Transport system for automatic pocket implantation apparatus

A system (10) for transporting sets of garment panels and pocket bags through work stations functioning to implant substantially finished pockets in the garment panels includes a transfer machine (12) with an endless belt (24) mounted for movement around the machine, and a plurality of carriers (14) secured to the belt. A template (46) is mounted on each carrier (14) for releasably holding a garment panel and pocket bag in proper relationship as the carriers are indexed. Means (60), (110) are provided for selectively opening the templates (46) for loading and unloading.

TECHNICAL FIELD 
The present invention relates generally to an apparatus for implanting 
pockets in garment panels during garment construction. More particularly, 
this invention involves a system for transporting sets of pocket blanks 
and garment panels between work stations of an apparatus for automatically 
implanting pockets into the garment panels. 
BACKGROUND ART 
In the manufacture of garments, pockets are provided as a means for 
conveniently carrying useful items such as currency, change, keys, a 
wallet, a handkerchief and the like. The pockets are integrated into the 
garment and take the general form of a pouch open at one end to receive 
such items. 
The two basic types of pocket constructions are the patch-type pocket and 
the regular pocket. The patch-type pocket is secured to the outside 
surface of the garment and is typically utilized in garments having less 
formal or leisure applications. Patch pockets are relatively easily 
constructed and attached to a garment. 
In contrast, the regular pocket is positioned inside the garment thereby 
presenting a much neater, finished appearance. An opening, usually a slot 
in the garment, provides access to the standard pocket. However, the 
regular pocket is relatively complicated in construction and has required 
numerous manual operations including material cutting, positioning, sewing 
and trimming. Such manual operations are time consuming and can contribute 
significant expense to the cost of manufacturing a garment. Since the 
garment industry is characterized by high volume production, it will be 
appreciated that the overall costs of constructing and finishing such 
pockets can be substantial. 
In an attempt to improve upon the manual sewing techniques of the prior 
art, there has been increasing interest in the use of adhesive as a 
supplement or complete substitute for sewn stitches. For example, U.S. 
Pat. No. 4,156,293 to Joseph W. A. Off discloses a pocket construction 
wherein a garment panel and rectangular pocket blank are secured together 
and formed into a finished pocket through various folding and adhesive 
connection steps. Application Ser. No. (B7685), to Joseph W. A. Off and 
Judson H. Early discloses an apparatus for manufacturing prefabricated 
pocket bags like that shown in U.S. Pat. No. 4,156,293. Application Ser. 
No. (B7410), to Joseph W. A. Off and Judson H. Early discloses an 
apparatus for integrating prefabricated pocket bags into garment panels on 
a semi-automatic basis wherein each pocket bag and corresponding garment 
panel are clamped in a template and manually advanced between work 
stations of the apparatus, however, the production capability of this 
apparatus is somewhat limited. All of these inventions are assigned to 
Haggar Company of Dallas, Texas. 
Although the adhesive pocket construction techniques developed thus far 
have proven satisfactory, a need has arisen for an apparatus for 
transporting and indexing sets of garment panels and prefabricated pocket 
bags between work stations to achieve greater rates of production. 
SUMMARY OF INVENTION 
The present invention comprises a transport and index apparatus which 
overcomes the foregoing and other difficulties associated with the prior 
art. In accordance with the invention, there is provided an apparatus for 
precision transport of a plurality of sets of garment panels and 
prefabricated pocket bags during indexing through various work stations to 
form garment panels with finished pockets constructed therein. Each 
garment panel and corresponding prefabricated pocket bag are held in 
proper relationship by a movable template clamp assembly, a plurality of 
which are provided. The system herein allows construction of garment 
panels with substantially finished pockets at greater production rates to 
reduce overall fabrication costs of the garment. 
More particularly, the present invention comprises the transport system for 
an automatic apparatus for implanting pockets in garment panels. The 
apparatus includes a table with an endless belt mounted for movement 
around the periphery thereof and a drive system for indexing the belt. A 
plurality of carriers are secured to the movable belt. Each carrier 
includes a template clamp assembly adapted to releasably receive a garment 
panel and prefabricated pocket bag for transport between work stations 
situated around the table. The templates are normally biased in closed 
positions by springs, however, means are provided at the loading and 
unloading stations for opening the templates. Also located at the loading 
station is a control panel interfaced with a microprocessor controller for 
controlling the system.

DETAILED DESCRIPTION 
Referring now to the Drawings, wherein like reference numerals designate 
like or corresponding parts throughout the views, and particularly 
referring to FIG. 1, there is shown a system for implanting pockets 10 
incorporating the invention. System 10 is particularly adapted for 
operation on a continuous basis to construct pockets in accordance with 
the techniques of U.S. Pat. No. 4,156,293 utilizing prefabricated pocket 
bags like those fabricated with the device shown in application Ser. No. 
(B7685), which inventions are assigned to Haggar Company as is the present 
one. 
System 10 includes a transfer machine 12 with a plurality of carriers 14 
mounted for movement therearound. In the preferred embodiment, system 10 
includes about eighteen carriers 14. A control box 16 is situated at one 
end of machine 12 at the loading station of apparatus 10. Control box 16 
is interfaced with a microprocessor 18 within a cabinet located at the 
opposite end of machine 12. Microprocessor 18 functions to control 
operations at the various stations of system 10, which have been omitted 
for clarity inasmuch as the subject matter of the present application is 
directed primarily toward the transport portion of system 10. In actual 
practice, however, it will be appreciated that several work stations are 
mounted around transfer machine 12 to carry out various cutting, folding, 
adhesive application and bonding steps as carriers 14 are indexed between 
the stations. 
Transfer machine 12 itself is of substantially conventional construction, 
and comprises a table top 20 supported on pedestals 22. A segmented belt 
24 is mounted for movement around table top 20. Belt 24 is driven 
intermittently by a precision drive system including a clutch/brake motor 
26 and anti-backlash speed reducer 28 coupled to a studded drum (not 
shown) located beneath table top 20 for engaging belt 24 to advance 
carriers 14. Transfer machine 12 can comprise a TRANS-O-MATOR type AW 
machine available from Ferguson Machine Company of St. Louis, MO, for 
example; however, other machines of suitable construction and precision 
can be utilized, if desired. 
Referring now to FIG. 2, further details of the loading station of system 
10 can be seen. Control box 16 includes a panel 30 having several switches 
32, 34, 36 and 38 and enunciator panel 40 for use by the operator 
responsible for loading carriers 14. A tray 42 is provided adjacent to 
control box 16 for holding a supply of prefabricated pocket bags 44 for 
loading into templates 46 of carriers 14 together with garment panels (not 
shown), as will be more fully explained hereinafter. Each carrier 14 
comprises a back plate 48, top plate 50 and front plate 52. The back plate 
48 of each carrier 14 is secured to belt 24 for movement therewith. The 
front plates 52 act as protective guards. Templates 46, each of which 
includes a pivotal upper portion 46a and pivotal lower portion 46b, are 
mounted on top plates 50 of carriers 14. 
Each carrier 14 is further supported by a pair of glides 54, only one of 
which can be seen on each carrier in FIG. 2. Glides 54 can be formed of 
TEFLON brand material, and are similar to chair glides. Glides 54 of 
carriers 14 are movable on a rail 56 surrounding transfer machine 12. Rail 
56 is mounted on a support structure 58 comprising a framework of 
horizontal and vertical members affixed to machine 12. Opening of template 
46 at the loading station is controlled by an assembly 60, which is shown 
in more detail in FIGS. 3 and 4. 
Referring still to FIG. 2, the loading sequence for carriers 14 goes as 
follows. First, pushbutton 34 is depressed to start up and initialize 
system 10. The pivotal positions of template portions 46a and 46b are 
controlled by opening assembly 60 via foot switch 62, which is shown in 
FIG. 1. After both portions of template 46 have been pivoted upwardly, a 
garment panel is positioned on top plate 50 of carrier 14 before foot 
switch 62 is actuated to lower template portion 46b clamping and clamp it 
in place. Any type of garment panel requiring implantation of a pocket 
therein can be utilized with system 10. For example, in the case of 
trousers or pants, the upper portion of a pants panel would be clamped 
between template portion 46b and top plate 50 with the lower portion of 
the panel hanging over the edge of carrier 14. 
A prefabricated pocket bag 44 is then inserted between template portions 
46a and 46b, followed by actuation of foot switch 62 again to lower the 
upper template portion and thus clamp the pocket bag in place. If desired, 
twin light sources 64 can be mounted underneath control box 16 to project 
reference beams or cross hairs of light onto a carrier 14 positioned at 
the loading station to facilitate manual positioning of the garment panel 
and prefabricated pocket bag 44 relative to template 46. 
A beep tone eminates from control box 16 prior to automatic indexing of the 
next carrier 14. If the loading sequence is not sufficientally complete at 
the beep tone, the operator would then depress pushbutton 36 to initiate a 
predetermined delay timeout to allow completion of loading before 
advancement of carriers 14. On the other hand, the operator could depress 
push buttons 38 if loading were completed before the beep tone to initiate 
early advancement of carriers 14. It will thus be apparent that indexing 
of carriers 14 of system 10 normally occurs at programmable preset 
intervals which can be extended or shortened by means of switches 36 or 
38, respectively. 
Switch 32 comprises an emergency pushbutton for stopping advancement of 
carriers 14 and all other moving components of system 10 in the event of a 
hangup or other emergency condition. Enunciator panel 40 which is coupled 
to various sensors that monitor performance of system 10 via 
microprocessor 18 functions to notify the operator of conditions, such as 
low pressure or vacuum levels, which could adversely affect performance of 
the system so that appropriate corrective action can be taken. 
Referring now to FIGS. 3 and 4, there are shown further constructional 
details of template 46 and the assembly 60 for opening the template at the 
loading station. Template portions 46a and 46b are each of split 
construction, with the sections of each portion being generally C-shaped 
and facing inwardly. Each portion of template 46 thus defines a generally 
rectangular opening which is positioned over a relatively smaller 
rectangular opening 66 in top plate 50 of each carrier 14. Four clips 68 
are provided on upper template portion 46a for exerting additional 
clamping pressure on the garment panel and pocket bag (not shown) around 
opening 66. Top plate 50 also includes a pair of guide blocks 70 mounted 
thereon for centering template 46 in the down position. 
The portions of template 46 are mounted for pivotal movement about half 
shafts 72 located at the rear edge of each carrier 14. The sections of 
upper template portion 46a are secured to outer yokes 74, while the 
sections of lower template portion 46b are secured to inner yokes 76. 
Yokes 74 and 76 in turn are mounted on half shafts 72 for sliding and 
rotating movement. Template portions 46a and 46b are normally biased in 
the down or clamping position against top plate 50 by torsion springs 78, 
two of which are provided for each corresponding pair of yokes 74 and 76. 
A block 80, which is slidable on one of the half shafts 72, is provided 
between each pair of springs 78. One end of each spring 78 reacts against 
an integral ledge provided on its corresponding block 80. The other ends 
of the outer pair of springs 78 engage pins 82 on inner yokes 76. The 
other ends of the inner pair of springs 78 engage pins 84 on outer yokes 
74. Blocks 80 are constrained against rotation about half shafts 72 by 
rollers 86 mounted on the blocks in engagement with fixed bars located at 
the rear of carriers 14. 
It will thus be apparent that the portions of template 46 are supported for 
pivotal and slidable motion along half shafts 72, and are normally biased 
in the down position by springs 78. 
Referring still to FIGS. 3 and 4, opening assembly 60 is adapted for 
selective pivotal actuation of template 46 on each carrier 14. As is best 
seen in FIG. 4, a rod 90 extends between the sides of each outer yoke 74. 
The sides of outer yokes 74 and rods 90 have been broken away in FIG. 3 
for clarity, however, the retracted positions of the rods have been shown 
in phanton. An L-shaped hook 92, which comprises a portion of assembly 60, 
is associated with each pin 90 and corresponding support yoke assembly. 
Hooks 92 are secured to a block 94 which is supported for sliding movement 
on a gib 96. 
Movement of hooks 92 between the positions shown in full and phantom lines 
in FIG. 4 is effected by a pair of double-acting cylinders 98 and 100 
connected in parallel. Cylinders 98 and 100 are secured together by a 
plate 102. The piston rod of upper cylinder 98 is connected to a base 
plate on which gib 96 is mounted for carrying block 94. An extension 104 
at the other end of cylinder 98 protrudes through an opening in a bracket 
106 secured to the base plate. Extension 104 and the corresponding opening 
in bracket 106 are preferably of non-circular cross section to prevent 
rotation of cylinder 98 during operation. The piston rod of lower cylinder 
100, which is secured to upper cylinder 98, is connected directly to 
sliding block 94. Incremental extension or retraction of hooks 92 can thus 
be achieved with cylinders 98 and 100. 
It will thus be apparent that assembly 60 is operable to raise or lower the 
template 46 of each carrier 14 for loading a garment panel and 
prefabricated pocket bag 44 thereinto. Hooks 92 are normally located in 
the outermost position, shown in phantom lines in FIG. 4, such that yokes 
74 and rods 90 can pass underneath the hooks. Once a carrier 14 has 
stopped at the loading station, cylinders 98 and 100 are both retracted to 
pivot the template portions 46a and 46b to the open positions shown in 
phantom lines in FIG. 4. Yokes 74 and 76 are sized to interfere with each 
other during pivotal movement so that upper template portion 46a opens 
first followed by lower template portion 46b. After the garment panel has 
been positioned on top plate 50, cylinder 100 is relaxed allowing lower 
template portion 46b to close under the actions of springs 78. After the 
prefabricated pocket bag 44 has been positioned over template portion 46b, 
cylinder 98 is relaxed allowing upper template portion 46a to complete 
closure under spring action. 
Referring now to FIGS. 5 and 6, there is shown an assembly 110 which is 
utilized to open and spread the template 46 of each carrier 14 at the 
unloading station of system 10 for removal of the finished garment panels. 
Assembly 110 includes a base plate 112 secured to table top 20 of machine 
12. Attached to plate 112 is a double-acting cylinder 114 whose piston rod 
is coupled to a block 116 mounted on plate 112 for sliding movement toward 
and away from carriers 14. Block 116 supports a second block 118 on which 
hooks 120 are mounted for sliding movement toward and away from each other 
in a direction transverse to movement of the first block. A pair of 
double-acting cylinders 122 are secured to second block 118, with the 
piston rod of one cylinder being coupled to one hook 120 and the piston 
rod of the other cylinder being connected to the other hook. Hooks 120 are 
substantially similar to hooks 92 of assembly 60 shown in FIGS. 3 and 4, 
and function to engage rods 90 on yokes 74 in similar fashion. 
After a carriage 14 has completed indexing through the various work 
stations of system 10 to implant a prefabricated pocket bag 44 into a 
garment panel, the finished garment panel must be unloaded from the 
carriage before reloading. Upon arrival at the unloading station, of 
course, template portions 46a and 46b are closed in a down position 
against top plate 50 of carriage 14. Cylinder 114 is then retracted to 
pivot template portions 46a and 46b upwardly to positions similar to those 
shown in phantom lines in FIG. 4. Cylinders 122 are then extended to 
spread apart the sections of template portions 46a and 46b to the 
positions shown in FIG. 5, thereby releasing the finished garment panel 
for collection by an attendant. After passage of a predetermined time 
interval, as controlled by microprocessor 18, cylinders 114 and 122 are 
actuated in opposite directions to return template 46 to its initial 
position in preparation for the next advancement of carriages 14. 
In accordance with the preferred construction, upper and lower 
double-acting cylinders 124 and 126 as included in assembly 110, as shown 
in FIG. 6, for immobilizing the finished garment panel as template 
portions 46a and 46b are spaced apart. Cylinders 124 and 126 have been 
omitted from FIG. 5 for clarity. Upper cylinder 124 is mounted on a plate 
127 attached to a bracket 128. Lower cylinder 126 is mounted on structure 
underneath the unloading station. When template 46 opens, the heads 124a 
and 126a of cylinders 124 and 126 respectively, come together as shown in 
phantom lines momentarily to pinch or clamp the garment panel as template 
portions move outwardly so that the panel can be removed before the 
template closes and carriers 14 advance again. 
Referring now to FIG. 7, there are shown two optional attachments which are 
utilized in the preferred embodiment of system 10. A backup assembly 130 
is preferably provided at each working station around transfer machine 12 
for providing additional support to carriers 14. For example, a backup 
assembly 130 can be mounted at each work station wherein a clamping force 
is applied to the garment panel and prefabricated pocket bag 44 through 
the template 46 on a carrier 14. Each assembly 130 can be mounted directly 
on support structure 58 surrounding transfer machine 12. 
Assembly 130 comprises an anvil 132 secured to the end of a piston rod 134 
of a double-acting cylinder 136. The top face of anvil 32 is profiled to 
engage the underside of top plate 50 around opening 66 in accordance with 
the type of clamping and/or bonding contact being applied at that 
particular work station. For example, anvil 132 can be provided with a pad 
138 of TEFLON brand material configured to substantially fill opening 66 
in top plate 50. Assembly 130 further includes a smooth shield 140 
surrounding piston rod 134 to prevent snagging of any material drooping 
over carriers 14 as the carriers are indexed. 
A stabilizer assembly 142 is preferably provided at those work stations 
located near or on the ends of transfer machine 12. As belt 24 rounds the 
ends of machine 12, some play could develop between back plate 48 and the 
belt which would interfere with precise location of each carrier 14. A 
pair of buttons 144, only one of which is shown in FIG. 6, are thus 
provided on back plate 48 of each carrier 14 for engagement with a mating 
button 146 of assembly 142. Button 146 is actuated by a double-acting 
pancake cylinder 148 on a bracket 150 fixed to support structure 58. Upon 
arrival of a carrier 14 at such a station, cylinder 148 is actuated to 
clamp back plate 48 thereby taking out any play or wobble of that carrier 
and stabilizing it. A metal flange 152 is attached to button 146 for 
sensing by a magnetic sensor 154 to monitor the on/off condition of 
stabilizer assembly 142. Cylinder 148, of course, is only actuated between 
advancements of carriers 14. 
From the foregoing, it will be apparent that the present invention 
comprises a transport system for a pocket implantation apparatus having 
numerous advantages over the prior art. The invention includes a plurality 
of carriers each of which can be loaded with a garment panel and 
prefabricated pocket bag for indexing through various work stations to 
construct garment panels with substantially finished pockets which then 
can be assembled into entire garments. The present invention eliminates 
many manual operations which have heretofore typified pocket construction, 
thereby achieving significant savings in the overall cost of fabricating 
garments. Other advantages will be apparent to those skilled in the art. 
Although particular embodiments of the invention have been illustrated in 
the accompanying Drawings and described in the foregoing Detailed 
Description, it shall be understood that the invention is not limited to 
the embodiments disclosed, but is intended to embrace any alternatives, 
equivalents, modifications and/or rearrangements of elements falling 
within the spirit and scope of the invention as defined by the following 
Claims.