Sample garment making system

Abstract: A sample garment making system (10) including: a controller (12) for creating a marker based on data representing individual pattern pieces defining corresponding parts of the sample garment, and data representing selected portions of sheet material on which the pattern pieces are to be arranged and the corresponding garment parts are to be cut; and an apparatus (14) controlled by command signals received from the controller for performing at least one work operation on the sheet material the improvement comprising: a table (24) including: a porous, air-permeable core (28), said core defining a vacuum plenum (30), the plenum having a sheet material support surface (34) for supporting the sheet material (36) during a work operation and an opposite surface (32); a digitizer (60) disposed adjacent to the opposite surface (32), the digitizer being in electromagnetic communication with the support surface (34) through the plenum (30) and in communication with the controller (12) to provide the controller with data defining the sheet material (36).

Description: The present invention relates to a table for supporting sheet material during a work operation, comprising an air-permeable core and a vaccum plenum, said core having a sheet material support surface. A table of this kind is described in WO-A-87/04657 and consists of a porous core of a foamed material and a separate vaccum plenum disposed below the core. The vacuum plenum is in fluid communication with a vacuum source for applying vacuum via the vacuum plenum and the air permeable core at the upper surface of the core upon which the sheet material is held down during the work operation. GB-A-2 188 170 describes a similar apparatus having a table in the form of a drum. The interior of the drum defines a vacuum plenum which is in fluid communication with a vacuum pump via an air line. The drum has an outer surface penetrable to some degree by a cutting knife for sheet material which is held on the drum surface by vacuum applied to it through the surface material. Accordingly the drum works on the same principle as the table described in WO-A-87/04657. The overall thickness of the known table is determined by the vertical dimension of the air-permeable core and the vacuum plenum. However, the vertical dimension of the table should be adequately small for the sake of a simple and light construction. Furthermore, a large vertical dimension is disadvantageous especially for those tables having a digitizer beneath the vacuum plenum. Such digitizer is electromagnetically coupled through the core to a tool for working on the sheet material on the support surface. The digitizer feeds electrical signals to a controller depending on the characteristics of said electromagnetic coupling. The problem to be solved by the invention is to provide a table of the kind mentioned above, having a small overall thickness without affecting the vacuum hold-down efficiency. The invention solves this problem by the features of the independent claim. Advantageous further developments are specified in the dependent claims. The invention provides a table comprising a porous, air-permeable core. The core defines a vacuum plenum having a lower surface and a sheet material support surface for supporting the sheet material during a work operation. A digitizer can be disposed adjacent to the lower surface of the plenum. The digitizer is in electromagnetic communication with the support surface through the plenum and also communicates with a controller to provide the controller with data defining selected portions of the material supported on the support surface. The invention will now be further described with reference to the enclosed drawings, wherein: Fig. 1 is a perspective view of a sample garment making system embodying the invention. Fig. 2 is a fragmentary sectional view of the table which forms a part of the system shown in Fig. 1. Fig. 3 is a top view of the core which forms a part of the table shown in Figs. 1 and 2. Figs. 1 and 2 illustrate a sample garment making system embodying the invention. The system, generally designated 10, includes a controller 12 and an apparatus 14 driven by command signals from the controller for cutting and performing related work operations on sheet material supported on the apparatus. As shown in Fig. 1, the system 10 presents a very low profile and is similar in general appearance to plotters typically found in the design studio environment. This is accomplished by the particular design of several of the apparatus' major mechanical components, as will be discussed further below, and by the use of coverings to shield the mechanical components of the apparatus from view. Several of these coverings, such as table end covers 16, 16, beam end covers 18, 18, tool carriage cover 20, and base enclosure 22 are shown in place in Fig. 1. For the purposes of clarity, these coverings have been removed in subsequent figures. The controller 12 includes a central processor linked to a pattern development system (not shown) for receiving digitized representations of the individual pattern pieces comprising the sample garment. Any known pattern development system may be employed to create the digitized representations of the pattern pieces; however, in the preferred embodiment of the invention a pattern development system sold by Gerber Garment Technology, Inc. under the trademark SILHOUETTE™ is used. Based on the digitized representations of the pattern pieces provided by the design development system, the central processing unit of the controller 12 creates a marker defining the arrangement of the individual pattern pieces on the sheet material as the corresponding garment parts are to be cut from the material. Typically, the sample garment is made from fabric; however, it should be understood that the invention is in no way limited in this regard and that the system 10 can be utilized with other sheet materials commonly used in garment making such as, for example, leather and suede. Once the marker has been created, the controller forwards command signals to the apparatus 14 based on the marker instructions to cut the garment parts comprising the sample garment from the material. Thus, the system 10 permits complete automation of the sample garment making process up to the final step wherein the cut parts comprising the sample garment are sewn together or otherwise assembled. In the illustrated embodiment of the system 10, the apparatus 14 comprises a vacuum hold-down table 24 which includes a frame 26 and a stationary, porous, air-permeable core 28. The core 28 defines a vacuum plenum 30 having a lower surface 32, and a generally horizontally disposed sheet material support surface 34 for supporting a layer of sheet material, such as the illustrated layer of fabric 36, in a spread condition. A support assembly, generally designated 38, is provided for supporting a cutting wheel 40 for movement relative to the support surface 34 in the illustrated X and Y coordinate directions along predetermined cutting paths to cut the illustrated garment parts 41, 41. The cutting wheel 40 is mounted on a toolhead 42 which moves the cutting wheel into and out of cutting engagement with the fabric 36. As will be explained below, the toolhead also supports, in addition to the cutting wheel, other tools which enable the apparatus 14 to perform multiple work operations on the fabric 36. Referring now to the vacuum hold down table 24 in more detail, and in particular to Figs. 1, 3 and 4, the core 28 is formed from a rigid plastic material 44 defining a plurality of apertures 46, 46 in both the lower surface 32 and the support surface 34 of the core. The material 44 further defines a plurality of interconnected vertical 48 and horizontal 50 air passageways which communicate with the apertures 46, 46. Accordingly, the core functions as a single structural element which defines not only the support surface 34, but also the vacuum plenum 30 for applying vacuum to the surface through the interconnected passageways. Vacuum is applied by a vacuum source (not shown) housed within the base enclosure 22. The vacuum source communicates with the plenum 30 via an associated conduit and manifold (also not shown), and, since the plenum defined by the rigid plastic core has interconnected vertical and horizontal air passageways, vacuum may be applied to the entire support surface 34 by coupling the manifold to either the lower surface 32 or a side portion of the core 28. In the preferred embodiment of the invention, vacuum is applied along a side portion of the core. Accordingly, the table 24 includes a thin layer or skin 47 of plastic disposed immediately adjacent to the lower surface 32 and glued or otherwise attached to the core 28 to seal the apertures 46, 46 in this surface, thus maximizing the vacuum applied to the support surface 34. In the illustrated embodiment of the invention, the core 28 measures about 3,05m (120 inches) in length and about 1,78m (70 inches)in width, although the usable portion of the support surface 34 has somewhat reduced length and width dimensions. The core measures about 1,9cm (0.75 inches) in thickness and the plastic skin 47 measures about 1,5mm (0.06 inches) in thickness. Of course, the length and width dimensions of the core 28 may be made larger or smaller depending on the particular application for which the system 10 and its associated table 24 are intended. The plastic material 44 forming the core 28 is preferably an over-expanded ABS copolymer manufactured and sold under the trademark NoreCore® by the Norfield Corporation of Danbury, CT. The core is made by partially melting a sheet of the copolymer between two heated, apertured plates. Vacuum is applied to the plastic sheet through the appetures in the plates, and the plates are pulled apart to draw and stretch the partially melted plastic to form webs 52, 52 extending between the lower surface 32 and the support surface 34. The plates continue to be pulled apart until the webs rupture to form holes 54, 54, thus providing the interconnected vertical and horizontal passageways 48 and 50. After the plastic sheet cools it is removed from between the plates with the appetures 46, 46 already formed in the lower and support surfaces by the vacuum applied through the apertures in the heating plates. Depending on the degree to which the webs 52, 52 have ruptured, additional holes 54, 54 may have to be punched or drilled in the webs in order to provide the core with adequate air permeability. It should be understood that the invention is not limited to a core formed from this material and in the manner just described. Instead, the core may be formed by any suitable material which simultaneously defines the support surface 34 and the vacuum plenum 30. Thus, for example, other thermoplastic materials, open cell foams, or even ceramic could be utilized to form the core 28. To provide a well dispersed, evenly distributed vacuum across the entire extent of the support surface 34, as well as a uniform work surface as the cutting wheel 40 or other tool is directed along a work path by command signals from the controller 12, a layer 56 of fluid permeable material is supported on the table 24. The upper surface of this layer defines a uniform work surface 58 against which the fabric 36 is firmly held as vacuum is applied through the layer 56 during a work operation. In the preferred embodiment of the invention, the layer 56 comprise a 1,5mm (0,06 inches) thick sheet layer of air permeable paper available under the trademark TEXTRON™. Of course, other known fluid permeable materials could be used to form the layer 56 such as, for example, porous cardboard, a rigid porous foam, or a high density filter media having pore sizes in the range of about 80 microns. Since the core 28 combines both the support surface 34 and the vacuum plenum 30 in a single structural element, the overall distance from the work surface 58 to the bottom of the plastic skin 47 measures less than 2,5cm (an inch). This feature of the invention permits the placement of a digitizer 60 directly below the plastic skin 47, and in the case where such a skin is not utilized, the digitizer 60 may be placed immediately adjacent the lower surface 32. The digitizer 60 is electromagnetically coupled, directly through the core 28, to a stylus 62 (see Fig. 1) used for marking on the fabric 36 as it is supported in a spread condition on the support surface 34. The digitizer itself is linked to the controller 12. Thus, digitized representations of any markings made on the fabric 36 using the stylus 62 are received by the controller and may be utilized in preparation of the marker. For example, if the fabric 36 has a flawed area that the designer wishes to avoid when the pattern pieces are arranged and the corresponding garment parts cut, this area may be marked out using the stylus 62. Digitized data representing this marked out area is received by the controller 12, and the central processor of the controller adjusts the marker instructions to rearrange the, pattern pieces so as to avoid this area during cutting of the individual garment parts. It may also be the case that a particular garment part is intended to include a specified design or appliqué. Where the design is already incorporated in a particular portion of the fabric 36 or the appliqué has been pre-applied at a specific location on the fabric, the corresponding area of the fabric is marked using the stylus and the marker adjusted to insure that when the particular garment part is cut, it includes this area of the fabric with the design or appliqué properly positioned within the part. Any number of other possibilities for use of the digitizer 60 and its associated stylus 62 will be immediately obvious to the those skilled in the art. The important point to be recognized is that the controller 12 can create the marker based not only on data representing the pattern pieces which correspond to the individual garment parts comprising the sample garment, but also data representing selected portions of the fabric or other sheet material from which the parts will be cut. As shown best in Fig. 3, the digitizer 60 is not provided as a single digitizing tablet but, instead, comprises a series of overlapping digitizer panels. In the illustrated embodiment of the invention, three such panels are provided 64, 66 and 68. Each of the panels measures about 1,08m (42.7 inches)in width, 1,78m (70 inches) in length about 1,68mm (0.066 inches)in thickness. Adjacent panels form overlap areas measuring about 10,2cm (4 inches)in width, and the spacing between non-adjacent panels is taken up by plastic spacing elements 70, 72 and 74. The number, arrangement and dimensions of the panels may, of course, vary depending on the dimensions of the table 24, and it is also possible, although not preferred, to provide the digitizer 60 as a single tablet. While in the illustrated embodiment of the invention the vacuum table 24 includes the digitizer 60 disposed adjacent to the lower surface 32 of the core, the invention is not limited in this regard. The invention also encompasses vacuum tables which include a digitizer or other coordinate generating technology positioned above the work surface 58, such as, for example, tables utilizing ultrasonic or optical digitizers. The invention further encompasses tables which do not include a digitizing device. In either case, the core 28 may be formed from a material which is partially or completely opaque to electromagnetic fields such as, for example, porous metal composites.

Claims: A table (24) for supporting sheet material (36) during a work operation, comprising an air permeable core (28) and a vacuum plenum (30), said core (28) having a sheet material support surface (34), characterized by said air-permeable core (28), defining said vacuum plenum (30). The table (24) of claim 1 further comprising a vacuum source in fluid communication with the air-permeable core (28) for applying vacuum at the support surface (34). The table (24) of claim 1 or 2 further comprising a layer of fluid-permeable material (56) supported on the support surface (34) and defining a work surface (58), said work surface being in fluid communication with the plenum (30). The table (24) of claim 1, 2 or 3 further comprising a digitizer (60) disposed beneath the core (28), said digitizer being in electromagnetic communication with the work surface (58) through the plenum (30). The table (24) of any of the foregoing claims wherein the digitizer (60) comprises a plurality of overlapping digitizer panels (64,66,68). The table (24) of any of the foregoing claims wherein the core (28) comprises an overexpanded plastic, said overexpanded plastic defining a plurality of interconnected vertical (48) and horizontal (50) air passageways.

Inventors: BUCKLE ALLAN, LEBLOND CLAUDE, STEIN DARRYL COLBURN, WILLIAMS KEVIN M, ZUSMANOVICH ALEX, BUCKLE, ALLAN, LEBLOND, CLAUDE, STEIN, DARRYL COLBURN, WILLIAMS, KEVIN M., ZUSMANOVICH, ALEX
Applicants: GERBER TECHNOLOGY INC, GERBER TECHNOLOGY, INC.
Application year: 1996
Main classification: A41H3
IPC codes: A41H43, A41H3, B26F1, B26D7, B26D1, B26D5