Method and Apparatus for Applying a Patch to Manufactured Goods

This invention relates to a method of applying gussets to pantyhose. More specifically, this invention relates to applying gussets to pantyhose formed as a single unit without a seam in the crotch, and provides a reinforcing gusset for the seamless crotch zone.

At present it is known to form women's pantyhose with a gusset or reinforcing a member by joining two spearately made tubular shaped legs by sewing. Coincident with the sewing of the two leg portions together, a reinforcing gusset, which overlaps the edges of the leg portions, is sewn thereon.

The object of the present invention is to provide a method for applying a gusset to tubular articles in general such as women's pantyhose.

According to the invention, these results have been achieved by adopting the idea of utilizing a tubular article, made separately by known means, formed by a pantyhose without gusset and lacing the seam at the crotch; stretching the edge of the seamless zone of the article according to the form of the gusset to be applied; placing thereon a gusset of a form and dimensions adapted to cover the zone free of fabric of the stretched article; and, removing the ready-made article with the gusset.

Advantages and characteristics of the invention will be better understood by any technician in the field from the description which follows and from the annexed drawings, which show a schematic exemplification of a machine usable to practice the method according to the present invention and wherein:

FIG. 1 is a schematic top plan view of a machine with several stations, according to the invention;

FIG. 2 is an elevational view of said machine;

FIG. 3 is a section along AA of FIG. 1 showing the article in the arrangement of initial positioning;

FIG. 4 is a section along BB of FIG. 1 showing the article in the arrangement of reversed positioning; and

FIG. 5 is a section along CC of FIG. 1 showing the placing on of the gusset;

FIG. 6 is a section along DD of FIG. 1 showing the article in the position for trimming the excess fabric of the gusset of the article;

FIG. 7 is a section along EE of FIG. 1 showing the article held in position for sewing the gusset;

FIG. 8 is a section along FF of FIG. 1 showing the finished article detached from the support 2;

FIG. 9 is a section along FF of FIG. 1 showing the finished article after it has been turned right side out again;

FIG. 10 is a section along FF of FIG. 1 showing the finished article as it is being removed from the machine;

FIG. 11 is a front elevational view of a completed pantyhose article formed by the present invention;

FIG. 12 is a sectional view of FIG. 11 taken through line 12--12 of FIG. 11; and

FIG. 13 is a view similar to FIG. 12 showing the pantyhose article stretched to illustrate the flattened shape of a gusset.

Reduced to its essential structure, the method for applying a gusset, e.g. a circular one, to tubular articles and in particular women's pantyhose (FIGS. 11-13) according to the present invention, includes: (a) stretching and fastening by hand the edge of the seamless crotch zone of a pantyhose, made separately by known means, on the horizontal edge of a support in the form of an inverted funnel so that the article is in a hanging position relative to the support; (b) pneumatically turning the body of the article over and introducing therein the legs thereof so that the edge of the fabric on which the gusset must be applied is ready for sewing; (c) mechanically placing a gusset, e.g. a circular one (FIG. 13), on a horizontal circular support plate; (d) mechanically laying said plate with the gusset thereon on the aforesaid funnel-shaped support so that the edge of the gusset is pressed and held fixed in juxtaposition to the stretched edge of the seamless zone of the article; (e) trimming the excess fabric beyond the seam line, of the article and of the gusset, simultaneously; (f) sewing the gusset to the article along the superposed edges; (g) pneumatically turning the ready-made article with gusset right side out again and removing it from the support.

For a better understanding of the method, reference is made to FIGS. 11-13 which illustrate a completed pantyhose article 3 of the type discussed above, which the present invention is intended to complete automatically. As illustrated in FIGS. 11-13, body portion 19, 19 sewn together at seam 20 is provided with a gusset 17 over the stretched out portion or seamless zone 21. When the two tubular halves 18, 18 are sewn together without a gusset, the interconnection of pantyhose halves 18, 18 is subject to tearing in the crotch region. Therefore, gusset 17 spans zone 21 to remove the tension which each pantyhose half 18, 18 subjects to the other upon being sewn directly together. Gusset 17 covers zone 21 and is sewn thereover by the present invention machine so that the two halves 18, 18 are not sewn directly together.

As to the machine for carrying out said method in accordance with the invention and with reference to the attached drawings FIGS. 1-10, it comprises, essentially:

a six-armed carrousel type structure 1 intermittently rotating horizontally, with stops at each of the six stations, which are, respectively; One (A) for laying the article while the edge of the seamless zone is being stretched; one (B) for pneumatically turning the article over; one (C) for laying the gusset with its edge superposed on the stretched edge of the article; one (D) for trimming excess portions of fabric of the article and of the gusset beyond the seam line; one (E) for sewing the gusset to the article; one (F) for pneumatically turning the ready-made article with the gusset right side out again and discharging it.

More particularly, at the free end of each arm 1, a support 2 in the form of an inverted funnel is provided, having the function of retaining a pantyhose 3 and stretching the seamless zone of the crotch, a known means 4 being provided for setting said support 2 in horizontal rotation in the cutting and sewing stations. Above said support 2 are a cylindrical guiding chamber 5 and a jacket 6 such as to permit the possibly elastic edge 3' of the body of the pantyhose 3 to turn over completely and to permit the pantyhose legs to slip into the body with the toe up due to the suction produced inside a tubing 7 connected to the upper end of said jacket 6, the article thus positioned presenting on the outer conical surface of the support 2 the edge of the crotch zone ready to have a gusset sewn to it. Above the jacket 6, in addition to the connection of the suction tubing 7, there is provided a horizontally traversing stop device 8, having the function of retaining the free ends of the article after they have been sucked at 7 so that the article does not fall back through the funnel-shaped support 2 when the suction at 7 ceases, known means being provided for the forward and backward movement of said stop device 8.

In addition, the wall of the jacket 6 is provided with several holes 9 with respective obturating devices, the holes being intended to be open in station F during the phase of turning right side out and discharge of the finished article; cooperating to this end is a series of compressed air cocks 10 disposed on a cylindrical collector at the top of the aforesaid chamber 5 and inclined downward and into the chamber 5.

Below each above described support 2 is provided a circular, horizontal plate 11, traversing vertically and horizontally, having the function of supporting a gusset 12 of fabric identical with or different from that of the article, placed thereon by known means 13, and of pressing it against the edge of said support 2 with interposition of the fabric of the article to which it is to be sewn, known means being provided for the horizontal radial movement toward the center of the carrousel so as to free the zone under the support 2 to enable the operator to load the article on said support 2 in station A (FIG. 3) and to make possible in station F (FIGS. 8-10) the presence of a suction duct 14 under support 2 intended to transfer the completed article with the gusset.

At the cutting station D (FIG. 6) known means 15 are provided, disposed on the exterior of the carrousel, for trimming the excess parts of fabric beyond the seam line during one complete revolution of the support 2 and also to cause said cutting means 15 to move toward and away from the support 2.

At the sewing station E (FIG. 7) a sewing machine 16 of known type is provided to carry out the sewing of the superposed edges of the gusset and of the article during one complete revolution of the support 2, and also known means are provided for causing said sewing machine 16 to move toward and away from said support 2.

At the station F (FIGS. 8-10) for discharging the finished article, known means are provided for opening the holes 9 of the jacket 6, to activate the compressed air cocks 10 and to inactivate the stop device 8.

The mode of operation is the following: During the standstill of an arm 1 of the carrousel in station A (FIG. 3), the edge of the unsewn crotch zone of a pantyhose 3 is laid by hand, while stretching it, on the lower edge of the support 2 in such a way that the article is in a hanging position illustrated in FIG. 3 of the annexed drawings. Then said arm is transferred to station B (FIG. 4) where, by pneumatic suction from duct 7, the body of the pantyhose introduces itself inside out into chamber 5, and the pantyhose legs, passing through the body, arrange themselves with the toe up in duct 7 and are held there by the stop device 8. Subsequently arm 1 transfers to station C (FIG. 5) where plate 11, on which a gusset 12 previously placed is held fixed by suction from below, rises coming up against and compressing the gusset 12 under the fabric of the article stretched on the support 2. In the next station D (FIG. 6) the support 2 is set in rotation while a cutting blade of the means 15 fixed in a position near the edge of the support 2 provides to trim the fabric of the gusset and of the article outside the stitching line. Then arm 1 moves on to station E (FIG. 7) where the sewing machine performs the continuous sewing of the gusset to the article along the entire circumference of the support 2 maintained in rotation. Lastly, as soon as arm 1 has reached station F (FIGS. 8-10) by effect of the suction from below provided in duct 14 by the opening of the holes 9 and by the action of the compressed air issuing from the cocks 10, the zone of the ready-made article with the gusset is disengaged from the support 2, and while the article is still being retained by the toes due to the device 8, the body is formed to fall down, turning itself right side out; thereafter the article, let go by 8, is sucked through 14 in straight position.

In the practice, the details of execution may vary in any equivalent manner as to form, dimensions, arrangement of the elements, nature of the materials employed without going outside the scope of the idea of solution adopted and therefore remaining within the limits of protection granted by the present patent of invention.