CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of priority of U.S. provisional application number 63/363,423, filed April 22, 2022, the contents of which are herein incorporated by reference

BACKGROUND OF THE INVENTION

[0002] The present invention relates to sewing machines, and more particularly to alignment devices for aligning a fabric to be sewn with a feed path to the sewing needle.

[0003] Conventional alignment devices for sewing machines typically rely on an etched alignment grid on a feed path to the sewing needle or mechanical attachments to the sewing machine, such as binding attachments, and the like. While these mechanical devices may be suitable for the particular purpose to which they are adapted, they are ineffective for freehand sewing operations. In freehand operations, such as quilting, alignment grids are ineffective since the quilt will overly and completely obscure the alignment grid.

[0004] As can be seen, there is a need for improved alignment devices for sewing machines

SUMMARY OF THE INVENTION

[0005] In one aspect of the present invention, a laser alignment device for a sewing machine is disclosed. The laser alignment device includes a laser assembly having a laser configured to produce a linear light projection when operably coupled with a power source. A mounting assembly adjustably couples the laser assembly with a body of the sewing machine to orient the linear light projection along a desired feed path of the sewing machine.

[0006] In some embodiments, the laser assembly may include a ball element containing the laser; and a conductor adapted to couple the laser with the power source. The mounting assembly may include a socket having an interior cavity dimensioned to receive the ball element. A protrusion extends into the interior cavity. The protrusion is adapted to support the ball element within the mount assembly. The protrusion may be an annular rim extending into a lower portion of the interior cavity.

[0007] In some embodiments, an alignment lock is adapted to retain the laser assembly at a desired orientation within the mount assembly.

[0008] In some embodiments, the laser assembly is adjustably coupled with the mounting assembly for a multi-axial adjustment of the laser assembly.

[0009] In other aspects of the invention, a sewing machine is disclosed. The sewing machine includes a housing containing a sewing mechanism for applying a stitch to a fabric material via a reciprocating needle carrying a thread to form the stitch. A feed path supports the fabric material for engagement with the reciprocating needle. A laser alignment device is adjustably coupled with the housing. The laser alignment device includes a laser adapted to produce a linear light projection along the feed path.

[0010] In some embodiments, the laser alignment device includes a laser assembly containing the laser and a mounting assembly for adjustably coupling the laser assembly with the housing to orient the linear light projection along a desired feed path of the sewing machine.

[0011 ] In some embodiments, laser assembly includes a ball element containing the laser. The mounting assembly includes a socket having an interior cavity dimensioned to receive the ball element. A protrusion extends into the interior cavity. The protrusion is adapted to support the ball element within the interior cavity.

[0012] In some embodiments, an alignment lock is adapted to retain the laser assembly at a desired orientation within the mount assembly.

[0013] In some embodiments, the laser assembly is adjustably coupled with the mounting assembly for a multi-axial adjustment of the laser assembly.

[0014] In some embodiments, an alignment tool for alignment of the linear light projection with the desired feed path is included. The alignment tool is formed as a flat plate having a proximal end and a distal end. At least one longitudinal alignment line oriented along a feed direction of the sewing machine is defined on a top surface of the alignment tool. At least one transverse line, oriented orthogonal with the at least one longitudinal alignment line, is defined on the top surface.

[0015] In other aspects of the invention, a method of aligning a fabric material in a feed path of a sewing machine is disclosed. The method includes coupling a laser alignment device with the sewing machine. The laser alignment device is adapted to emit a linear light projection. The linear light projection is projected on a desired feed path of the sewing machine.

[0016] In some embodiments, the method includes placing the fabric material on the feed path of the sewing machine and aligning the fabric material with the linear light projection.

[0017] In some embodiments, the method includes feeding the fabric material into a reciprocating needle of the sewing machine to apply a stitch to the fabric material while maintaining an alignment of the fabric material with the linear light projection.

[0018] In some embodiments, the method includes adjusting the laser alignment device so that the linear light projection is aligned with the desired feed path.

[0019] In some embodiments, the method includes locking the laser alignment device with the linear light projection in an alignment with the desired feed path.

[0020] These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description, and claims.

BRIEF DESCRIPTION OF DRAWINGS

[0021] FIG. 1 is a component view of a laser alignment device for a sewing machine.

[0022] FIG. 2A is a front perspective view of the laser alignment device for a sewing machine.

[0023] FIG. 2B is a front perspective view of the laser alignment device for a sewing machine with a mount adapter.

[0024] FIG. 3 is a DETAILED DESCRIPTION OF THE INVENTION

[0025] The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense but is made merely for the purpose of illustrating the general principles of the invention.

[0026] As seen in reference to the drawings of FIG. 1 -4, a laser alignment device 10 for a sewing machine 40 according to aspects of the invention includes a laser assembly 12 and a mounting assembly 14. The drawings also illustrate another aspect of the invention, a sewing machine 40 with a projection alignment tool 44 to provide a linear projection of the laser light 46 in a desired alignment with the feed path 42 of the sewing machine 40.

[0027] In a non-limiting embodiment, the laser assembly 12 includes a laser module 16, containing a laser or light emitting diode (LED) light source with optics to produce a beam of coherent light aligned to project a straight line along a linear path. In a non-limiting example, the laser module 16 may be contained in a 9mmx21 mm package containing a light emitter in the 650nm wavelength. Preferably the laser module 16 is a low power module of about 5m W and utilizes a 3-5V power source. Preferably, the laser module 16 produces emitted light with a fixed focus at a working distance of 150 mm.

[0028] The laser module 16 may be provisioned with optics 18, such as a lens 18, configured to project a linear light projection 46 on a feed path 42 aligned with a needle 46 of the sewing machine 40. By way of non-limiting example, the laser module 16 may be arranged to project the linear light projection line 46 from an elevation of six inches off the mounted surface of the sewing machine 40. Alternatively, the linear light projection 46 on the feed path 42 may be achieved with a rapid oscillation of a beam of laser light. The laser assembly 12 may include a ball element 20 to contain the laser module 16, optics 18, when equipped, the conductor, and in some instances, a power source.

[0029] The laser mount 14 permits the laser module 16 to be adjustably mounted with the sewing machine 40. The laser module 16 may also be integrally mounted with the sewing machine 40. Preferably, the laser mount 14 provides for a multi-axis alignment of the linear light projection 46. [0030] In the embodiments shown, the laser mount 14 may include a mount socket 22 dimensioned to receive the ball element 20, with the laser module 16, and optics 18, carried within the ball element 20. The mount socket 22 has an upper opening of an interior cavity that is dimensioned to receive the ball element 20. A protrusion 26, such as an annular rim 26, extends into the interior cavity at a lower portion of the interior cavity. The protrusion 26 supports the ball element 20 within the interior cavity. The ball element 20 may have an outer diameter to be rotationally and pivotally carried within a cylindrical opening of the laser mount. The inner diameter of the mount 14 has an inner diameter dimensioned to receive the laser module 16 with a close interference fit. Alternatively, an adhesive can be applied, or the ball element 20 may be molded with the laser module 16.

[0031] The laser mount 14 may also include an alignment lock 24, such as a thumb screw 26 carried through a sidewall of the mount socket 22 to impinge against an outer surface of the ball element 20. The alignment lock 24 retains the ball element 20 such that the linear light projection 46 may be set at the desired orientation along the feed path 42.

[0032] To align the linear light projection 46 at the desired orientation on the feed path 42, the ball element 20 may be rotated within the socket 22 about a vertical, or Z-axis, for a radial adjustment of the linear projection of the laser light 46 on the feed path 42. The ball element 20 may also be rotated about a transverse, or Y- axis, for a lateral adjustment of the linear projection of the laser light 46 on the feed path 42. Likewise, the ball element 20 may also be rotated about a longitudinal, or X-axis, for a fore-aft adjustment of the linear light projection 46 along the feed path 42.

[0033] The projection alignment tool 44 may be placed on the feed path 42 to facilitate alignment of the linear light projection 46 along the feed path 42. A notch 45, preferably a V- shaped notch, is disposed at a proximal end of the projection alignment tool 44 which can be positioned in abutment with the needle of the sewing machine 40 (when oriented in the downward position) for centering of the proximal end of the alignment tool 44. The alignment tool 44 includes one or more longitudinal lines 48 extending along a feed path 42. A first longitudinal line 48 may extend from the notch 45 to align with the needle 46 of the sewing machine 40. The one or more secondary longitudinal lines 48 may be spaced apart from the first longitudinal line by a predefined lateral spacing. [0034] One or more transverse lines 50 are disposed at a distal end of the alignment tool 46 orthogonal to the one or more longitudinal lines 48. The one or more transverse lines 50 provide an a reference for positioning of the alignment tool with a forward edge of the feed path 42 such that the one or more longitudinal lines 48 are aligned with the feed path 42. The linear light projection 46 may be adjusted, as previously described, for alignment with a selected one of the one or more longitudinal lines 48 for a desired offset from the feed path 42.

[0035] A conductor 28 connects the laser module 16 with a power source, such as a battery contained within a battery compartment 30. The laser module 16 may be controlled by a switch 32. The power source may also include a USB 34 power source connection or connection to an electrical utility service via an adapter 36. Preferably, the external power source may be integrated with the electronics and power for the sewing machine 40. In the embodiments shown, the power source may be a 9v battery, or a 5-volt USB cable connection 34. The laser assembly 12 may also include a switch 32 for selectively activating the laser module 16.

[0036] The mount assembly 14 may include an adhesive or may be integrally molded with a case of the sewing machine 40. Preferably, base 14 is coupled with the sewing machine 40 via an adhesive, such as a double-sided tape.

[0037] The mount assembly 14 is configured to project a laser light line 46 along a feed path 42 of the sewing machine 40, such that a material fabric may be fed into the reciprocating needle 46 of the sewing machine 40 so that the fabric may be sewn by a thread carried by the needle 46 and a bobbin (not shown, subjacent to the feed path 42.

[0038] In a preferred embodiment, the mount assembly 14 includes a base 15 having a cylindrical opening through the body of the base 15. The cylindrical opening is dimensioned to couple with the ball element 20, rotatably and pivotally carried within the cylindrical opening. The base 15 has an outer sidewall having a surface of varying radii along each face of the body. The radius of each face may be selected for adaptation of the base 15 to couple with a surface of the head of the of the sewing machine 40 proximal to the needle 46. One or more base elements may be included in a kit to adapt the laser module 16 for a universal or near universal adaptation of the laser to the sewing machine. [0039] The base 15 may also include an adapter 17 for adaption to particular irregular surfaces of the sewing machine 40. The adapter 17 may include a slotted connection 19 with the mount assembly 14.

[0040] In use, the mount assembly 14 is connected with the housing of the sewing machine 40. The laser assembly 12 is connected with a desired power supply and activated with the switch 32. The ball element 20 is adjusted within the mount assembly 14 so that the linear light projection 46 is projected along a desired alignment of the feed path 42. As previously described, the alignment tool 44 may be utilized for alignment of the linear light projection 46. Once a desired alignment is obtained, the ball element 20 is secured in the mount 14 via the alignment lock 24.

[0041] With the laser module 16 secured on the sewing machine 40, the user may then utilize the sewing machine 40 to sew their articles. Unlike conventional sewing machines, that may be equipped with alignment marks on the feed tray 42 that become obscured when the fabrics to be sewn are fed into the sewing machine, the linear light projection 46 of the present invention provides the user an alignment reference that is projected on a top surface of the materials as they are fed into sewing machine 40 to be joined. With the laser alignment device 10 of the present invention, the user can more reliably maintain a straight line while sewing fabric materials. Advantageously, the multi-axial adjustment of the laser module 16 allows the user to set a desired offset for the linear light projection 46, to permit sewing hems, bindings, and the like, while the needle path is positioned at the desired placement to join the respective fabric materials.

[0042] It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.