Field of Invention:

The present invention relates to an embroidery machine, particularly, the present invention relates to vertical embroidery machine capable of performing continuous embroidery along grain line of fabric.

Background of the Invention:

In embroidery machines, embroidery frame is displaceable or movable in two orthogonal directions i.e. in horizontal direction (X-X direction) and vertical direction (Y-Y direction). .

US Patent No. 4603646 describes a frame work for embroidery machine which is shown in figure 1. As shown in figure 1, the frame work is displaceable in horizontal and vertical directions by related drives and contains a circumferentially closed embroidery frame. A side member of the embroidery frame is held in a vertically extending guide rail for vertical movement of the frame. A horizontal bracket projects from the vertically extending guide rail which forms a T shaped constructional unit. The T shaped constructional unit is guided in horizontal direction.

Another US patent no.5438941 discloses an embroidery machine and its tenter frame, guide and drive which is shown in figure 2. As shown in figure 2, the embroidery machine having horizontally parallel fabric shafts for the vertically arranged embroidery fabric. A plurality of upper and lower horizontal guides are distributed over the length of the machine. The upper horizontal guides and the lower horizontal guides are connected by vertical connection means thereby forming several horizontal guide elements. The horizontal guide elements and the fabric shafts are vertically adjustable by positioning drive in guides mounted on the machine. The fabric shafts are horizontally adjustable by horizontal positioning drive in the horizontal guides mounted on the machine.

As mentioned in previous paragraph, the conventional embroidery machine comprises an embroidery frame which is mounted on cross guides permitting independent movement of the embroidery frame in horizontal and vertical directions. One such conventional embroidery machine has been shown in figure 3. As pointed earlier, the embroidery machines are provided with a drive for moving the frame in a horizontal direction and another drive for moving the frame in vertical direction. Each of the drive comprises a motor and a transmission system for transmitting the motor rotation as a vertical and horizontal displacement to the embroidery frame.

In conventional embroidery machines, the frame comprises a pair of upper and lower rollers for clipping width of fabric, which are located across the width of the fabric_or across the height of the frame. Similarly, the frame comprises another pair of clamp for clipping length of the fabric, which is located across the length of the fabric or across the length the machine. As can be understood from that in conventional embroidery machines, the fabric to be embroidered is mounted on the machine so that width of the fabric is vertically placed while the length of the fabric is horizontally placed. Moreover, in conventional machines, because of clipping the width and length of fabric, the complete fabric is not available for embroidery and which leads to wastage of fabric. Also, in conventional embroidery machines, the embroidery is done width wise and the fabric is moved length wise so as to make another width wise region of fabric be available for embroidery. As it can be clearly understood, the conventional machine performs embroidery against the grain line of the fabric (i.e. direction of embroidery is lateral to the grain line of the fabric) which leads to shrinkage of garments made out of the fabric embroidered with conventional machines. Figure 4 shows the embroidery produced by a conventional machine.

The conventional machines are not continuous machines and the length of the machine is fixed. Also require lot of space i.e. lateral space for accommodating the large length of the embroidery machine which involve huge investment for land, excessive labor. Further, in conventional embroidery machine, the machine-frame is required to be displaced or moved in horizontal and vertical direction. Due to the big size of the frame or due to the large numbers small size frames their movements in horizontal and vertical direction involves huge electricity consumption. Therefore, there exists a need to develop an embroidery machine which overcomes at least one of the problems associated with conventional embroidery machine and which is suitable for mass production of embroidery with high efficiency. Objects of the Present Invention:

The main object of the present invention is to provide a vertical embroidery machine.

Another object of the present invention is to provide a vertical embroidery machine which overcomes at least one of the problem associated with conventional embroidery machines.

Summary of the Invention:

Accordingly, the present invention provides a vertical embroidery machine which comprises a support structure, a Frame movement section, needle and thread assembly, shuttle movement assembly, a roller assembly and electronic control system.

In the embroidery machine of the present invention, the roller assembly comprises a feed roller for supplying length of the fabric to be embroidered. The roller assembly comprises an End roller for receiving the fabric after embroidery. The roller assembly comprises an upper roller unit and a lower roller unit between which the fabric is vertically arranged for embroidery. The roller assembly further comprises one or more guide rollers and one or more support rollers for supporting length and width of the fabric respectively. There is provided a shuttle movement assembly which cooperates with needle and thread assembly for performing the embroidery on the fabric.

The roller assembly of the vertical embroidery machine of the present invention is mounted on a frame section. As can be clearly understood, the frame to be moved in horizontal and vertical direction to achieve the desired embroidery. In an embodiment of the present invention, this desired effect of vertical and horizontal frame movement can be achieved through synthetic rubber rollers and Servo Motors. In other words, said frame section is movable in a horizontal direction i.e. X-X direction and therefore, the roller assembly movable in horizontal direction (X-X direction). The roller assembly is rotatable about horizontal axis. In other words, when the fabric is provided over the roller assembly, the rotational motion of the roller moves the fabric in vertical direction i.e. Y-Y direction and horizontal movement of the roller assembly moves the fabric in horizontal direction i.e. X-X direction. As can be noticed there is no vertical movement of the frame section. According to an embodiment of the present invention the vertical embroidery machine can be constructed to perform more than one sets of embroidery in same time. In an embodiment of the present invention the vertical embroidery machine can perform two sets of embroidery at the same time. With the above construction of the vertical embroidery machine of the present invention the embroidery is done on the fabric along the grain length.

In the present embroidery machine, since embroidery is performed length wise the cloth/garment produced by this fabric is not affected by shrinkage.

Brief Description of figures:

Figures 1-3 shows embroidery machines of the prior art.

Figure 4 shows the embroidery produced by a conventional machine.

Figure 5 illustrates a support structure of the embroidery machine according to an embodiment of the present invention.

Figures 6(a) and 6(b) illustrates a support structure, a frame section and a frame structure of the embroidery machine according to an embodiment of the present invention.

Figures 7, 8 and 9 illustrate movement of cloth or fabric on the vertical embroidery machine according to an embodiment of the present invention.

Figure 10 illustrates a shuttle assembly of the embroidery machine according to an embodiment of the present invention.

Figures 11(a) and 11(b) illustrate a main cam drive assembly of the embroidery machine according to an embodiment of the present invention.

Figure 12 the embroidery produced by the vertical embroidery machine according to an embodiment of the present invention.

Detailed Description of the Present Invention:

Accordingly, the present provides an embroidery machine, comprising: (a) a support structure comprising:

a lower beam section comprising a first pair of parallel beams horizontally extending and mounted on vertical columns; an upper beam section comprising a second pair of parallel beams horizontally extending and mounted on vertical columns,

(b) a frame structure slidably mounted on the lower beam section and the upper beam section; said frame structure comprises:

a frame section;

a roller assembly mounted on the said frame section, said roller assembly comprises a lower roller unit and, an upper roller unit mounted above the said lower unit;

(d) a horizontal drive means for moving the said frame structure in horizontal direction thereby moving the said roller assembly in horizontal direction;

(e) a vertical drive unit for rotating the upper roller unit and the roller unit.

In an embodiment of the present invention the said vertical columns are mounted on a substantially flat base.

In another embodiment of the present invention the vertical columns are provided with brackets mounted on the said vertical columns and adapted to secure ends of the pair of parallel beams for mounting the lower beam section and the upper beam section on the vertical columns.

In still an embodiment of the present invention the frame section comprises:

(a) a first platform unit and a second platform unit, each of the platform unit comprises

(i) upper platform slidably mounted on and over the upper beam section,

(ii) a lower platform slidably mounted on and beneath the lower beam section;

(b) one or more vertically extending rigid side members connecting the upper platform with the lower platform.

In yet another embodiment of the present invention the upper beam section is provided with horizontal guides mounted on and above the beams of the upper beam section. In a further embodiment of the present invention the lower beam section is provided with horizontal guides mounted on and beneath the beams of the lower beam section. In a further more embodiment of the present invention each of the lower roller unit and the upper roller unit comprises a pair of horizontal rollers.

In a further more embodiment of the present invention in the frame structure ends of the horizontal roller of the lower roller unit is rotatably mounted on the lower platforms and -ends of the horizontal roller of the upper roller unit is rotatably mounted on the upper platforms so as to form a circumferentially closed frame structure with the said frame section.

In an embodiment of the present invention the roller assembly comprises a feed roller for supplying fabric length to the lower roller unit, ends of the said feed roller are supported on the lower platforms.

In another embodiment of the present invention the roller assembly comprises an End roller for receiving the fabric length from the upper roller unit, ends of the said End roller are supported on the upper platforms.

In still another embodiment of the present invention the roller assembly comprises a spring loaded upper guide roller mounted on the upper platforms for guiding and tensioning the fabric length received by the End roller unit from the upper roller unit. In yet another embodiment of the present invention the roller assembly comprises a spring loaded lower guide roller mounted on the lower platforms for guiding and tensioning the fabric length received by the lower roller unit from the feed roller.

In a further embodiment of the present invention the vertical drive unit comprises one motor or more than one motors synchronized with each other for rotating the horizontal rollers of the upper roller unit and the lower roller unit in synchronization.

In a further more embodiment of the present invention the horizontal drive unit comprises a motor coupled with the frame structure for moving the said frame structure in horizontal direction. In another embodiment of the present invention one or more guiding means are mounted on the frame structure for guiding the fabric length or supporting the width of the fabric running between the lower roller unit and the upper roller unit.

In one more embodiment of the present invention comprises a shuttle movement assembly for performing the embroidery, said shuttle movement assembly actuated by a main cam drive assembly which is driven by a motor. The present invention is described with reference to the figures and specific embodiments; this description is not meant to be construed in a limiting sense. Various alternate embodiments of the invention will become apparent to persons skilled in the art upon reference to the description of the invention. It is therefore contemplated that such alternative embodiments form part of the present invention.

Figure 5 is an exemplary illustration of construction of the vertical embroidery machine according to an embodiment of the present invention. As shown in figure 5, the embroidery machine comprises a lower beam section (1) formed by a pair of parallel beams (2) (hereinafter referred here as first pair of parallel beams) and an upper beam section (3) formed by another pair of parallel beams (4) (hereinafter referred as second pair of parallel beams). As can be observed from figure 5, the first and second pairs, of parallel beams (2, 4) are horizontally extending, and the second pair of beams (4) is located above the first pair of beams (2). The embroidery machine comprises four vertical columns (5) for supporting the first and second pair of parallel beams (2, 4). As shown in figure 5, one or more brackets (6) can be mounted on the vertical columns (5). Ends of the parallel beams (2, 4) can be mounted on the said brackets (6). The vertical columns (5) can be supported on one or more substantially flat base (7). The upper beam section (3), the lower beam section (1) and the vertical columns (5) together form a support structure of the embroidery machine of the present invention.

Referring to figures 6(a) and 6(b), the embroidery machine comprises a frame section (8) which is slidably mounted on the said upper beam section (3) and the said lower beam section (!) according to an embodiment of the present invention. As shown in figure 6 (a), the frame section (8) comprises a first horizontal platform unit (9) and second horizontal platform unit (10); each platform unit comprises an upper platform (9U, 10U) and a lower platform (9L, 10L). The upper platforms (9U, 10U) are slidably mounted on and over the upper beam section (3) while the lower platforms (9L, 10L) are slidably mounted on and beneath the lower beam section (1). For this purpose, rigid horizontal guides (11) are mounted .on and over the beams (4) of the upper beam section (3). Similarly, rigid horizontal guides (11) are mounted on and beneath the beams (2) of the lower beam section (1).

As can be observed from figures 6(a) and 6(b), each of the upper platforms (9U, 10U) is laterally mounted on the horizontal guides (11) such that each of the said upper platforms (9U, 10U) can slide horizontally over the two parallel beams (4) the said upper beam section (3). Similarly, each of the lower platforms (9L, 10L) is laterally mounted on the horizontal guides (11) such that each of the said lower platforms (9L, 10L) can slide horizontally below the two parallel beams (2) the said lower beam section (1).

In place of the parallel beams with horizontal guides, the upper beam section and the lower beam section can comprise horizontally extending parallel rails which can act as guides as well as parallel beams according to an embodiment of the present invention.

As shown in figures 6 (a) and 6(b), in the first platform unit (9), the upper platform (9U) is connected with the lower platform (9L) by vertically extending rigid side members (12). Also, in the second platform unit (10), the upper platform (10U) is connected with the lower platform (10L) by vertically extending rigid side members (12'). As can be observed from figure 6, the rigid side member (12, 12') holds the upper and lower platforms (9U, 9L and 10U, 10L) together thereby forming the said frame section (8) which slidably mounted on the guides of the upper and lower beam sections (1, 3). As shown in figures 6 (a) and 6(b), a lower roller unit (13) comprising one or more horizontal rollers is rotatably mounted on the frame section (8). For this purpose, the lower roller unit (13) is rotatably supported on the lower platforms (9L, 10L) of the first and second platform units (9, 10). In an embodiment of the present invention, ends of the said one or more horizontal rollers of the lower roller unit (13) is rotatably supported by bearings (14) mounted on the lower platforms (9L, 10L) of the first and second platform units (9, 10). Similarly, an upper roller unit (15) comprising one or more horizontal rollers is rotatably mounted on the frame section (8). For this purpose, the upper roller unit (15) is rotatably supported on the upper platforms (9U, 10U) of the first and second platform units (9, 10). In an embodiment of the present invention, ends of the said one or more horizontal rollers of the upper roller unit (9, 10) is rotatably supported by the bearing (14') mounted on the upper platforms (9U, 10U) of the first and second platform units (9, 10). As shown in figures 6(a) and 6(b), the upper roller unit (15) and the lower roller unit (13) is movable in horizontal direction. The upper roller unit (15), the lower roller unit (13) and the frame section (8) together form a circumferentially closed frame structure (16) (as shown in figure 7) which is movable in horizontal direction according to an embodiment of the present invention.

Referring to figures 6(a) and 6(b), a horizontally extending feed roller (17) is rotatably mounted on the frame section (8) for supplying the length of the fabric to be embroidered to the lower roller unit (13). For this purpose, ends of the feed roller (17) are rotatably supported on the lower platforms (9L, 10L) of the first and second platform units (9, 10). As shown in figure 6(a), a horizontally extending End roller (18) is rotatably mounted on the frame section (8) for receiving the embroidered fabric from the upper roller unit (15). For this purpose, ends of the End roller (18) are rotatably supported on the upper platforms (9U, 10U) of the first and second platform units (9, 10). In an embodiment of the present invention, the feed roller (17) and the End roller (18) are supported to the bearings mounted on the upper and lower platforms (9U, 9L and 10U, 10L). The upper roller unit (15), the lower roller unit (13), the feed roller (17) and the End roller (18) together form a roller assembly. In an embodiment, the horizontal rollers are synthetic rubber rollers. In an embodiment of the present invention, a horizontal drive means is coupled to the frame structure or frame section for moving the frame structure or frame section in horizontal direction (i.e. in X-X) direction. In an embodiment, the horizontal drive means can be a servo motor. In another embodiment of the present invention, a vertical drive unit is provided for rotating the horizontal rollers of the upper roller unit and the lower roller unit. In an embodiment, the vertical drive unit comprises one or more servo motor. A single motor can be used for rotating the said horizontal rollers or separate motors which are synchronized can be used for rotating the said horizontal rollers. The feed roller (17) and the End roller (18) can be rotated by separate motors.

The drive means, drive units, motors and other electronic control are conventional and therefore not shown in the drawings.

Figures 7, 8 and 9 illustrate movement of cloth or fabric on the vertical embroidery machine according to an embodiment of the present invention. As shown in figure 7, the fabric (19) is vertically arranged on the frame structure (16).

Referring to figures 7, 8 and 9, length of fabric (19) to be embroidered is rolled onto the feed roller. Fabric length travels between the horizontal rollers of the lower roller unit (13) and then between the horizontal rollers of the upper roller unit (15). As can be clearly understood, the fabric (19) is vertically arranged for embroidery between the lower roller unit and the upper roller unit.

As can be clearly understood, the frame structure was to be moved in horizontal and vertical direction to achieve the desired embroidery on the fabric which is vertically arranged on the frame structure. In the present invention, the vertical and horizontal fabric movement can be achieved through the upper roller unit (15), the lower roller unit (13), horizontal drive means and the vertical drive unit. In other words, said frame structure (16) is movable in a horizontal direction i.e. X-X direction by horizontal drive means and therefore, the fabric (19) is movable in horizontal direction (X-X direction). The fabric (19) is moved in vertical direction i.e. in Y-Y direction by rotational motion of the horizontal rollers or the upper and lower roller units (15, 13).

Once, the portion of the fabric length which is vertically arranged between the lower and the upper roller units (13, 15) is embroidered the End roller (18) takes the embroidered fabric length (19) which is replaced by the fabric length supplied by the feed roller (17). Figure 9 shows side view of the vertical embroidery machine according to an embodiment of the present invention. As can be observed from . figure 9, the structure of the vertical embroidery machine of the present invention is I-Shape (rectangular module). As can be clearly observed, in the embroidery machine of the present invention the embroidery is done length wise i.e. along the grain line of the fabric. In the present invention the length of the fabric is kept under tension and not the width. Since, the fabric is more stretchable widthwise as compared to the length wise therefore the embroidery of the desired geometry can be produced by the machine of the present invention. In other words, once the fabric is off loaded from the machine, the geometry of embroidery does not deform. Referring to figures 7, 8 and 9, guide rollers i.e. upper guide roller (20U) and lower guide roller (20L), can be mounted on the upper platforms (9U, 10U) and the lower platforms (9L, 10L) respectively. The upper guide roller (20U) is mounted on the upper platforms (9U, 10U) so as to increase the distance traveled by the fabric between the upper roller unit (15) and the End roller (18). Similarly, the lower guide roller (20L) is mounted on to the lower platforms (9L, 10L) to increase the distance traveled by the fabric between the feed roller (17) and the lower roller unit (13). In an embodiment of the present invention, the guide rollers (20U, 20L) are spring loaded thereby tensioning the fabric which is vertically arranged between the lower roller unit (13) and the upper roller unit (15).

In an embodiment of the present invention, two support rollers (not shown in figures) are mounted on the said frame structure between the upper and lower roller units and across the width of the fabric for supporting the width of. the vertically arranged fabric while embroidery is performed on the fabric.

Referring to figure 10, a shuttle movement assembly (21) is mounted on the support structure for cooperating with a needle-thread assembly (not shown in figures) and performing the embroidery on the vertically arranged fabric on the frame structure (16) according to an embodiment of the present invention,. As shown in figure 10, the shuttle movement assembly (21) comprises (a) a shuttle-fero assembly (22) having a shuttle box sub-assembly (23) and plurality of fero beams (24), (b) plurality of bearing assemblies (25) for vertical motion, (c) plurality of angular, guide rods (26). According to an embodiment of the present invention, the shuttle movement assembly (21) is mounted on the lower beam section. As shown in figure 10, the plurality of angular- guide rods is mounted on plurality of support plates (27) which are mounted on the rear beam (2a) of the lower beam section. The fero-beams (24) are slidably mounted on the plurality of angular-guide rods with the help of the bearing assemblies (25). A linear motion guide (28) is disposed on the front beam (2b) of the lower beam section and the shuttle box sub-assembly (23) is slidably mounted on the linear motion guide (28). As can be observed from figure 10, the movement of the shuttle box sub-assembly (23) moves the fero beam on the angular guide rods.

As shown in figure 10, the shuttle box sub-assembly (23) comprises a plurality of shuttle boxes. Each of the shuttle box is provided with holes for (23') needles and borers (not shown in the figure)

Figure 11(a) and 11(b) illustrate a main cam drive assembly (29), according to an embodiment of the present invention, is mounted on the support structure as shown in figure 11. For this purpose, the brackets (6), mounting the lower beam section (1), have extended portion (6e) as shown in figure 5. Referring to figures 5 and 11(a), a beam structure (30) comprising a pair of parallel beams is mounted on the extended portion (6e) of the brackets (6). In an embodiment of the present invention, the main cam drive assembly (29) comprises a cam shaft (31), a needle- movement cam (32), a cloth-pressure-cam (33), a shuttle-cam movement (34), a worm gear box (35), a drive motor (36), proxy sensor for start signal, proxy sensor for home. Referring to figures 1 1(a) and 11(b), a plurality of actuating means selected from shafts (37) for reciprocating motion and lever link (38) are disposed inside the beam structure (30). The said plurality of actuating means are actuated by cloth-pressure cam (33), needle-movement cam (32) the shuttle-movement cam (34) via power output blocks (39). The actuating means are operated by the main cam drive assembly and or directly by the motor. In an embodiment of the present invention, the borers are actuated by a borer actuating means is provided which can be operated by a motor.

The main cam drive can be considered as heart of the vertical embroidery machine of the present invention. The main cam drive assembly is constructed so as to have a constant velocity profile. In the main cam drive the rotory motion is converted into linear motion at constant speed on periphery of the cam disc. The main cam drive assembly is mounted on the beam structure of the shuttle movement assembly. The main cam drive assembly is balanced from its center and the cam shaft of the said main cam drive assembly is supported with two bearings. The power is delivered to the cam shaft by means of a Worm gear head mechanism enabling unidirectional power transmission. In an embodiment of the present invention, the possible jerks can be avoided with the sliding property of Worm gear in the worm gear box. The main cam drive assembly is compact and balanced shaped as compared to CAM mechanism of the conventional embroidery machine.

In conventional embroidery machines frame holds fixed length and fixed width of cloth/fabric on the frame at a time or for one embroidery session. Whereas, the vertical embroidery machine of the present invention is entirely different from conventional machines. In the vertical embroidery machine of the present invention, the cloth/fabric is loaded as the cloth is rolled after weaving. The length of the cloth/fabric is rolled to and fro for vertical axis movement (Y-Y) of the fabric to horizontal rollers of the roller assembly by rotating the same by the vertical drive unit.

In an embodiment of the present invention, a ball screw based actuator is coupled to the frame structure for effecting the left and right movement of the said frame structure. Hence, after the combined motion of vertical (i.e. to-and- fro) and horizontal (i.e. left- right) movement gives the embroidery on the cloths/fabric at continuous flow of cloth/fabric in up-ward or vertical direction. Figure 12 shows embroidery produced by vertical embroidery machine of the present according to an embodiment of the present invention. As can be observed from figure 12 that since the embroidery is done length wise the cloth produced by this fabric is not affected by shrinkage. According to an embodiment of the present invention, the vertical embroidery machine can be foot mountable as well as portable on wheels which make the machine easy to shift from one place to another place in a soft floor Viz. absolutely portable and handy. It is absolutely production . shop floor saving, compactness to handle by minimum labors and lowest maintenance cost throughout the year. Overall it is saving 20 percent fabric wastage in the entire process.

As the vertical embroidery machine is in integrated modular design fashion. So that, any accidental case can be cured in minimum possible time.

The vertical embroidery machine of the present invention is very economical machine for medium range products and manufacturers. Also the vertical embroidery machine of the present invention produces low noise and workable in ambient temperature operation (no air-conditioned environment is required); hence environmental friendly for workers operating the machine.

The vertical embroidery machine of the present invention can produce a special kind of embroideries which were so far extremely impossible on conventional embroidery machines. The vertical embroidery machine can create more designs with free hand. And cost for the embroidery will be less because of minimal electricity, minimal space, minimal labor and minimal wastage of fabrics and yarns (there will be very less standby position for the machine during low input of the orders).