garment C when the latter is disposed between the upper and 
lower units 20, 25. 
The indicator 90 further includes means for selectively changing the color 
of the light beam projected from the light source 96. The color changing 
means, as shown in FIG. 8, comprises a circular disc 106 having a 
plurality (four being shown in the illustrated embodiment) of concentric 
light-transmittable portions 108 spaced circumferentially at equal 
intervals. The disc 106 is rotatably mounted on the mounting block 98 in 
eccentric relation to the tubular housing 95. The disc 106 is partly 
received in the housing 95 between the light source 96 and the end of the 
optical fiber 94 such that when the disc 106 rotated the 
light-transmittable portions 108 pass successively across the light beam 
fed from the light source 96 to the optical fiber 94. As shown in FIG. 8, 
one of the light-transmittable portions 108 comprises an aperture, and the 
remaining portions 108 comprise color filters of different colors (blue, 
green and red), respectively, the filters preferably being made of a 
colored plastic film (FIG. 7). Thus, the light beam projected from the 
light source 96 changes in color as it passes, through,. the light 
transmittable portions 108. accordingly the light spot produced on the 
garment C is distinctive and can be observed even when the color of the 
garment fabric C is the same as or confusingly similar to the color of the 
light beam. 
The indicator 90 operates in the same manner as the indicator shown in FIG. 
6 at 31 and no description is necessary. The color-changing means 105 may 
be mounted on the light projector 79 of the indicator 31 shown in FIG. 6. 
The indicators 31, 90 have various advantages as follows: The stroke of 
reciprocation of the light projector 79 (FIG. 6) or the light reflecting 
unit 92 (FIG. 7) is relatively short because it is driven by the actuator 
80, 93 independent of the actuator of the first pusher mechanism 23. 
Accordingly, the provision of the indicator 31, 90 does not increase the 
whole size of the button attaching apparatus. Neither the light projector 
79 or the light reflecting unit 92 has any projection which would 
interfere with a garment fabric during placement of the latter. Thus the 
garment fabric can be set quickly with utmost ease. With the 
color-changing means 105, the light spot produced on the garment fabric C 
is always clear and distinctive even when the garment fabric has a color 
substantially the same as or confusingly similar to the color of the light 
source 82, 96. The indicator is structurally and operationally separated 
from the first pusher machanism and hence it operates reliably for a 
relatively long period of time and is easy to maintain. 
Although various minor modifications may be suggested by those versed in 
the art, it should be understood that I wish to embody within the scope of 
the patent warranted hereon, all such embodiments as reasonably and 
properly come within the scope of my contribution to the art.