Patent Publication Number: US-6336416-B1

Title: Embroidery frame with adapter arms

Description:
FIELD OF THE INVENTION 
     The present invention relates to the field of embroidery operations, and, more particularly to an improved device for holding small items to be embroidered during such operations. 
     BACKGROUND OF THE INVENTION 
     In the sewing and embroidery industry, fabric holding clamps, templates, and hoops are widely used for holding individual work pieces on single and multi-head embroidery machines. These devices are numerous, due in part to the number of different manufacturers and models of automated embroidery machines on the market and in use. For example, Tajima, Melco, Barudan, SWF, Brother, and Toyota each produce such machines. While certain features are similar, such as the general manner in which embroidery devices are mounted, these machines are neither designed nor constructed to have commonly-shaped mounts and are thus not capable of accepting fabric holding devices (frames) from other models. This means that an embroidery operation at the present time must limit itself to one model, or must purchase multiple frames of the same size and type for each of the different models in use. Most operations chose the latter course of action for economic reasons. As a result, the embroidery company must carry a different frame for each different make of machine. 
     An additional problem in the sewing industry associated with fabric holding devices is that, particularly for automated multi-head machines, these devices are pneumatically operated. While pneumatic controls provide some convenience for long runs, they are not conducive to operations that require frequent changing of fabric holding devices for the performance of different jobs, such as runs of small lots. Particularly for multi-head machines, the installation and hookup process for pneumatically operated machines is not only time consuming, but also requires a skilled technician to properly connect the system of pneumatic hoses to the fabric holding devices. In addition to the time, labor, and skill required, this switchover process means loss of production and thus, lost revenue, for extended periods during the production year. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to a fabric holding device that addresses both of the above problems. The holding device of the present invention is manually operable, rather than pneumatically operable. The same frame can also be easily and quickly installed on various models of automated embroidery machines without the need for modifications to the machine. This results in significant labor savings and a corresponding reduction in machine down time, and hence, less loss of production. The holding device also addresses the lack of interchangeability by providing an apparatus that is interchangeably mountable on automated embroidery machines via a set of adapters that are easily switched. 
     One aspect of the present invention is to provide a manually operable embroidery clamping frame for holding an article to be embroidered using automated embroidery equipment. The frame includes a base frame member and an upper clamping member, which is moveable from the open to closed position manually rather than pneumatically. 
     The base frame member is generally rectangular and flat, having opposed front and rear ends and opposed side edges. An embroidery opening defined by the front end and opposed side edges is formed through the base. Walls extend upward from at least some portion of each opposed side edge. The walls are desirably integrally formed with the base, but may be separated affixed. Preferably, although not required, flanges are attached to and extend inwardly from the top edges of the walls for attaching the upper clamping member to the base. 
     The upper clamping member having opposed front and rear ends and opposed side edges is pivotally connected to the base through the upstanding walls. Upper arms are integrally formed with and extend forwardly outward in parallel relation to one another from each of the opposed side edges. An upper frame, generally rectangular in shape, is pivotally mounted between the upper arms. The ends and side edges of the upper frame define an embroidery opening corresponding approximately in size and shape to the embroidery opening in the base. When the upper clamping member is pivoted to closed contact with the base, the embroidery opening in the upper frame is in approximate registration with the embroidery opening in the base. As used herein, “registration” means that the embroidery openings align one atop the other when the base and upper frame are in closed contact. Because the upper frame is pivotally attached to the forwardly extending arms of the upper clamping member, the holding surface of the upper frame is allowed to contact the holding surface of the base simultaneously and evenly when an article is being clamped between the two. This eliminates a problem known in the art whereby the opening and closing of frames and hoops tend to pull and distort the fabric, resulting in an inferior product. 
     A manual clamping mechanism is provided in which the upper clamping member is pivotally attached to and normally biased toward closed gripping contact with the base. This is achieved in part by attaching a spring between the upper clamping member and the base. A lever mechanism engages the clamping member to provide the mechanical advantage to overcome the spring bias and open the clamping frame so that the embroidered article may be positioned or removed. 
     All models contain mounting arms that extend outwardly from the clamping mechanism. Although the embroidery stations of the different models are generally the same width in currently available models, the outer edges of the mounting arms for different models are uniquely shaped for mating, engagement with a single make of automated embroidery machine. 
     A second aspect of the invention is therefore to make the fabric holding device interchangeable with at least several makes of embroidery machines. To accomplish this the mounting arms must be configured differently at the outer ends. One way of accomplishing this is to make the entire mounting arm replaceable. However, preferably, the mounting arms are provided with adapter plates at the outer ends thereof. Instead of having the outer ends of the mounting arms uniquely shaped for mating engagement with a particular model of automated embroidery machine, the outer ends of the mounting arms have threaded holes formed therethrough. A plurality of adapter plates are provided, each having holes corresponding to threaded holes in the mounting arms. A selected appropriate set of adapter plates is affixed to each outer end of the mounting arms via the threaded holes on the mounting arms. The free end of each plate set is configured to mate with the embroidery frame holders of a particular embroidery machine. For example, for a Tajima machine, adapters formed to mate with that machine are removably attached to the ends of the mounting arms. For a Melco machine a different set of adapters is used. So that a single embroidery clamping device may be interchangeably used from one model to another, the adapters may be quickly and easily changed. An embroiderer will have to purchase only one frame even if two or more different models of machines are being used within the same facility. 
     These and other aspects of the present invention will become apparent to those skilled in the art after a reading of the following description of the preferred embodiments when considered in conjunction with the drawings. It should be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a left front perspective view of the embroidery frame of the present invention with the base and upper clamping member in the open position; 
     FIG. 2 is a right rear perspective view of the device of FIG. 1 with a Melco adapter plate; 
     FIG. 2A is an exploded view of a mounting arm and adapter; 
     FIG. 3 is a right rear perspective view similar to FIG. 2, except with the base and upper clamping member in the closed clamping position; 
     FIG. 4 is an environmental view of the embroidery frame of the present invention installed on a typical automated Brother embroidery machine; 
     FIG. 5A is a top view of the adapters for a Melco embroidery machine; 
     FIG. 5B is a top view of the adapters for a Banidan embroidery machine; 
     FIG. 5C is a top view of the adapters for a SWF embroidery machine; 
     FIG. 5D is a top view of the adapters for a Tajima embroidery machine; and 
     FIG. 5E is a top view of the adapters for a Brother embroidery machine. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     As shown in FIG. 1, the present invention is directed to a manually operable clamping frame for holding an article to be embroidered using automated embroidery equipment. Shown generally as  10 , the embroidery frame includes a base  12 , an upper clamping member  22 , a manual clamping mechanism  32 , and mounting arms  42 . 
     FIGS. 1 and 2 are illustrative of the manually operable embroidery frame of the present invention, adaptable to an SWF embroidery machine, in an open position; i.e., the base  12  and upper clamping member  22  are not in closed contact with one another. Base  12  has opposed front and rear ends  13 , 14 , and opposed side edges  15  forming a framed opening adjacent the front end in which the embroidery operation takes place. Walls  16  extend upwardly from at least some portion of side edges  15  forming a framed opening adjacent the front end in which the embroidery operation takes place. Walls  16  are integrally formed with base  12 , but may be separately affixed. In the preferred embodiment, flanges  17  are formed with and extend inwardly from the top edges of walls  16 . Apertures  18  are formed through the flanges  17  for attachment of springs  33  which hold the clamping mechanism  32  thereto as will be described hereinafter. As seen in FIGS. 1 and 2, end  13  and sides  15  define a first rectangular embroidery opening through base  12 . Desirably, a non-slip material  46  such as rubber or course sandpaper is adhered around the periphery of the embroidery opening to enhance the capability of frame  10  to hold the article to be embroidered. 
     Upper clamping member  22  is pivotally mounted to base  12  between walls  16  with fasteners  23  extending through walls  16  and through side walls of upper clamping member  22 . Fasteners  23  are comprised of an elongate rod (not shown) with threaded ends. Nuts hold the rod in an inserted position through walls  16  and clamping member  22 . Alternatively, separate fasteners  23  may secure each wall  16  to opposed sides of upper clamping member  22 . Upper clamping member  22  includes opposed front and rear ends  24 ,  25  and opposed side edges  26 . As shown in FIGS. 1 and 2, the front portion of upper clamping member slopes forwardly and downwardly from peak  22 A, peak  22 A being in general alignment with fasteners  23 . Similarly, the rear portion of upper clamping member  22  slopes rearwardly and downwardly from peak  22 A. Arms  27 , integrally formed and downwardly with upper clamping member  22 , extend forwardly from each of said opposed side edges  26 . A frame  28  is pivotally attached to and between arms  27  with fasteners  54 . Fasteners  54  are screws with lock nuts, but other suitable fasteners conventionally known in the art will provide equally satisfactory results. Frame  28  is generally rectangularly shaped, having opposed front and rear edges  29  and opposed side edges  30  defining a second embroidery opening therethrough. The size of frame  28  and the corresponding embroidery opening formed therethrough are varied with the type and size of item to be embroidered. The second embroidery opening is dimensioned so that it is substantially the same size and orientation as the first embroidery opening and in registration with the first embroidery opening when the two are in closed contact. A non-slip material  47  is also adhered around the periphery of the second embroidery opening for gripping engagement. 
     Clamping mechanism  32  is provided to maintain the base  12  and upper clamping member  22  with frame  28  in positive closed contact. As used herein “positive closed contact” refers to a pressure exerted between the article holding surfaces that is sufficient to prevent slippage under expected operating conditions for automated embroidery machines. In the preferred embodiment, manual clamping mechanism  32  is comprised of tension springs  33 , levers  34  and  35 , rollers  36 , and a lever channel  37 . Springs  33  are attached to base  12  through slots  18  in flanges  17  and extend between flanges  17  and the rear end  25  of upper clamping member  22  where they attach through holes  38 . Springs  33  tensionally bias the rear end  25  of upper clamping member  22  upwardly to urge frame  28  downwardly into closed contact with base  12 . The amount of tensional holding force exerted is dependent upon the spring constant chosen for springs  33 . 
     As shown in FIGS. 1 and 2, levers  34  and  35  are integrally formed and connected through a common fulcrum axis  39  formed through walls  16 . As best seen in FIG. 1, lever  34  is formed with a handle portion having an end bent at a right angle for insertion through fulcrum  39 . The handle portion is of sufficient length to provide a mechanical advantage over springs  33 . As shown in FIG. 3, the handle portion of lever  34  is normally in a vertical orientation when base  12  and upper clamping member  22  are in closed contact. Lever  35 , formed through a right angle with lever  34  is in a generally horizontal orientation with its central portion contained within channel  37 . Rollers  36  surround portions of lever  35  to provide for rollable movement of lever  35  against upper clamping member  22  when lever  34  is manually pulled to the forward horizontal position shown in FIGS. 1 and 2. In operation, when lever arm  34  is pulled forwardly and downwardly, lever  35  with rollers  36  is pivoted and urged downwardly and rearwardly in channel  37 . This mechanical displacement overcomes the spring bias and causes upper clamping member  22  to pivot downwardly and springs  33  to stretch. The rearward pivot of upper clamping member  22  causes frame  28  to disengage from contact with base  12 . When lever arm  34  is pushed upwardly and rearwardly, the exact opposite occurs. The energy in springs  33  aids in pivoting upper clamping member  22  forward in closed contact with base  12 . 
     Referring again to FIG. 1, mounting arms  42  are attached to and extend outward from base  12 . Mounting arms  42  are separately fastened to base  12  with fasteners  43  conventional in the art, such as machine screws, bolts, etc., but alternatively may be integrally formed with base  12 . 
     A second aspect of the present invention is that clamping frame  10  is mounted to any model of automated embroidery machine without the need to move or alter any features or hardware, such as pneumatic hoses, from the embroidery machines. One way to accomplish this is to have mounting arms  42  removably attachable to base  12 . By using different configurations on the extremities of the arms, the mounting arms  42  may be interchanged to fit different models of automated embroidery machines. 
     However, in the preferred embodiment of the present invention, adapter plates are mounted on the end of arms  42 ,  42 ′ to adapt the embroidery frame to fit various models of machines. For this adaptable embroidery frame, the base  12 , upper clamping mechanism  22 , and clamping mechanism  32 , are desirably the same or similar to those described in detail hereinabove. Referring to FIGS. 2 and 3, clamping frame  10  is shown with mounting arms  42 ′ that, similar to the first aspect, attach to and extend generally outward from base  12 . However, mounting arms  42 ′ are dimensioned to receive adapters. Shown as  43 A and  43 B, adapters (shown here for an SWF machine) are selectively chosen to matingly engage with a particular model of embroidery machine. As best seen in FIG. 2A, arm  42 ′ has a series of threaded holes  44  that are formed in its outer ends. Adapters  43 A and  43 B are easily attached to arms  42 ′ with threaded fasteners  45 . When attached together, embroidery frame  10  is ready to be mounted on the selected embroidery machine. 
     FIG. 4 is an illustrative environmental view of the embroidery frame  10  mounted on a Brother machine illustrating how frame  28  defines an upper embroidery opening for the embroidery head  60 . Adapters  43  are received by the arms  50  of the mounting carriage of the machine to securely hold embroidery frame  10  in place during embroidery operations. Arms  50  will, of course, vary in configuration, shape, and form of mating engagement from one model of machine to another, but the distance between the arms that form a station is substantially the same. 
     FIGS. 5A through 5D are illustrative, though not exhaustive, of typical adapter pairs that are interchangeably mounted to arms  42 ′ of the present invention. FIGS. 5A through 5D schematically show adapter pairs for the Melco, Barudan, SWF, and Tajima machines, respectively. 
     Although the present invention has been described with a preferred embodiment, it is to be understood that modifications and variations may be utilized without departing from the spirit and scope of the invention, as those skilled in the art will readily understand. Such modifications and variations are considered to be within the purview and scope of the appended claims and their equivalents.