Method and apparatus for applying a gusset to manufactured goods

Apparatus for applying a gusset to tubular articles such as panty hose which includes a carrousel structure carrying hollow support members across which the panty hose is stretched, operating stations for inverting the panty hose and drawing the legs inwardly of the hollow support member, apparatus applying the gusset to the panty hose, excess fabric remover, a sewing device for sewing the gusset to the panty hose, and a panty hose reversing mechanism.

This invention relates to applying gussets to pantyhose. More specifically, 
this invention relates to applying gussets to pantyhose formed as a single 
unit without a seam in the crotch, and provides a reinforcing gusset for 
the seamles crotch zone. 
At present it is known to form women's pantyhose with a gusset or 
reinforcing member by joining two separately made tubular shaped legs by 
sewing. Coincident with the sewing of the two leg portions together, a 
reinforcing gusset, which overlaps the edges of the leg portions, is sewn 
thereon. 
The object of the present invention is to provide a method for applying a 
gusset to tubular articles in general such as women's pantyhose, and a 
machine for carrying out the method. 
According to the invention, these results have been achieved by adopting 
the idea of utilizing a tubular article, made separately by known means, 
formed by a pantyhose without gusset and lacking the seam at the crotch; 
stretching the edge of the seamless zone of said article according to the 
form of the patch to be applied; placing thereon a gusset of a form and 
dimensions adapted to cover the zone free of fabric of said stretched 
article; (and) removing the ready-made article with the gusset.

DESCRIPTION OF PREFERRED EMBODIMENT 
Reduced to its essential structure, the method for applying a gusset, e.g. 
a circular one, to tubular articles and in particular women's pantyhose 
(FIG. 11-13) according to the present invention, includes: (a) stretching 
and fastening by hand the edge of the seamless crotch zone of a pantyhose, 
made separately by known means, on the horizontal edge of a support in the 
form of an inverted funnel so that the article is in a hanging position 
relative to the support; (b) pneumatically turning the body of the article 
over and introducing therein the legs thereof so that the edge of the 
fabric on which the gusset must be applied is ready for sewing; (c) 
mechanically placing a gusset, e.g. a circular one (FIG. 13), on a 
horizontal circular support plate; (d) mechanically laying said plate with 
the gusset thereon on the aforesaid funnel-shaped support so that the edge 
of the gusset is pressed and held fixed in juxtaposition to the stretched 
edge of the seamless zone of the article; (e) trimming the excess fabric 
beyond the seam line, of the article and of the gusset, simultaneously; 
(f) sewing the gusset to the article along the superposed edges; (g) 
pneumatically turning the ready-made article with patch right side out 
again and removing it from the support. 
For a better understanding of the method, reference is made to FIGS. 11-13 
which illustrate a completed pantyhose article 3 of the type discussed 
above, which the present invention is intended to complete automatically. 
As illustrated in FIGS. 11-13, the premade pantyhose article formed by 
known means of two identical tubular halves 18, 18 having upper body 
portion 19, 19 sewn together at seam 20 is provided with a gusset 17 over 
the stretched out portion or seamless zone 21. When the two tubular halves 
18, 18 are sewn together without a gusset, the interconnection of 
pantyhose halves 18, 18 is subject to tearing in the crotch region. 
Therefore, gusset 17 spans zone 21 to remove the tension which each 
pantyhose half 18, 18 subjects to the other upon being sewn directly 
together. Gusset 17 covers zone 21 and is sewn thereover by the present 
invention machine so that the two halves 18, 18 are not sewn directly 
together. 
As to the machine for carrying out said method in accordance with the 
invention and with reference to the attached drawings showing FIGS. 1-10, 
it comprises, essentially: A six-armed carrousel type structure (1) 
intermittently rotating horizontally, with stops at each of the six 
stations, which are, respectively: One (A) for laying the article while 
the edge of the seamless zone is being stretched; one (B) for 
pneumatically turning the article over; one (C) for laying the gusset with 
its edge superposed on the stretched edge of the article; one (D) for 
trimming excess portions of fabric of the article and of the gusset, 
beyond the seam line; one (E) for sewing the gusset to the article; one 
(F) for pneumatically turning the ready-made article with the gusset right 
side out again and discharging it. 
More particularly, at the free end of each arm (1) a support (2) in the 
form of an inverted funnel is provided, having the function of retaining a 
pantyhose (3) and stretching the seamless zone of the crotch, a known 
means (4) being provided for setting said support (2) in horizontal 
rotation in the cutting and sewing stations. Above said support (2) are a 
cylindrical guiding chamber (5) and a jacket 6 such as to permit the 
possibly elastic edge (3') of the body of the pantyhose (3) to turn over 
completely and to permit the pantyhose legs to slip into the body with the 
toe up due to the suction produced inside a tubing (7) connected to the 
upper end of said jacket (6), the article thus positioned presenting on 
the outer conical surface of the support (2) the edge of the crotch zone 
ready to have a gusset sewn to it. Above the jacket (6), in addition to 
the connection of the suction tubing (7), there is provided a horizontally 
traversing stop device (8), having the function of retaining the free ends 
of the article after they have been sucked at (7) so that the article does 
not fall back through the funnel-shaped support (2) when the suction at 
(7) ceases, known means being provided for the forward and backward 
movement of said stop device (8). 
In addition, the wall of the jacket (6) is provided with several holes (9) 
with respective obturating devices, the holes being intended to be open in 
station (F) during the phase of turning right side out and discharge of 
the finished article; cooperating to this end is a series of compressed 
air cocks (10) disposed on a cylindrical collector at the top of the 
aforesaid chamber (5) and inclined downward and into the chamber (5). 
Below each above described support (2) is provided a circular, horizontal 
plate (11), traversing vertically and horizontally, having the function of 
supporting a gusset (12) of fabric identical with or different from that 
of the article, placed thereon by known means (13), and of pressing it 
against the edge of said support (2) with interposition of the fabric of 
the article to which it is to be sewn, known means being provided for the 
vertical displacement of the plate (11) against the support (2) and for 
the horizontal radial movement toward the center of the carrousel so as to 
free the zone under the support (2) to enable the operator to load the 
article on said support (2) in station (A) (FIG. 3) and to make possible 
in station (F) (FIGS. 8-10) the presence of a suction duct (14) under 
support (2) intended to transfer the completed article with the patch. 
At the cutting station (D) (FIG. 6) known means (15) are provided, disposed 
on the exterior of the carrousel, for trimming the excess parts of fabric 
beyond the seam line during one complete revolution of the support (2) and 
also to cause said cutting means (15) to move toward and away from the 
support (2). 
At the sewing station (E) (FIG. 7) a sewing machine (16) of known type is 
provided to carry out the sewing of the superposed edges of the patch and 
of the article during one complete revolution of the support (2), and also 
known means are provided for causing said sewing machine (16) to move 
toward and away from said support (2). 
At the station (F) (FIGS. 8-10) for discharging the finished article, known 
means are provided for opening the holes (9) of the jacket (6), to 
activate the compressed air cocks (10) and to inactivate the stop device 
(8). 
The mode of operation is the following: During the standstill of an arm (1) 
of the carrousel in station (A) (FIG. 3), the edge of the unsewn crotch 
zone of a pantyhose (3) is laid by hand, while stretching it, on the lower 
edge of the support (2) in such a way that the article is in hanging 
position as illustrated in FIG. 3 of the annexed drawings. Then said arm 
is transferred to station (B) (FIG. 4) where, by pneumatic suction from 
duct (7), the body of the pantyhose introduces itself inside out into 
chamber (5), and the pantyhose legs, passing through the body, arrange 
themselves with the toe up in duct (7) and are held by the stop device 
(8). Subsequently arm (1) transfers to station (C) (FIG. 5) where plate 
(11), on which a patch (12) previously placed is held fixed by suction 
from below, rises coming up against and compressing the gusset (12) under 
the fabric of the article stretched on the support (2). In the next 
station (D) (FIG. 6) the support (2) is set in rotation while a cutting 
blade of the means (15) fixed in a position near the edge of the support 
(2) provides to trim the fabric of the patch and of the article outside 
the stitching line. Then arm (1) moves on to station (E) (FIG. 7) where 
the sewing machine performs the continuous sewing of the gusset to the 
article along the entire circumference of the support (2) maintained in 
rotation. Lastly, as soon as arm (1) has reached station (F) (FIGS. 8-10), 
by effect of the suction from below provided in duct (14) by the opening 
of the holes (9) and by the action of the compressed air issuing from the 
cocks (10), the zone of the ready-made article with the path is disengaged 
from the support (2), and while the article is still being retained by the 
toes due to the device (8), the body is formed to fall down, turning 
itself right side out; thereafter the article, let go by (8), is sucked 
through (14) in straight position. 
In the practice the details of execution may vary in equivalent manner as 
to form, dimensions, arrangement of the elements, nature of the materials 
employed without going outside the scope of the idea of solution adopted 
and therefore remaining within the limits of portection granted by the 
present patent of invention.