US20190145034A1 - Method of Automatically Fabricating Pattern Composite Fabric Pieces with Seam Allowance Flaps - Google Patents
Method of Automatically Fabricating Pattern Composite Fabric Pieces with Seam Allowance Flaps Download PDFInfo
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- US20190145034A1 US20190145034A1 US16/350,753 US201916350753A US2019145034A1 US 20190145034 A1 US20190145034 A1 US 20190145034A1 US 201916350753 A US201916350753 A US 201916350753A US 2019145034 A1 US2019145034 A1 US 2019145034A1
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- Prior art keywords
- fabric
- seam allowance
- pieces
- composite material
- pattern
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- A—HUMAN NECESSITIES
- A41—WEARING APPAREL
- A41H—APPLIANCES OR METHODS FOR MAKING CLOTHES, e.g. FOR DRESS-MAKING OR FOR TAILORING, NOT OTHERWISE PROVIDED FOR
- A41H42/00—Multi-step production lines for making clothes
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- D—TEXTILES; PAPER
- D05—SEWING; EMBROIDERING; TUFTING
- D05B—SEWING
- D05B37/00—Devices incorporated in sewing machines for slitting, grooving, or cutting
- D05B37/04—Cutting devices
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- D—TEXTILES; PAPER
- D05—SEWING; EMBROIDERING; TUFTING
- D05B—SEWING
- D05B11/00—Machines for sewing quilts or mattresses
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- D—TEXTILES; PAPER
- D05—SEWING; EMBROIDERING; TUFTING
- D05B—SEWING
- D05B19/00—Programme-controlled sewing machines
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- D—TEXTILES; PAPER
- D05—SEWING; EMBROIDERING; TUFTING
- D05B—SEWING
- D05B27/00—Work-feeding means
Definitions
- the present invention relates to a method of automatically fabricating pattern composite fabric pieces with seam allowance flaps for interconnecting the fabric pieces together to form, for example, articles of apparel.
- Another feature of the present invention is to provide such a process in a clean and non-polluting environment.
- a further feature of the present invention is to provide an automatic machine for the fabrication of fabric articles and wherein the articles are of uniform quality due to precision manufacturing.
- Another feature of the present invention is to provide a less labor intensive and faster and more efficient method of manufacturing pattern articles of fabric with interconnecting seam allowance flaps.
- Another feature of the present invention is to provide a method of fabricating pattern composite fabric pieces incorporating therein embroidery patterns, and printing information and designs all combined in a single machine and process and performed automatically from a computer containing the fabrication information for the pattern composite fabric pieces.
- a still further feature of the present invention is to provide a composite insulating material pattern piece wherein the insulation is held captive between opposed fabric layers and fabricated in accordance with the method of the present invention and wherein any waste insulation material, such as down or other insulation material may be recycled.
- the present invention provides a method of fabricating pattern composite fabric pieces which comprises the steps of feeding a composite fabric sheet having two or more overlaid fabric sheets in an automatic pattern processing machine.
- the processing machine performs, in one or more specific order, the steps of laser or thermal cutting one or more pattern pieces from the composite fabric sheet, and forming one or more seam allowance flaps in outer edge portions of the pattern pieces.
- an in a stage of the machine the pattern pieces and trailing sheet parts are separated and the pattern pieces are gathered.
- the pattern pieces are assembled and interconnected by their seam allowance flaps in a predetermined order to form a complete fabric article.
- an automatically fabricated composite material pattern piece having an outer and inner fabric sheet secured together along a pattern seam line by fastening means. Seam allowance flaps are formed adjacent the pattern seam line and project from under outer edge portions of the outer fabric sheet to provide for attachment of the composite material pattern pieces in a specific order to form an insulating finished fabric article.
- a method of fabricating pattern composite fabric pieces which comprises the steps of feeding a composite fabric sheet having at least an outer and an inner fabric sheet, in an automatic pattern fabric article piece processing machine.
- the processing machine performs, in one or more specific order the steps of (i) cutting one or more pattern pieces from the composite fabric sheet, and (ii) forming one or more seam allowance flaps in outer edge portions of the pattern pieces.
- FIG. 1 is a schematic illustration of the automatic pattern fabric article piece processing machine of the present invention to fabricate pattern composite fabric pieces
- FIG. 2 is a further schematic illustration of the laser and stitching machine supports mounted in a dust free enclosure of a stage of the processing machine;
- FIG. 3 is a fragmented side view of a composite fabric material sheet
- FIG. 4 is a fragmented side view of the composite fabric material sheet showing the sheet being compressed
- FIG. 5 is a further fragmented side view showing two laser cuts within the composite fabric material piece to form an allowance flap
- FIG. 6 is a still further fragmented side view showing a stitch seam formed in the composite fabric material piece adjacent one of the laser cut lines where the top fabric piece and insulation only has been cut;
- FIG. 7 is a further fragmented side view showing the outer trailing piece having been removed with a trailing piece still present on the seam allowance flap;
- FIG. 8 is a further fragmented side view showing the trailing piece on the seam allowance flap removed and thus the formation of the clean seam flap to receive an identification mark thereon;
- FIG. 9 is a fragmented view of a pattern fabric article piece showing identification printed matter on the scant allowance flaps
- FIG. 10 is a plan view of a pattern fabric article piece wherein decorative stitch seams have been formed by the processing machine and a decorative label has been applied;
- FIG. 11 is a fragmented side view showing two pattern fabric article pieces wherein the seam allowance flaps have been joined together by stitching or gluing;
- FIG. 12 is a view similar to FIG. 11 showing the interconnected seam allowance flaps being folded back and glued to the bottom fabric sheet of the composite material pieces;
- FIGS. 13A to 13C are plan views of a few pattern fabric article pieces formed in accordance with the present invention and ready for interconnection together to form a complete fabric article, herein a jacket article of apparel;
- FIGS. 14A and 14B are fragmented side views showing two fabric sheets to be interconnected together to form a pattern article for interconnection with other pattern fabric articles and further illustrating two methods of forming the seam allowance flaps, one by cutting an outer one of the fabric sheets and the other by bonding a seam allowance strip along an edge portion of the outer surface of the inner fabric sheet;
- FIG. 15 is a simplified flow block diagram illustrating a sequence of steps performed by the method of fabricating a complete fabric article including the pattern composite fabric pieces formed in accordance with the present invention.
- FIGS. 1 and 2 there is shown, generally at 10 an example of the automatic pattern fabric article piece processing machine of the present invention and its method of operation. It is comprised of different stages and three stages are herein shown, namely a first stage 11 which is comprised of a conveyor 12 having a perforated or air permeable endless conveyor belt 13 on which is fed a composite fabric sheet 14 from a supply roll 15 for processing by the machine 10 .
- a first stage 11 which is comprised of a conveyor 12 having a perforated or air permeable endless conveyor belt 13 on which is fed a composite fabric sheet 14 from a supply roll 15 for processing by the machine 10 .
- the endless belt 13 is operated by a motor which drives a drive drum 16 as obvious to a person skilled in the art and represented in FIG. 2 where it is shown controlled by a controller computer 17 .
- a vacuum chamber 18 is disposed under the top run 13 ′ of the endless belt 13 and connected to a vacuum pump 31 which is connected to a vacuum pump 31 which is operated to retain the bottom fabric sheet of the composite fabric sheet 14 stationary on the belt for job functions to be performed by the first stage 11 of the machine 10 .
- the first stage 11 has a top housing 19 to which is connected to a vacuum pump 20 to aspire dust or other material particle in the air within the housing 19 whereby the equipment in the housing can operate in a substantially dust proof environment.
- a support rail assembly 21 on which is displaceably supported one or more laser or thermal cutter head(s) 22 and an automatic stitching or ultrasonic bonding machine 23 .
- the rail assembly 21 is comprised of a pair of fixed rails 24 across which is displaceably mounted transverse rails 25 and 25 ′.
- the transverse rails are displaceable in the directions of arrow 26 .
- the laser or thermal cutter head 22 is displaceably mounted on rail 25 ′ and displaceable in the directions of arrow 27 .
- the composite material sheet 14 is herein comprised of an insulating material, for example a synthetic, polyester, wool or down insulating material 35 , held captive between a synthetic bottom fabric sheet 36 and a top fabric sheet 37 .
- These fabric sheets may be constituted by two or more sheets to have a decorative outer sheet layer.
- the composite material sheet 14 is held captive and stationary under the housing 19 by the vacuum in the vacuum chamber 18 causing the material to also compress itself, as shown in FIG. 4 making it easier for the operations to be performed in a less dense material.
- the laser or thermal cutter head(s) 22 performs two pattern cuts in the composite fabric sheet 14 , one cut 38 which cuts through the entire sheet 14 to define the outline of the pattern fabric piece to be manufactured and a second cut 39 which extends through the top fabric layer 37 and the insulating material 35 but not the bottom fabric sheet 36 . Accordingly, a seam allowance flap 40 is being formed by the bottom fabric layer defined between the laser cuts 38 and 39 . The end portions 40 ′′ of the seam allowance flaps, as shown in FIG. 10 , are made by cuts formed in the inner fabric sheet.
- the controller 17 then actuates the automatic stitching machine 23 to be engaged and the laser cutter 22 to return to a storage position.
- the automatic stitching machine 23 then effects one or more stitch seam lines 41 , as shown in FIG.
- Trailing pieces 43 and 44 now have to be discarded and recycled where possible.
- the seam allowance flap 40 has a free outer face 40 ′. Trailing pieces consists of waste material of the fabric sheet remaining between the cut pattern pieces and over the seam allowance flaps.
- the laser or thermal cutter heads cuts the sheet there across.
- the conveyor 12 is then operated to transfer the composite fabric sheet with the cut fabric pieces 45 to the second stage 11 ′ onto a perforated conveyor 46 of the processing machine 10 and input a further sheet length from the supply roll 15 into the first stage 11 .
- the trailing pieces 43 and 44 are removed. This can be done manually, but in the present machine, this is accomplished by firstly positioning the composite fabric sheet 14 with the cut fabric pieces 45 and trailing pieces 43 on a patterned vacuum plate 44 under which only the pattern pieces are held by a suction force under the plate created by a vacuum chamber 44 ′ there under and connected to vacuum pump 44 ′′.
- a suction chamber 60 is disposed above the composite fabric sheet 14 to create a suction only sufficient to suck out the trailing pieces 43 , some of which have insulation thereon. This suction force is inferior to the retaining suction force applied under the cut fabric pieces 45 .
- a detector 48 detects the transferred pattern fabric pieces 45 and feed the controller position and orientation information relating to the pattern cut fabric pieces 45 . If desired, the cut fabric pieces can now be discharged in a collector or manually removed. However, the machine incorporates a third stage 11 ′′.
- the third stage 11 ′′ also has a controllable conveyor 61 to displace the composite fabric sheet with the cut fabric pieces.
- the third stage 11 ′′ comprises a laser printer 51 to print identification means such as codes 52 , as shown in FIG. 9 to identify the nature of the pattern fabric piece and a match connection code or number to another cut fabric piece for matching interconnection together, thus providing ease of matching pattern pieces for interconnection with one another.
- the printed information can also be substituted by other identification means.
- a decorative label or patch applicator 53 can also form part of the second stage to apply decorative labels automatically thereto to selected ones of the cut patter fabric pieces.
- Such a label 54 is illustrated in FIG. 10 .
- a decorative quilt stitch pattern 55 was effected by the automatic stitching machine 23 in the first stage.
- a glue applicator device 56 may also form part of the third stage 11 ′′ to apply a glue substance on the seam allowance flaps 40 for interconnection.
- the displaceable devices in the third stage are also supported on a rail support assembly as in the first stage. After all job functions having been performed, the conveyor 61 ejects the fabric pieces 45 on a discharge conveyor 50 .
- the pattern pieces 45 are interconnected together by the seam allowances by matching printed codes and sewing or heat fusing the seam allowance flaps to form a complete fabric article, such as an article of apparel, a bedspread which may be quilted, a cushion, etc. These assembly of pattern pieces 45 are interconnected by their seam allowance flaps 40 and by such means as glue or stitching. The heat fusing process is, of course, much faster and less skill demanding than the stitching process.
- FIGS. 11 and 12 illustrates the interconnection of the seam allowance flaps 40 and 40 ′ of two pattern fabric pieces 45 and 45 ′, respectively. The flaps 40 and 40 ′ have their glue faces brought together to bind with one another forming a glue seam 57 .
- FIGS. 13A to 13C illustrate certain pattern fabric pieces 45 of an article of apparel and their interconnecting features of the seam allowance flaps.
- FIG. 14A there is shown a composite fabric piece 60 formed of an outer fabric sheet 61 secured to an inner fabric sheet 62 by stitching or thermal fusing.
- the outer fabric sheet may have a design pattern embroidery 63 formed on the outer surface thereof or a stitch pattern (not shown) formed therein.
- the outer fabric sheet 61 may also consist of several fabric layers of different type fabrics and colors, herein illustrated a further fabric layer 64 , which layer(s) are die cut by the laser or thermal cutting head(s) 22 of FIG. 1 . These cutters are programmed to penetrate only the top layer or two or more fabric layers disposed on the inner layer (liner) and perform programmed cut outlines different from layer to layer to create design features.
- the seam allowance flap 65 is formed in a peripheral portion of the composite fabric piece 60 which is not fused, and this is accomplished by a laser or thermal cut 66 formed only through the outer fabric sheet 61 , which may consist of several layers as above mentioned.
- the trailing piece 44 is removed in a manner as previously described.
- the seam allowance flap 66 is formed, in the first stage 11 of the machine, by a roll of fabric tape which is cut to size to form seam allowance flaps and heat fused in an outer surface overlapping portion 67 thereof of the inner fabric sheet 62 , which is usually a lining fabric material.
- the projecting portion 68 forms the seam allowance flap 66 .
- a supply roll 15 of a composite fabric sheet 14 is disposed at the inlet of a conveyor 12 at a first stage 11 of the automatic processing machine 10 .
- the sheet is moved by the conveyor to be positioned at a predetermined location and then held captive by a suction chamber under the air permeable conveyor belt 13 ′.
- the computer controller 17 then actuates the laser or thermal cutter head(s) 22 to effect cuts in the composite material sheet, as described herein above.
- the stitching device 23 then effects stitch seam lines or pattern designs as inputted in the memory of the computer.
- the vacuum is cut off and the conveyor moves the composite fabric sheet with the cut pattern pieces 45 to the second stage 11 ′ where the trailing pieces from the composite fabric sheet are removed and redirected for collection and conveyance to a remote area where the insulating material may be recycled or discarded.
- various other operations can be performed as selected by the inputted information in the computer controller 17 .
- Such other operations may include the application of decorative labels or other information labels, the printing of decorative motifs and identification and matching codes to the seam allowance flaps, and the application of glue on these flaps.
- the glue would be transparent not to conceal the printed information of the flaps.
- the pattern pieces 45 are maintained stationary in the third stage onto an air permeable conveyor belt by a vacuum chamber 47 positioned there under. The pattern pieces are then conveyed out of the third stage 11 ′′ and gathered and assembled for interconnection in a manner as above described to form a complete fabric piece. It is pointed out that some of the operations effected in the third stage may be effected in the first stage or previously in the composite fabric sheet 14 before being rolled to form the supply roll 15 , illustrated in FIG. 1 .
Abstract
An automatically fabricated composite material pattern piece is formed with an outer and inner fabric sheet secured together along a pattern seam line by stitching or heat glue fusing. Seam allowance flaps are formed adjacent pattern seam lines and project outwardly from under outer edge portions of the outer fabric sheet to provide for attachment of the composite material pattern pieces together in a specific order to form a finished fabric article.
Description
- This is a divisional application of patent application Ser. No. 14/998,509 filed on Jan. 15, 2016 and relating to automatically fabricated composite fabric pieces with seam allowance flaps and its method of fabrication.
- The present invention relates to a method of automatically fabricating pattern composite fabric pieces with seam allowance flaps for interconnecting the fabric pieces together to form, for example, articles of apparel.
- The fabrication of articles formed of fabric pieces, such as articles of apparel, is very labour intensive and results in excessive material loss. It is also a slow manufacturing process and hence the reason why most of such articles are fabricated in countries where the labour is plentiful and the cost thereof is very low. Articles formed from fabric also requires stitching to interconnect fabric piece material together. This process becomes even more labour intensive when the articles are fabricated from composite material pieces wherein thermal insulation, in a solid or loose form, is sandwiched between opposed fabric material layers. If the fabric pieces require design features, such as embroidery, printing, patchwork, etc., this further adds to the cost.
- The fabrication of such articles generally requires large factories with a great volume of stitching machines and assembly lines where semi-finished articles are passed on from person to person to arrive at a finish product. This often results in errors in the fabrication of fabric articles and waste. Any imperfect articles that find themselves on the marketplace results in poor quality goods and damage to the reputation of the product mark and its manufacturer. To substantially reduce these errors would require extensive on site inspection and further adding to the cost of producing the goods.
- In view of the above, there is a need to fabricate articles of fabric at a reduced cost and in a non-polluting environment and with reduced labour content. Also, material waste should be reduced to the maximum and the articles of fabric should be assembled with precision and substantially free of errors in its assembly to produce a quality product.
- It is a feature of the present invention to provide a method of fabricating pattern composite fabric pieces which substantially overcomes the above mentioned disadvantages and produces the above mentioned need.
- It is a further feature of the present invention to provide an automatic processing machine to produce composite pattern fabric pieces and wherein the fabric pieces are easy to assemble in reduced time.
- Another feature of the present invention is to provide such a process in a clean and non-polluting environment.
- A further feature of the present invention is to provide an automatic machine for the fabrication of fabric articles and wherein the articles are of uniform quality due to precision manufacturing.
- Another feature of the present invention is to provide a less labor intensive and faster and more efficient method of manufacturing pattern articles of fabric with interconnecting seam allowance flaps.
- Another feature of the present invention is to provide a method of fabricating pattern composite fabric pieces incorporating therein embroidery patterns, and printing information and designs all combined in a single machine and process and performed automatically from a computer containing the fabrication information for the pattern composite fabric pieces.
- A still further feature of the present invention is to provide a composite insulating material pattern piece wherein the insulation is held captive between opposed fabric layers and fabricated in accordance with the method of the present invention and wherein any waste insulation material, such as down or other insulation material may be recycled.
- According to the above features, from a broad aspect, the present invention provides a method of fabricating pattern composite fabric pieces which comprises the steps of feeding a composite fabric sheet having two or more overlaid fabric sheets in an automatic pattern processing machine. The processing machine performs, in one or more specific order, the steps of laser or thermal cutting one or more pattern pieces from the composite fabric sheet, and forming one or more seam allowance flaps in outer edge portions of the pattern pieces.
- According to another broad aspect, an in a stage of the machine, the pattern pieces and trailing sheet parts are separated and the pattern pieces are gathered. The pattern pieces are assembled and interconnected by their seam allowance flaps in a predetermined order to form a complete fabric article.
- According to a further broad aspect of the present invention there is provided an automatically fabricated composite material pattern piece having an outer and inner fabric sheet secured together along a pattern seam line by fastening means. Seam allowance flaps are formed adjacent the pattern seam line and project from under outer edge portions of the outer fabric sheet to provide for attachment of the composite material pattern pieces in a specific order to form an insulating finished fabric article.
- According to a still further broad aspect of the invention, there is provided a method of fabricating pattern composite fabric pieces and which comprises the steps of feeding a composite fabric sheet having at least an outer and an inner fabric sheet, in an automatic pattern fabric article piece processing machine. The processing machine performs, in one or more specific order the steps of (i) cutting one or more pattern pieces from the composite fabric sheet, and (ii) forming one or more seam allowance flaps in outer edge portions of the pattern pieces.
- A preferred embodiment of the present invention will now be described with reference to the accompanying drawings wherein:
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FIG. 1 is a schematic illustration of the automatic pattern fabric article piece processing machine of the present invention to fabricate pattern composite fabric pieces; -
FIG. 2 is a further schematic illustration of the laser and stitching machine supports mounted in a dust free enclosure of a stage of the processing machine; -
FIG. 3 is a fragmented side view of a composite fabric material sheet; -
FIG. 4 is a fragmented side view of the composite fabric material sheet showing the sheet being compressed; -
FIG. 5 is a further fragmented side view showing two laser cuts within the composite fabric material piece to form an allowance flap; -
FIG. 6 is a still further fragmented side view showing a stitch seam formed in the composite fabric material piece adjacent one of the laser cut lines where the top fabric piece and insulation only has been cut; -
FIG. 7 is a further fragmented side view showing the outer trailing piece having been removed with a trailing piece still present on the seam allowance flap; -
FIG. 8 is a further fragmented side view showing the trailing piece on the seam allowance flap removed and thus the formation of the clean seam flap to receive an identification mark thereon; -
FIG. 9 is a fragmented view of a pattern fabric article piece showing identification printed matter on the scant allowance flaps; -
FIG. 10 is a plan view of a pattern fabric article piece wherein decorative stitch seams have been formed by the processing machine and a decorative label has been applied; -
FIG. 11 is a fragmented side view showing two pattern fabric article pieces wherein the seam allowance flaps have been joined together by stitching or gluing; -
FIG. 12 is a view similar toFIG. 11 showing the interconnected seam allowance flaps being folded back and glued to the bottom fabric sheet of the composite material pieces; -
FIGS. 13A to 13C are plan views of a few pattern fabric article pieces formed in accordance with the present invention and ready for interconnection together to form a complete fabric article, herein a jacket article of apparel; -
FIGS. 14A and 14B are fragmented side views showing two fabric sheets to be interconnected together to form a pattern article for interconnection with other pattern fabric articles and further illustrating two methods of forming the seam allowance flaps, one by cutting an outer one of the fabric sheets and the other by bonding a seam allowance strip along an edge portion of the outer surface of the inner fabric sheet; and -
FIG. 15 is a simplified flow block diagram illustrating a sequence of steps performed by the method of fabricating a complete fabric article including the pattern composite fabric pieces formed in accordance with the present invention. - Referring now to the drawings and more particularly to
FIGS. 1 and 2 , there is shown, generally at 10 an example of the automatic pattern fabric article piece processing machine of the present invention and its method of operation. It is comprised of different stages and three stages are herein shown, namely afirst stage 11 which is comprised of aconveyor 12 having a perforated or air permeableendless conveyor belt 13 on which is fed acomposite fabric sheet 14 from asupply roll 15 for processing by themachine 10. - The
endless belt 13 is operated by a motor which drives adrive drum 16 as obvious to a person skilled in the art and represented inFIG. 2 where it is shown controlled by acontroller computer 17. Avacuum chamber 18 is disposed under thetop run 13′ of theendless belt 13 and connected to avacuum pump 31 which is connected to avacuum pump 31 which is operated to retain the bottom fabric sheet of thecomposite fabric sheet 14 stationary on the belt for job functions to be performed by thefirst stage 11 of themachine 10. As herein illustrated thefirst stage 11 has atop housing 19 to which is connected to avacuum pump 20 to aspire dust or other material particle in the air within thehousing 19 whereby the equipment in the housing can operate in a substantially dust proof environment. - Housed within the
housing 19 is asupport rail assembly 21 on which is displaceably supported one or more laser or thermal cutter head(s) 22 and an automatic stitching orultrasonic bonding machine 23. Such mounting arrangement is schematically illustrated inFIG. 2 . As shown, therail assembly 21 is comprised of a pair of fixedrails 24 across which is displaceably mountedtransverse rails arrow 26. The laser orthermal cutter head 22 is displaceably mounted onrail 25′ and displaceable in the directions ofarrow 27. These displacements are effected my motors not shown and controlled by thecontroller computer 17 to effect any shaped cuts in the composite material sheet in accordance with a pattern programmed in thememory 28 of theprocessor 29 of the computer by theinputting module 30. Likewise, thestitching machine 23 is controlled to effect pattern stitches in thecomposite material sheet 14. The laser or thermal cutter head(s) perform high precision cutting without arming the fabric sheets and the thermal cutting head does not produce fumes and therefore no special venting is required nor any pollution results from the cutting stage. - With additional reference now to
FIGS. 3 to 8 there will be described the steps of operation performed by thefirst stage 11 of theprocessing machine 10. As shown inFIG. 3 , thecomposite material sheet 14 is herein comprised of an insulating material, for example a synthetic, polyester, wool or down insulatingmaterial 35, held captive between a syntheticbottom fabric sheet 36 and atop fabric sheet 37. These fabric sheets may be constituted by two or more sheets to have a decorative outer sheet layer. Thecomposite material sheet 14 is held captive and stationary under thehousing 19 by the vacuum in thevacuum chamber 18 causing the material to also compress itself, as shown inFIG. 4 making it easier for the operations to be performed in a less dense material. - As shown in
FIG. 5 the laser or thermal cutter head(s) 22 performs two pattern cuts in thecomposite fabric sheet 14, one cut 38 which cuts through theentire sheet 14 to define the outline of the pattern fabric piece to be manufactured and asecond cut 39 which extends through thetop fabric layer 37 and the insulatingmaterial 35 but not thebottom fabric sheet 36. Accordingly, aseam allowance flap 40 is being formed by the bottom fabric layer defined between the laser cuts 38 and 39. Theend portions 40″ of the seam allowance flaps, as shown inFIG. 10 , are made by cuts formed in the inner fabric sheet. Thecontroller 17 then actuates theautomatic stitching machine 23 to be engaged and thelaser cutter 22 to return to a storage position. Theautomatic stitching machine 23 then effects one or morestitch seam lines 41, as shown inFIG. 6 , in the pattern piece being formed in afree edge portion 42 of thetop sheet 37 adjacent the laser cut 39. As shown inFIGS. 6 and 7 , trailingpieces piece 44 is removed theseam allowance flap 40 has a freeouter face 40′. Trailing pieces consists of waste material of the fabric sheet remaining between the cut pattern pieces and over the seam allowance flaps. - Referring back to
FIG. 1 , once the pattern composite fabric pieces have been formed in the composite fabric sheet the laser or thermal cutter heads cuts the sheet there across. Theconveyor 12 is then operated to transfer the composite fabric sheet with thecut fabric pieces 45 to thesecond stage 11′ onto aperforated conveyor 46 of theprocessing machine 10 and input a further sheet length from thesupply roll 15 into thefirst stage 11. In thesecond stage 11′, the trailingpieces composite fabric sheet 14 with thecut fabric pieces 45 and trailingpieces 43 on a patternedvacuum plate 44 under which only the pattern pieces are held by a suction force under the plate created by avacuum chamber 44′ there under and connected tovacuum pump 44″. Asuction chamber 60 is disposed above thecomposite fabric sheet 14 to create a suction only sufficient to suck out the trailingpieces 43, some of which have insulation thereon. This suction force is inferior to the retaining suction force applied under thecut fabric pieces 45. Adetector 48 detects the transferredpattern fabric pieces 45 and feed the controller position and orientation information relating to the pattern cutfabric pieces 45. If desired, the cut fabric pieces can now be discharged in a collector or manually removed. However, the machine incorporates athird stage 11″. - The
third stage 11″ also has acontrollable conveyor 61 to displace the composite fabric sheet with the cut fabric pieces. Avacuum chamber 47 connected to avacuum pump 32 arrest and retain the fabric pieces at their specific position whereby further job functions can be effected thereto. As herein shown, thethird stage 11″ comprises alaser printer 51 to print identification means such ascodes 52, as shown inFIG. 9 to identify the nature of the pattern fabric piece and a match connection code or number to another cut fabric piece for matching interconnection together, thus providing ease of matching pattern pieces for interconnection with one another. The printed information can also be substituted by other identification means. A decorative label orpatch applicator 53 can also form part of the second stage to apply decorative labels automatically thereto to selected ones of the cut patter fabric pieces. Such alabel 54 is illustrated inFIG. 10 . As can also be seen inFIG. 10 , a decorativequilt stitch pattern 55 was effected by theautomatic stitching machine 23 in the first stage. Aglue applicator device 56 may also form part of thethird stage 11″ to apply a glue substance on the seam allowance flaps 40 for interconnection. The displaceable devices in the third stage are also supported on a rail support assembly as in the first stage. After all job functions having been performed, theconveyor 61 ejects thefabric pieces 45 on adischarge conveyor 50. - The
pattern pieces 45 are interconnected together by the seam allowances by matching printed codes and sewing or heat fusing the seam allowance flaps to form a complete fabric article, such as an article of apparel, a bedspread which may be quilted, a cushion, etc. These assembly ofpattern pieces 45 are interconnected by their seam allowance flaps 40 and by such means as glue or stitching. The heat fusing process is, of course, much faster and less skill demanding than the stitching process.FIGS. 11 and 12 illustrates the interconnection of the seam allowance flaps 40 and 40′ of twopattern fabric pieces flaps glue seam 57.Glue 58 is then applied to an outer face of one of the flaps and the attached flaps are bent over thebottom fabric layer 36 of one of the pattern fabric pieces. Accordingly two of the pieces are interconnected together without the use of stitching machines which is time consuming. The glue may be a powder-like glue activated by heat.FIGS. 13A to 13C illustrate certainpattern fabric pieces 45 of an article of apparel and their interconnecting features of the seam allowance flaps. - Referring now to
FIG. 14A , there is shown acomposite fabric piece 60 formed of anouter fabric sheet 61 secured to aninner fabric sheet 62 by stitching or thermal fusing. The outer fabric sheet may have adesign pattern embroidery 63 formed on the outer surface thereof or a stitch pattern (not shown) formed therein. Theouter fabric sheet 61 may also consist of several fabric layers of different type fabrics and colors, herein illustrated a further fabric layer 64, which layer(s) are die cut by the laser or thermal cutting head(s) 22 ofFIG. 1 . These cutters are programmed to penetrate only the top layer or two or more fabric layers disposed on the inner layer (liner) and perform programmed cut outlines different from layer to layer to create design features. All sorts of design features may be formed in the outer fabric piece(s) 60. Theseam allowance flap 65 is formed in a peripheral portion of thecomposite fabric piece 60 which is not fused, and this is accomplished by a laser orthermal cut 66 formed only through theouter fabric sheet 61, which may consist of several layers as above mentioned. The trailingpiece 44 is removed in a manner as previously described. - In the embodiment illustrated in
FIG. 14B , theseam allowance flap 66 is formed, in thefirst stage 11 of the machine, by a roll of fabric tape which is cut to size to form seam allowance flaps and heat fused in an outersurface overlapping portion 67 thereof of theinner fabric sheet 62, which is usually a lining fabric material. The projectingportion 68 forms theseam allowance flap 66. - With reference to
FIG. 15 a brief summary of the method of fabricating patterncomposite fabric pieces 45 in accordance with the present invention follows. Asupply roll 15 of acomposite fabric sheet 14 is disposed at the inlet of aconveyor 12 at afirst stage 11 of theautomatic processing machine 10. The sheet is moved by the conveyor to be positioned at a predetermined location and then held captive by a suction chamber under the airpermeable conveyor belt 13′. Thecomputer controller 17 then actuates the laser or thermal cutter head(s) 22 to effect cuts in the composite material sheet, as described herein above. Thestitching device 23 then effects stitch seam lines or pattern designs as inputted in the memory of the computer. After the operations in the first stage terminated, the vacuum is cut off and the conveyor moves the composite fabric sheet with thecut pattern pieces 45 to thesecond stage 11′ where the trailing pieces from the composite fabric sheet are removed and redirected for collection and conveyance to a remote area where the insulating material may be recycled or discarded. - In the
third stage 11″ various other operations can be performed as selected by the inputted information in thecomputer controller 17. Such other operations may include the application of decorative labels or other information labels, the printing of decorative motifs and identification and matching codes to the seam allowance flaps, and the application of glue on these flaps. Of course, the glue would be transparent not to conceal the printed information of the flaps. Thepattern pieces 45 are maintained stationary in the third stage onto an air permeable conveyor belt by avacuum chamber 47 positioned there under. The pattern pieces are then conveyed out of thethird stage 11″ and gathered and assembled for interconnection in a manner as above described to form a complete fabric piece. It is pointed out that some of the operations effected in the third stage may be effected in the first stage or previously in thecomposite fabric sheet 14 before being rolled to form thesupply roll 15, illustrated inFIG. 1 . - As can be appreciated from the above description of the preferred embodiment and its modifications, many phase in the fabrication of pattern composite fabric articles can be manufactured automatically in much smaller spaces within a clean and substantially dust particle free environment and with very little labour involvement and within a reduced time frame. Also, other devices may be incorporated in the stages described herein and other stages may be added to perform functions previously requiring labour content. By automating fabric pattern piece fabrication the labour content is greatly reduced and the quality in its fabrication is substantially improved and further resulting in less pollution and product waste. Such automated fabrication method now makes it commercially feasible to fabricate articles of apparel in countries without regard to higher labour costs.
- It is within the ambit of the present invention to cover any obvious modifications of the preferred embodiments described herein, provided such modifications fall within the scope of the appended claims.
Claims (11)
1. An automatically fabricated composite material pattern piece comprising an outer and inner fabric sheet secured together along a pattern seam line by fastening means, and seam allowance flaps formed adjacent said pattern seam line and projecting outwardly from under outer edge portions of said outer fabric sheet to provide for attachment of said composite material pattern pieces together in a specific order to form a finished fabric article.
2. The automatically fabricated composite material pattern piece as claimed in claim 1 wherein said seam allowance flaps are one of an integrally formed outer edge projecting portion of said inner fabric sheet projecting beyond said outer fabric piece, and a seam allowance fabric material strip secured to an outer edge surface portion of said inner fabric sheet at specific predefined locations and projecting beyond said outer fabric piece.
3. The automatically fabricated composite material pattern piece as claimed in claim 1 wherein an insulating material sheet is retained between said outer and inner fabric sheet, said insulating material being one of polyester insulation, wool insulation, acrylic insulation and down insulation material.
4. The automatically fabricated composite material pattern piece as claimed in claim 1 wherein said seam allowance flaps are provided with identification means to interconnect said seam allowance flaps to complimentary seam allowance flaps of one or more other pattern pieces to form said finished article.
5. The automatically fabricated composite material pattern pieces as claimed in claim 4 wherein said identification means is a printed identification means in the form of a matching code for matching interconnection with other pattern pieces for interconnecting said pattern pieces together.
6. The automatically fabricated composite material pattern pieces as claimed in claim 4 wherein said identification means is in the form of a label or patch for matching interconnection with other pattern pieces for interconnecting said pattern pieces together.
7. The automatically fabricated composite material pattern pieces as claimed in claim 4 wherein said seam allowance flaps are provided with glue substance for interconnection with associated flaps of other fabric pieces by heat fusing.
8. The automatically fabricated composite material pattern pieces as claimed in claim 4 wherein an assembly of said seam allowance flaps are interconnected together by associated ones of said seam allowance flaps by stitches or heat fusing glue to form a fabric article.
9. The automatically fabricated composite material pattern pieces as claimed in claim 1 wherein said fastening means is one of stitching and thermal fusing a glue applied to at least one of said seam allowance flaps of a matching pair of seam allowance flaps of matching fabric pieces.
10. The automatically fabricated composite material pattern pieces as claimed in claim 9 wherein said composite material pattern pieces are fabric sheets, one of said fabric sheets being an inner liner fabric sheet in which said seam allowance flaps are formed and one or more outer fabric sheets secured to said inner liner.
11. The automatically fabricated composite material pattern pieces as claimed in claim 10 wherein an outer surface of said outer fabric sheets which is outermost is provided with a design pattern.
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US16/350,753 US20190145034A1 (en) | 2016-01-15 | 2019-01-02 | Method of Automatically Fabricating Pattern Composite Fabric Pieces with Seam Allowance Flaps |
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US14/998,509 US10208415B2 (en) | 2016-01-15 | 2016-01-15 | Method of automatically fabricating pattern composite fabric pieces with seam allowance flaps |
US16/350,753 US20190145034A1 (en) | 2016-01-15 | 2019-01-02 | Method of Automatically Fabricating Pattern Composite Fabric Pieces with Seam Allowance Flaps |
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US14/998,509 Division US10208415B2 (en) | 2016-01-15 | 2016-01-15 | Method of automatically fabricating pattern composite fabric pieces with seam allowance flaps |
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US20190145034A1 true US20190145034A1 (en) | 2019-05-16 |
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US16/350,753 Abandoned US20190145034A1 (en) | 2016-01-15 | 2019-01-02 | Method of Automatically Fabricating Pattern Composite Fabric Pieces with Seam Allowance Flaps |
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EP3735483A4 (en) | 2018-01-05 | 2022-01-05 | Ronie Reuben | Fabric sheet loading and unloading machine for a computer controlled pattern forming machine |
US20200023537A1 (en) * | 2018-07-20 | 2020-01-23 | Aurora Flight Sciences Corporation | Composite manufacturing system and method |
US10920351B2 (en) * | 2019-03-29 | 2021-02-16 | Xerox Corporation | Sewing method and apparatus to increase 3D object strength |
DE102019210286B4 (en) | 2019-07-11 | 2024-03-28 | Adidas Ag | Cutting process and system for clothing and footwear manufacturing |
CN110725075A (en) * | 2019-11-21 | 2020-01-24 | 杭州临安凯瑞服饰有限公司 | Can automatic tangent line draw waist machine |
CN113679126B (en) * | 2021-08-30 | 2022-08-26 | 迈迪康医疗用品江苏有限公司 | Disposable operating coat, production method and equipment thereof |
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US2164499A (en) * | 1936-06-29 | 1939-07-04 | Harry L Bernstein | Fabric |
US4502153A (en) * | 1982-08-30 | 1985-03-05 | Lion Uniform, Inc. | Apparel liner |
US4739910A (en) * | 1986-10-07 | 1988-04-26 | Kimberly-Clark Corporation | Apparatus and method for inverting a child's training pant or the like |
US5150476A (en) * | 1991-03-22 | 1992-09-29 | Southern Mills, Inc. | Insulating fabric and method of producing same |
US5460686A (en) * | 1993-11-04 | 1995-10-24 | Chung; Wen-Hui | Apparatus for synchronous production of a shirt covering and raincoat |
EP0877565A1 (en) * | 1996-10-08 | 1998-11-18 | Teijin Limited | Protective goods |
US6371977B1 (en) * | 1997-10-08 | 2002-04-16 | Aquatex Industries, Inc. | Protective multi-layered liquid retaining composite |
US7560399B2 (en) * | 1998-08-28 | 2009-07-14 | Mmi-Ipco, Llc | Multi-layer composite fabric garment |
US6098557A (en) * | 1999-06-23 | 2000-08-08 | Kimberly-Clark Worldwide, Inc. | High speed method for producing pant-like garments |
US6497188B2 (en) * | 2000-06-07 | 2002-12-24 | Kimberly-Clark Worldwide, Inc. | Alternate process for manufacturing shirts with inset sleeves |
US6557479B2 (en) * | 2000-06-07 | 2003-05-06 | Kimberly-Clark Worldwide, Inc. | Process for manufacturing shirts with inset sleeves |
US6435116B2 (en) * | 2000-06-07 | 2002-08-20 | Kimberly-Clark Worldwide, Inc. | Process for manufacturing shirts with raglan sleeves |
US6830543B2 (en) * | 2000-06-07 | 2004-12-14 | Kimberly-Clark Worldwide, Inc. | Process for manufacturing unibody shirts with sleeves |
US6578504B2 (en) * | 2000-06-07 | 2003-06-17 | Kimberly-Clark Worldwide, Inc. | Process for manufacturing unibody shirts with sleeves |
US6964238B2 (en) * | 2003-12-31 | 2005-11-15 | Kimberly-Clark Worldwide, Inc. | Process for making a garment having hanging legs |
US20070281567A1 (en) * | 2004-04-05 | 2007-12-06 | Solid Water Holding | Waterproof/breathable technical apparel |
US20110035949A1 (en) * | 2009-08-17 | 2011-02-17 | Fesler Jon P | Scissors with specific cut length |
WO2013075133A2 (en) * | 2011-11-17 | 2013-05-23 | Jarbouai Stephane | Garment production system |
US9730479B2 (en) * | 2013-02-06 | 2017-08-15 | Aeris | Insulating apparel |
US10366175B2 (en) * | 2013-03-15 | 2019-07-30 | 3D Tech Llc | System and method for automated manufacturing of custom apparel |
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US10208415B2 (en) | 2019-02-19 |
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