GB2233006A - Apparatus for fabricating textile articles such as bath throw rugs - Google Patents

Abstract

Apparatus 10 for automatically fabricating textile articles A, such as bath throw rugs includes feed rolls 15, 16 for intermittently feeding continuous textile material M suitable for fabricating the articles A from a supply position 11 to a cutting position 12. A cutting mechanism 22 successively cuts slightly oversized textile articles A. A robot mechanism 25 successively picks-up and transports each cut article from the cutting position 12 to an edge finishing position 26, rotates the cut articles in a predetermined pattern during edge finishing thereof and then transports each finished textile article A to a stacking position 28. An edge finishing apparatus 60 receives each slightly oversized cut textile article A in the edge finishing position 26, as the article is being rotated by the robot device in its predetermined pattern, and includes devices for simultaneously trimming off a predetermined width of the outside edge portion of the cut article, positioning an edge binding tape around the trimmed edge and sewing the edge binding tape to the trimmed edge of the article. <IMAGE>

Description

APPARATUS FOR FABRICATING TEXTILE ARTICLES SUCH AS THROW RUGS This invention relates to an apparatus for automatically fabricating textile articles, such as hath throw rugs, having a trimmed outside peripheral edge wit edge binding tape sewn therearound.

It has previously been the practice in fabri- cating such textile articles, particularly bath throw rugs, to utilize a number of individual machines, locations and operator steps invcluding utt.ra a continuous length of textile fabric into incividual articles of slightly oversized dimensions. These cut articles were then taken to individual Machines which would trim off a predetermined wisth of the outside edge portion of the textile article, apply an edge binding tape around the trimmed edge of the article and sew the edge bindung tape to the trimmed edge of the article to complete fabrication thereof. The fabricated article would then be stacked for packaging, etc.

This type of article fabricating operation was necessarily expensive and time consuming. No autonatic fabricating apparatus has been conmercially available to applicant's knowledge for automatically performing the above described fabricating steps, nor has an edge finishing apparatus been commercially available which will simultan-eously edge trim, apply an edge binding tape and sew the edge binding tape to the trimmed edge automatcally and satisfactorily without excessive operator handling, It is, therefore, an object of this invention to provide an apparatus for automatically performing such fabricating steps in the manufacture of textile articles, such as bath throw rugs, which. will eliminate excessive operator time and expense.

It is a further object of this invention to provide an edge finishing apparatus for use in fabricating such textile articles which will automatically perform the above described edge finishing operations.

By this invention it has been found that this object may be accomplished by providing an apparatus for automatically fabricating textile articles, such as bath throw rugs having an edge binding tape sewn therearound in which such apparatus includes generally the following.

Means are provided for intermittently feeding continuous textile materials, suitable for fabricating such articles, from a supply to a cutting position in the apparatus. Means successively cut slightly oversized textile articles from the continuous material in the cutting position. Robot means successively pick-up and transport each cut textile article from the cutting position to an edge finishing position in the apparatus, rotate the cut textile article in a predetermined pattern about an axis perpendicular to the faces of the cut textile article during edge finishing thereof, and then transport the fabricated article to a stacking position and release the fabricated article.

Edge finishing means receive the slightly oversized cut textile article in the finishing position as such article is rotated by the robot means in its predetermined pattern and includes means for trimming-off a predetermined width of the outside edge portion of the textile article, means for simulaneously positioning edge binding tape around the outside trimmed edge of the textile article and means for simultaneously sewing the edge binding tape around the outside trimmed edge of the textile article. Means are operatively connected with and control the sequential cycles of operations of the feeding means, the cutting means, the robot means and the edge finishing means for automatic fabrication of the textile articles.

Preferably, the means for trimming-off a predetermined width of the outside edge portion of the textile article of the edge finishing means includes means for disengaging the trimming means when trimming is no longer desired. Preferably, the means for supplying and positioning an edge binding tape around the trimmed edge of the textile article of the edge finishing means includes neans o c=+ing the edge binding tape at the end of a cyle of operation.

In accordance with a preferred embodiment of this invention, the textile material is a tufted pile material, the robot means further rotates the cut textile article in a second predetermined pattern about an axis perpendicular to the faces of the cut textile article after rotation thereof in the first predetermined pattern, and the edge finishing means includes a tufting machine for receiving the textile article during rotation in its second predetermined pattern for applying pile tufts through the edge binding tape sewn around the outside of the trimmed edge of the textile article for providing a tufted pile edge to the fabricated article.

In order that the present invention may be more readily understood, reference will now be made to the accompanying drawings, in which: Figure 1 is a perspective, somewhat schematic, view of an apparatus constructed in accordance with this invention; Figure 2 is an enlarged perspective detail of a portion of the robot means utilized in the apparatus of Figure 1; Figure 3 is a schematic perspective view of the control means utilized or the apparatus of Fibre 1; Figure 4 is a sectional schematiac view through the apparatus and taken generally along the line 4- of Figure 1;; Figure 5 is a perspective view of a textile article, such as a bath throw rug, constructed in accordance with this invention: Figure 6 is an enlarced perspective view C: pile corner portion of the fabricated textile article of Figure 5; Figure 7 is a sectional view taken generally along the line 7-7 of Figure 6: Figure 8 is a sectional view taken generally along the line 8-8 of Figure 6: Figure 9 is a Fartial perspective view of a portion of a modified textile article which can be produced with the apparatus of Figure 1; Figure 10 is a sectional view taken generally along the line 10-10 of Figure 9:: Figure 11 is a partial perspective view of the end effector of the robot means holding a textile article for rotating the textile article through the edge finishing machine of this invention: Figure 12 is an enlarged perspective view of the edge finishing machine performing its edge finishing operations on the textile article; Figure 13 is a front elevational view of the edge finishing machine of Figures 11 and 12; Figure 14 is a top plan view of the edge finishing machine of Figure 13:: Figure 15 15 a sectional view taken generally along the line 15-15 of Figure 13; Figure 16 is a perspective detail cf the trimming device utilized in the edge finishing machine; Figure 17 is a perspective detail of the edge binding tape cutting device utilized n the edge -risning machine: Figure :8 is a sectional detail through a par- tion of the edge binding tape cutting device; and Figure 19 is a perspective view of the edge binding @g tape after having been cut by the cutting device Referring no to the drawings, Where is illustrated in Figure . an apparatus. generally referred to at 10, for automatically fabricating textile articles .n, such as bath throw rugs.

This apparatus 10 includes means for intermit- gently feeding continuous textile material M suitable or fabricating such articles A from a supply position 11 to a cutting position 12 in the apparatus 10. The supply of the material M can be in any suitable form.

such as the dolly 13 illustrated in Figure 1.

The material M is fed from its supply 13 in the supply position 11 to the cutting position 12 by any suitable means, such as feed rolls 15,16 suitably mounted on a portion of the frame of the apparatus, collectively indicated at 17. The feed rolls 15,16 include suitable drive means1 such as the selectively'operated motor 18 and belt and pulley drive 19 carried by the apparatus frame 17 and connected with the feed roll 15. The feed rolls 15,16 intermittently feed the continuous material M around tension rolls 20 onto conveyor belts 46 and past a cutting nechanism 22.This cutting mechanism 22 may be any suitable sort of cutting mechanism including a rotating cutter mounted on a motor belt and pulley arrangement 23 and driven by selectively-oper2ted motor 24, all suitably mounted on apparatus frame 17. The motor driven belt and pulley arrangement 23 will selectively move the rotating cutter 22 transversely across the continuous material M after it has been fed past the cutter 22 by the feed rolls 15,16 to cut the continuous material M into slightly oversized cut textile articles A.

The apparatus 10 further includes robot means, 25 mounted on a portion of the apparatus frame 17 for successively picking-up and transporting each ct textile article A from the cutting position 12 to an edge finishing position 26, for rotating the cut textile article A in a predetermined pattern V about an axis perpendicular to the faces of the cut textile article A in the edge finishing position 26, and for then transporting the fabricated textile article A to a stacking position 28 and releasing the fabricated textile article A.

The robot means 25 preferably includes a selectively-operable suction-head end-effector 29 for picking-up, holding and releasing the textile articles A. This suction-head end-effector :nay be in the Corm of a flat hollow housing having apertures in the bottom surface thereof (not shown) and connected to a vacuum source 30 through a flexible hose connection 31 to be selectively-operated by a solenoid valve 41 to apply a vacuum within the houeing of the end effector 29 to create a suction on the bottom surface thereof when it is desired to pick-up. transport and hold the textile articles and which may be disengaged to shut off the suction when it is desired to release the textile article A.

The robot means 25 also includes devices for selectively moving the robot means 25 in a forward and reverse longitudinal horizontal path of travel X, a forward and reverse transverse horizontal path of travel Y, an up and down vertical path of travel Z, the rotating path of travel V about a vertical axis (all of which are indicated by the arrows in Figures 1 and 2), and com binationa of such paths of travel to effect the desired transporting and pattern rotation of the textile articles A by the robot means 25.

The means for effecting these paths of travel V, X, Y, Z of the robot means 25 may be any selectively operated drive mechanisms including a pneE atically- operated piston and cylinder device 32 connected to a suitable air source through selectively-operated solenoid valve 42 for carrying the end effector 29 for the up and down vertical path of travel Z. This piston and cylinder mechanism 32 may be connected to and carried by a circular driven gearing arrangement 33 driven by selectively-operated motor 34 for rotating the end effector 29 in its rotating path of travel V about a vertical axis.The gearing arrangement 33 may be carried by a suitable transversely movable carriage 35 mounted on a. rotating worm gear 36 which is driven by selectively-operated motor 37 and extends in the trans- verse directions to move the end effector 29 and other above described mechanisms in a forward and reverse transverse horizontal path of travel Y. These mecha nisms may in turn be carried by a carriage 38 which is mounted on another rotating worm gear 39 which is driven by selectively-operated motor 40 and extends in a longi tudinal direction and is carried by a portion of the frame 17 for moving the end effector 29 and other above described mechanisms in a forward and reverse longitudi nal horizontal path of travel X.Thus, by selective actuation of the piston and cylinder device 32, rotating gear and motor device 33,34, worm gear and motor device 36,37, and worm gear and motor device 39,40, the above described paths of travel V, X, Y, Z for the end ef fec tor 29 and cut textile article A carried thereby can be effected.

In order to properly position the cut article A for pick-up by the robot means 25, the apparatus 10 pre ferably includes means 45 for positioning the cut tex tile article A in a predetermined longitudinal and transverse position for pick-up by the robot means 25.

This positioning means 45 may comprise means for moving the textile article longitudinally from the cutting position and as disclosed in Figures 1, 3 and 4, is in the form of endless conveyor belts 46 driven by selectively-operated motor 47. The positioning means further includes means for sensing the cut textile article A when it has moved longitudinally to the prede termined position which may be in the form of a pho toelectric cell 48 for sensing the forward edge of the cut textile article A when it has moved longitudinally forwardly to the predetermined position and which is operatively connected to the motor 47 for stopping forward movement of the conveyor belts 46.The positioning means further includes means for moving the cut textile article A transversely from the cutting position and, as illustrated in Figures 1, 3 and 4, this means includes a carriage device 50 mounted on a worm gear 51 driven by sclectively-operated motor 52 and extending transversely of the cut textile article A for moving the conveyor belts 46 transversely of the textile article A to the predetermined position. There is further included a means, in the form of a photoelectric cell 54 operatively connected to the motor 52, for sensing the cut textile article A when it has moved transversely to the predetermined position and for stopping operation of the motor 52 to stop transverse movement of the cut textile article A when it has reached the predetermined position.

The apparatus 10 further includes edge finishing means 60 for receiving the slightly oversized cut textile article A in the edge finishing position 26 as such article A fr being rotated by the robot means 25 in its predetermined pattern and includes a trimming mechanism 61 for trimming off a predetermined width of the outside edge portion of the textile. article A, an edge binding tape positioning mechanism 62 for aimultaneously positioning an edge binding tape T around the trimmed edge of the article A, and a sewing machine 63 for sewing the edge binding tape to the trimmed edge of the article A by stitches S. As may be seen particularly in Figures 11-13. this edge finishing neans 60 including trimming mechanism 61, edge binding tape posi toning mechanism 62 and sewing machine 63 are all part of a unitary edge finishing apparatus 60 and operate simultaneously for performing the above edge finishing operations to form a fabricated textile article A having a trimmed edge with edge binding tape T sewn by stitches S around such trimmed edge, as illustratel in Figures 5-7.

The edge trimming means 61 may comprise reciprocating cooperating blades 65, 66 in which blade 65 is suitably attached to sewing machine 63 drive mechanisms (not shown) for reciprocation up and down in a vertical path of travel (Figures 15, 16) into and out of cutting engagement with normally stationary blade 66.

The cutting blades 65, 66 are positioned just prior to the needle 67 and other stitching mechanisms of the sewing machine 63 for trimming a predetermined width of the outside edge portion of the textile article A as such article A is fed through the sewing machine 63 of the edge finishing apparatus 60.

The edge trimming means 61 further includes means for disengaging said edge trimming means at the end of a desired cycle of operation or preferably after the entire peripheral edge of the article A has been fed through the edge finishing apparatus 60. This means for disengaging the trimming means 61 may comprise a pneumatically-operated selectively-operated piston and cylinder 69 having the piston thereof connected to an arm 70 which is in turn connected to a rod 71 contained within a cylindrical hollow housing 72 and connected at its outer end to the blade 66. A suitable spring 73 may be contained within the housing 72 for biasing the rod 71 and thus the blade 63 into its normal cutting position (Figures 15, 16).However, when the piston and cylinder mechanism 69 is selectively-operated, the rod 71 and the blade 66 ill be moved te the totted line positions shown in Figure 15 to move the cutting blade 66 out of cutting engagement with the reciprocating blade 65 to disengage the trimming mechanism. Control of this means for disengaging the trimming mechanism 61 after the textile article has been rotated 360 or otherwise, can be contained within the edge finishing mechanism 60 and could be associated with operation of the feed dogs 74 of the sewing machine 63 and would include means (not shown) for adjustment to accommodate different textile articles A.The controls ray also be tied into the overall machine sequence control eans of the edge finishing apparatus 60, to be described below, for the entire textile article fabricating apparatus 10.

A full illustration and description of such controls are nct Selievcd necessary for full understanding of this invention.

The edge binding tape supplying and positioning teans ay be in the for: of a suitable supply of edge bind-'ng tape T, such as a spool 76 (Figures 13, 14), which supply the edge binding tape T to v suitable guiding device 77 which guides the edge binding tape aroun- and positions the edge binding tape r in a suitable, generally U-shaped configuration around the outside trimmed edge of the textile article A between the edge trimming blades 65, 66 and the sewing needle 67 of The sewing machine 63 so that the edge binding tape @ is properly positioned on the trimmed edge of the textile article A after trimming by the edge trimming reins 61 and prior to stitching by the sewing machine 63.

The edge binding tape supply and positioning means 62 further includes means for cutting the edge binding tape T after the edge binding tape T has been positioned around at least the entire peripheral trimmed edge of the textile article A. This cutting means, as shown particularly in Figures 17, 18, may be in the form of a cutting blade 80 suitably carried by a block 81 mounted on a plate 82 which is in turn pivotally carried by the piston of a selectively-operated piston and cylinder mechanism 83. The cylinder of the piston and cylinder mechanism 83 is carried by a plate 85 which also provides an anvil surface or cutting surface for cooperation with the blade 80. The plates a2 85 are biased apart in a noncutting position by a spring 86 extending therebetween and a guide 87 may be provided for the plates 82, 83.With this arrangement, when the piston and cylinder mechanism 83 is 8electively- operated, the piston thereof will move the plate 82 and the cutting blade 80 so that the cutting blade 80 will contact the plate 85, as may be clearly seen in Figure 17. Inasmuch as the edge binding tape T is fed between the plates 82, 85 by a suitable feeding mechanism, such as feed dog device 88, the tape T will be cut when the piston and cylinder snechanislo 83 is selectively operated.

The cutting blade 80 is preferably in the form of a generally V-shaped blade with a cut-out portion in the middle thereof so that the edge binding tape T will be transversely cut from each outside edge toward the middle thereof while leaving a small center section uncut, as shown in Figures 18, 19. This will allow the edge binding tape T to be fed from the cutting mechanism through the guide 77 and into position around the trimmed edge of the article A for breaking under tension when the cut portion of the edge binding tape T reaches the textile article A and to leave a leading edge of the tape T in position through the guide 77 for the next textile article A to be fabricated.Controls for the piston and cylinder mechanism 83 may also be contained within the edge finishing apparatus 60 and may be keyed to the feed of the textile article A through the sewing machine 63 by the feed dogs 74 or otherwise. Also, controls for the piston and cylinder mechanism 83 for the edge binding tape cutting means may also be tied into the overall machine sequence control means to be described below, with respect to the overall textile article fabricating apparatus 10. It is not believed that an illustration and description of such control weans is necessary for a full understanding of this invention.

;n fabricating textile articles A, such as bath rugs, it is often desired to stitch the edge binding tape around a small portion of the leading trimmed edge to which edge binding tape T has already been positioned, as shown in Figures 6 and 8.For this purpose, the robot -eans 25 will be controlled to rotate the tex tie article A slightly crater than a 360 path of rotation, the above described means for disengaging the edge trimming means 61 would be controlled to disengage the edge trimming means 61 after the entire peripheral edge of the textile article has been fed through the edge finishing means 60 and rotated by the robot means 25 in a 360 path of rotation, and the above described means ror cutting the edge binding tape T would be controlled to cut the edge binding tape T so that an additional segment of edge binding tape r is provided or being positioned by the edge binding tape positioning means 62 around a small portion of the leading trimmed edge of the texticle article A to which the edge binding tape has already been positioned.

When the textile article A being fabricated is in the form of a tufted pile material, as shown in Figures 7 and 8, for the fabrication of a bath rug the edge finishing apparatus 60 may further include means 90 positioned slightly in advance of the textile article edge trimming means 65 and the edge binding tape applying means 62 for applying a stream of air against the pile face of the textile article A (Figure 12) along the trim line to open up the pile of the textile article A along such trim line to facilitate trimming of the textile article A without undesirable trimming of the pile. This means for applying a stream of air. 90 may be in the form of a suitable nozzle connected to an air supply source.

when the textile article A being fabricated by the apparatus 10 is in the form of the tufted pile article, particularly a bath throw rug, it is often desirable to apply extra pile tufts through the edge binding tape T after having been stitched around the trimmed edge of the textile article A, as shown in Figures 9 and 10. For this purpose, the robot means 25 would be controlled to further rotate the cut textile article A in a second predetermined pattern V about an axis perpendicular to the faces of the cut textile article A after rotation thereof through the above described edge finishing 60.The edge finishing neans 60 would also include a separate tufting machine 96 positioned in the apparatus 10 in the edge finishing position 26, but on the other side of the apparatus 10 (Figures 1 and 3) for receiving the textile article A as such article A is being rotated by the robot means 25 in the second predetermined pattern V for applying tufts t through the edge binding tape T sewn around the outside of the trimmed edge of the textile article A.

The article fabricating apparatus 10 further includes machine sequence control jeans 100 (Figure 3) operatively connected with and controlling the seqen- tial cycles of operation of the material feeding means through motor 18, the article cutting means through motor 23, the cut article positioning means through motors 41, 52, the robot means through solenoid valves 41, 42 and motors 34, 37, 40, and to the edge finishing means 60 through internal drives.

This machine sequence control means 100 may be in the worm of any electronic control means for sequencing the operations of the above described mecha- nisms. These electronic control means are generally comercially available and an illustration and descrip tion thereof herein is not deemed necessary for a full understanding of this invention. Schematic electrical connections have been shown in Figure 3 from such machine sequence control weans to all of the above described mechanisms.

Thus, this invention has provided an apparatus '0 or automatically fabricating textile articles A1 such as bath throw rugs, having a trimmed Outside peripheral edge with edge binding tape T sewn therearound by stiches S, which will automatically perfor ne fabricating operations in the manufacture of such textile articles A to eliminate heretofore necessary operator tfe and expense. Further, an edge ir. sr.ir.- apparatus 60 has been provided for "se 'n fabricating such textile articles A which will automatically form the edge finishing functions of trimming off a predetermined width of the outside edge portion of the textile article A. simultaneously positioning an edge binding tape T around the trimmed edge of the textile article A and simultaneously sewing the edge binding tape T to the trimmed edge of the textile article A, thus eliminating heretofore required manual operations in suc edge finishing operations.

Claims (3)

1. Apparatus for fabricating a textile article, such as a bath throw rug, comprising: means for feeding an outside edge portion of the textile article through the apparatus; means for trimming-off a predetermined width of the outside edge portion of the textile article as the textile article is fed through the apparatus; means for simultaneously supplying and positioning an edge binding tape around the trimmed edge of the textile article as the textile article is fed through the apparatus; means for sewing the edge binding tape to the trimmed edge of the textile article as the textile article is fed through the apparatus; means for cutting the edge binding tape after the tape has been applied to the entire circumference of the article; and means for selectively disengaging the trimming-off means upon completion of trimming the entire circumference of the article to prevent cutting of the tape as the portion of the trimmed edge to which edge binding tape has been previously applied is advanced through the apparatus.

2. Apparatus as claimed in claim 1, for fabricating a textile article which is a pile material, in which means is positioned slightly in advance of the edge trimming means and the edge binding tape applying means for applying a stream of air against the pile face of the textile article along the trim line to open up the pile of the textile article along the trim line to facilitate trimming of the textile article without undesirable trimming of the pile.

3. Apparatus as claimed in claim 1 or 2, in which means for cutting the edge binding tape comprises cutting means for cutting the binding transversely from each outside edge toward the middle thereof while leaving a small center section uncut for breaking under tension when the cut portion is fed to the textile article and to leave a leading edge of the tape in position for the next textile article to be fabricated.