Patent Publication Number: US-6216617-B1

Title: Apparatus and method for embroidery hoop mounting

Description:
The present invention relates to apparatus and methods for embroidering which enable the embroidery hoop and the article to be embroidered to be perfectly straight relative to one another and in the correct location without excessive marking of the article or repeated rehooping. 
    
    
     BACKGROUND 
     As well known in the embroidery industry, before embroidery material is embroidered by an automated machine, the portion of the material to be embroidered must first be placed within a matched pair of rings forming an embroidery hoop. The matched pair of embroidery rings comprise inner and outer rings such that when the two rings are properly mounted on the article to be embroidered, the smaller or inner ring fits snugly inside the larger or outer ring with portions of the material of the article pinched between the rings. The hoop, comprised of the inner and outer rings, of course, can be of any closed configuration such as circular, rectangular, D-shaped or otherwise. Embroidery hoops are used to ensure that the area of the article to be embroidered is stretched tightly and evenly between the hoop rings to ensure that the embroidery is even and not distorted, as well as to facilitate handling of the article to be embroidered. Certain automated embroidery machines also require the use of hoops for proper operation. 
     The embroidery industry is generally segmented into commercial and household markets. In the commercial market, the hoops are mounted for use in custom die sets. The article to be embroidered is positioned over one of the rings and a mechanical press forces the rings together with the material of the article to be embroidered secured between the rings. In the household market, the rings of the embroidery hoop are mounted onto the article by hand. Particularly, the area of the material to be embroidered is positioned over the outer ring and the inner ring is then placed over the material and manually forced into the outer ring. One device particularly useful in the household market for assisting the embroiderer in this aspect is described and illustrated in U.S. Pat. No. 5,784,988. 
     In both the commercial and household markets, however, the embroidery must first be located on the material, for example, a garment such as a tee-shirt, sleeve or pant leg or on flat goods such as towels, sheets and the like, all hereafter individually or collectively called an article or articles. Typically, the center of the embroidery is marked on the article and additional markings are applied to the article to attempt to align the article and the hoop. If the article and hoop are not properly aligned, the resulting embroidery on the article is not straight relative to the article. For example, the embroidery may be canted or angled or positioned above, below, to the right or left of the desired position. Consequently, it is highly desirable to ensure straight hooping without excessive marking of the article or repeated rehooping to properly and correctly align the article and hoop. 
     DISCLOSURE OF THE INVENTION 
     In accordance with a preferred embodiment of the present invention, an embroidering apparatus is provided which enables the mounting of the hoop square to the article without excessive marking or rehooping. The apparatus in one preferred embodiment hereof includes a flat base having a plurality of columns and rows of apertures orthogonally related to one another, a pair of mounting brackets for positioning the hoop on the base and one or more eccentrics to loosely confine the outer ring on the base during application of the inner ring to the material and outer ring, i.e., during hooping. The brackets and eccentrics are mounted to the base by flathead mounting screws. The screws are receivable from the back of the base through apertures in the base and nuts or wingnuts are threaded onto their projecting distal ends to secure the brackets and eccentrics in place. Also, the flat base preferably has a central projection at one end for aligning an article, for example, a garment such as a tee-shirt, on the base and a flange at its opposite end turned preferably 90°. The flat base is preferably laid on a flat table with the flange end pressed between a table edge and the individual hooping the article to maintain the base stable while hooping. 
     To employ this first embodiment of the present invention, the location of the hoop on the base is first ascertained, generally depending on where the embroidery is to be placed on the article. With the location identified, the complete hoop is placed on the flat base and the brackets and eccentrics are disposed about the hoop in positions essentially confining the hoop with sufficient play about the hoop to enable the hoop to expand. The flathead bolts are passed through the apertures from the underside of the base and through the holes in the brackets. The nuts or wingnuts are threaded onto the bolts to maintain the brackets in place. The eccentrics are similarly secured to the base using offset mounting holes so that the eccentrics can be rotated into a final position and secured by the bolt and nut arrangements. With the hoop located, the inner ring is removed and a stabilizer is temporarily secured, e.g., by tape, to the brackets overlying the outer ring. With the center of the article ascertained, the article is placed over the base and outer ring. The article is aligned to the base using an index guide which may comprise the orthogonally related rows of apertures, grid lines applied to the base, or a groove formed along the middle of the base, squaring the article relative to the outer ring of the hoop previously placed on the base. By aligning the article relative to the base, the area to be embroidered is square to the outer hoop ring on the base and to the article. The inner ring of the hoop is then applied to the outer ring, securing portions of the material of the article and the stabilizer between the hoop rings, rendering the material spanning the inside of the rings taut. The hoop and article are then removed from the base and the material is embroidered, with the assurance that the embroidery is straight to the article. 
     In a further embodiment of the present invention, a kit is provided comprised of a plurality of similar flat bases having angled flanges at one end. In this form, the bases may be mounted on an inclined surface of a stand with the angled flange engaged against a table edge or an edge of the stand to maintain the base in a stable position on the stand. The base is provided in several sizes. For example, a large sized-base with orthogonally related columns and rows of apertures, a central projection at one end and a flange at an angle of about 120°, is provided for use with large-size articles such as adult tee-shirts. An intermediate sized base of similar construction but of reduced width relative to the large base is provided with a reduced number of columns of apertures. The intermediate sized base is used, for example, for embroidering children-sized tee-shirts. Similarly, a small flat base of reduced width relative to the intermediate sized base is provided with a reduced number of columns of apertures for locating embroidery on articles such as sleeves, pant legs and the like. Each of the bases of the kit of this second embodiment is employed similarly as previously described with respect to the base of the first embodiment. Preferably, however, these bases are used with an inclined stand. Also, pins are preferably employed for placement through the brackets and eccentrics from the outer surface of the base. This avoids any need to insert screws from the backsides of the bases. 
     In this further form, one of the bases is selected depending upon the nature and size of the article to be embroidered, and the selected base is secured to the stand. The location of the article on the hoop proceeds similarly as in the first mentioned embodiment with the exception that the mounting brackets and eccentrics are secured to the selected base by removable pins inserted through the brackets and eccentrics from the front working surface of the selected base. 
     In a preferred embodiment according to the present invention, there is provided a mounting system for placement of a hoop having inner and outer rings for embroidering an article, comprising a flat base having a plurality of spaced apertures arranged in orthogonally related rows and columns, a pair of mounting brackets each having a linear surface, mounting pins for securing each bracket to the base in a selected position with the linear surface of each bracket extending generally parallel to one of the columns or rows of apertures and positioned to locate both inner and outer rings of an embroidery hoop on the base and at least one eccentric having an off-center mounting pin engageable in one of the apertures to mount the eccentric on the base and enable rotation thereof into a position to substantially confine the hoop between the mounting brackets and the eccentric. 
     In a further preferred embodiment according to the present invention, there is provided a kit for mounting a hoop having inner and outer rings for embroidering articles of different types and sizes, comprising a flat first base having a plurality of spaced apertures arranged in orthogonally related rows and columns and having a first predetermined width for embroidering articles of a large size, a second flat base having a plurality of spaced apertures arranged in orthogonally related rows and columns having a width less than the predetermined width of the base enabling embroidering articles of an intermediate size, a third flat base having a plurality of spaced apertures arranged in orthogonally related rows and columns having a predetermined width less than the predetermined width of the second base enabling embroidering articles of a small size, a pair of mounting brackets each having a guide surface, mounting pins for securing each of the brackets to a selected one of the bases in a position with the guide surfaces of the brackets arranged to at least in part confine an embroidery hoop on one base and at least one eccentric having an off-center mounting pin engageable in one of the apertures of one base to mount the eccentric to one base and enable rotation thereof into a position to substantially confine the hoop between the mounting brackets and the eccentric mounted to the base. 
     In a still further preferred embodiment according to the present invention, there is provided a method of squaring an inner ring of an embroidery hoop to a flat base and aligning an article to be embroidered relative to the base, comprising the steps of mounting a pair of brackets each having a linear surface to and in selected locations along the base to at least partially define the location of an outer ring of the embroidery hoop along the base, mounting a pair of eccentrics to and at selected locations along the base and rotating the eccentrics to positions further defining the location of the outer ring along the base, disposing a surface of the article to be embroidered along the base overlying the outer ring of the embroidery hoop, aligning the article to be embroidered relative to the base by aligning selected portions of the article with at least one guide carried by the base and engaging an inner ring of the embroidery hoop along the article and along an interior margin of the outer ring to locate portions of the article between the rings thereby tensioning portions of the article spanning the inner ring. 
    
    
     BRIEF DESCRIPTION OF THE DRAWING 
     FIG. 1 is a plan view of an apparatus for centering an article to be embroidered and an embroidery hoop relative to one another according to a first embodiment of the present invention; 
     FIG. 2 is a cross-sectional view thereof taken about on line  2 — 2  in FIG. 1; 
     FIGS. 3,  4  and  5  are views similar to FIG. 1 illustrating a plurality of different sizes of bases similar to the base of FIG. 1 for use in a second embodiment of the present invention; 
     FIG. 6 is a side elevational view illustrating a stand and one of the bases illustrated in FIG. 3 in position for squaring the article relative to the hoop; and 
     FIGS. 7 and 8 are schematic cross-sectional views illustrating the manner of placement of the article and the hoop rings on the selected base. 
    
    
     BEST MODE FOR CARRYING OUT THE INVENTION 
     Referring now to the drawing figures, particularly to a first embodiment of the present invention illustrated in FIGS. 1 and 2, there is illustrated an embroidery apparatus, generally designated  10 , including a flat base  12  having a plurality of apertures  14  preferably arranged in orthogonally related columns and rows thereof. The base  12  may be formed of any suitable material, for example, pressed particleboard. As best illustrated in FIG. 1, one edge of the base  12  has a central projection  15  used for centering a garment on the base. As illustrated in FIG. 2, an opposite edge of base  12  has a flange  16  projecting from the flat base  12  at right angles thereto for stabilizing the base as explained hereafter. A central groove  19  extends along the front or working surface of the base  12  parallel to the columns of apertures  14  and grid lines  23  are also applied, forming gradations. The central groove  19 , the grid lines  23  or the columns and rows of apertures  14  form guides for aligning the article on the base  12 . 
     The apparatus also includes a pair of mounting brackets  18  and  20 , as well as one or more and preferably a pair of eccentrics  22 . The mounting brackets  18  and  20  have respective guide surfaces  24  and  26 , preferably linear, for engaging a corresponding linear surface of the outer ring of a hoop, generally designated  28 . The surfaces  24  and  26 , however, need not be linear. As illustrated in FIG. 1, hoop  28  includes an outer ring  30  and an inner ring  32 , it being appreciated that the rings can be circular, rectilinear, D-shaped or otherwise. The outer and inner rings are sized such that the inner ring  32  fits snugly within the outer ring  30  with portions of the material of the article to be embroidered therebetween whereby the material spanning the hoop can be tightly and evenly stretched, i.e., held taut. The mounting brackets  18  and  20  also have a plurality of holes  34  therethrough whereby the location of the brackets along the base  12  can be adjusted as necessary to confine the outer ring  30  within the brackets. 
     In this embodiment of the invention, flathead bolts  36  (FIG. 2) are disposed through the apertures  14  from the underside or backside of the base  12  for reception in the holes  34  of the brackets  18  and  20 . The apertures  14  are preferably countersunk on the backside of the base such that the bolt heads lie flush with or are recessed within the underside of the base  12 . The distal ends of the bolts project through the holes  34  and nuts or wingnuts  36  may be threaded on the bolt ends to secure the brackets to the base  12 . As illustrated in FIG. 1, the eccentrics  22  have an offset opening  40 . With a bolt passing through the offset opening  40 , it will be appreciated that the eccentrics  22  can be pivoted about the bolts into positions lying closer to or further away from the margin of the hoop  28 . Additional openings  42  are provided in each eccentric and similar nut-and-bolt arrangements are used to secure the eccentrics in appropriate rotary position relative to the hoop to substantially locate the hoop  28  on the base  12 . 
     To employ the apparatus illustrated in FIGS. 1 and 2 to ensure straight hooping without excessive marking and repeated rehooping of the article, the hoop  28  is first located on the flat base  12  depending on the location of the desired embroidery on the article. In the illustrated example, the hoop  28  is located in the right upper corner of the base  12  for a left front breast placement of the embroidery. The complete hoop  28 , including the outer and inner rings  30  and  32 , respectively, is placed on the base  12  at the proper location, i.e., the upper left corner of base  12 , and the brackets  18  and  20  are secured to the base  12 . The brackets may be mounted by lifting the base from a work surface, e.g., a table T (FIG. 2) and pushing the flathead bolts  36  through selected apertures  14  corresponding holes  34  in the bracket. While holding the bolt in place, a nut or wingnut  38  is applied to the end of each bolt projecting from the upper faces of the brackets. Preferably, the two brackets  18  and  20  are placed on the base at right angles to one another, although other positions such as 45° angles can be used. The eccentrics can then be mounted by similarly inserting bolts from the backside of base  12  through the aligned apertures  14  and holes  40 . Once each eccentric is secured by a single bolt, the eccentrics are rotated into appropriate position and secured in that position similarly by inserting bolts from the backside of the base and threading nuts on the projecting ends of the bolts. Sufficient room should be allowed between the brackets, including the eccentrics, and the hoop to enable the hoop to expand and thus the brackets and eccentrics only loosely confine the hoop. The inner ring  32  of hoop  28  is then removed. 
     The center point of the embroidery on the article is then ascertained. For example, if the article comprises a tee-shirt, the garment may be folded vertically with the shoulder seam and centerline of the garment at the fold serving as base points for measuring to the center of the intended embroidery. For the illustrated left breast placement, a measurement six to eight inches down from the shoulder seam and four to six inches over from the front centerline can be used to locate the center of the embroidery for left breast placement. 
     With the center of the embroidery located and marked on the tee-shirt, and the outer ring of the hoop within the brackets and eccentrics, a stabilizer is first disposed over the brackets, eccentrics and outer ring  30  and is taped to the brackets. The garment is then pulled over the base  12  with the working surface of the garment on the front. With the shoulder seams of the garment aligned with the upper shoulder edges  46  of base  12 , the collar of the tee-shirt centered about the projection  15 , and the center of the garment aligned with the center groove  19  along the base, the garment is straight to the base  12  and to the hoop  28 . The garment centerline and groove  19  are aligned by feeling through the garment to the groove. With the base  12  placed on a table and the flange  16  of the base pressed against the table edge to stabilize the base  12  as illustrated in FIG. 2, the inner ring  32  of the hoop  28  can be applied to the outer ring  30  to snugly secure the garment and stabilizer between the inner and outer rings, for example, by using the apparatus set forth in prior U.S. Pat. No. 5,784,988. 
     It will be appreciated that the apparatus of FIGS. 1 and 2 can similarly be employed to embroider flat goods. To accomplish this, the center of the material to be embroidered is marked. With the hoop and brackets located as previously described, and the stabilizer applied, the gridlines on the base, as well as the columns and rows of apertures, or the groove  19  may serve as index guides to square the flat goods relative to the base and hence to the hoop. 
     Referring now to FIGS. 3-8, a hooping kit is provided. In FIGS. 3,  4  and  5 , bases similar to the base  12  of FIG. 1 are provided in different sizes. For example, a flat base  60  is provided in a large size of a predetermined width. An intermediate sized base  62  is provided with a reduced width. Finally, a small base  64  is provided with a width reduced from that of both bases  60  and  62 . In each base  60 ,  62  and  64 , rows and columns of orthogonally related apertures  66  are provided. As in the previous embodiment, each of the bases  60 ,  62  and  64  includes a central projection  68 ,  70  and  72  along one edge thereof. Along the opposite edge, a flange  74 ,  76  and  78  is formed which extends at an angle α in excess of 90°, preferably about 120°, as illustrated in FIG.  6 . Also in this embodiment, a plurality of mounting slots  80  and  82  are provided each of the bases  60  and  62  adjacent the upper and lower corners thereof, whereas a pair of mounting slots  84  are provided along a centerline of the base  64 . Each base also includes a central groove  86  and grid lines  88  as in the prior embodiment. 
     The bases  60 ,  62  and  64  are provided as part of a kit which also includes the mounting brackets  18   a  and  20   a , as well as the eccentrics  22   a  similar to the prior embodiment. Thus, depending upon the article to be embroidered, one or another of the bases of the kit is utilized in conjunction with the mounting brackets and eccentrics. As part of the kit and as illustrated in FIG. 6, a stand  90  is provided. The selected base  60 ,  62  or  64  is preferably secured to the inclined brackets  92  of the stand  90  by threaded bolts  94  received through the openings  80 ,  82  or  84 . The stand  90  includes a flat base frame  96  for lying on a table with the flanges  74 ,  76  or  78  of the selected base disposed along an edge of the frame  96 . Also, instead of flatheaded bolts and thumbscrews or nuts as used in the embodiment of FIGS. 1 and 2, pins  98  engageable through the brackets and eccentrics from the front side of the selected base and into the apertures  14   a  are employed to releasably secure the brackets and eccentrics to the selected base on the stand  90 . The pins  98  have springbiased, laterally projecting balls on their distal ends to releasably retain the pins in place on the selected base. 
     In use, with the selected base  60 ,  62  or  64  disposed on the inclined surface of the stand  90 , the brackets and eccentrics are located along the selected base as previously described and pinned in place. For example, the pins  98  may be received through the aligned openings of the brackets and apertures from the upper side of the base. The brackets and eccentrics are thus secured to the selected base to confine the hoop on the base. As illustrated in FIG. 7, and after the center of the article has been located as previously described, a stabilizer  100  is taped to the brackets in overlying relation to the outer ring  30  of the hoop  28 . The article is then placed over the selected base as well as the inclined portions  92  of the stand with one or more of the upper edges  46   a  of the base, the columns or rows of apertures, the central groove or the grid lines  88  providing guides for aligning the article relative to the selected base with the center of the embroidery located within the outer ring  30  of the hoop  28 . The inner ring  32  of the hoop is then inserted within the outer ring  30 , snugly securing the stabilizer and portions of the article between the two rings and rendering the material spanning the inner ring  32  taut. The hoop  28  and article can then be removed from the selected base and the embroidering may proceed. 
     While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.