Opelika Manufacturing Corporation

Sew Simple Systems, Inc.

Charles E Brocklehurst

Perry E Burton

Bruce H Cooper

William C Griffith, Jr

A sheet material advancing and cutting apparatus for incrementally advancing the cut end of a supply of terry cloth sheet material (11) past a cutting blade (66), drawing out the supply of material to its cutting position, and cutting the material along laterally extending napless bands (26) in the material. The apparatus includes a sheet material advancing mechanism (13) for engaging the sheet material and pushing the cut end of the material across the cutting station (14). A material draw out assembly (16) includes a draw out bar (81) which moves downwardly into engagement with the leading edge of the material and pulls the material into its cutting position. The draw out bar (81) is pivoted by cylinder (111) if necessary to stretch the side of the material that is behind in its movement toward the cutting station, causing the following napless band to be straightened.

Material feeding, aligning cutting and edge finishing system

Corner controller (62) (FIG. 5) includes a conically shaped corner control wheel (90) that is rotated so as to apply a sweeping motion against the facing surface of the textile segment (12). This results in removing any folds or wrinkles from the textile segment as it moves to the sewing station (64). The corner control wheel is up the sewing path, ahead of the turning axis (111) of the textile segment. Therefore, when the textile segment is turned by the turning plate (45) through 90.degree. to form a curved corner about the textile segment (FIG. 6), the corner control wheel (90) urges the corner to move through its turning motion, so as to avoid nonuniform turning of the corner and any wrinkling of the corner material, and therefore avoiding the doubling up or bunching of the stitches formed about the rounded corner of the final textile segment.

Edge hemmer with corner controller

The edge portion (18) of sheet material moves about a turning plate (65), moving through first and second right angle turns (44) and (45). A turning belt (50) moves in unison with the edge portion (18) through the first two turns, and then moves through third and fourth right angle turns to advance along its return flight. An open ended slot (73) is formed between the first and second right angle turns to allow the turning belt and edge portion to move from beneath the turning plate to above the turning plate, so as to permit the edge portion of the sheet material to always turn in a downward direction as it is being turned over and placed in a folded position. Folding plate (77) guides the sheet material to help form the fold (20) in the sheet material, and separator plate (76) separates the edge portion (18) of the sheet material from the turning belt (50).

Flat sheet hemming method and folding and separating apparatus

Sheet material 30 is taken from a supply 32 and is cut by cutter 36 into segments 35. The segments are moved rapidly parallel to their cut edges into a slower operating first sewing station 40 where elastic bands are sewn to the side edges of the segments. The rapidly moving trailing portion of the segment 35 of sheet material is temporarily accumulated at the accumulation station 39 and progressively fed at a slower rate through the first sewing station 40. The side edges are folded into overlying relationship with respect to the main body portion at folding station 42. Sewing machines 64 and 165 are moved inwardly of the sewing path to simultaneously cut and sew diagonal corners at the trailing and leading edges of the segments, with the sewing machines pivoting so as to face the relative movement of the sheet material, and the removed corners 25 and elastic banding 21 are pulled away from the work product by a vacuum system 186.

Fitted sheet hemmer

Transport plate (28) is moved downwardly into engagement with work product (25) and the plate (28) moves the work product to the edge finisher, such as sewing head (12) (FIG. 3). When the first edge (68) covers the first sensor (61), the transport plate (28) begins its movement from right to left (FIG. 4) so as to move the first edge (28) through the edge finisher, and the edge is finished as with an overedge stitch. When the second edge (69) uncovers the second sensor (62), the transport plate (28) rotates around an axis of rotation (75) (FIG. 5), causing the work product (25) to be rotated about the same axis of rotation (75) and the edge finisher forms the overedge stitch about the curved path until the second edge (69) covers first sensor (61), whereupon the linear right to left movement is resumed (FIG. 7).

Edge finishing system

Sheet material (30) is cut into rectangular segments (35). The segments are then moved parallel to their cut edges rapidly away from the cutting station into a slower operating first sewing station (40) where elastic bands are sewn to the cut head and foot edge portions of the segment. The rapidly moving trailing portion of the segment (35) of sheet material is temporarily accumulated at the accumulation station (39) and progressively fed at a lower rate from the accumulation station to the first sewing station. The head and foot edge portions are folded into overlying relationship with respect to the main body portion by passing the main body portion through a U-shaped turn and at the same time passing the head and foot edge portions though a pair of 90 degree turns. Sewing machines are moved first inwardly and then outwardly across the folded edge portions of the segment, thus forming the sewn line of chain stitching at the corners of the bedsheet.

Sheet material (30) is cut into rectangular segments (35). The segments are then moved in sequence parallel to their cut edges (26) rapidly away from the cutting station (34) into a slower operating first sewing station (40) where elastic bands (20, 21) are sewn to the cut head and foot edge portions (26, 27) of the segments. The rapidly moving trailing portion of each segment (35) of sheet material is temporarily accumulated at the accumulation station (39) and progressively fed at a lower rate from the accumulation station to the first sewing station (40). The head and foot edge portions (26, 27) of each segment are folded into overlying relationship with respect to the main body portion by passing the main body portion through a U-shaped turn (49) and at the same time passing the head and foot edge portions through a pair of reverse 90 degree turns (50 and 53). Sewing machines (164, 165) are moved inwardly and then outwardly across the folded edge portions of the segment, thus forming the sewn line of chain stitching (25) diagonally across the corners of the bedsheet (10).

Sheet material (30) is cut into rectangular segments (35). The segments are then moved parallel to their cut edges rapidly away from the cutting station into a slower operating first sewing station (40) where elastic bands are sewn to the cut head and foot edge portions of the segment. The rapidly moving trailing portion of the segment (35) of sheet material is temporarily accumulated at the accumulation station (39) and progressively fed at a lower rate from the accumulation station to the first sewing station. The head and foot edge portions are folded into overlying relationship with respect the main body portion by passing the main body portion through a U-shaped turn and at the same time passing the head and foot edge portions through a pair of 90 degree turns. Sewing machines are moved first inwardly and then outwardly across the folded edge portions of the segment, thus forming the sewn line of chain stitching at the corners of the bedsheet.

In a sewing machine a thread 20 moves through a check spring 30, through a takeup arm 32, and to a needle 15. During normal operation, a proximity detector 55 detects the movement of a flag 50 attached to a loop 36 of the check spring during each movement of the takeup arm 32. The proximity detector is supported in a position adjacent the path of movement of the flag. When the thread breaks at the needle, tension is no longer applied to the thread by takeuparm 32, so that check spring 36 and its flag 50 no longer move in front of the detector 55, causing a control circuit to deactivate the sewing machine motor.

Sewing machine thread breakage detector

Sheet material 10 is advanced from a reel 11, cut by cutter 14 and then each segment is moved parallel to its cut edges through sewing machines 22, 23 so as to sew the hems of the work product. The finished product is advanced rapidly in its direction of movement to transfer roll 85, one end 18 of the work product is pulled over a conveyor while the trailing end is urged against the high speed transfer roll 85 which rapidly pulls the trailing portion 19 of the work product out of the way of the next oncoming work product and directs the trailing portion of the work product downwardly to the near side of the conveyor. Each bundle 28 of work products is advanced out of the way so as to make room for accumulating a subsequent bundle on the conveyor.

Compact high speed stacker

Terry cloth towel (18) moves from a supply along its length through an aligning and cutting system (14), to a transfer station (15). As the untufted bands (20) of the toweling material approach the transfer station, a plurality of fingers (28) of a gate (25) engage the untufted portion of the toweling, an as the toweling continues to move, the oncoming edge (22) of the plush surface (19) of the toweling engages and is retarded by the fingers. In the meantime, a plurality of presser feet (92) each of which is aligned with the fingers of the gate urge the toweling into engagement with a feed roller (85) that pulls the toweling through the processing path, and tension in the toweling tends to lift one or more of the presser feet (92) to relieve the pull applied to the toweling. This function is to straighten the band of the toweling. The toweling is then cut across its length with cutter (45), and the cut segment of towel in the transfer station (15) is then moved in a path parallel to its cut edges through a hemming station (16) where the cut edges are folded over and sewn by sewing machines (17).

Automatic towel aligning, cutting and hemming system

Terry cloth toweling (18) moves from a supply along its length through an aligning and cutting system (14), to a transfer station (15). As the untufted bands (20) of the toweling material approach the transfer station, a plurality of fingers (28) of a gate (25) engage the untufted portion of the toweling, and as the toweling continues to move, the oncoming edge (22) of the plush surface (19) of the toweling engages and is retarded by the fingers. In the meantime, a plurality of presser feet (92) each of which is aligned with the fingers of the gate urge the toweling into engagement with a feed roller (85) that pulls the toweling through the processing path, and tension in the toweling tends to lift one or more of the presser feet (92) to relieve the pull applied to the toweling. This functions to straighten the band of the toweling. The toweling is then cut across its length with cutter (45), and the cut segment of towel in the transfer station (15) is then moved in a path parallel to its cut edges through a hemming station (16) where the cut edges are folded over and sewn by sewing machines (17).

Towel aligning, cutting and hemming system

Labels 36 are arranged in a stack and supported in a tray 11, and the open end 49 of a suction tube 46 is reciprocated toward and away from the label at the end of the stack, to draw the end label away from the stack. A fork member 12 straddles the suction tube and reciprocates about the suction tube so as to engage the label on opposite sides of the tube and push the label off the tube, thereby dropping the label into an inclined chute 72. A conveyor belt 85 positioned in the inclined chute moves the label downwardly toward engagement with the moving work product 14, and the lower conveyor roller 81 presses the label into position on the work piece and a band 90 extends about the lower conveyor roller and extends toward the sewing machine 20 to hold the label in place as it advances to the sewing machine.

Label dispenser with suction hold and fork member release

Sheet material is taken from a supply, moved along its length to a cutting station, the sheet material is cut into segments, and the cut segments are moved parallel to their cut edges, the cut edges are hemmed, and the segments are folded. At the cutting station the leading portion of the sheet material is gripped and pulled from the entrance to the cutting station to the other side thereof, a slack bar is moved downwardly into the segment of sheet material in the cutting station to form slack in the segment, and the segment in the cutting station is clamped against parallel conveyor tapes. A cutting disc is drawn across the sheet material at the entrance to the cutting station, and the parallel conveyor tapes move the sheet parallel to its cut edges to a hemming station where the edges are folded and hemmed. The hems of the side edges are expanded after being mechanically formed and prior to being sewn. The leading and trailing edges of the folded portions of the hems are aligned with the leading and trailing edges of the unfolded portion of the hem as the segment approaches the sewing machine.

Sheet production system with hem expander

Sheet material 14, such as a continuous supply of terry cloth towel 16, is moved along its length through a path and toward a cutting station 15 where it is cut into lengths 139. The sheet material is formed with bands 166 extending across its length, such as bands of reduced thickness, and the sheet material is cut in these bands. The bands are detected by rollers 144, 145 at opposite edges of the sheet material as the bands approach the cutting station 15, and each edge portion of the sheet material is fed by feed rollers 51, 52 independently of the other edge portion into the cutting station so as to cause one side of the sheet material which may lag the other side to be properly located at the cutting station prior to cutting the sheet material. The sheet material is pulled taut across its length by cylinders 155, 156 at positions straddling the cutting station and on opposite sides of the longitudinal centerline of the sheet material so that the filler threads of the sheet material are induced to extend at a right angle with respect to the longitudinal centerline of the sheet material, and the cut is then made across the sheet material.

Growing community of inventors

Fountain Inn, SC, United States of America

Charles E Brocklehurst