Patent Publication Number: US-11377768-B2

Title: Feed assist apparatus for a flexible sheet material spreader

Description:
RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional Application No. 62/855,516, filed May 31, 2019, the disclosure and teachings of which are incorporated herein by reference for any purpose whatsoever. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The invention disclosed herein relates to a single operator spreading and material feeding apparatus, and in particular to an apparatus for dispensing fabric that is unrolled one ply at a time. 
     2. Description of the Related Art 
     Sheet material, such as cloth, laminates, and the like, is used in a variety of products. Included are garments, upholstery, and many other products. High production volume necessitates efficient work practices with sophisticated equipment. Examples of equipment useful for preparing sheet material in the manufacturing process include cutting tables and fabric spreaders. Generally, a fabric spreader will spread the sheet material for subsequent cutting with the cutting table. The exceedingly competitive nature of such enterprises requires manufacturers to work quickly and make as much use as possible of the sheet material consumed. 
     Fabric spreaders are generally part of a system, in which the fabric spreader is disposed over a table. The fabric spreader contains an operator panel, throttle, and controller, whereby the operator panel and throttle communicate with the controller to control various sub-components of the fabric spreader. 
     Fabric spreaders utilize a cradle to support the roll of material that is rolled one ply at a time as the fabric spreader advances over a table. The cradle has a fabric supply for loading a roll of material and using it for spreading. The cradle may be bounded by a series of belts, which are driven by a driven roller. The belts are driven by a motor that is remote from the cradle. As the driven roller spins, it causes the belts to move about idler rollers. When the roll of material is placed within the cradle, action of the belts causes the roll of material to spin as well. The spinning of the roll of material provides for dispensing of the fabric to the fabric spreader. 
     Depicted in  FIG. 1  is a conventional fabric spreader. The fabric spreader can have a V-shaped cradle, including a first arm and a second arm, and have a length at least equal to that of the material. Generally, between the first arm and the second arm of the V-shaped cradle is a material fabric supply (not pictured), wherein a roll of material or a bundle of material can be positioned for spreading. More information regarding conventional fabric spreaders can be found in co-pending U.S. patent application Ser. No. 16/204,127. 
     Both flattening and coning of the roll of material are conditions that cause inconsistent dispensing of fabric from the roll of material. Aside from the dispensing of fabric from the roll of material under a consistent, constant tension, it is advantageous to dispense the fabric in a constant orientation. Accordingly, adjustment of the positioning of the roll of material during production to accommodate such goals provides for improved fabrication processes. 
     Typically, to ensure proper spreading of the material, two operators tug laterally on the material to provide uniform distribution and remove wrinkles in the material. Performing this process with one operator is challenging, generally two operators work simultaneously to smooth and position the fabric. 
     Thus, what are needed are methods and system to provide improved dispensing of sheet of material from a spreading machine using only one operator, thereby increasing efficiency, reducing setup time, and improving safety. Preferably, the system may be supplied as part of a new spreading machine or as a retrofit to an existing spreading machine. 
     SUMMARY OF THE INVENTION 
     Disclosed herein is a feed assist apparatus for a flexible sheet material spreader, more particularly for feeding fabric. The feed assist apparatus for a flexible sheet material spreader includes a material retainer and swing arm, the pinch roller is preferably self-releasing. The feed assist apparatus for a flexible sheet material spreader of the present disclosure is configured to evenly spread material on a material assembly for later cutting. Preferably, by incorporating the use of a swing arm and the material retainer into the feed assist apparatus for a flexible sheet material spreader, the feed assist apparatus for a flexible sheet material spreader can feed fan folded material, or a roll of material, evenly onto a table using solely one operator. 
     The feed assist apparatus for a flexible sheet material spreader includes a swing arm, having a material retainer, preferably comprised of a pinch roller, stationary roller, and guide plates. The pinch roller can be moved between a released position and a load position, preferably by an operator. In a release configuration, the pinch roller is positioned at a second end of a guide plate, preferably distal to the stationary roller, located at a first end of a guide plate, at a pre-determined distance. The release position thereby allows the insertion or release of fabric between the stationary roller and pinch roller. Alternatively, the pinch roller can be moved to a load position wherein the pinch roller is positioned adjacent to the stationary roller, such that a piece of material is secured between the pinch roller and the stationary roller. 
     The swing arm can be moved using a set of arms attached from the guide plates to a pivot point of a fabric spreader. The spreading panel can include a hollow curve attached to a flat table-like structure, assisting in maintaining tension within the fabric for even spreading. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The features and advantages of the invention are apparent from the following description taken in conjunction with the accompanying drawings in which: 
         FIG. 1  is an illustration of a conventional fabric spreader. 
         FIG. 2  is a view of the feed assist apparatus for a flexible sheet material spreader wherein the material retainer is in the pre-load position. 
         FIG. 3  is a second view of the feed assist apparatus for a flexible sheet material spreader wherein the material retainer is in a load position. 
         FIG. 4  is a view of the reconfiguration of the material retainer after the light shock load, wherein the material retainer is in the release position, as well as the feeding of the material into the V-shaped cradle. 
         FIG. 5  is an illustration of the material retainer and swing arm, spreading the material over the spreading panel. 
         FIG. 6A  is a simplified view of the material retainer in the pre-load position. 
         FIG. 6B  is a simplified view of the material retainer in the load position. 
         FIG. 6C  is a simplified view of the material retainer in the release position after the light shock load has been administered. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Disclosed herein is an apparatus for dispensing sheet material in a material spreading machine while only using one operator. Advantageously, application of the methods and system results in a substantially uniform dispensing of the sheet material for fabrication processes using only one operator. 
     Generally, a material spreading machine, or “fabric spreader” is a machine useful for spreading sheet material for one or more fabric layers. Specifically, in a production environment for spreading one or more fabric layers on a cutting table. The sheet material may be spread to provide for subsequent cutting of the material to a desired size. In embodiments disclosed herein, the material spreading machine is used for production of consumer goods such as garments, upholstery for residential, commercial and/or automotive furnishings and for other similar products. 
     The term “material” is used herein related to material that is supplied in a fanfold or roll form for use with the workstation described herein. Any other forms of material as deemed suitable may be used with the teachings herein. The term “fabric” may be used interchangeably with the term “material.” No limitations are to be construed by the terminology used. 
     Disclosed herein is a preferred embodiment of the invention. The present invention comprises a feed assist apparatus for a flexible sheet material spreader including flexible material  208 , preferably fabric, and a swing arm  260 . In the embodiment depicted in  FIGS. 2 and 3 , a fabric supply, which in this embodiment is a folded bundle  206  of material  208 , having a leading raw edge  210 , is positioned on the top surface  214  of a table  212 . It may be appreciated that a second embodiment of the system can exist wherein the folded bundle of material is a roll of material. 
     Positioned at a pre-determined distance above the table  212  is a guide rod  226 . The left  228  and right (not pictured) sides of the guide rod  226  are attached to a set of arms  236 , and the guide rod  226  has a length at least equal to that of the material  208 . It may be appreciated that a single operator (not pictured) can pull the leading edge  210  of the material  208  over the top surface  232  of the guide rod  226 , to guide the material  208  to the pinch roller  272  and stationary roller  278 . 
     Each arm within the set of arms  236  has a first end  238  and a second end  240 . The first ends  238  of the arms  236  can be attached to a pivot point  280  located on the material spreader, as illustrated in  FIGS. 2 and 5 . The second ends  240  of the arms  236  may extend to first  284  and second  285  guide plates. Once an operator pulls the leading edge  210  of the material  208  over the top surface  232  of the guide rod  226 , the operator may further pull the leading edge  210  over the top surface  266  of a pinch roller  272 . 
     The pinch roller  272  is positioned between the first and second guide plates  284 ,  285 , such that each end of the pinch roller  272  is secured within the elongated slots  294  of each guide plate  284 ,  285 . The pinch roller  272  may be comprised of, but is not limited to, a metal tube coated with uniform elastomer along its axial direction. It may be appreciated that the width, diameter, and durometer of the elastomer coating may vary depending on the properties of materials the pinch roller  272  will transport. As see in  FIG. 3 , positioned above and adjacent to the pinch roller  272  is a stationary roller  278 . Similarly, the stationary roller  278  is positioned within the elongated slots  294  of each guide plate  284 ,  285 . 
     The guide plates  284 ,  285  assist in guiding the material  208  over the top surface  266  of the pinch roller  272 . As seen in  FIG. 2 , the guide plates  284 ,  285  have first  286  and second  288  ends, the first ends  286  are adjacent to the pinch roller  272 , and the second ends  288  are adjacent to the second ends  240  of the arms  236 . Each guide plate  284 ,  285  may have elongated slots  294 . Preferably, as seen in the example in  FIG. 3 , the elongated slots  294  have a long end  216  and a short end  218 . 
     As seen in the examples in  FIGS. 2 and 6A  the pinch roller  272  can be in a first configuration for feeding flexible sheet material, more particularly, as seen in  FIG. 6A , a pre-load position  296 . The pinch roller  272  can also be in a second configuration for retaining flexible sheet material, more particularly, as seen in  FIGS. 3 and 6B , a load position  298 . In the pre-load position  296 , the pinch roller  272  is positioned at the first end  286  of the guide plates  284 ,  285  within the long end  216  of the elongated slots  294 . It can be appreciated that the pinch roller  272  may be slid and rotated from a pre-load position  296  to a load position  298  through the use of force by an operator. To enter the load position  298 , as depicted in  FIGS. 3 and 6B , the operator may push the pinch roller  272 , causing it to slide through the elongated slots  294  from the first ends  286  of the guide plates  284  to the second ends  288 , such that the pinch roller  272  sits adjacent to the stationary roller  278 . Preferably, the moveable roller is moved about elongated slots  294  of the material retainers  202  from a pre-load position ( FIG. 2 ) to a load position ( FIG. 3 ) with assistance by gravity. As illustrated in  FIG. 3 , the pinch roller  272 , stationary roller  278 , and guide plates  284  work together to form a material retainer  202 . 
     In  FIG. 6A , the material retainer  202  is in the pre-load position  296 , thereby providing a space  300 , of a pre-determined length, from the pinch roller  272  to the stationary roller  278 . This space  300  allows for the material  208  to glide under the stationary roller  278 , and over the top surface  266  of the pinch roller  272 . Once an operator has situated the material  208  onto the top surface  266  of the pinch roller  272 , the operator can push the pinch roller  272  into the load position  298 , as seen in  FIGS. 3 and 6B . In the example in  FIG. 3 , this change in configuration presses and secures the material  208  between the pinch roller  272  and the stationary roller  278 , thereby creating tension in the fabric for easy spreading. It may be appreciated that the material retainer  202  eliminates the need of assistance from a second operator to ensure the material is evenly spread. 
     Once the material  208  is securely positioned between the top surface  266  of the pinch roller  272  and the bottom surface (not pictured) of the stationary roller  278 , a single operator can swing the swing arm  260  above and over a spreading panel  302 . As seen in  FIG. 5 , the spreading panel  302  comprises a flat table-like structure  304 , having a rectangular shape. Attached perpendicularly to the underside of the table-like structure  304  of the spreading panel  302  is a pivot point  280 , and attached to the front end  308  of the table-like structure  304  of the spreading panel  302  is a hollow curve. As best seen in  FIGS. 2 and 3 , the arms  236  are moved with assistance by a spring mechanism  239 , which includes a spring  241  extending from each arm  236  to an upright portion  243  of the table-like structure  304 . 
     The swinging of the material  208  and swing arm  260  over the spreading panel  302 , coupled with the tension in the material  208 , produced by the load position  298  of the material retainer  202 , spreads the fabric tightly over the hollow curve of the flat table-like structure  304  of the spreading panel  302 . Once the swing arm  260  swings into a predetermined angle over the spreading panel  302 , a hard stop occurs, sending a light shock load to the guide plates  284 ,  285 . As seen in  FIGS. 4 and 6C , the swinging of the swing arm  260  causes the guide plates  284 ,  285  to flip into a third configuration. The light shock load causes the pinch roller  272  to disengage from the material  208  and stationary roller  278  and move into a release position  299 . In the example embodiment depicted in  FIGS. 4 and 6C , the pinch roller  272  retreats into the release position  299  and the pinch roller moves to the short end  218  of the guide plates  284 ,  285 . This mechanism releases the material  208  into the bottom of the V-shaped cradle  242 . As seen in  FIG. 4 , the V-shaped cradle  242  includes a first roller  248  and a second roller  250 , and has a length at least equal to that of the material  208 . Between the first roller  248  and the second roller  250  of the V-shaped cradle  242  is a drive roller  254 . 
     When the material  208  is released from the swing arm  260 , by the material retainer  202 , the material  208  is laid over the first arm  248  of the V-shaped cradle  242  and fed into the tension roller  254 . Through the use of a controller  320  and a throttle  322 , the drive roller  254  spins, thereby winding the material  208  around itself. The material  208  may then be released over the second arm  250  of the V-shaped cradle  242  in a conventional manner. 
     The present invention is not to be limited in scope by the specific embodiments described herein. Indeed, various modifications of the present invention, in addition to those described herein, will be apparent to those of ordinary skill in the art from the foregoing description and accompanying drawings. Thus, such modifications are intended to fall within the scope of the invention. Further, although aspects of the present invention have been described herein in the context of a particular implementation in a particular environment for a particular purpose, those of ordinary skill in the art will recognize that its usefulness is not limited thereto and that the present invention can be beneficially implemented in any number of environments for any number of purposes.