Cap Frame Elastic Clamping for Embroidery Area Extension
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cap frames for embroidery machines limit the embroidery area on caps, particularly restricting the ability to embroider patterns on the crown of caps due to their design, which does not allow for an extended range of embroidery.
Innovation Solution
A cap frame with a body member featuring a curved wall and an attaching portion, along with a retaining member having a clamping portion and facing portion, where the clamping portion is elastically deformed to press against the cap, and the facing portion aligns with the curved wall, allowing the cap to be securely held between the curved wall and the clamping portion, thereby reducing the distance from the cap's boundary to the needle plate, thus extending the embroidery area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a traditional cap frame design is used, then the cap can be held securely, but the embroidery area on the crown is limited
Solution Approach 1:
The retaining member is designed with elastic flexibility, allowing it to deform dynamically during cap insertion and then maintain a stable clamping force. The elastic portion can be pushed by the cap to deform, and then elastically restores to hold the cap securely, enabling both easy operation and extended embroidery area.
Solution Approach 2:
The cap frame structure is modified to change the positional parameter of the cap relative to the needle plate. By repositioning the curved wall and clamping portion, the distance from the cap boundary to the needle plate is reduced, effectively extending the embroidery area without compromising cap holding capability.
2Area of stationary object
If the cap frame is positioned to maximize embroidery area, then more of the crown can be embroidered, but the cap may not be held as securely
Solution Approach 1:
The elastic retaining member provides dynamic adaptation: during cap insertion it deforms to accommodate the cap, then elastically restores to provide consistent clamping force. This ensures reliable cap holding stability even when positioned for maximum embroidery area coverage.
Solution Approach 2:
The retaining member combines elastic material properties to achieve both flexibility during insertion and rigid clamping force during embroidery. The elastic portion allows deformation during cap placement while maintaining secure holding stability during the embroidery process.
3Area of stationary object
If the distance from cap boundary to needle plate is reduced, then embroidery area is extended, but the cap frame structure becomes more complex
Solution Approach 1:
The cap frame is segmented into distinct functional portions: a curved wall portion, an elastic retaining member with clamping portion and facing portion. This segmentation allows each component to be optimized for its specific function while collectively achieving the extended embroidery area without excessive overall complexity.
Solution Approach 2:
The cap frame structure applies local quality changes by positioning the curved wall and clamping portion to specifically reduce the distance from cap boundary to needle plate in the embroidery area, while maintaining simple overall structure. The elastic portion is localized to where it is most effective for both extension and holding.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the embroidery machine to define a larger embroidery area on the crown of the cap, allowing for more extensive and precise embroidery patterns by positioning the cap frame such that the distance from the cap's boundary to the needle plate is minimized, compared to traditional cap frames.
Implementation Method 1
The clamping portion is configured to, in a state where the retaining member is attached to the body member, be elastically deformed in conformance with the curved wall and press, toward the curved wall, a cap sandwiched between the curved wall and the clamping portion
Data Source
AI summary
A cap frame includes a body member including an arc-shaped curved wall extending in a particular direction, an attaching portion connected to the body member, and a retaining member including a clamping portion having a plurality of protrusions aligned along the particular direction, and a facing portion. The attaching portion is removably attachable to a moving mechanism of an embroidery machine. In a state where the retaining member is attached to the body member, the clamping portion is elastically deformed in conformance with the curved wall and presses, toward the curved wall, a cap sandwiched between the curved wall and the clamping portion. The facing portion faces the curved wall of the body member. Each protrusion extends toward the curved wall from a leading end of the facing portion in a removing direction and faces a leading end of the curved wall of the body member in the removing direction.