BUTTON COLLET AND METHOD AND APPARATUS FOR MAKING THE SAME

Abstract: A domed cap button collet and the method and apparatus for the manufacture of same by deforming a flat domed button collet having an elastic body including: a shank (16); a radially extending plate-like flange (18) located one end of the shank (16); and, a cap (20) formed of malleable material overlying the outer surface of the flange (18) and crimped to the peripheral portion of the flange. Pressure is simultaneously applied to bend the flange (18) and cap member (20) into a substantially convex dome shape (24). Upon removal of the pressure, the cap member (20) retains its dome shape (24) and the flange member (18) reverts to its original plate-like configuration.

Description: The invention relates to a button collet having a domed cap and the method and apparatus for the manufacture of the same. A variety of button are in use which comprise a button collet and a tack member adapted to be joined together to form a button when attached to a compliant material such as a garment fabric. Generally, the cap or head, of the button carries a design on its surface face to serve as either an ornamental decoration, or an aid to grasping the button and inserting the same through a button hole of a garment. Further, the head of the button appears in at least two different forms e.g.: flat or domed. Such a button having a substantially flat surface on its face is shown in US. Pat. No 4 662 033 and in U.S. Pat. No. 4,457,050 where a decorative disk is mounted to the surface in engagement with the base plate of the collet. US Pat No 4,475,273 illustrates a domed button in which the front piece is crimped to embrace the surface in engagement with the base plate of the collet. US Pat No 2 211 322 discloses a doomed button wherein the cap member formed of a malleable material is deformed into a convex shape by temporary application of pressure, said cap member retaining its dome configuration upon removal of the pressure. U.S. Pat. No. 4,475,273 illustrates a domed button in which the front piece is crimped to embrace the periphery of the back piece of the button collet. Both flat and domed buttons are used depending on the styling or utilitarian needs of the customer and the manufacturer must be prepared to quickly supply those needs. A major problem is thus evident as both flat and domed buttons must be carried in inventory so that a ready supply of buttons is immediately available all carrying the appropriate information on the button face. As described hereinafter, the button collet of the subject invention is constructed with a minimum of structural elements whose cap can be readily and easily changed from a flat configuration to a domed configuration. The invention is summarized as a domed button collet, and the method and apparatus for making the same, that includes: an elastic body, having a shank member and a plate-like flange member located at one end thereof; and, a cap member, overlying the outer surface of said flange member and secured to the peripheral edge portion of the flange member, the flange and cap member being deformed by the application of pressure to simultaneously bend the flange and cap members into a substantially convex dome shape such that upon removal of pressure, the cap member retains its dome shape and the flange member reverts to its original plate-like configuration. The preamble of claim 1 is based on US-A-4662033. An object of this invention is a button collet having a cap member that can be readily formed with a domed configuration. Another object of this invention is a button collet that can be simultaneously attached to an article and have its cap deformed into a domed shape. One advantage of the invention is that button collets can be manufactured in a uniform configuration but can be attached to an article with either a flat or a domed cap. Other objects, advantages and features of the invention will be apparent from the following description of the preferred embodiments taken in conjunction with the accompanying drawings. Figure 1 is a side elevational view of a button having a flat faced cap embodying the present invention secured to a sheet of compliant material by a rivet; Figure 2 is a view similar to Figure 1 showing a button having a domed cap; Figure 3 is an enlarged cross sectional view of Figure 2; Figure 4 is a diagrammatical view, partly in section, of the apparatus for securing the button collet and tack to a sheet of compliant material. Figure 5 is a diagrammatical view similar to Figure 4 and showing attachment of the button collet and tack to sheet material and simultaneously forming a domed collet; and Figure 6 is a diagrammatical view, partly in section, of another embodiment of apparatus for forming a domed collet. The present invention is particularly useful when embodied in a button collet 10 as shown in Figure 1, attached by a rivet 12 to a sheet of compliant material, such as fabric 14, interposed therebetween, to form a button. Button collet 10, formed from an elastic material, includes a shank 16 and a plate-like flange member 18 and a cap 20 formed from a malleable material, such as metal or plastic which can be permanently deformed under pressure in a punch operation from a flat sheet to the curved domed cap. As shown in Figure 1, the cap 20 has its outer peripheral portion 22 crimped under the flange 18 of the collet 10 to permanently secure the cap 20 thereto. The shank 16 of the collet 10 spaces the cap 20 and the flange 18 above the upper surface of the fabric 14. Figure 2 illustrates another embodiment of a button in which a cap 20 is similarly secured to the collet 10 and has a convex dome shape configuration at 24. A particular design or ornamentation can be embossed or otherwise placed on the cap 20, in each instance, to provide product identification or as an aid to grasping the button. A domed button collet 10 is shown in Figure 3, and more clearly illustrates how the peripheral portion 22 of the cap 20 is turned under and crimpted onto the flange 18 to poermanently secure the cap 20 to the collet 10. While for purposes of illustration, the button collet 10 and its flange 18 and cap 20 appear to be circular in configuration, when viewed from above, the button can assume any configuration e.g.: square, octangonal, etc., and still be included in this invention. A rivet or tack 12 having a head 26 and a pronged member 28 secures the button collet 10 to the material 14. The outer peripheral portion of the flange 18 extends radially outward from the shank 16 and provides a lip on which the cap 20 can be crimped to support the same. As shown in Figures 4 and 5, the apparatus for converting a flat head button to a domed head button includes a punch 30 and a ram 32 both mounted and positioned to move towards each other along the same axis in a manner known in the art, and better illustrated and described in a patent to Schmidt et al, U.S. Pat. No. 3,803,698. The button collet 10 and the tack 12 are fed from respective storage supply containers (not shown) to be positioned relative to the punch 30 and the ram 32, respectively. Arms 34 and 36 hold the collet 10 in position on the punch 30 until the apparatus is actuated. Also, the collet 10 and the tack 12 cna be hand fed to the punch 30 and the ram 32, respectively. The punch 30 includes a concave surface 40 which forms a recess 38 that subtends the diameter of the cap 20 including the peripheral portion 22 of the cap 20 crimped about the edge of the flange 18. The arms 34 and 36 initially support the collet 10 in the recess 38 but on the downstroke of the punch 30 are moved out of engagement in a known manner. An opening 42 is centrally located in the shank 16 and projects upwardly from a bottom surface 44 of the collet 10. The rivet or tack 12 is carried in a recess 46 of the ram 32 and is positioned beneath the material 14, with the pronged member 28 positione to enter the opening 42 of the collet 10. The longitudinal axis of the opening 42 and the pronged member 28 is the same as the punch 30 and the ram 32. As shown in Figure 5, when the attaching equipment is actuated, the ram 32 moves upwardly and the pronged member 28 of the tack 12 moves to pierce the material 14 and enters the opening 42 of the collet 10. Simultaneous, with the upward movement of the ram 32, the punch 30 carrying the collet 10 with it descends until the bottom surface 44 of the shank 16 engages the material 14. A tip 48 of the pronged member 28 now pierces the material 14 and enters the opening 42. The downward movement of the punch 30 drives the outer peripheral portions of the cap 20 and the elastic flange 18 of the collet 10 further downward, whereby the cap 20 and the flange 18 are acted upon by the concave surface 40 of the punch 30, to assume a convex domed shape. The tack or rivet 12 continues its upward movement until the pronged member 28 is fully seated in the opening 42 at which time the head 26 prevents further upward movement as the material 14 is captured between the bottom surface 44 of the collet 10 and the head 26 of the tack 12. When the punch 30 is retracted at the end of its cycle, and the pressure exerted thereby is removed, the cap 20 retains its convex shape, whereas the flange 18 reverts to its generally flat original shape as shown in Figure 3. Another embodiment of the invention is illustrated in Figure 6 wherein a holder 50 secured by means such as screws or clamps (not shown) is mounted to a table 52. The holder 50 has a central opening 54 which accepts the shank 16 of the collet 10 and maintains the collet in a vertical position with the axis of the shank 16 vertical to the horizontal plane of the table 52. An upper wall 56 of the holder 50 slopes away from the uppermost end of the opening 54. In a manner similar to that shown and described with reference to Figures 4 and 5, a punch 30 having a concave surface 40 will act on and deform the flange 18 and the cap 20 to generate a collet having a cap 20 with a dome configuration 24 identical to that shown in Figure 3. Such a collet with a dome configuration can be supplied by the button manufacturer to the garment manufacturer for attachment to an article using apparatus similar to the punch and ram mechanisms shown and described above. At present, button collets of this invention are delivered to the garment manufacturer by the button manufacturer in both the flat head form or the domed head form. Thus the garment manufacturer as well as the button manufacturer must maintain two inventories. However, by this invention, only one inventory need be maintained by both the button manufacturer as well as the garment manufacturer.

Claims: A button collet comprising: a collet body having a shank member (16) and a plate-like flange member (18), said shank member (16) having a central axis and including a central opening (42) in the bottom having the same central axis as said shank member (16), said opening (42) overlying a compliant sheet material (14); a domed cap member (20) overlying an upper surface of and secured to a peripheral edge portion of said flange member (18) said cap member (20) being formed of a malleable material and deformed by temporary application of pressure to bend said cap member (20) into a substantially convex dome shape (24), said cap member (20) retaining its dome configuration; and a tack member (12) adapted to pierce said sheet material (14) and to be inserted into and retained in said central opening (42) characterized in that said collet body is elastic and said flange member (18) is simultaneously bent with said cap member (20) into a substantially convex dome shape (24) and reverts to its original configuration upon removal of said pressure. A method of forming a domed cap on a button collet comprising the steps of: retaining in a given position an elastic collet body that includes a shank member (16) having a central axis and a plate-like flange member (18) located at one end of said shank member, and a cap member (20) that overlies the surface of said flange member and secured to the peripheral edge portion of said flange member; moving a punch member (30) having a concave surface (40) along said central axis toward said collet body to engage said cap member; simultaneously bending said cap member (20) and said flange member (18) into a substantially convex dome shape; and disengaging said punch member (30) from said cap member (20) whereby said cap member retains a dome shape and said flange member reverts to the original plate-like configuration. A method as claimed in claim 2 wherein said step of retaining includes supporting the shank member (16) to maintain the central axis thereof in a given direction. A method of forming a domed cap button during attachment to a sheet of compliant material of: a button collet (10), formed of elastic material, that has a shank (16) with a central opening (42) in one end thereof, a plate-like flange member (18) on said shank opposite to said opening, and a cap member (20) of malleable material overlying said flange member and secured to the peripheral edge portion of said flange member; and, a tack member (12) having a head (26) and a pronged member (28) adapted to enter said opening, comprising the steps of: locating said sheet of compliant material (14) in a given plane intermediate said collet (10) and said tack member (12); positioning said button collet on one side of said material beneath a punch member (30) having a concave surface (40) to engage said cap; positioning said tack member (12) over a moveable ram member (32) on the opposite side of said material with said pronged member in coaxial alignment with said opening in said collet body; moving said punch member (30) and said ram member (32) toward each other wherein said pronged member pierces said material, enters and is seated within said opening to capture said material between said shank of said collet and said head of said tack; simultaneously bending said cap member and said flange into a substantially convex dome shape as said punch member drives said elastic button collet into engagement with said prong member; and retracting said punch member and said ram member out of contact with said collet and said tack, respectively; whereby said cap member (20) retains a dome shape and said flange member (18) reverts to its original plate-like configuration. A method as claimed in claim 4 including feeding individual button collets (10) to the punch member and individual tack members (12) to the ram member when both are retracted. A method as claimed in claim 4 including supporting the button collet in said punch member and said tack in said ram member to maintain the central axis of each coaxial. An apparatus for forming a domed cap (24) on a button collet (10) having an elastic body that includes a shank (16) and a radially extending flange (18) at one end of said shank, a cap member (20) formed of malleable material overlying and crimped to the peripheral edge portion of said flange, comprising: means supporting said button collet along a longitudinal axis, a punch member (30) with a centrally disposed concave surface (40) for moving along said longitudinal axis and engaging the cap member (20) on said flange of said collet, and means for actuating said punch member in a reciprocal movement to simultaneously bend under pressure said cap and said flange member into a convex dome shape, whereby upon removal of said pressure, said cap member (20) retains the dome shaped configuration (24) and said flange member (18) reverts to its original configuration. An apparatus as claimed in claim 7 wherein said means for supporting said button collet includes a holder (50) having a centrally disposed opening (54) having the same longitudinal axis adapted to accept said shank. An apparatus as claimed in claim 8 wherein the inner surface of said holder that encompasses said shank of said collet has a height substantially the same as the length of said shank, with the radially extending surface (56) positioned under said flange sloping away from said upper end of said holder. An apparatus as claimed in claim 9 for use with a button collet whose shank is circular in cross section wherein said holder is ring shaped with said opening accepting said shank of said collet. An apparatus for forming a domed cap (24) on a button during attachment of a button collet and a tack member to a sheet of fabric wherein: the button collet (10) has an elastic body that includes a shank (16), a central opening (42) having a longitudinal axis in one end of said shank and a radially extending flange (18) at the other end, and a cap member (20) formed of a malleable material overlying and crimped to the peripheral edge portion of said flange (18); and said tack member (12) has a head (26) and a pronged member (28) adapted to enter said central opening, comprising; reciprocable punch means (30) for supporting said button collet on the longitudinal axis of said central opening, a concave surface (40) on said punch means for engaging said cap member (20) when moving said collet, reciprocable ram means (32) for supporting said tack member (12) on the longitudinal axis, means for actuating said punch means and said ram means to move toward each other wherein said prong for member first pierces said fabric and enters and seats in said central opening of said collet, and said concave surface simultaneously bending both said cap member and said flange into a substantially convex dome shape as said punch member drives said elastic button collet into engagement with said prong member of said tack member, whereby said cap member (20) retains a dome shape (24) and said flange member (18) reverts to its original plate-like configuration upon the reverse reciprocable movement of both said punch means and said ram means. An apparatus as claimed in claim 11 wherein said reciprocable punch means moves said collet to seat the bottom surface of said shank on the surface of said fabric, and said ram means moves so that the tip of said pronged member pierces said fabric substantially at the same time.

Inventors: SPARROW, TIMOTHY HAINES
Applicants: YOSHIDA KOGYO K.K.
Application year: 1988
Main classification: A44B1
IPC codes: B21D53, A41H37, A44B1