Abstract:
A method and device are provided for producing a double roll fabric construction useful as a receptacle for, e.g., eyeglasses. The construction is comprised of adjacent rolled up portions disposed in side by side relation so as to be unrollable to form a receiving space therebetween. The rolling device includes a pair of spindles disposed in parallel relation and adapted to respectively receive opposite ends of a stretchable fabric so that rotation of the spindles causes rolling up of the fabric around the spindles. Respective pinion gears are mounted on the spindles and are disposed in engagement with, and ride along, a rack member. A drive unit produces movement of the pinion gears toward each other along the rack member so as to produce rotation of the second spindles and resultant wrapping of the fabric around the respective spindles to produce respective fabric rolls of the double roll fabric construction. After the construction is removed from the spindles, the ends are sewn to produce the receptacle.

Description:
FIELD OF THE INVENTION 
     The present invention relates to rolling devices or machines for rolling fabric into rolled up configurations and, more particularly, to a double roll rolling device, and a corresponding method, for providing a stretchy or elasticized fabric configuration comprising adjacent double rolls which can be unrolled to, e.g., create a receiving space for articles. 
     BACKGROUND OF THE INVENTION 
     Although the present invention is not limited to such an application, one important application of the device and method of the present invention is in making eyeglasses cases such as disclosed in U.S. Pat. No. 5,102,216 to Mitchell, the subject matter of which is hereby incorporated by reference. The eyeglasses case described in this patent comprises a stretchy or elasticized fabric which is double rolled and then sewn to tubular straps at each end to form an eyeglasses retainer-case combination, with the tubular straps being attached to the stems of the eyeglasses to retain the eyeglasses in place around the neck of a user. The double roll configuration of the case permits the eyeglasses to be placed, in folded state, within the cavity or receiving space formed by unrolling the normally rolled up double roll portions. Other products also use this double roll configuration of elasticized fabric and the present invention is applicable to making such devices as well. 
     SUMMARY OF THE INVENTION 
     In accordance with one aspect of the invention, there is provided a rolling device for producing a double roll fabric construction comprising adjacent rolled up portions disposed in side by side relation so as to be unrollable to form a receiving space therebetween, the device comprising: 
     first and second spindles disposed in parallel relation and adapted to respectively receive opposite ends of a stretchable fabric so that rotation of the spindles causes rolling up of the fabric around the spindles; 
     a rack member; 
     first and second pinion gears mounted on the first and second spindles, respectively, and disposed in engagement with said rack member; and 
     drive means for producing movement of the first and second pinion gears toward each other along the rack member so as to produce rotation of the first and second spindles and resultant wrapping of the fabric around the respective spindles to produce respective fabric rolls of the double roll fabric construction. 
     Preferably, the device further comprises retaining means for retaining the fabric against the spindles so as to permit wrapping of the fabric around the spindles. Advantageously, the retaining means comprises first and second spaced, resilient fingers, between which said fabric is initially stretched, for holding the opposite ends of the fabric against the first and second spindles, respectively. The resilient fingers are preferably spaced apart a distance relative to the width of the fabric such that excess portions of the fabric extend beyond the fingers at both of said opposite ends of the fabric. Advantageously, the fingers comprise oppositely extending finger members formed integrally with a common base member. 
     Preferably, the device further comprises securing means for securing fabric to the spindles. The securing means preferably comprises respective removable clip members. Advantageously, the clip members comprise substantially semicircular mandrels. 
     The device preferably comprises first and second sliding blocks on which said first and second spindles are mounted. Advantageously, the device further includes a support assembly for supporting the device on a support member and the sliding blocks include bearings which engage, and ride on, linear bearing surfaces of the support assembly. 
     The drive means preferably comprises spindle movement control means for producing equal movements of the first and second pinion gears along the rack member. Advantageously, the spindle movement control means comprises a bell crank, and first and second links of equal length coupling the bell crank to the spindles. The bell crank is preferably mounted on the support assembly. 
     In accordance with a further aspect of the invention, there is provided a method for producing a double roll receptacle of a stretchable fabric comprising adjacent rolls of the fabric, the rolls having parallel longitudinal axes and being capable of being unrolled to form a receiving space therebetween, the method comprising: 
     disposing opposite ends of the stretchable fabric on first and second parallel spindles, respectively, so as to enable rolling up of the fabric on the spindles; 
     rotating the spindles to cause the fabric to be rolled onto the spindles from the opposite ends of the fabric so as to form a rolled fabric comprising two parallel rolls in side by side relation; 
     removing the rolled fabric from the spindles with the two parallel rolls formed in the fabric; and 
     affixing the rolled fabric together at opposed longitudinal ends to form a double roll receptacle. 
     Preferably, an excess portion of fabric is initially created at the opposite ends (sides) thereof and each said excess portion is wrapped around the respective spindle. 
     Advantageously, the fabric is initially stretched across first and second spaced fabric retaining means to create the excess fabric portions. 
     Preferably, the excess fabric portions are removably clipped by clip members to the spindles so as to retain the fabric in place on the spindles and the clip members are removed prior to affixing the rolled fabric together at said opposed ends. 
     Other features and advantages of the invention will be set forth in, or apparent from, the detailed description of preferred embodiments of the invention, which follows. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a simplified perspective view of a double roll apparatus in accordance with one preferred embodiment of the invention, showing an operator using the apparatus; 
     FIG. 2 is a simplified perspective view, drawn to a larger scale, of a portion of the apparatus of FIG. 1; 
     FIG. 3 is an end elevational view of a double roll fabric configuration produced by the invention; 
     FIG. 4 is a side elevation view of the operating mechanism of the apparatus of FIGS. 1 and 2; 
     FIG. 5 is an exploded perspective view of the operating mechanism of FIG. 4; 
     FIG. 6 is a front elevational view of the overall apparatus of FIGS. 1 and 2; 
     FIG. 7 is a side elevational view of the apparatus of FIGS. 1 and 2; 
     FIG. 8 is a top plan view of the apparatus of FIGS. 1 and 2; 
     FIGS.  9 ( a ) to  9 ( e ) are simplified front elevational views of part of a double roll apparatus in accordance with a further embodiment of the invention; 
     FIG. 10 is a front elevational view of the apparatus of FIGS.  9 ( a ) to  9 ( e ); and 
     FIG. 11 is a side elevational view of the apparatus of FIG.  10 . 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     In order to provide an overview of a first embodiment of the invention, reference is first made to FIG. 1, wherein an operator O is shown seated in front of a double roll machine  10  constructed in accordance with one preferred embodiment of the invention. The operator O feeds a suitable length of elasticized fabric F into machine  10  and, in this embodiment, controls operation of the machine  10  by depressing and releasing of a pedal  12  pivotably mounted on a base portion  14  of the machine  10  and extending between a pair of support pillars  16  and  18 . This movement of pedal  12  controls the movement of a drive belt  20  shown, inter alia, in FIG. 2, to, in turn, control movement of a pair of spindles  22  and  24 . 
     Referring to FIG. 2, as illustrated, belt  20  includes a horizontal portion  20   a  which is looped in a horizontal plane around the pair of spindles  22  and  24 , and two vertically extending, downwardly depending portions  20   b  and  20   c  which are affixed to foot pedal  12  and, as indicated by arrow A, are pulled downwardly by pedal  12  when the latter is depressed. 
     Spindles  22  and  24  each include two spaced pinion gears  22   a ,  22   b  and  24   a ,  24   b , respectively. Pinion gears  22   a  and  24   a  engage a first rack  26  disposed on one side of belt  20  while pinion gears  22   b  and  24   b  engage a second rack  28  disposed on the other side of belt  20 . 
     It will be appreciated that pulling down on belt  20  in response to depression of pedal  12  will cause rotation of spindles  22  and  24  as indicated by arrows B and C, and consequent movement of spindles  22  and  24  toward each other as indicated by arrows D and E. This movement is effected by the travel of pinion gears  22   a ,  24   a  on rack  26  and of pinion gears  22   b ,  24   b  on rack  28 . 
     The initially flat elasticized fabric F is engaged at opposite edges thereof by spindles  22  and  24  and thus rotation of spindles  22  and  24  causes the fabric F to roll up around the spindles  22  and  24  to produce two closely spaced rolled portions. When the fabric is removed or released from the spindles  22  and  24 , the fabric will retain its rolled up configuration, i.e., the configuration shown in FIG. 3 in which two rolled up portions, denoted F 1  and F 2 , are disposed adjacent to one another, as shown. As a final step, the ends of the double rolled fabric F are sewn, using, e.g., a bar tack machine (not shown), to produce the final doubled rolled receptacle or retainer device. 
     Referring to FIGS. 4 to  8 , there are shown further details of the preferred embodiment of the invention illustrated in FIG.  2 . Referring first to FIGS. 4 and 5, in this specific embodiment, the spindles  22  and  24  are of a similar multipiece construction. Considering spindle  22  as typical and referring to FIG. 5, spindle  22  includes a spindle member  22   c  at the front end of the device  10  which has internal screw threading  22   d  adapted to receive the threaded end  22   e  of a further spindle member or armature  22   f . The latter also includes a central portion  22   g  and a cooperating sleeve  22   h  and an associated collar or end cap  22   i  secured in place by a set screw  22   j  (see FIG.  4 ). 
     A short length of surgical tubing  22   k  surrounds the spindle member  22   c  and serves to mount upper and lower L-shaped channel members  22   l ,  22   m  used to grip the fabric to be rolled. 
     A cylindrical belt guide  22   n  is mounted on armature  22   f  while two further shaft collars, denoted  22   o  and  22   p , respectively, serve in securing pinion gears  22   a  and  22   b  in place on spindle  22  as is best seen in FIG.  4 . 
     As indicated above, spindle  24  is similar to spindle  22  and corresponding elements have been given the reference number  24  with the same letter designations, so that, e.g., spindle member  24   c  corresponds to spindle member  22   c . Because of this similarity, spindle  24  will not be separately described. 
     Racks  26  and  28  are affixed to a base plate or mounting plate  30  by suitable means such as screws, one of which denoted  32 , is shown in FIG.  5 . 
     A pair of armature guide/retainer members  34  and  36  are affixed to base plate  30  by suitable means such as screws, three of which are shown at  38  in FIG.  5 . The armatures  22   f ,  24   f  of spindles  22  and  24  extend through guide/retainers  34  and  36  as can be best seen in FIG.  5 . 
     Also mounted or captured on spindles  22  and  24  are a pair of spring frames or frame members  40  and  42 . The spring frames  40  and  42  and the associated spring mechanisms are of a similar construction and considering frame  40  as typical, frame member  40  is of a U-shaped configuration with the legs  40   a  and  40   b  thereof having aligned openings therein which provide mounting of frame member  40  on armature  22   f  of spindle  22 . A set screw or other fastener  40   c  is used to affix one end of a spring  40   d  to frame member  40 . The other end of spring  40   d  is affixed in place by a screw  40   e  and a screw retainer  40   f  affixed to a mounting platform  44  (see, e.g., FIG. 6) for base plate  30 . Relatively long screws, indicated at  46 , are used to secure base plate  30  to mounting platform  44 . 
     Referring to FIGS. 6 to  8 , the pillar construction referred to above is shown in somewhat more detail, with the basic double roll mechanism shown in FIG. 5 being denoted  48 . As illustrated above in connection with FIG. 1, pillars  16  and  18  are mounted to base  14  which includes parallel legs  14   a  and  14   b . Leveling devices or levelers  50  affixed to legs  14   a ,  14   b  are used to support the device  10  in a level, stable manner. As described above, bolt portions  20   b  and  20   c  extend between pillars  16  and  18  and are affixed to pedal  12  while rubber bumpers  52  are disposed on pedal  12  as shown in FIG.  6 . 
     As shown in FIGS. 6 and 8, a pedal link  12   c  of pedal  12  is pivotably mounted at one end by a simple pivot arrangement, indicated at  54 , mounted on a cross strut  14   c  of base  14  and, as shown in FIG. 7, link  12   c  is also supported by a spring  56  affixed to support pillar  18 . Two such springs are preferably provided. 
     To complete the description, an outwardly extending platform shield is indicated at  58  while a cover/housing for the drive mechanism  48  is denoted  60 . 
     The basic operation of the embodiment of FIGS. 1 to  8  has been described above. 
     Referring to FIGS.  9 ( a ) to  9 ( e ),  10  and  11 , a further, currently preferred embodiment of the invention is shown. This embodiment is broadly similar to that of FIGS. 1 to  8 , while providing certain important advantages thereover, and to provide an overview reference is first made to FIGS.  9 ( a ) to  9 ( e ) which show five steps in the double roll operation provided by this embodiment. 
     As described in more detail below, the double roll unit of this embodiment, which is generally denoted  10 , includes, similarly to the embodiment of FIGS. 1 to  8 , and as shown in FIG.  9 ( a ), a pair of spindles  72  and  74  which carry respective pinion gears  72   a  and  74   a  that engage a common rack  76 . In contrast to the previous embodiment, the fabric, again denoted F, is held in place by two fingers  78   a  and  78   b  preferably made of sheet metal and connected to a common base indicated schematically at  78   c . As shown in FIG.  9 ( a ), the fabric or material F is spread across the fingers  78   a ,  78   b  and the spindles  72 ,  74  are located in an intermediate position. 
     As shown in FIG.  9 ( b ), the spindles  72 ,  74  are next caused to move on rack  76  to the outermost positions thereof wherein the spindles  72 ,  74  hold end portions of the fabric F against fingers  78   a ,  78   b , with some excess fabric being left at the edges. The operator, of course, releases the fabric at this point. In this embodiment, a knee pad actuator (not shown) is preferably used to effect this movement of spindles  72 ,  74 . However, it will be appreciated that the pedal and belt arrangement of FIGS. 1-8 could also be used and that other suitable actuators for the spindle drive mechanism described below could also be employed. 
     Referring to FIG.  9 ( c ), in the next step, the excess fabric at the ends is wrapped around the two spindles  72 ,  74 . This prepares the fabric F for fastening or securing of the ends thereof. 
     With the excess material wrapped around spindles  72 ,  74 , a pair of semicircular mandrels or clip members  80  and  82  are clipped onto the spindles  72 .  74  so as to hold the fabric F in place, as illustrated in FIG.  9 ( d ). 
     Next, as shown in FIG.  9 ( e ), the actuator (knee pad) mechanism is pressed in the opposite direction so as to draw the spindles  72 ,  74  together. The spindles  72 ,  74  travel equal distances along rack  76  and the fabric F is drawn up onto the spindles  72 ,  74  equally. Thereafter, the rolled up fabric is removed and is sewn as described above to produce the final double rolled product. 
     Referring to FIGS. 10 and 11, the drive or actuator mechanism for spindles  72 ,  74  is shown. As illustrated, the spring fingers  78   a ,  78   b  are mounted on a central support arm  84  which is affixed to base  78   c.    
     As shown in FIG. 11 for pinion gear  72   a  of the two pinion gears  72   a ,  74   a , pinion gear  72   a  is mounted on a ball bearing shaft  86  which is coupled by a coupling element  88  to spindle  72  and which is mounted in a sliding bearing block  90 . The bearing block  90  is preferably made of aluminum or the like and, in the illustrated embodiment, is of the multipiece construction shown. A u-shaped bearing portion  90   a  of bearing block  90  slides on a pair of linear bearings  92   a  and  92   b  mounted on a bearing support  94  affixed to a clamp or clamping member  96  on which rack  76  is mounted. Clamp  96  is clamped to the edge of a work table  98  and support arm  84  is connected to clamp  96  by a support member  100  which is affixed thereto by screws  102 . It will be appreciated that spindle  74  is similarly mounted and a second bearing block  91 , corresponding to, and of the same construction as, bearing block  90 , is shown in FIG.  10 . 
     As shown in both FIGS. 10 and 11, a bellcrank  104  is mounted for rotation on a downwardly depending shaft  106  affixed to support member  100 . As shown in FIG. 10, bellcrank  104  is connected by connecting arms  108  and  109 , respectively, to the bearing blocks  90  and  91 , such that the throw of the two bearing blocks  90 ,  91  is equalized. It will, of course, be appreciated that such a bellcrank arrangement is completely conventional in and of itself and that by rotating bellcrank  104  the bearing blocks  90  and  91  will be caused to move, and thus the spindles  72 ,  74  will move, toward and away from each other as described above so as to, for example, move spindles  72 ,  74  from the widely spaced positions shown in solid lines in FIG. 10 to closely spaced positions shown in phantom in FIG.  10 . 
     As indicated above, a knee pad actuator (not shown) is preferably employed to effect rotation of bellcrank  104  but any suitable actuator mechanism for imparting rotation can be used. 
     Again, the basic operation of device  10  has been described above in connection with FIGS.  9 ( a ) to  9 ( e ). The device or machine of FIGS. 10 and 11 is designed to tightly roll fabrics of different weights for several products including the sunglasses or eyeglasses receptacle or retainer device mentioned above. In an exemplary, non-limiting implementation, fabric F is formed as a square of about six inches on a side and the spindles  72  and  74  travel over a distance of about five and one-half inches, so that when the fabric is first stretched out as shown in FIG.  9 ( a ), the excess portion freely extending beyond each spindle as shown in FIG.  9 ( b ), is about one-half inch. With the spindles  72 ,  74  rolled together as shown in FIG.  9 ( c ), they are spaced apart about one-half inch center to center. 
     The mandrels or clips  80  and  82  discussed above are removed as unit with the rolled fabric F. It will be understood that the mandrels  80 ,  82  will still be rolled tightly with the fabric F at this point and make it much easier to remove the stretchy or elasticized fabric from the spindles  72 ,  74 . Moreover, the mandrels  80 ,  82  act as a temporary backbone or spine which facilitates storing the rolled fabric between operations, i.e., prior to affixing the two rolled ends by sewing or other means, as mentioned above. 
     Although the invention has been described above in relation to preferred embodiments thereof, it will be understood by those skilled in the art that variations and modifications can be effected in these preferred embodiments without departing from the scope and spirit of the invention.