Quilting machine with tilting sewing assembly

Abstract

A quilting machine includes a frame sized and configured to support a sheet of fabric and a tilting sewing assembly. The tilting sewing assembly includes a needle beam defining a needle beam longitudinal axis, and a needle head attached to the needle that translates along the needle beam longitudinal axis. The assembly includes a hook beam defining a hook beam longitudinal axis disposed separate from and parallel to the needle beam longitudinal axis, and an axis of rotation parallel to the needle beam and the hook beam with the hook beam disposed between the needle beam and the hook beam. The needle head is between the needle beam and the hook beam. The tilting sewing assembly is configured to pivot about the axis of rotation with the needle beam and the hook beam translating laterally about the axis of rotation to move the needle head relative to the frame.

Claims

1. A quilting machine for use with sewing a sheet of fabric with the quilting machine being supported upon a floor, the quilting machine comprising: a machine frame including legs sized and configured to rest upon the floor upon which the quilting machine is supported and support arms sized and configured to support a sheet of fabric; and a tilting sewing assembly supported by the machine frame including: a needle beam defining a needle beam longitudinal axis; a needle head attached to the needle beam and sized and configured to translate along the needle beam along the needle beam longitudinal axis; a hook beam defining a hook beam longitudinal axis disposed separate from and parallel to the needle beam longitudinal axis, the needle head being positioned between the needle beam and the hook beam; an axis of rotation parallel to the needle beam and the hook beam with the hook beam disposed between the needle beam and the axis of rotation, the tilting sewing assembly being configured to pivot about the axis of rotation with the needle beam and the hook beam moving about the axis of rotation to move the needle head relative to the machine frame when the legs are resting upon the floor; and a pivot shaft that axially defines the axis of rotation with the tilting sewing assembly configured to pivot about the pivot shaft.

2. The quilting machine of claim 1 wherein the tilting sewing assembly includes a beam support attached to the needle beam and the hook beam and configured to move the needle beam and the hook beam about the axis of rotation.

3. The quilting machine of claim 1 wherein the support arms are sized and configured to position the sheet of fabric between the needle head and the hook beam.

4. The quilting machine of claim 3 wherein the support arms includes first, second, third and fourth arms, the tilting sewing assembly is disposed between the first and second arms and the third and fourth arms, the first, second, third and fourth arms are sized and configured to cooperatively support the sheet of fabric between the first and second arms and the third and fourth arms.

5. The quilting machine of claim 4 the first and second arms are sized and configured to cooperatively support ends of a fabric roll, the third and fourth arms are sized and configured to cooperatively support ends of another fabric roll.

6. The quilting machine of claim 5 wherein the first, second, third and fourth arms each include an extended position and a stored position, in the stored position the first, second, third and fourth arms are closer to the needle beam than in the extended position.

7. The quilting machine of claim 6 wherein each of the first, second, third and fourth arms pivot between the extended and stored position.

8. The quilting machine of claim 1 wherein the needle beam includes first and second needle beam sections, the tilting sewing assembly includes a deployed position with the first and second needle beam sections longitudinally endwise aligned.

9. The quilting machine of claim 8 wherein the tilting sewing assembly includes a folded position with the first and second needle beam sections disposed laterally along each other.

10. The quilting machine of claim 9 wherein the first and second needle beam sections each include an inner end hingedly attached to each other.

11. The quilting machine of claim 8 wherein the hook beam includes first and second hook beam sections, the first and second hook beam sections are longitudinally endwise aligned in the deployed position of the tilting sewing assembly.

12. The quilting machine of claim 11 wherein the tilting sewing assembly includes a folded position with the first and second needle beam sections disposed laterally along each other.

13. The quilting machine of claim 12 wherein the first and second hook beam sections each include an inner end hingedly attached to each other.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) These and other features and advantages of the various embodiments disclosed herein will be better understood with respect to the following description and drawings, in which:

(2) FIG. 1 is a perspective view of a quilting machine with a tilting sewing assembly and with first, second, third and fourth support arms in an extended position with quilt rollers;

(3) FIG. 2 is a perspective view of the quilting machine of FIG. 1 with the first, second, third and fourth support arms in a stored position without quilt rollers;

(4) FIG. 3 is a perspective view of the quilting machine of FIG. 2 with the tilting sewing assembly in a folded position, suitable for storage;

(5) FIG. 4 is a perspective view of the quilting machine of FIG. 1 with fabric wound upon the quilt rollers;

(6) FIG. 5 is a cross-sectional side view of the quilting machine of FIG. 4 as viewed along axis 5-5;

(7) FIG. 6 is a perspective view of the quilting machine;

(8) FIG. 6a is an enlarged perspective view of a portion of the quilting machine of FIG. 6;

(9) FIG. 7 is a cross-sectional view of the quilting machine with quilt bottom fabric being rolled upon a quilt bottom roller with an opposite fabric edge attached to a quilt take-up roller;

(10) FIG. 8 is a cross-sectional view of the quilting machine of FIG. 7 with a portion of the quilt top fabric being rolled upon a quilt top roller with the opposite fabric edge attached to the quilt take-up roller with the quilt bottom roller is rolled taut;

(11) FIG. 9 is a cross-sectional view of the quilting machine with portions of quilt top fabric and quilt bottom fabric being rolled taut with the opposite fabric edges started upon the quilt take-up roller;

(12) FIG. 10 is a cross-sectional view of the quilting machine with a portion of quilt top fabric and quilt bottom fabric being rolled onto the quilt take-up roller;

(13) FIG. 11 is a perspective view of the quilting machine of FIG. 4 as shown with a needle head in a different position along a needle beam;

(14) FIG. 12 is a perspective view of the quilting machine of FIG. 11 as shown from an opposite perspective view;

(15) FIG. 13 is a perspective view of the quilting machine of FIG. 11 with the tilting sewing assembly pivoted into a different position; and

(16) FIG. 14 is cross-sectional side view of the quilting machine of FIG. 13 as viewed along axis 14-14.

(17) Common reference numerals are used throughout the drawings and the detailed description to indicate the same elements.

DETAILED DESCRIPTION

(18) The detailed description set forth below in connection with the appended drawings is intended as a description of certain embodiments of the present disclosure, and is not intended to represent the only forms that may be developed or utilized. The description sets forth the various functions in connection with the illustrated embodiments, but it is to be understood, however, that the same or equivalent functions may be accomplished by different embodiments that are also intended to be encompassed within the scope of the present disclosure. It is further understood that the use of relational terms such as top and bottom, first and second, and the like are used solely to distinguish one entity from another without necessarily requiring or implying any actual such relationship or order between such entities.

(19) Referring now to FIG. 1 there is depicted a perspective view of a quilting machine 10. As will be appreciated, the quilting machine 10 is configured for use with a sheet of fabric. In this regard, the quilting machine 10 may be utilized to sew or stich together multiple sheets of different fabric such as in the case of producing a quilt. As used herein fabric refers to any cloth, textile or other material, whether woven, knitted or wadded, and any sewable material that is generally is sheet, strip or swath like form. Often fabric is provided in rolls or spools. Various sheets or layers of fabric may be overlaid upon each other and the quilting machine 10 may be used to sew through the sheets to combine them in a finished quilt.

(20) As will be discussed in detail below the quilting machine 10 includes a machine frame 12 and a tilting sewing assembly 14 that includes a needle beam 16, a needle head 18, a hook beam 20 and an axis of rotation 22. In the embodiment shown, the machine frame 12 includes a beam support in the form of side beams 24a-b. The needle beam 16 defines a needle beam longitudinal axis 26. The needle head 18 is attached to the needle beam 16 and sized and configured to translate along the needle beam longitudinal axis 26. The hook beam 20 defines a hook beam longitudinal axis 28 disposed separate from and parallel to the needle beam longitudinal axis 26. The needle head 18 is positioned between the needle beam 16 and the hook beam 20. The axis of rotation 22 is parallel to the needle beam 16 and the hook beam 20 with the needle head 18 disposed between the needle beam 16 and the hook beam 20. The tilting sewing assembly 14 is configured to pivot about the axis of rotation 22 with the needle beam 16 and the hook beam 20 translating laterally about the axis of rotation 22 to move the needle head 18 relative to the machine frame 12.

(21) In the embodiment depicted, the machine frame 12 may include first, second, third and fourth support arms 30a-d. FIG. 1 depicts the first, second, third and fourth support arms 30a-d in an extended position. FIG. 2 is a perspective view of the quilting machine 10 of FIG. 1 with the first, second, third and fourth support arms 30a-d in a stored position. FIG. 3 is a perspective view of the quilting machine 10 of FIG. 2 with the tilting sewing assembly 14 in a folded position. FIG. 4 is a perspective view of the quilting machine 10 of FIG. 1 with fabric rolls. FIG. 5 is a cross-sectional side view of the quilting machine 10 as viewed along axis 5-5. FIG. 6 is a perspective view of the quilting machine 10 and FIG. 6a is an enlarged portion of the quilting machine of FIG. 6.

(22) As used herein the term machine frame 12 broadly refers to a structural member which is supportive of the tilting sewing assembly 14 such that the tilting sewing assembly 14 may move relative to the machine frame 12. The machine frame 12 may be connected with the tilting sewing assembly 14 directly or via intermediate components. The machine frame 12 may be used to place quilting machine 10 upon a working surface, such as a floor of a room.

(23) According to various embodiments, the tilting sewing assembly 14 may include a beam support, such as in the form of the of the side beams 24a-b. The side beams 24a-b are attached to the needle beam 16 and the hook beam 20 and configured to laterally translate the needle beam 16 and the hook beam 20 about the axis of rotation 22. The side beams 24a-b are attached to the respective ends of the needle beam 16 and the hook beam 20.

(24) As mentioned above the machine frame 12 may include the first, second, third and fourth support arms 30a-d. Legs 60a-d may be provided to provide structural support to the first, second, third and fourth support arms 30a-d and may be pivotally connected so as to allow the legs 60a-d to be folded open for deployment and closed for compact storage. The lower portion of the legs 60a-d may rest upon the floor upon which the quilting machine 10 is supported. The tilting sewing assembly 14 is disposed between the first and second support arms 30a,b and the third and fourth support arms 30c,d. The first and second support arms 30a,b may be sized and configured to cooperatively support ends of a fabric roller, such as a quilt top roller 32 and a quilt bottom roller 34. The third and fourth support arms 30c-d may be sized and configured to cooperatively support ends of a fabric roller, such as a quilt take-up roller 36. The first, second, third and fourth support arms 30a-d may be sized and configured to position a sheet of fabric between the needle head 18 and the hook beam 20. The first, second, third and fourth support arms 30a-d may be sized and configured to cooperatively support a sheet of fabric between the first and second support arms 30a-b and the third and fourth support arms 30c-d.

(25) The first, second, third and fourth support arms 30a-d may each include an extended position and a stored position. In the stored position the first, second, third and fourth support arms 30a-d are closer to the needle beam 16 than in the extended position. Each of the first, second, third and fourth support arms 30a-d may pivot between the extended and stored position. FIG. 2 depicts the first, second, third and fourth support arms 30a-d collapsed in a vertical position immediately adjacent to the needle beam 16 in the stored position. In this regard, the stored position is a position of the first, second, third and fourth support arms 30a-d that reduces the overall size dimensions of the quilting machine 10. In the embodiment depicted, in the stored position, the width of the quilting machine 10 is significantly reduced compared to that of the extended position. It is contemplated that one of ordinary skill in the art will recognize other arrangements that may be implemented to facilitate such folded position.

(26) The tilting sewing assembly 14 may include first and second pivot shafts 38a-b. The tilting sewing assembly 14 is configured to pivot about the pivot shafts 38a-b. The first and second pivot shafts 38a-b may be aligned along the axis of rotation 22. In this respect the first and second pivot shafts 38a-b define the axis of rotation 22. The side beams 24a-b may be configured to be respectively engaged with the first and second pivot shafts 38a-b to allow rotational movement of the side beam 24a relative to the first pivot shaft 38a and the side beam 24b to the second pivot shaft 38b. Moreover, the first, second, third and fourth support arms 30a-d may be coupled to the tilting sewing assembly 14 via the first and second pivot shafts 38a-b. The first and third support arms 30a,c may be attached to the side beam 24a with the first pivot shaft 38a. The second and fourth support arms 30b,d maybe attached to the side beam 24b with the second pivot shaft 38b.

(27) The tilting sewing assembly 14 may include a deployed position and a folded position. In this regard, the needle beam 16 may include first and second needle beam sections 40a-b and the hook beam 20 may include first and second hook beam section 42a-b. In the deployed position the first and second needle beam sections 40a-b are longitudinally endwise aligned. Similarly, in the deployed position the first and second hook beam sections 42a-b are longitudinally endwise aligned. In this regard FIGS. 1 and 2 depict the tilting sewing assembly 14 in the deployed position. FIG. 3 depicts the tilting sewing assembly 14 in the folded position with the first and second needle beam sections 40a-b are disposed laterally along each other.

(28) The first and second needle beam sections 40a-b may each include an inner end 44a-b and an outer end 46a-b. The first and second hook beam sections 42a-b may each include an inner end 48a-b and an outer end 50a-b. The side beam 24a is attached to the needle beam 16 and hook beam 20 at the outer ends 46a, 48a, and the side beam 24b is attached to the needle beam 16 and hook beam 20 at the outer ends 46b, 48b. The first and second needle beam sections 40a-b may be endwise connected to each other at the inner ends 44a-b, and the first and second hook beam sections 42a-b may be endwise connected to each other at the inner ends 48a-b. The first and second needle beam sections 40a-b may be hingedly attached to each other, and the first and second hook beam sections 42a-b may be hingedly attached to each other. In this regard, the tilting sewing assembly 14 may include a needle beam hinge 52 and a hook beam hinge 54 to facilitate the tilting sewing assembly 14 to be configured between the deployed and folded positions. The needle beam hinge 52 is attached to and connects the inner ends 44a-b of the first and second needle beam sections 40a-b. The hook beam hinge 54 is attached to and connects the inner ends 48a-b of the first and second hook beam sections 42a-b. A machine frame hinge 70 connects a lower portion of the machine frame 12. With the tilting sewing assembly 14 in the folded position, the length of the quilting machine 10 is significantly reduced compared to that of the deployed position. In the embodiment depicted the overall length of the quilting machine 10 is about halved when in the folded position compared to the deployed position. It is contemplated that one of ordinary skill in the art will recognize other arrangements that may be implemented to facilitate such folded position.

(29) The tilting sewing assembly 14 further includes a hook head 56 that is attached to and configured to move along or inside the hook beam 20. The hook head 56 is connected to the hook beam 20 in a manner which allows the hook head 56 to translate along the hook beam longitudinal axis 28. The hook head 56 is aligned with the needle head 18. The needle head 18 and the hook head 56 are coupled either mechanically or electro-mechanically so that motion of the needle head 16 moves the hook head 56 synchronously, thus maintaining alignment between the needle head 16 and the hook head 56. In this respect various computer controllers and servo motors and such may be additionally provided for controlling and moving the tilting of the tilting sewing assembly 14 and the movements of the needle head 18 and the hook head 56 respectively along the needle beam 16 and the hook beam 20. The needle head 18 and hook head 56 includes all necessary components and sub-assemblies to cooperatively function to perform sewing functions to create stitches through fabric with needle and thread. It is contemplated that the various components of the needle head 18 may be selected from those which are well known to one of ordinary skill in the art and may include needle, thread spools, thread tension controls, thread guides, motors and controllers, pulleys, fabric feeder, and/or any other components and sub-assemblies.

(30) The needle head 18 is connected to the needle beam 16 in a manner which allows the needle head 18 to translate along the needle beam longitudinal axis 26. As denoted herein such translation along the needle beam longitudinal axis 26 refers to the needle head 18 being constrained to move along a linear path parallel to the needle beam 16. In this regard, the needle beam 16 may include guide rails or other arrangements that run the length of the needle beam 16 to facilitate such relative movement and may include any of those components, such as rollers, wheels, sliders, etc., which are well known to one of ordinary skill in the art. With a sheet of fabric positioned between and orthogonal to the needle beam 16 and the hook beam 20, such movement allows the needle head 18 to translate in a direction parallel to the quilt top roller 32, the quilt bottom roller 34, the quilt take-up roller 36, the needle beam longitudinal axis 26 and the hook beam longitudinal axis 28 (this may be referred to as an “X-direction” relative to fabric immediately under and engaged with the needle head 18).

(31) The tilting sewing assembly 14 is configured to swing the needle head 18 though a shallow arc relative to the machine frame 12 between the first and second support arms 30a-b and the third and fourth support arms 30c-d. In this respect the needle beam 16 and the hook beam 20 are configured to translate parallel and lateral to the axis of rotation 22. With a sheet of fabric positioned between and orthogonal to the needle beam 16 and the hook beam 20, such tilting allows the needle head 18 to have a component of movement in a direction perpendicular to the quilt top roller 32, the quilt bottom roller 34, the quilt take-up roller 36, the needle beam longitudinal axis 26 and the hook beam longitudinal axis 28 (this may be referred to as a “Y-direction” relative to fabric immediately under and engaged with the needle head 18).

(32) The needle head 18 may include handles 58. The handles 58 may allow a user to move the needle head 18 along the needle beam 16 and tilt the tilting sewing assembly 14 back and forth to facilitate an ease of movement of the needle head 18 in both the X-direction and Y-direction either independently or together. This may thus allow for the smooth sewing of stitches in lines and curves.

(33) The following is a discussion of how the quilting machine 10 may be used in operation. Referring now to FIG. 7 there is a cross-sectional view of the quilting machine 10 with a quilt bottom fabric 66 being initially rolled upon the quilt bottom roller 34 with an opposite fabric edge attached to the quilt take-up roller 36. FIG. 8 is a cross-sectional view of the quilting machine 10 of FIG. 7 with a portion of quilt top fabric 64 being rolled from the quilt bottom roller 34 onto the quilt take-up roller 36. The machine frame 10 may further include deflector rollers 60a-c. The fabric may be looped or draped about the deflector rollers 60a,c. FIG. 9 is a cross-sectional view of the quilting machine 10 with portions of quilt top fabric 64 and quilt bottom fabric 66 being rolled taut with the opposite fabric edges started upon the quilt top roller 32. FIG. 10 is a cross-sectional view of the quilting machine 10 with a portion of quilt top fabric 64 and quilt bottom fabric 66 being rolled onto the quilt take-up roller 36. The fabric may be looped or draped about the deflector rollers 60b,c. The deflector rollers 60a-c are sized and configured to position the fabric generally orthogonal to and between the needle beam 16 and the hook beam 20 to allow the needle head 18 and the hook head 56 to carry out sewing operations through the fabric. As seen in the cross-sectional side view of FIG. 5, the portion of the quilt top fabric 64 from the quilt top roller 32 and the portion of the quilt bottom fabric 66 from the quilt bottom roller 34 are positioned coplanar with and overlaid upon each other and together are rolled upon the quilt take-up roller 36. When the quilt top fabric 64 and the quilt bottom fabric 66 are sewn, this forms sewn quilt fabric 68 that is wound upon the quilt take-up roller 36.

(34) FIG. 11 is a perspective view of the quilting machine of FIG. 4 as shown with the needle head 18 in a different position along a needle beam 16 (i.e., moved along the X-direction). FIG. 12 is a perspective view of the quilting machine of FIG. 11 as shown from an opposite perspective view. FIG. 13 is a perspective view of the quilting machine 10 of FIG. 11 with the tilting sewing assembly 14 pivoted into a different position as tilted or pivoted from the previous positioning (i.e., moved along the X-direction). FIG. 14 is a cross-sectional side view of the quilting machine of FIG. 13 as viewed along axis 14-14. As such, it is understood that an operator may simultaneously move the needle head 18 in the X-direction and Y-direction to perform sewing or stitching across and through the layers or sheets of fabric between the needle head 18 and the hook head 58. It is further understood that the tilting sewing assembly 14 is configured to tilt or swing through various positions other than as shown in the exemplary figures. Likewise, the needle head 18 and the hook head 58 are configured to move along various positions respectively along the needle beam 16 and the hook beam 20 other than as shown in the exemplary figures. As the operator finishes the desired stitches the combined fabric may be progressively wound onto the quilt take-up roller 36. As such, the quilt take-up roller 36 includes the finished portions of the stitched material (i.e., finished portions of the resulting quilt).

(35) The particulars shown herein are by way of example only for purposes of illustrative discussion, and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the various embodiments set forth in the present disclosure. In this regard, no attempt is made to show any more detail than is necessary for a fundamental understanding of the different features of the various embodiments, the description taken with the drawings making apparent to those skilled in the art how these may be implemented in practice.