Patent Publication Number: US-11396721-B2

Title: Hybrid standing sit-down quilting apparatus

Description:
BACKGROUND OF THE INVENTION 
     Field of the Invention 
     The present disclosure relates to a method and apparatus for stitching. The present disclosure relates more specifically to a method and apparatus for stitching in different positions. 
     Description of Related Art 
     A sewing machine is a machine used to stitch fabric and other materials together with thread. Home sewing machines are designed for one person to sew individual items while using a single stitch type. 
     Machine quilting is quilting made using a machine to stitch rows or patterns using select techniques to stitch through layers of fabric and batting in the manner of old-style hand quilting. 
     Free motion quilting is a process used to stitch the layers of a quilt together using a domestic sewing machine. The operator controls t the direction of the stitching by moving the quilt with their hands. The stitching can be made in any direction to produce both curvilinear lines or straight lines. Each design, whether drawn on the quilt top or held in the imagination of the quilter, is formed with a line of stitching that is guided by the movement of the quilt under the machine needle. The length of each stitch is determined by the distance the quilt has been moved since the previous stitch. 
     Longarm quilting is the process by which a longarm sewing machine is used to sew together a quilt top, quilt batting and quilt backing into a finished quilt. The longarm sewing machine typically ranges from 10 to 14 feet in length. Quilting using a longarm machine can take significantly less time than hand quilting or more traditional machine quilting. This time saving is a large factor in the gain in popularity of longarm quilting. 
     BRIEF SUMMARY OF THE INVENTION 
     In view of the foregoing, it is an object of the present disclosure to provide a method and apparatus for stitching. 
     A first exemplary embodiment of the present disclosure provides a method. The method comprises securing a moveable support surface in a first position adjacent to a sewing head having a reciprocating needle, and moving the support surface to a second position to define a working window adjacent to the sewing head. The method further comprises moving the sewing head within the working window relative to the support surface in the second position. 
     A second exemplary embodiment of the present disclosure provides an apparatus. The apparatus comprises a frame, and a sewing head operably connected relative to the frame, the sewing head including a reciprocating needle. The apparatus further comprises a support surface moveably connected to the frame between a first position adjacent to the sewing head and a second position spaced from the sewing head to define a working window adjacent to the sewing head. 
     A third exemplary embodiment of the present disclosure provides an apparatus. The apparatus comprising a frame, and a support surface coupled to the frame, the support frame having two parallel short sides and two parallel long sides. The apparatus further comprising a sewing head having a reciprocating needle, and a rail system interconnecting the support frame and the sewing, the rail system comprising two parallel short rails, one of each of the two parallel short rails fixedly coupled to the support surface along opposing edges of the short sides of the support surface, the railing system further comprising at least one long rail moveably connected to the two parallel short rails allowing movement of the at least one long rail through a long axis of the two parallel short rails, and wherein the sewing head is moveably connected to the at least one long rail allowing movement of the sewing head through the long axis of the at least one long rail. 
     The following will describe embodiments of the present disclosure, but it should be appreciated that the present disclosure is not limited to the described embodiments and various modifications of the disclosure are possible without departing from the basic principle. The scope of the present disclosure is therefore to be determined solely by the appended claims. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S) 
         FIG. 1  presents a perspective view of a first configuration of an exemplary quilting machine suitable for use in practicing exemplary embodiments of this disclosure. 
         FIG. 2  presents a perspective view of a second configuration of an exemplary quilting machine suitable for use in practicing exemplary embodiments of this disclosure. 
         FIG. 3  presents a logic flow diagram in accordance with a method and apparatus for performing exemplary embodiments of this disclosure. 
         FIG. 4  presents a perspective view of an exemplary quilting machine suitable for practicing exemplary embodiments of this disclosure. 
         FIG. 5  presents a top view of an exemplary quilting machine suitable for practicing exemplary embodiments of this disclosure. 
         FIG. 6  presents a perspective view of the second configuration of an exemplary quilting machine with a larger working window suitable for use in practicing exemplary embodiments of this disclosure. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     In free motion quilting, the location as well as the movement of the needle relative to a location of a work piece is determined by a user. That is, the user moves the sewing head of the sewing machine in whichever direction they desire to create a pattern in a work piece such as a quilt. Hence, the location of each stitch in free motion quilting is determined by the user and not preprogrammed by a computer. 
     For a “sit-down” quilting machine, a user operates a stationary sewing head to stitch patterns or other designs into a work piece. A user moves the work piece below a reciprocating needle in order to create a desired pattern or stitching. A “sit-down” quilting machine is more favorable for smaller venues due to its compact size. A user who only has a small room to devote to quilting often finds a “sit-down” quilting machine quite appealing. However, for larger work pieces, a “sit-down” quilting machine is quite cumbersome to operate. Longarm quilting machines have the capacity to effectively stitch or quilt larger work pieces where a “sit-down” quilting machine does not. Yet, due to their size, longarm quilting machines can only effectively operate in areas or rooms that are generally larger. 
     Exemplary embodiments of the present disclosure provide an apparatus and method for quilting with a sewing head that can be configured to operate such that it is fixed relative to a support surface in one embodiment and in a second embodiment configured to be moveable relative to the support surface. Exemplary embodiments of the present disclosure also provide for the support surface to provide a working plane in one configuration and a working window in a second configuration. 
     Referring to  FIG. 1 , shown is a perspective view of a first configuration of an exemplary quilting machine  100  suitable for use in practicing exemplary embodiments of this disclosure. It can be appreciated that embodiments of the present disclosure are not limited to the particular configurations of quilting machine  100 . 
     The term quilting machine  100  incorporate any device operable to stitch or embroider a work piece, fabric or quilt. The term quilting machine  100  also includes quilting machines able to stitch together multiple layers, such as a filler layer between a top and bottom textile layer, as well as an embroidery machine. 
     The term work piece incorporates any article of manufacture or fabric made by weaving, felting, knitting, crocheting, stitching, quilting, and compressing natural or synthetic fibers. In one configuration, the work piece is a quilt. 
     As depicted in  FIG. 1 , quilting machine  100  includes a frame  102 , a support surface  104  for supporting or retaining at least a portion of a work piece or fabric, a sewing machine  106 , a sewing head  108 , and reciprocating needle  110 . Quilting machine  100  further includes a motor  112 , a controller  114  operably connected to the sewing head  108 , and in some embodiments an encoder  116 . 
     The controller  114  can include a computer processor (not shown) and memory (not shown) for storing computer program instructions. The computer program instructions when executed on the computer processor allow for quilting machine  100  to perform the operations described herein. 
     Frame  102  can be arranged in any variety of configurations such that it can properly maintain support surface  104 , sewing machine  106  and any other items necessary for the operation of sewing machine  106 . For example, frame  102  as illustrated in  FIG. 1  can include struts or supports for engaging components described herein. The frame  102  can be composed of any variety of materials or combinations of materials, such as metals, metal alloys, aluminum alloys, plastics, composites or wood. 
     Sewing machine  106  includes sewing head  108  having a portion above support surface  104  and a second portion below or within support surface  104 . A passage is provided in support surface  104  such that a portion of reciprocating needle  110  can pass through a work piece placed on top of support surface  104  and selectively engaging the passage of a length of thread through the work piece. 
     In some embodiments, quilting machine  100  also includes a first sensor  124  and a second sensor  126  located on support surface  104 . First sensor  124  and second sensor  126 , as shown in  FIG. 1 , are optimally located on opposite sides of the drop location of the reciprocating needle  110 . The first sensor  124  and second sensor  126  include motion sensors or any type of sensor capable of monitoring the movement of a work piece relative to the sewing head  108 . 
     An optical sensor operates by using a small camera that takes upward of 1,500 pictures every second. The images are compared with one another such that over a sequence of images it can be determined when movement occurs. An exemplary optical sensor in the marketplace is found in a commercially sold optical mouse for a computer. In other exemplary embodiments of quilting machine  100 , the first sensor  124  and the second sensor  126  are located on sewing head  108  such that they can monitor the movement of the work piece relative to the sewing head  108 . Thus, the sensors  124  and  126  may be located below the work piece or above the work piece on support surface  104 . 
     Exemplary embodiments of controller  114  can include a display and input, such as a touch screen, keyboard, keypad, and/or mouse. The controller  14  can be physically connected to the support surface  104  or the sewing machine  106 . Alternatively, the controller  114  can be a stand-alone device, which communicates with the sewing machine  106 , motor  112 , and encoder  116  through a wired or wireless connection. 
     Encoder  116  is operably able to communicate with the controller  114  as well as computer processor  118  and memory  120 . Encoder  116  receives the movement information determined by the computer processor  118  and memory  120 . Encoder  116  then translates or converts the movement information into a format readable by motor  112 , such that motor  112  operates reciprocating needle  110  in a manner that maintains a uniform stitch length or the stitch length desired by a user. 
     Reference is now made to  FIG. 2 , which depicts a perspective view of a second configuration of an exemplary quilting machine suitable for use in practicing exemplary embodiments of this disclosure. Shown in  FIG. 2  is quilting machine  100  with frame  102 , support surface  104  with a first portion  120  and a second portion  123  in the open position, sewing machine  106 , sewing head  108 , reciprocating needle  110 , work piece retaining frame  132 , and leaves or extensions  122 . 
     Support surface  104  provides a flat area for the work piece to be placed while sewing machine  106  is sewing or operating on the work piece. Support surface  104  includes first portion  120  and second portion  123 . In another embodiment, support surface  104  further includes leaves or extensions  122 . Leaves or extensions  122  are moveably coupled to support surface  104  such that they can be moved between an extended position and retracted to a compact position. 
     First and second portions  120 ,  123  are moveable relative to frame  102  between a closed position as depicted in  FIG. 1  and an open position as depicted in  FIG. 2 . In the embodiment shown in  FIG. 1 , first portion  120  includes half of support surface  104  and the second portion  123  includes the other half of support surface  104 . However, it should be appreciated that first portion  120  and second portion  123  need not be equal and separate portions of support surface  104 , and that embodiments of this disclosure include first portion  120  and second portion  123  including different percentage surface areas of support surface  104 . 
     In the open position, the first portion  120  and second portion  123  are laterally spaced along the plane of support surface  104  from one another such that between first portion  120  and second portions  123  is defined a working window  121 . In this configuration, sewing head  108  is moveable within the working window  121  such that sewing head  108  is able to create stitches on a work piece that is placed within the working window  121 . Embodiments of first portion  120  and second portions  123  are moveable between the open position and the closed position through the use of rails, slides, wheels, or combinations of all three. 
     In the extended position, leaves or extensions  122  provide additional surface area to the flat area of support surface  104  for a work piece to be placed. In the compact position, leaves or extensions  122  are located in a position that does not add additional surface area to the support surface  104  and allows for operation of sewing machine  106 . In one embodiment, leaves or extensions  122  can moveably slide together such that they are overlapping and located underneath support surface  104  in the compact position. In the embodiment illustrated in  FIG. 1 , support surface  104  is shown in the compact configuration. Leaves or extensions  122  in  FIG. 1  are not shown, but are located beneath support surface  104 . An exemplary support surface  104  in the closed or compact configuration provides a flat area in the range of 36 inches by 48 inches. An exemplary support surface  104  in the extended position provides a flat area in the range of 36 inches by 72 inches. However, it should be appreciated that embodiments of this disclosure include a flat area that is either smaller or larger than those dimensions disclosed herein. 
     As shown in  FIG. 2 , the first portion  120 , the second portion  123  and leaves or extensions  122  are in the extended position. As depicted in  FIG. 2 , leaves or extensions  122  include three (3) leaves or extensions  122  on the left side of support surface  104  and three (3) leaves or extensions  122  on the right side of support surface  104 . However, it should be appreciated that embodiments of the present disclosure also include more or less leaves or extensions  122  as depicted in  FIG. 2 . In another embodiment, support surface  104  includes one or two leaves or extensions  122  that are able to foldably extend or collapse to a user&#39;s desired length. 
     Sewing head  108  includes reciprocating needle  110 . Exemplary embodiments of reciprocating needle  110  provide that it can operably move in an up and down (or along an X-axis or Y-axis) motion along rails or tracks  111 , such that a portion of reciprocating needle  110  can pierce a work piece that lies on support surface  104 . In the configuration depicted in  FIG. 1 , sewing head  108  is stationary relative to support surface  104  and frame  102 . Embodiments of the present disclosure provide that while first portion  120  and second portion  123  are in the closed position, sewing head  108  is maintained in a fixed position relative to the support surface  104  and frame  102 . Thus, in the illustration shown in  FIG. 1 , a user that desires to stitch a work piece will move the work piece in a desired pattern while the sewing head  108  remains motionless. Embodiments further include that while first portion  120  and second portion  123  are in the open position, sewing head  108  is moveable relative to support surface  104  and frame  102  within the working window  121 . Thus, in the illustration in  FIG. 2 , a user that desires to stitch a work piece will move the sewing head  108  in a desired pattern while the work piece remains motionless. 
     Work piece retaining frame  132  is rotatably affixed to support surface  104  through hinges  134  such that work piece retaining frame  132  can rotate about hinges  134  to and from a down position (as depicted in  FIG. 2 ) and an up position. The down position, which is depicted in  FIG. 2 , allows work piece retaining frame  132  to be placed over a work piece on support surface  104  thereby maintaining its position relative to sewing head  108 . In the up position, work piece retaining frame  132  allows a work piece to be moved and relocated such that other segments of the work piece can be stitched by sewing head  108  within working window  121 . 
     It should be appreciated that embodiments of work piece retaining frame  132  provide that hinges  134  can be placed either on the end of support surface  104  or anywhere in the mid-section of support surface  104  allowing work piece retaining frame  132  to rotate into the up position such that a work piece on support surface  104  can be freely moved within working window  121 . Exemplary embodiments of work piece retaining frame  132  include any combination of clamps, hinges, frames, and hold downs that allow a work piece to be both maintained in one configuration and moveable in a second configuration. 
     Embodiments of rails or tracks  111  include the use of wheels, belts, pulleys, and/or ball bearings moveable maintained within precision rails (as shown in  FIG. 2 ) that are rotatably attached to sewing head  108  to allow sewing head  108  to move within working window  121 . 
     Exemplary embodiments provide that encoder  116 , while sewing machine  106  is in a moveable configuration, may operably track the movement of the sewing head  108  relative to support surface  104  such that motor  112  operates reciprocating needle  110  in a manner that maintains a uniform stitch length or the stitch length desired by a user. 
     In another exemplary embodiment, while sewing machine  106  is in the moveable configuration, motor  112 , controller  114  with computer processor  118 , memory  120  storing computer program instructions, and encoder  116  can automatically stitch a predetermined pattern on a work piece. In this embodiment, motor  112  controls both the movement of reciprocating needle  110  and the movement of sewing machine  106  over support surface  104 . 
     In the configuration depicted in  FIG. 2 , since the first portion  120  and the second portion  123  are in the open position, a working window  121  is defined by the space between the first portion  120  and the second portion  123  in which sewing head  108  can operably move or stich. The working window  121  provides an area on or within support surface  104  wherein a user can move and stitch with sewing head  108 . In this embodiment, a user will maintain a work piece in a fixed or stationary position while moving the sewing head  108  within the working window to create a desired pattern or stitching. A work piece can be fixed relative to the support surface  104  through the use of clamps, clips, rollers, or a combination of the like. 
     In the configuration depicted in  FIG. 2 , sewing machine  106  may include handles  128  for selectively moving sewing head  108  over the working window. In this configuration, handles  128  may include one or two handles and may also include a switch or button  130  for selectively operating reciprocating needle  110 . Exemplary embodiments of handles  128  are moveable between a use position and a closed position. In the use position, handles  128  can be used by a user to move and operate sewing head  108 . In the closed position, handles  128  cannot be used to move or operate sewing head  108 . In the closed position, handles  128  allow for unobstructed view of the work piece and reciprocating needle  110  for a user. 
     In one exemplary embodiment, placement of the first portion  120  and the second portion  123  into an extended position will automatically define or reveal a working window  121  and place sewing machine  106  in a moveable configuration. In another exemplary embodiment, placement of sewing machine  106  into the moveable configuration will automatically open the first portion  120  and the second portion  123  defining working window  123 . 
     Reference is now made to  FIG. 6  which depicts a perspective view of a second configuration of an exemplary quilting machine with a larger working window  121  suitable for use in practicing exemplary embodiments of this disclosure. Shown in  FIG. 6  is quilting machine  100  with frame  102 , support surface  104  with a first portion  120  and a second portion  123  in the open position, sewing machine  106 , sewing head  108 , reciprocating needle  110 , rails  111 , work piece retaining frame  132 , and leaves or extensions  122 . 
     Quilting machine  100  as shown in  FIG. 6  operates similar to that as shown in  FIG. 2 , however, the working window  121  shown in  FIG. 6  is larger than that shown in  FIG. 2 , allowing for a larger range of motion of sewing head  108 . In the embodiment shown in  FIG. 6 , sewing head  108  is able to move along rails  111  in the X-axis and/or Y-axis directions within working window  121  to create or stitch patterns on a work piece placed on top of first portion  120  and/or second portion  123 . The larger working window  121  shown in  FIG. 6 , allows a user to stitch or create larger patterns on a work piece without having to adjust the location of the work piece. 
     In one exemplary embodiment, the working window  121  as shown in  FIG. 6  is 20 inches by 24 inches. In another exemplary embodiment, the working window  121  as shown in  FIG. 6  is 20 inches by 12 inches. It should be appreciated that the working window  121  may be any dimension that allows for the sewing head  108  to stitch a quilt. In one embodiment, a user is able to stitch a pattern on a work piece in standard quilt blocks of 10 inches by 10 inches, 12 inches by 12 inches, and/or 18 inches by 18 inches. 
       FIG. 3  presents a logic flow diagram in accordance with a method and apparatus for performing exemplary embodiments of this disclosure. Block  302  presents (a) securing a moveable support surface in a first position adjacent to a sewing head having a reciprocating needle; (b) moving the support surface to a second position to define a working window adjacent to the sewing head; and (c) moving the sewing head within the working window relative to the support surface in the second position. Then block  304  specifies further comprising fixing a work piece relative to a portion of the support surface in the second position. Block  306  then states wherein the sewing head is moveable within the working window relative to the support surface in the second position. 
     The present system thus provides a first configuration wherein a sewing machine is fixed relative in a support surface and a second configuration wherein the sewing machine is moveable relative to the support surface, wherein the support surface in the second configuration includes a working window in which the sewing head is moveable relative to the frame. 
     It should be appreciated that though the embodiments depicted in  FIG. 1  and  FIG. 2  show a support surface  104  with a first portion  120  and a second portion  123  that in an open position define a working window  121 , embodiments of this disclosure further include a support surface  104  that has 2 or more portions that are separable to create a working window for stitching. 
     In most longarm quilting machines, the sewing machine is moveable throughout a given area such that the sewing machine can stitch patterns on a work piece located in the given area. The more exact a user or computer can move the sewing machine, the more accurate the user or computer can stitch and create patterns on the work piece. However, most longarm quilting machines are able to “wiggle” or slightly rotate in a given location due to give between the different rails that allow the sewing machine to move throughout a given stitching area. Exemplary embodiments of the present disclosure provide a longarm quilting machine which reduces inaccuracies in moving a sewing machine throughout a given area by reducing the “wiggle” or the ability of the sewing machine to rotate in a given location. 
     Reference is now made to  FIG. 4 , which depicts a perspective view of an exemplary quilting machine suitable for practicing exemplary embodiments of this disclosure. Shown in  FIG. 4  is quilting machine  400  with frame  402 , sewing machine  404 , sewing head  406  with reciprocating needle  408 , short rails  410 , long rails  412 , wheels  414 , motor  416 , and controller  418  having a computer processor  420  (not shown) and memory  422  (not shown) storing computer program instructions. 
     In one configuration, quilting machine  400  includes a supply roll assembly  424  and a take up roll assembly  426  which cooperate to define a work piece retention area  428 . The supply roll assembly  424  and the take up roll assembly  426  each retain a portion of a work piece such that a portion of the work piece is maintained with a certain tension optimal for stitching between the supply roll assembly  424  and the take up roll assembly  426  within the work piece retention area. 
     As shown in  FIG. 4 , sewing machine  404  is attached, sits on, or is placed on long rails  412  and indirectly short rails  410 . Exemplary embodiments of short rails  412  and long rails  410  allow sewing machine  404  to move throughout the extent of the work piece retention area. 
     Exemplary embodiments of short rails  412  include a set of rails located on an edge of frame  402  perpendicular to the long axis of frame  402  and allow movement of sewing machine  404  through the short axis direction of frame  402  along the work piece retention area. Exemplary embodiments of the long rails  410  provide a set of rails located parallel to the long axis of frame  402  and allow movement of sewing machine  404  through the long axis direction of frame  402  along the work piece retention area. 
     Wheels  414  are coupled to sewing machine  404  such that sewing machine  404  can move along long rails  412  through the long axis of frame  402 . In another exemplary embodiment, sewing machine  404  can slide along long rails  412  for movement of sewing machine  404  throughout the work piece retention area with or without the aid of wheels  414 . It should be appreciated that exemplary embodiments of the present disclosure include a sewing machine  404  that can operably move throughout the work piece retention area along short rails  410  and long rails  412 . 
     Exemplary embodiments of short rails  410  and long rails  412  are substantially planar elongate, strip like members, wherein the wheels  414  engage a longitude edge of short rails  410  or long rails  412 . Exemplary rails can be flat, such that manufacturing costs are substantially reduced relative to prior bent or multi-thickness rails. However, exemplary embodiments of the present disclosure provide for the combination of any type of rails and wheels such that sewing machine  404  can move throughout the work piece retention area while “wiggle” or rotation of sewing machine  404  at a given location is reduced. 
     Referring to  FIG. 5 , shown is a top view of an exemplary quilting machine suitable for practicing exemplary embodiments of this disclosure. Illustrated in  FIG. 5  are frame  402 , long rails  412 , short rails  410 , and wheels  414 . As shown in  FIG. 5 , longs rails  412  run parallel to the long axis of frame  402  and short rails  410  run parallel to the short axis of frame  402 . Long rails  412  with wheels  414  provide a means for sewing machine  404  to move along the long axis of frame  402 . Short rails  410  provide a means for sewing machine  404  to move along the short axis of frame  402 . In the arrangement depicted in  FIG. 5 , a sewing machine or other device located on top of long rails  412  are prevented from or substantially prevented from “wiggling” or rotating around the vertical axis in a given position. This can aid in preventing error in the movement, change of movement or location of sewing machine  404 . 
     The disclosure has been described in detail with particular reference to an embodiment, but it will be understood that variations and modifications can be effected within the spirit and scope of the disclosure. The presently disclosed embodiments are therefore considered in all respects to be illustrative and not restrictive. The scope of the invention is indicated by the appended claims, and all changes that come within the meaning and range of equivalents thereof are intended to be embraced therein.