Material processing system

Abstract

A system for joining a keder to a material includes a frame having a longitudinal axis and a gantry movable along the longitudinal axis. A belt system extends along the longitudinal axis and moves through a cavity within the gantry. A joining system is movable along a cross-frame axis perpendicular to the longitudinal axis and a keder application system automatically feeds a keder material to be joined to a first material by the joining system.

Description

Atty. Dkt. No. F160-106-WO MATERIAL PROCESSING SYSTEM CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

[0001] This application claims the benefit of US Provisional Application 63 / 636,681 entitled Material Processing System filed on April 19, 2024, US Provisional Application 63 / 692,667 entitled Material Processing System filed on September 9, 2024 and US Provisional Application 63 / 723,459 entitled Material Processing System filed on November 21, 2024 all of which are incorporated herein by reference in their entirety. BACKGROUND

[0002] The present invention relates to the field of automated material joining systems for keder and flexible strip materials. SUMMARY

[0003] In some aspects, the techniques described herein relate to an automated material processing system including: a frame having a longitudinal axis; a gantry movable along the longitudinal axis of the frame; a first belt extending along the longitudinal axis and moving about a cavity having a cavity opening within the gantry; a second belt supported by the gantry extending across the frame in a cross- frame direction perpendicular to the longitudinal axis and covering at least a portion of the cavity opening; a material treatment system to treat a material extending across at least a portion of the first belt and a portion of the second belt; and a vacuum system movable with the gantry and operatively connected to a manifold adjacent to both sides of the cavity opening.

[0004] In some aspects, the techniques described herein relate to an automated system for joining and cutting flexible materials including: a frame having a longitudinal axis; a gantry movable along the longitudinal axis; a belt system extending along the longitudinal axis and moving through a cavity within the gantry; a joining system supported by the gantry and movable along a cross-frame axis perpendicular to theAtty. Dkt. No. F160-106-WO longitudinal axis to join at least two materials together; a cutting system supported by the gantry and movable along the cross-frame axis to cut the material together in more than one direction within a plane defined by the longitudinal axis and the cross-frame axis a vacuum system movable with the gantry and operatively connected to a manifold on both sides of the cavity opening.

[0005] In some aspects, the techniques described herein relate to an automated system for joining and cutting flexible materials including: a frame having a longitudinal axis; a gantry movable along the longitudinal axis; a vacuum system having a duct movable with and along a cross-frame axis perpendicular to the longitudinal axis of the gantry; a belt system extending along the longitudinal axis and moving through a cavity within the gantry; and a material treatment system movably supported by and along the gantry configured to treat a material supported by the belt system. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] FIG 1 is an isometric view of an automated material joining system.

[0007] FIG 2 is a partial side view of the system of FIG 1.

[0008] FIG 3 is a side perspective view of a joining system within the gantry.

[0009] FIG 4 is an isometric view of the gantry.

[0010] FIG 5A is a cross-sectional side view of the gantry.

[0011] FIG 5B is a cross-sectional side view of the gantry in one implementation.

[0012] FIG 5C is a schematic view of a cross belt path within the gantry cavity.

[0013] FIG 6 is a close-up view of the cross belt.

[0014] FIG 7 is a perspective top side view of the manifold and guide plate.

[0015] FIG 8 is a side view of a guide plate.

[0016] FIG 9 is a side perspective view of the joining system.

[0017] FIG 10 a bottom perspective view of the vacuum system.

[0018] FIG 11 is a partial side view of the system of FIG 2 with the gantry in a second location.

[0019] FIG 12 is a view of materials being loaded onto the system.

[0020] FIG 13 is a view of materials after being joined and cut.Atty. Dkt. No. F160-106-WO

[0021] FIG 14 is a schematic view of a creasing module.

[0022] FIG 15 is a schematic view of a grommet Insertion module.

[0023] FIG 16 is a schematic view of a metal snap insertion module.

[0024] FIG 17 is a schematic view of a CNC routing module.

[0025] FIG 18A-18D are schematic views of a blade cutting module.

[0026] FIG 19 is a schematic view of an embossing module.

[0027] FIG 20 is a schematic view of a printing module.

[0028] FIG 21 is a schematic view of an ultrasonic bonding module.

[0029] FIG 22 is a schematic view of laser dump device with sensor

[0030] FIG 23 is a schematic view of a laser feedback control system.

[0031] FIG 24 is an isometric view of the gantry in one implementation.

[0032] FIG 25 is an isometric view of a vacuum cassette.

[0033] FIG 26 is a cross sectional view of opposing vacuum cassettes forming the gantry cavity.

[0034] FIG 27 is an isometric view of vacuum cassettes on a portion of the gantry.

[0035] FIG 28 is an isometric view of a cassette.

[0036] FIG 29 is an exploded view of the cassette of FIG 28.

[0037] FIG 30 is a partial perspective view of an automated material joining and cutting system.

[0038] FIG 31 is a partial perspective view of the automated material and cutting system of FIG 30 with belts.

[0039] FIG 32 is a partial perspective plan view of a keder application system.

[0040] FIG 33 is a sketch of a keder application system with a motorized feed dispenser device.

[0041] FIG 34 includes a number of view of a dispenser shoe.

[0042] FIG 35 is a partial cross sectional view of the dispenser shoe and keder application system.

[0043] FIG 36 is a view illustrating a drive wheel engaging apertures in a keder.

[0044] FIG 37 is a plan view of material with keders secured thereto.

[0045] FIG 38 is an isometric view of a keder dispensing system on an automated material sewing and cutting system.Atty. Dkt. No. F160-106-WO

[0046] FIG 39 is a plan view of the keder dispensing system of FIG 38,

[0047] FIG 40 is a view of the keder dispensing system with a cover plate removed.

[0048] FIG 41 is the keder dispensing system of FIG 40 with a keder.

[0049] FIG 42 is a material processing system with a waterjet cutter.

[0050] FIG 43A is a schematic of the material processing system of FIG 42 in a first position.

[0051] FIG 43B is a schematic of the material processing system of FIG 42 in a second position.

[0052] FIG 44 is a partial view of the material processing system of FIG 42 with a water chamber.

[0053] FIG 45 is a close-up view of FIG 44.

[0054] FIG 46 is a partial view of the material processing system of FIG 42 with a cross-frame belt.

[0055] FIG 47 is a view of a partial belt system for the material processing system of FIG 42 using wires for belts.

[0056] FIG 48 is an isometric view of part of a portion of the cross table gantry and a keder application system, sewing system and cutting system.

[0057] FIG 49 close up view of the keder application system, sewing system and cutting system of FIG 48.

[0058] FIG 50 is an isometric view of the keder feeder in a position on the keder feeder guide between a first end position and a second end position.

[0059] FIG 51 is a top view of the keder application system.

[0060] FIG 51A-51B are top views of the keder application system in two different positions that are greater than 90 degrees from a center point.

[0061] FIG 52 is an isometric view of the keder feeder with a cover removed.

[0062] FIG 53 is a plan view of a user input for the keder application system.

[0063] FIG 54 is an isometric view of the keder application system in a first position applying a first keder strip.

[0064] FIG 55 is an isometric view of the keder application system in a second position applying another keder strip.Atty. Dkt. No. F160-106-WO

[0065] FIG 56 is a close up isometric view of the material joining system with the cutting system cutting the material after the keder strips have been sewn to the material.

[0066] FIG 57 is an isometric view of the keder application system with a lateral actuator.

[0067] FIG 58 is a top plan view of a keder material having a series of spaced physical locators.

[0068] FIG 58B is a cross sectional view of the keder material taken along line 58B- 58B of FIG 58.

[0069] FIG 59 is a schematic view of a drive for driving the keder material of FIG 58.

[0070] FIG 60 is a schematic view of another drive for driving the keder material of FIG 58.

[0071] FIG 61 is a schematic view of a punch module.

[0072] FIG 62A is schematic view of the keder with notches for a left turn.

[0073] FIG 62B is a schematic view of the keder with notches for a right turn.

[0074] FIG 62C is a schematic view of a keder material with slits along one longitudinal edge.

[0075] FIG 62D is a schematic view of a keder material with slits along a first longitudinal edge and notches along a second longitudinal edge.

[0076] FIG 63A is an isometric view of a keder system having a keder guide rail extending over 180 degrees with the keder feeder in a first position.

[0077] FIG 63B is a top plan view of keder secured to a material forming a 360 degree circle.

[0078] FIG 63C is an isometric view of the keder system of FIG 63A with the keder feeder in a second position.

[0079] FIG 63D is an isometric view of the keder system of FIG 63A with the keder feeder in a third position.

[0080] FIG 63E is an isometric view of the keder system of FIG 63A with the keder feeder in a fourth position.

[0081] FIG 63F is an isometric view of the keder system of FIG 63A with the keder feeder in a fifth position.Atty. Dkt. No. F160-106-WO

[0082] FIG 63G is a top pan view of the keder system of FIG 63G with a keder attached forming a circle. DETAILED DESCRIPTION OF THE EXAMPLE EMBODIMENTS

[0083] Referring to FIG 1 and FIG 2 an automated material joining and cutting system 110 (system 110) for joining materials 112. System 110 includes a frame 114 supporting a gantry 116 movable along a longitudinal axis 118 of frame 114. A belt system 120 includes a first longitudinal belt system 122. In one implementation belt system 120 further includes a horizontal belt 126 system within gantry 116 that extends perpendicular to longitudinal axis 118 and first longitudinal belt system 122. In one implementation longitudinal belt system 122 includes a plurality of individual belts 124 that are separated from extend parallel to one another. As described herein, individual belts 124 are selectively movable relative to frame 114 and gantry 116. In one implementation system 110 has the same features as described in pending PCT Application No. PCT / EP2022 / 064663 ( “ ‘663 application”) entitled Automated Sewing System and being incorporated herein in its entirety. The ‘663 application is attached hereto as Appendix A and is part of the specification.

[0084] In one implementation system 110 includes a joining system 128 that is movably supported by gantry 116 for joining materials 112. In one implementation joining system 128 includes a sewing system 130 that joins materials 112 together by sewing. In one implementation a vision system may be supported by an arch member 127 that is stationary with respect to frame 114. In one implementation arch member 127 moves with gantry 116.

[0085] In one implementation system 110 includes a cutting system 134 that cuts materials 112. In one implementation, joining system 128 and cutting system 134 are both secured to gantry 116 at the same time allowing system 110 to both join materials 112 and cut materials 112 while materials 112 on the same system without the need to change joining system 128 with cutting system 134. In one implementation a joining head of joining system 128 and a cutting head of cuttingAtty. Dkt. No. F160-106-WO system 134 are mounted to gantry 116 next to each other and automatically moved into an operating position by a controller.

[0086] Referring to FIGS 1-3, frame 114 includes a chassis including longitudinal members 136 extending parallel to longitudinal axis 118 and cross members 138 extending perpendicular to longitudinal members 136 and parallel to one another. A pair of longitudinal gantry support members 140 support gantry 116 for movement along longitudinal axis 118. Gantry includes a cross member 142 that supports joining system 128 and cutting system 134 for movement in the cross frame direction which is perpendicular to longitudinal axis 118. In one implementation gantry 116 is moved longitudinally along longitudinal gantry support members 140 with a motor 144 that moves gantry 116 between a first longitudinal end 146 and a second longitudinal end 148. Systems for moving a gantry on frame are known in the art and may include a single lead screw or a double lead screw and stepper motors that may be controlled by a controller. Similarly, joining system 128 and cutting system 134 are moved along cross member 142 in a direction perpendicular to longitudinal axis 118 by a motor that is controlled by a controller.

[0087] Referring to FIG 1 and FIG 4 first longitudinal belt system 122 includes individual belts 124 that form a belt path. In one implementation belt system 122 includes a single belt extending substantially along the entire width (along the Y-axis) of frame 114. 124. The belt path is defined by gantry 116, and a fist set of proximal cross bars 150a, 150b proximate first longitudinal end 146 and a second set of distal cross bars 152a, 152b proximate second longitudinal end 148. Gantry 116 includes a first bar 154, a second bar 156, a third bar 158 and a fourth bar 160. Each of the bars, 150a, 150b, 152a, 152b, 154, 156, 158, and 160 extend in a cross system direction along the Y axis as show in FIG 1 and perpendicular to longitudinal axis 118. Note that the term along the Y axis will refer to an axis that is co-axial with a Y axis and parallel to a Y axis in the X-Y plane. Belt 124 extends over cross bar 150a to gantry 116 then over first bar 154 along or parallel to longitudinal axis 118 then extends in a downward and rearward direction toward and about second bar 156. Belt 124 then extends forward toward and about third bar 158 and then rearward and upward and about fourth bar 160. Belt 124 then extends toward and over upper distal cross barAtty. Dkt. No. F160-106-WO 152a and then extends rearward toward and about lower distal cross bar 152b. Belt 124 then extends forward toward and over lower proximal cross bar 150b. The term upward as used herein refers to the positive Z axis and the term downward refers to the negative Z axis. Similarly, the term rearward refers to the negative X direction and the term forward refers to the positive X direction. Angle support brackets 151 and 153 extend from lower support bars 150b and 152b respectively. Brackets 151, 153 support Manifold 168. Referring to FIG 2, the positive X direction extends from a loading side of system 110 toward the unloading side of system 110. Referring to FIG 12 and FIG 13, the material being processed moves generally is loaded from first longitudinal end 146 and unloaded at second longitudinal end 148.

[0088] In one implementation each of the bars 154, 156, 158, and 160 rotate along their entire longitudinal axis about a bearing. One of bars 154, 156, 158, and 160 is a driven bar by a motor to drive belt 124 about the belt path. In one implementation more than one bar is a driven bar to drive belts 124 about the belt path synchronously, such that each belt 124 moves uniformly in the same direction. In implementation, individual rollers are provided on each bar for each belt, such that the individual rollers rotate about one or more of bars 150-160 independently of one another. In one implementation one or more of bars 150-160 and / or separate rollers on the bars do not rotate but rather belt 124 rotates about the bar without the bar or without separate roller rotating about the longitudinal axis of the bar. For example, bars 154 and 158 may have a smooth edge. Note that rollers 154 in one implementation are small (to reduce y belt width), and have a radius of 10mm. In contrast in one implementation rollers 158 are larger than the rollers 154 and range between 50mm and 100mm to create more traction if they are motor driven. The motor drive can also be located at a far end of the frame driving the end rollers.

[0089] Belts 124 create a cavity 162 between rollers 154, 156, 158 and 160. The distance in the longitudinal direction between roller 154 and 158 is less than the distance between roller 156 and roller 160. In one implementation cavity 162 has a generally frustum prism shape with a narrow opening 170 and a wider base 172. Stated another way opening of cavity 162 is defined by the space between bar 154 and bar 158 between a first side 164 of gantry 116 and a second side 166 of gantry 116.Atty. Dkt. No. F160-106-WO Note that since gantry 116 moves in the cross system direction cavity 162 moves relative to frame 114.

[0090] Referring to FIG 5A-C, FIG 6 and FIG 7, a manifold 168 defines an opening 174 that is adjacent to narrow opening 170 of cavity 162. Opening 174 has a first longitudinal edge and a second longitudinal edge spaced from and parallel to first longitudinal edge and extending in the cross system direction. Manifold 168 has a proximal region 180 and a second distal region 182. Proximal region 180 and second distal region 182 of manifold 168 have a plurality of openings 176 extending therethrough generally aligned with each belt 124. In one implementation proximal region 180 and second distal region 182 are closely adjacent to opening 174 along the longitudinal axis. In one implementation each belt 124 is separated by 5 mm in the Y axis direction. Manifold 168 includes a first set of belt openings 184 adjacent proximal region 180 and a second set of belt openings 186 adjacent second distal region 182. Each belt 124 extends through one of the openings in first belt openings 184 and one of the openings in second belt openings 186. In one implementation manifold 168 does not have openings through which belts 124 extend, but rather belts are guided over a ledge. In one implementation the horizontal belt 126 has a first longitudinal edge end that is closely adjacent to the portions of belts 124 that extend downward into the gantry cavity area and a second longitudinal edge that is closely adjacent to the portion of belts 124 that extend upward from the gantry cavity area. In one implementation the distance between the longitudinal edges of horizontal belt 126 and the portions of belts 124 proximate gantry 116 is 5mm or less.

[0091] Referring to FIG 2 and FIG 5C, horizontal belt 126 extends in a cross system direction about a first roller 188, a second roller 190, a third roller 192 and a fourth roller 194. One of rollers 188, 190, 192, and 194 is a drive roller and the other rollers is a driven roller. In one implementation more of rollers 188, 190, 192 and 194 is a drive roller. In one implementation none of rollers 188, 190, 192 and 194 is a drive roller, rather belt 126 is secured to a plate 198 which is automatically driven by a motor. Horizontal belt 126 includes at least one opening 196 allowing a joining member such as a needle to extend therethrough. In one implementation horizontal belt 126 includes more than one opening allowing a separate cutting instrument toAtty. Dkt. No. F160-106-WO extend therethrough including a laser, a knife, or other cutting instruments described herein or known in the art.

[0092] Horizontal belt 126 has an outside surface that extends outward and an opposing second surface. As noted above in one implementation plate 198 is secured to horizontal belt 126 and adjacent to the second surface. Plate 198 is rigid and moves in cross-system direction along with horizontal belt 126. In one implementation plate 198 is connected to and moves horizontal belt 126 by a screw actuator or other known drive mechanisms. In one implementation plate 198 and horizontal belt 126 can be moved independently and automatically aligned during a process in which an aperture in horizontal belt 126 and an aperture in plate 198 need to be aligned.

[0093] Referring to FIG 1, 2 and 7, gantry 116 includes an upper member 200 and a lower housing 202. Joining system 128 includes an upper portion 204 movably supported on upper member 200 of gantry 116 and a lower portion 206 movably supported on lower housing 202. In one implementation joining system 128 is a sewing system 130 and an upper portion 204 includes the needle mechanism and lower portion 206 includes a bobbin. A needle 208 of sewing system 130 extends through opening in horizontal belt 126 and an opening in plate 198. In one implementation the upper and lower members of gantry 116 move along the longitudinal axis 118 (X-axis) and the cross system axis (Y-axis) with high accuracy such as + / - 0.05 mm so that the needle and hook will connect the threads and create sewing knots.

[0094] Gantry 116 also supports a cutting system 134 having an upper portion 210 and a lower portion 212. Where upper portion 210 is movably supported on upper member 200 of gantry 116 and lower portion 212 is movably supported on lower housing 202. In one implementation horizontal belt 126 includes a second opening through which a cutting member extends between upper portion 210 and lower portion 212 of cutting system 134. In one implementation cutting system 134 is a laser cutting system in which a laser is generated in upper portion 210 and a base member in lower portion 212 to dissipate any laser energy and remove fumes after the materials have been cut. In one implementation cutting system 134 includes a laserAtty. Dkt. No. F160-106-WO system that can cut from both the bottom and the top of materials 112. In this implementation both the upper module and the lower module would include both a laser and a base member.

[0095] Referring to FIG 5A a vacuum system 214 is supported by gantry 116 and includes a vacuum pump operatively connected to a first duct 216 and a second duct 218. In one implementation vacuum system 214 is secured to an outside portion of gantry 116 that is outside of cavity 162. First duct 216 extends from a location below cavity 162 to a position adjacent a lower surface 220 of proximal region 180 of manifold 168. Second duct 218 extends from a location below cavity 162 to a position adjacent a lower surface 222 of second distal region 182 of manifold 168. First duct 216 and second duct 218 include openings facing the openings extending through proximal region 180 and second distal region 182. Vacuum system 214 applies a vacuum to materials 112 being joined and cut adjacent to the opening 170 providing a force to materials 112 to maintain the location of materials 112 as gantry 116 is moved longitudinally within frame 114. Belts 124 glide on top of the vacuum boxes despite any friction created between the lower surface of belt 124 and vacuum box surface – aka printing belts. Belts 124 have low friction backside and top high friction to better grip the materials 112.

[0096] In one implementation vacuum system 214 provides a vacuum sufficient to allow materials 112 to be held in a fixed position relative to frame 114 as gantry 116 moves along longitudinal axis 118.

[0097] Referring to FIG 8, in one implementation manifold 168 includes a belt bend plate 224 configured to guide belt 124 into gantry 116 toward bars 154 and 160. Belt bend plate 224 includes a first opening 226 having a radius R1 and a path 228 that guides belt 124 at an angle 230 greater less than 90 degrees toward and away from bar 154. In one implementation the angle 230 is less than 45 degrees. Belt 124 then extends about first bar 154 as belt 124 is directed toward second bar 156. Similarly, belt bend plate 224 includes a second opening 232 that includes a second guide path 234 extending toward away from bar 160, having similar but opposite geometry to the path 228.Atty. Dkt. No. F160-106-WO

[0098] In one implementation system 110 includes an internal cavity vacuum system which includes a vacuum pump located outside of gantry 116 and either supported by frame 114 for external to frame 114 that is operatively connected to a hose or duct within gantry 116 that removes gases associated with laser cutting and / or material removed during a cutting process. In one implementation, system 110 includes an air pump (not shown) that includes an air pump located outside of gantry 116 and either supported by frame 114 or external to frame 114 that is operatively connected to a hose or duct within gantry 116 that provides a positive air pressure within gantry 116 where the air escapes through horizontal belt 126 to create a cushion of air on the portion of materials 112 directly over horizontal belt 126. In one implementation the operation of the internal cavity vacuum system and the air pump are controlled by a controller to operate only when needed. Stated another way, internal cavity vacuum system may be automatically operated solely when cutting system 134 is operational. Similarly, the air pump may be automatically operated solely when gantry 116 is moving along longitudinal axis 118. Similarly, vacuum system 214 may be automatically operated solely when gantry 116 is moving along longitudinal axis 118. A controller may operate all three air devices (one vacuum system 214, internal cavity vacuum system, and the air pump) automatically turning each system on and off based upon movement gantry 116 along longitudinal axis 118 and / or operation of cutting system 134.

[0099] In one implementation, the air pump operates to provide positive air pressure to lift the portion of materials 112 away from a base of frame 114 along the substantially the entire operational width of frame 114 along which materials 112 extend. In one implementation the air pressure provided is sufficient to minimize friction between horizontal belt 126 and materials 112 as gantry 116 is being moved along the longitudinal axis 118 to avoid buckling or any disruption or unintended movement of the material being processed. In this way positional control of the material being processed is maintained. In one implementation the region in which air pump provides air pressure is limited to the region in which material 112 is present. In one implementation a sensor detects the location of materials 112 proximate horizontal belt 126 and limits the air flow to the region of horizontal belt 126 whereAtty. Dkt. No. F160-106-WO materials 112 is present. In one implementation the cavity vacuum system provides a vacuum proximate the cutting system 134 is operating. Stated another way, the cavity vacuum system includes a hose that moves along with cutting system 134 along gantry 116 such that the cavity vacuum system focuses the air and material removal adjacent to the portion of materials 112 being removed as the portion of materials 112 is being removed. In one implementation a single vacuum pump is provided for both the removal of gases and / or materials removed from materials 112 during a cutting operation as well as for providing a vacuum to materials 112 through manifold 168 external to the cavity region. An automatically controlled valve and / or damper operatively connected to the vacuum pump provides the vacuum where needed as described herein. A single vacuum pump in one implementation is located on and travels with gantry 116. In one implementation the single vacuum pump is operatively connected both to the cavity vacuum system and vacuum system 214 bias hoses and / or ducts and is located external to the gantry. In this implementation a hose management system known in the art maintains a portion of the hose outside of the gantry within frame 114 to allow for free movement of gantry 116.

[0100] Referring to FIG 7, belt 124 includes a plurality of openings 242 allowing air to enter therethrough in response to vacuum 214. In one implementation the pattern of plurality of openings 242 through belts 124 are sufficient to allow the vacuum to be applied to an underside of the material being processed adjacent the cavity opening 174. In one implementation the vacuum applied is sufficient to maintain two or more stacked materials together provided at least the first material adjacent belts 124 is porous.

[0101] In one implementation horizontal belt 126 does not extend entirely above lower housing 202 and lower portion 206 and lower portion 212 of joining system 128 and sewing system 130 respectively. Referring to FIG 5C a horizontal belt 126 diversion system includes a first upper bar 243 a first bottom bar 244, a second bottom bar 246 and a second upper bar 248. Bars 243, 244, 246 and 248 may rotate and / or include a roller bearing. A portion of horizontal belt 126A (see FIG 5A where 126 is shown in dashed lines if a horizontal belt diversion system were employed) would extend below lower housing 202 and lower portion 206 as sewing systemAtty. Dkt. No. F160-106-WO joining system 128 and cutting system 134 moves along gantry 126 along a cross system axis which is perpendicular to longitudinal axis 118. In one implementation a portion of horizontal belt 126A would extend below the gantry but above the lower portions of belts 124. The cross system axis and longitudinal axis 118 lie in a plane that is generally perpendicular to gravity when system 110 is in an-use orientation. Stated another way longitudinal axis 118 lies along the X axis as shown in FIG 1 and FIG 2 and the cross system axis lies along the Y axis as shown in FIG 1 and FIG 2. Referring to FIG 5C in one embodiment lower housing 202 and lower portion 206 are elevated from a base member 250 that moves along the cross system axis or a line parallel to the cross system axis. In one implementation, sewing system joining system 128 and cutting system 134 move together and in one implementation joining system 128 and cutting system 134 may move independently of one another along or parallel to the cross system axis. Referring to FIG 5B and FIG 5C, horizontal belt 126 forms a second cavity within cavity 162. In one implementation system 110 includes two or more gantries 116 acting independent of oneanother, wherein each of gantries includes a material treatment module. In one implementation each of the multiple gantries includes different modules. For example, one gantry includes a cutting module, while another gantry includes a sewing module. Similarly, one or more of the multiple gantries may include more than one sewing module. In one implementation at least one of the multiple gantries includes more than one cutting module. In one implementation one gantry includes a sewing unit that provides a cross stitch, while a second gantry includes a sewing unit that provides a lock stitch. In one implementation, one gantry includes two sewing unit, where the sewing units perform different stitch types.

[0102] In one implementation belt 126 is replaced by a telescoping plates or the like that extend and retract as the gantry housing holding the material processing modules such as the joining and cutting modules move back and forth between the longitudinal sides of frame 114. In this manner the region directly above the cavity opening would be free of any belt material. In one implementation the second belt in the claims provided herein below is replaced with telescoping plates.Atty. Dkt. No. F160-106-WO

[0103] In one implementation belt 124 has several features. In one implementation the friction on one side of the belt that comes into contact with materials 112 has a higher coefficient of friction than the second side of the belt that does not contact materials 112. Belt 124 includes a plurality of perforated holes that allow vacuum air flow to secure materials 112 so the joining operation such as sewing / and cutting operation does not move the materials 112. In one implementation belt 1249s must be thin and flexible to enter and exit the gantry as described herein. In one implementation belt 124 is sufficient thin and / or flexible to bend over the small rollers where belts turn downwards 110 - 120 degrees into cavity 162. In one implementation belt 124 has minimal stretch along the longitudinal axis and is durable to last 1 or 2 years in heavy use. In one implementation the commercially Habasit FAB-2E material is used. But there are numerous other brands and types to choose from. In one implementation belts 124 include parallel grooves on the back side to assist in belt tracking. The belt grooves will match grooves on one of the rollers or the rounded path as shown in Fig 8 to ensure tracking. In one implementation each belt 124 may vary in width perpendicular to the longitudinal axis of the belt from 25mm to 100 mm. However, the width of each belt 124 may be less than 25mm or greater than 100mm. In one implementation the width of each belt is 25mm. In implementation each belt has two rolls of holes. In one implementation each hole has a diameter of 4 mm. In one implementation each longitudinal row of holes are offset from one another such that the holes are offset from one another along or parallel to the cross system axis or Y axis.

[0104] In one implementation horizontal belt 126 is a single belt. In one implementation horizontal belt 126 is not perforated and has no holes except for the holes to allow a joining member and cutting member to extend there through. In one implementation horizontal belt 126 includes perforations to provide an air cushion to help slightly lift materials 112 over the active area (where the belt is moving below the fabric 112), so the friction between horizontal belt 126 and materials 112 does not push the materials 112 sideways in the cross system direction (along Y axis). In one implementation horizontal belt 126 has a top surface that faces / contacts materials 112 with a low coefficient of friction. Horizontal belt 126 has a strong tensileAtty. Dkt. No. F160-106-WO strength to allow it to move lower housing 202 and lower portion 206 along the cross system axis. In one implementation horizontal belt 126 is driven by a motor and the connection between horizontal belt 126 and lower housing 202 and 206 is what moves lower housing 202 and lower portion 206 including base member 238. One of rollers 188, 190, 192 and 194 is a drive roller that moves horizontal belt 126 along the horizontal belt 126 path. In one implementation base member 238 is driven by a motor independently of horizontal belt 126. In one implementation base member 238 is driven by a motor is operatively connected to horizontal belt 126 and moves horizontal belt 126 when base member 238 is moved along or parallel to the cross system axis.

[0105] Referring to FIG 4 gantry 116 includes a housing formed with a plurality of rib members 236 providing guidance for each belt 124. Rib members 236 extend from a base member 238 toward an upper member 240 proximate the cavity opening.

[0106] Referring to FIG 2, materials 112 may be fed to system 110 by a first feeder roll 252 feeding a first material and a second feeder roll 254 feeding a second material. A take-up roll 256 is configured to take up the joined first material and second material. In one mode of operation materials 112 are placed onto the upper surface of belt 124 through gantry 116 along longitudinal axis 118 between the entry side of system 110 toward the exit side of system 110 in the region in which gantry 116 can operate to join and cut materials 112. Gantry 116 is automatically moved along the longitudinal axis 118 as joining system 128 and cutting system 134 are moved along the cross system axis of system 110 to join and cut materials 112 in a predetermined pattern. In this first mode, materials 112 remain stationary during the joining system 128 and cutting system 134 operations. Once the materials 112 have been joined and cut the processed material is moved toward the exit by take-up roll 256. In one implementation belts 124 are moved in exit direction such that the processed materials 112 are moved from the entry side toward the exit side. In one implementation where parts of materials 112 are joined and cut apart take-up roll 256 can be replaced with a tray or another conveyor to move the joined and cut products to packing or for further processing.Atty. Dkt. No. F160-106-WO

[0107] In one implementation system 110 includes a vision registration system to register a joining path where materials 112 are joined and a cutting path where materials 112 are cut to a printed image. In one implementation the vision system will be able to obtain an image of the materials 112 where a printed image is on the face of the materials facing downward, so that the printed fabric materials can be joined (sewn) and cut in registration with the printed image. In one implementation a first camera is mounted above the material being processed on the gantry and movable with the gantry. In one implementation a second camera is fixed relative to system 110 and does not move relative to the frame.

[0108] In a second mode of operation, materials 112 that are not part of a roll are placed on belts 124 (either manually or by a robotic loader) between the upper member of gantry 116 and horizontal belt 126. In this mode materials 112 remain stationary relative to frame 114 as gantry 116 is moved along the longitudinal axis 118 and joining system 128 and cutting system 134 are moved along or parallel to the cross system axis to join and cut materials 112. The processed materials 112 may then be manually removed from system 110 (either by hand or by a robotic loader) or belts 124 are moved such that the processed materials are moved in a direction toward the exit side of system 110.

[0109] In a third mode of operation materials 112 are separate from a roll and placed on system as described above with respect to the second mode of operation. In this third mode belts 124 move toward away from the exit side to move the material toward and away from the exit side as gantry 116 also moves along longitudinal axis 118. Joining system 128 and cutting system 134 move along or parallel to gantry 116 in the cross-system axis as described herein. Two or more layers of rolls or two or more sheets can be loaded on top of each other to be sewn and cut together. In one implementation system 110 is used for quilting in which an inner foam layer is between two outer layers of fabric. In one implementation system 110 is also used for embroidery.

[0110] Referring to FIG 2 and FIG 11, in the first mode belts 124 are fixed relative to bars 150a, 150b, 152a, and 152b. However, the portion of belts 124 between bars 150a and 152a move along the belt path through gantry 116. Referring to FIG 2 aAtty. Dkt. No. F160-106-WO point A on belts 124 in a first position is moved through gantry 116 as gantry 116 is moved from the exit side toward the entry side. The vacuum created by vacuum system 214 helps to maintain materials 112 in a stationary position relative to frame 114 as gantry 116 moves along longitudinal axis 118.

[0111] In one implementation system 110 includes processing a flexible or rigid material from both ends simultaneously on a flatbed formed by belts 124. In this implementation a second gantry 116 may be used that includes additional process modules to be used separately or in conjunction with joining system 128 and / or cutting system 134. The second gantry system could also include a second joining system 128 and a second cutting system 134. It is also contemplated that a second system 110 may be used in serial with a first system 110. For example when processing material to create automotive airbags a first system 110 could have special vent holes on one side and then joined to another material in a second system 110. Further straps and fitting or other tabs can also be added (with a robot) on the first system run and then sewn together with layer #2 in a 2ndrun on the second system.

[0112] Creasing Tool: Referring to FIG 14, a creasing module 258 includes an upper member 260 supported by gantry 116 and a lower member 262 supported by base member 250. Creasing module 258 may be used in the creasing of folding cartons and corrugated materials, utilizing a male and a female hard tool die to create a quality crease (fold). Creasing module upper member 260 and lower member 262 form the male and female portions a creaser and are manipulated by gantry 116 the two opposing creasing wheels are moved together simultaneously, with a male creasing wheel in the upper tool position and female creasing wheel in the lower position (inside the moving cavity). Note that creasing module 258 includes independent vertical movement of the male creasing wheel and the female creasing wheel to engage and disengage the wheels from materials 112 being crease. In one implementation both wheels will be operating in the same direction (tangentially) and synchronously in the X and the Y direction. In one implementation the male wheel is positioned in the cavity and the female wheel is positioned above the material being creased mounted outside of the cavity.Atty. Dkt. No. F160-106-WO

[0113] Referring to FIG 15 a Grommet insertion module 264 is used independently or in conjunction with joining system 128 and / or cutting system 134 to insert one or more grommets into materials 112. Grommets are used to avoid tearing, to add strength, or for aesthetic value in connection with sewn goods such as banners, flags, tarps, sails, bags, curtains, shower curtains and more. A Grommet typically consists of two round parts, which are pressed together from both sides into a precut hole. Using system 110, a grommet dispensing tool supported by an upper portion 265a of gantry 116 will automatically insert the top grommet part. A matching lower tool 265b (inside the moving cavity) will dispense the lower grommet part after which the two parts are pressed together to secure them. By adding automated insertion of grommets, the system 110 will be able to sew, cut and add grommets thereby enabling fully automated production of a wide range of sewn goods. A grommet is a ring or edge strip inserted into a hole through thin material, typically a sheet of textile fabric, sheet metal or composite of carbon fiber, wood or honeycomb. Grommets are generally flared or collared on each side to keep them in place, and are often made of metal, plastic, or rubber. They may be used to prevent tearing or abrasion of the pierced material or protection from abrasion of the insulation on the wire, cable, line being routed through the penetration, and to cover sharp edges of the piercing, or all of the above. A small grommet may also be called an eyelet, used for example on shoes, tarps and sails for lacing purpose

[0114] A description of an automated grommet known equipment can be found at: https: / / plastgrommet.com / us / grommet-presses / automatic / multipress.php. By separating the upper portion of the automated grommet equipment from the bottom portion and placing the upper portion in a module supported by the upper portion of gantry 116 and placing the bottom portion in a lower module supported by base member 250 below materials 112. The automated system is integrated into system 110. The use of the automated grommet module would allow for banner, curtain and tarp making fully automated including roll-off, sewing, cutting and grommeting all in one system. Banners, curtains, tarps could also be sewn, cut and grommeted in non- rectangular shapes without any added cost. It would also be possible to insert grommets at any position on a surface of materials 112 and not just at the edges. NewAtty. Dkt. No. F160-106-WO creative products can be produced with system 110 when sewn products do not need to be rectangular and can be grommeted in the middle (or anywhere) for pole or wire support, such as simple tents, temporary awnings and more.

[0115] Referring to FIG 16 a metal snap and button insertion module 266 is used independently or in conjunction with joining system 128 and / or cutting system 134. Snaps and buttons are used provide for temporary attachment of fabric pieces to each other, as opposed to grommets that allow the fabric to be mounted in other applications such as boat covers, grill covers, bags, tents, luggage. Just like for grommets, there are two pieces with snaps, except that two such dual attachments are on the two fabrics to be connected, one a male and the other a female piece that “snap” together and hold. In the metal button application, rather than being sewn on, the button is attached via a bottom pin that is inserted through the fabric into the button head. By adding automated insertion of buttons and snaps, system 110 will be able to sew, cut and add snaps / buttons thereby enabling fully automated production of a wide range of sewn goods

[0116] Referring to FIG 17 in one implementation cutting system 134 includes a routing tool 268 to cut materials 112. A router module includes a top portion supported by the upper portion of gantry 116 and a lower portion supported by the lower portion of gantry 116 such as base 250. When using smaller diameter routing bits or drills (ranging from 0.1mm up to 5mm in diameter) these tools are prone to breaking when moving in the X or Y direction on a flatbed table. Therefore, the speed the tool is moving with must be significantly reduced. The rotation speed of the bit or drill must also be reduced to avoid vibrations which will cause poor edge quality of the materials being processed. By supporting the bit 270 or drill at the top and at the bottom in a small bearing 272 within the moving cavity the bit or drill can move at a higher X and Y speed and a higher rotation speed, or use thinner bits which is an advantage in many situations (less dust, less material waste, finer details can be routed, higher speed). It is also possible to process thicker materials in one routing pass vs several subsequent passes. In this manner a router bit is held both by the upper module and the lower module.Atty. Dkt. No. F160-106-WO

[0117] Referring to FIG 18A – FIG 18D cutting system 134 includes a long thin oscillating blade274 that is supported at one end by an upper module 276 attached to the upper portion of gantry 116 and supported at the other opposing end by a lower module 278 within the cavity 162. The oscillating blade module is used for cutting thru multiple layers (up to 100 layers or more) of fabric up to 10cm – 20cm thick, or when cutting thru harder & thicker materials, blades are prone to flex causing inaccurate cutting or breaking. Though the oscillating blade system could be used with multiple layers of fabric that are less than 10cm or greater than 20cm. The cutting speed, number of fabric layers and material thickness is reduced using the oscillating blade system. In some cases, the flatbed motion control software must also dynamically adjust (slow down) the cutting movements (rotation, lifts, lowering, oscillations) to compensate for the flexing and to avoid breaking the blade. By using system 110 the oscillating blade can be lowered into the moving cavity 162 and the blade thereby supported from both the upper blade holder and the cavity below. This will result in faster cutting of thick stacks / layers of fabric or thicker / harder materials. It will also be possible to automatically sharpen the part of the blade when it is inside the cavity. In one implementation the oscillating blade and holder in the cavity are tangentially controlled. In this manner the holder pivots as the blade pivots.

[0118] Referring to FIG 18B, cutting system 134 is a wire cutting module 280 that uses a thin metal wire or cable 282 for mechanical cutting of material such as foam, nonwoven textiles, wood, glass, stone, ferrites, metals, crystals etc. Industrial wire saws are usually powered. Wire saws are classified as continuous (or endless, or loop) or oscillating (or reciprocating). Sometimes the wire itself is referred to as a "blade". In some applications the wire moves at high speeds up to 200 km / h.

[0119] Cutting system 134 may include a heated wire module in which a heated wire element is used to cut materials 112. A heated wire module would include an upper portion supported by the upper portion of gantry 116 and a lower module supported by the lower portion of gantry 116 such as base member 250 within cavity 162.

[0120] Each of the modules discussed herein can be used with system 110 either alone or in combination with one or more of the other modules discussed herein. It is further contemplated that system 110 includes one or more additional gantries that areAtty. Dkt. No. F160-106-WO automatically controlled to perform operations on different regions of materials 112 simultaneously.

[0121] System 110 supports materials 112 without the need for a separate frame member or the need to separately secure the longitudinal edges of materials 112. In one implementation system 110 operates to join, cut and perform the other functions to materials 112 identified herein without securing the longitudinal edges of materials 112. In one implementation system 110 operates to join, cut and / or perform the other functions to materials 112 without securing any edge of materials 112 relative to frame 114.

[0122] Referring to FIG 19 in one implementation the upper module and the lower module include embossing wheels 286 that emboss a pattern on materials 112. Referring to FIG 20 In one implementation upper module and / or the lower module can include a printing module to impart a printed image onto one or both sides of materials 112.

[0123] Referring to FIG 21, in one implementation, joining system 128 includes an ultrasonic welding system 132 that ultrasonically joins materials 112 together. The upper module includes an ultrasonic horn 290 as is known in the art. The horn vibrates ultrasonically and acts to bond plastic materials 112 together positioned between the horn and an anvil in the lower module. In one implementation one or both the horn and anvil 292 are rotary members. In one implementation the axis of the rotary members pivots in the direction that gantry is moving relative to frame 114. Ultrasonic welding is an industrial process whereby high frequency ultrasonic acoustic vibrations are locally applied to work pieces being held together under pressure to create a solid-state weld. It is commonly used for plastics and metals, and especially for joining dissimilar materials. In ultrasonic welding, there are no connective bolts, nails, soldering materials, or adhesives necessary to bind the materials together. The benefit of ultrasonic welding is that it is much faster than conventional adhesives or solvents, and it will create ab airtight bond without punching holes in the materials as the case with sewing. Ultrasonic welding can be used for both hard and soft plastics, and metals. For ultrasonic welding two types of machines are used – First, machines with a 1) fixed sonotrode and a rotating wheel forAtty. Dkt. No. F160-106-WO fast and precise welding (especially for curves) and 2) second, machines with a rotating sonotrode and a rotating wheel for fast welding (for straight seams). System 110 has the ability to provide pressure from both sides of the work piece while the two tools are moving synchronously in the X and the Y directions, providing for a fully automated welding process of various materials. This allows the welding of non-linear contours. After welding the pieces can be cut while the materials are still fixed by the vacuum hold down. In one implementation the ultrasonic horn uses a rotating wheel on top and a receiving metal plate (anvil) below (or alternatively another wheel to reduce drag while moving). In one implementation when the horn and anvil are wheels, they will be operating in the same direction (tangentially) and synchronously in the X and the Y direction.

[0124] In one implementation joining system 128 includes a laser welding system that joins materials 112 together using laser energy. Laser welding systems may use various types of lasers including a CO2 laser or a diode laser that are often used for cutting fabrics. There are many advantages of laser cutting fabrics vs using a blade cutting tool: A laser system provides no mechanical force (friction) on the fabric as the laser uses a light beam to evaporate the cut path. The eliminates the risk that the fabrics moves during cutting. Further a laser provides finer for details to be cut at higher cutting speeds. A laser has the ability to cut several layers of materials 112. A laser can Seal the free edges of the material thereby reducing fraying when cutting fabrics containing polyester

[0125] The fumes can be extracted into one smaller hole within the moving cavity (into a hole next to the needle sewing hole). In regular laser cutters, a full surface area as large as the flatbed table itself will normally have vacuum extraction. As discussed herein a vacuum within cavity 162 effectively vacates fumes associated with the laser cutting process. Stated another way within the moving cavity 162 there will be a mechanical laser diffusing surface with vacuum extraction. By reducing the vacuum area from several square meters of the entire frame to a single hole only a few mm in diameter will allow much higher vacuum flow and efficiency. This also saves energy compared to vacuum extracting a full size machine. Typically, full size extraction fumes will be vented outside, so new air coming into the building must be heated orAtty. Dkt. No. F160-106-WO cooled with HVAC (heating cooling air conditioning) systems. A typical 20hp blower will push a lot of air volume outside and require a lot of new fresh air to enter. That is especially expensive to operate during air conditioning season. In one implementation the laser beam is the range of .05mm to .1 mm. In one implement the hole through horizontal belt 126 is larger than the laser beam. In one implementation the hole size in horizontal belt 126 that the laser beam passes is between 1mm and 2mm.

[0126] System 110 is capable of dual sided processing by using an upper portion and a lower portion located on opposite sides of materials 112. This is accomplished by moving the opening through which the upper and lower portions interact with one another and materials 112. The opening is provided by the belt path of belts 124 that moves a portion of belt 124 through the lower portion of gantry 116 about cavity 162.

[0127] LASER FEEDBACK SYSTEM

[0128] Referring to FIG 22 and FIG 23 cutting system 134 is a laser cutting system in which a laser is generated in upper portion 210 and a base member positioned within cavity 162 or in lower portion 212 dissipates any laser energy and removes fumes after the materials have been cut. In one implementation an automatic laser calibration system 300 automatically adjusts the laser energy to regulate the power of the laser during movement of the laser head over a specific substrate that the laser is acting upon. Laser calibration system 300 includes a laser beam dump device 302 including a light sensor 304 that detects laser light that is a function of the laser energy being transmitted by the laser beam of the laser nozzle 306 in upper portion 210. In one implementation light sensor 304 includes a phototransistor such as the one available from Vishay Semiconductor Opto Division under part number BPW85B having a frequency of 180 kHz. The speed in which measurements can be taken allows automatic laser calibration system 300 to adjust the strength of the laser in real time to account for change in material thickness, material color, material seams or other material variations as the material is being processed by system 110.

[0129] In one implementation laser beam dump 302 is positioned within lower portion 212 of cutting system 134. Laser beam dump device 302 is secured to gantry 116 and to cross member 142 to allow laser beam dump device 302 to be movedAtty. Dkt. No. F160-106-WO along longitudinal axis 118 and in a cross-table direction perpendicular to a direction parallel to longitudinal axis 118. Laser beam dump 302 includes a housing 308 defining a chamber 310 including a highly reflective surface 312 located therein. Laser beam dump 302 devices are well known in the art. US Patent 10,345,561 describes laser beam dump devices and is incorporated herein by reference to describe the general operation of a laser beam dump 302 device. Highly reflective surface 312 can be in the shape of a cone or angled planar surface that reflects the laser energy that enters into chamber 310 toward an inner surface 314 of the housing 308.

[0130] In one implementation a laser light sensor 304 is placed on or adjacent to surface 314 that detects an amount of light energy that is received from highly reflective surface 312. The amount of light energy detected by light sensor 304 is a function of the light energy emitted from laser nozzle 306 after the laser beam cuts through the material being cut by the laser. The signal from the light sensor is provided to a controller 326 that acts to increase or decrease the laser energy being emitted from laser nozzle 306 to a predetermined strength.

[0131] In one implementation, a user calibrates the laser energy during a setup stage based on the type of material being cut and the speed in which the laser nozzle is being moved over the material being cut. For example, the amount of laser energy in the laser beam applied to the material being cut is a constant predetermined value for a specific speed of the laser nozzle moving over the material. In one implementation the speed of the laser module movement relative to the material may vary depending on the type of cut being performed. For example, movement of the nozzle head in a straight line may be a first speed measured in inches / minute while movement of the nozzle head in an arcuate or non-linear line may be a second speed different than the first speed. In one implementation the second speed is less than the first speed. In one implementation the actual amount of energy being emitted by the laser beam varies during the cutting operation.

[0132] In one implementation light sensor 304 may detect a percentage of energy being emitted from the laser beam. For example, once the laser energy has been set to obtain proper cutting of a specific type of material at a given speed, the amount of light energy being detected by light sensor 304 is determined. By way of aAtty. Dkt. No. F160-106-WO nonlimiting example after the laser beam cuts the material the amount of laser energy that enters laser beam dump device 302 and reflected from highly reflective surface 312 light sensor 304 may detect 10% of the energy of the laser beam. This desired light detection value referred to herein as the calibration value is then stored during actual cutting of material during a production run. If during the production run the amount of energy detected by laser beam dump device 302 falls below the calibration value of 10%, the controller signals to the laser device to increase the strength of the laser until laser light sensor 304 is recording the proper light detection value. Similarly, if the amount of energy detected by light sensor 304 is greater than the calibration value of 10% the controller sends a signal to the laser beam to reduce the level of energy until the energy detected by light sensor 304 is within a predetermined value of the desired light detection value. In one implementation when the calibration value exceeds an upper limit, the controller provides instructions to increase the speed of the gantry through actuator or motor controls 500. Similarly, in one implementation when the calibration value is lower than a lower limit, the controller provides instructions to decrease the speed of the gantry. In one implementation, but the calibration value being outside the lower limit or the upper limit the controller provides instructions to both change the speed of the gantry and change the energy of the laser.

[0133] Referring to FIG 15, laser beam dump device 302 includes a cooling loop 316 that circulates a coolant adjacent highly reflective surface 312 to prevent heat damage to highly reflective surface 312. In one implementation, an air pump 318 introduces air via at least one aperture 320 into chamber 310 of housing 308. The air pumped into chamber 310 is removed via a second exit aperture by a vacuum 322 applied to the second exit aperture 324. In one implementation the vacuum applied to the chamber 308 is connected to vacuum system 214 or may be connected to a separate vacuum. The volume of air introduced and removed from housing 308 per unit of time can be varied depending on the amount of particulate being formed within the housing 308 to ensure that light sensor 304 accurately measures the light energy reflected from highly reflective surface 312. In one implementation there is no airAtty. Dkt. No. F160-106-WO pump 318, but rather ambient air enters at least one aperture 320 as a result of the application of the vacuum pressure through second exit aperture 324.

[0134] In one implementation an external air filter is installed in the vacuum system 214 to filter out any unpleasant smells and pollutants from the fumes being vacated from the system. Since the extraction of the fumes is directly below the cutting position the opening 301 is between a 1mm and 5 mm diameter hole and in one implementation opening 301 is a 2 mm diameter hole. This reduction assists in minimizing a portion of the material from being pulled into the aperture. This results in several magnitudes of concentration of the extraction area which significantly reduces the size of the required vacuum pump and the energy needed to drive it. A smaller filter system can also be applied. It is expected that the volume of air being removed will be reduced by factor 10 – 100 vs current technology where a flat surface (the size of the overall system) must be vacuumed. Stated another way since there is a moving vacuum 322 operatively connected to housing 308 the size of opening 301 may be small since any fumes in the laser beam dump device 302 are evacuated through second exit aperture 324 and do not need to be evacuated by a vacuum located on the top side of the material proximate laser nozzle 306. Additionally, the use of laser beam dump device 302 in cavity 404 eliminates for belts that are formed of metal or other material that will not burn in the presence of the laser energy. Metal belts reflect the laser energy and result in a burning or brown residue on a portion of the material being processed. A nonmetal belt material minimizes this condition. Further as discussed herein the laser beam dump device 302 that moves with the gantry and along the gantry eliminates the bounce back effect of the laser energy. In one implementation a vacuum is applied to the top portion of the laser module and a separate vacuum is applied to the lower portion of the laser module and both the top portion and the bottom portion move with the gantry along longitudinal axis 118 and in the cross-frame direction along the gantry. The cross-frame direction is perpendicular to longitudinal axis 118 and not perpendicular to the material being processed (not in the Z-axis direction).Atty. Dkt. No. F160-106-WO

[0135] It would also be possible to significantly increase the airflow speed by which will further remove the risk that fumes will escape the system and result in bad smells in the room and for the operators.

[0136] Laser nozzle 306 and laser beam dump device 302 move with the gantry in both the longitudinal direction parallel to or along longitudinal axis 118 and along the longitudinal axis of the gantry that is perpendicular to longitudinal axis 118 of the frame.

[0137] Certain materials being cut have threads or regions that require different levels of laser energy to be cut. Referring to FIG 23 the feedback system includes a controller that can instantaneously change the energy level of the laser beam to ensure a proper cut through all of the different regions of the material being cut by the laser.

[0138] Referring to FIG 1 and FIGS 24-27 in one implementation cross member 142 of gantry 116 defining cavity 162 is formed by a first cross member plate 350 and a second cross member plate 352 and a base plate 354 extending perpendicular and between first cross member plate 350 and second cross member plate 352. First cross member plate 350 and second cross member plate 352 have an inner surface facing one another and an outer surface facing away from the inner surfaces. First cross member plate 350 and second cross member plate 352 generally lay in a plane that is perpendicular to longitudinal axis 118 (Y-Z plane). In this implementation first cross member plate 350 and second cross member plate 352 replace bars 150a, 150b, 152a and 152b in the implementation illustrated in FIG 4 and discussed herein above. Referring to FIG 25 vacuum system 214 includes a plurality of vacuum cassettes 356 that replace brackets 151, 153 and cross bars and rollers 155, 156, 158 and 160 of the implementation described herein above. A pair of vacuum cassettes 356 are provided for each belt 124. Vacuum cassettes 356 that are positioned closer to the proximal region 180 of system 110 will be identified by reference 356a and vacuum cassettes that are positioned closer to second distal region 182 will be identified by reference 356b.

[0139] Each vacuum cassette 356 includes a first upper roller 358, a second upper roller 360, and a lower roller 362. For description purposes vacuum cassette 356 and the features identified therein will be identified with a suffix a for the vacuum cassetteAtty. Dkt. No. F160-106-WO 356 closer to proximal region 180 and with a suffix b for the vacuum cassette 356 closer to second distal region 182. Belt 124 extends over and about first upper roller first upper roller 358a of second vacuum cassette 356a toward and about second upper roller 360 of vacuum cassette 356a then toward and about first lower roller 362a of vacuum cassette 356a then below base plate 354 toward and about lower roller 362b of vacuum cassette 356b then toward and about second upper roller 360b of vacuum cassette 356b and then toward and about first upper roller 358b of vacuum cassette 356b and then toward second distal region 182. Each vacuum cassette 356 has a first region 364 that is in fluid communication with one of first duct 216 and second duct 218 and a second region 366 that is not in fluid communication with either first duct 216 or second duct 218. First region 364 of each vacuum cassette 356 is in fluid communication with an adjacent vacuum cassette 356. Second region 366 supports second upper roller 360 and lower roller 362.

[0140] Each vacuum cassette 356 includes a top plate 368 and includes a plurality of apertures 370 extending therethrough that is in fluid communication with a vacuum path 372 in fluid communication with first region 364. Vacuum path 372 is defined by the region between top plate 368, a bottom plate 374 and first region 364. Belt 124 includes a first surface 376 that contacts material being processed and a second opposed surface 378. An upper surface 380 of top plate 368 is in contact with second opposed surface 378 of belt 124. Note the top plates 368 of vacuum cassette 356 form the manifold through which the vacuum is applied through plurality of openings 242 of belts 124 to the underside of the material being treated or processed.

[0141] Referring to FIG 26 and FIG 27 first cross member plate 350 and second cross member plate 352 include a tab 382 and 384 respectively. Vacuum cassette 356a includes a notch 386 that receives tab 382 of first cross member plate 350 to position vacuum cassette 356 relative to first cross member plate 350 in an installed position. Similarly, vacuum cassette 356b includes a notch 386 that receives tab 384 of second cross member plate 352 to position vacuum cassette 356b relative to second cross member plate 352 in an installed position.

[0142] Vacuum cassette 356a is secured to first cross member plate 350 by a fastener extending though a boss 388 in second region 366 and is threadedly received within aAtty. Dkt. No. F160-106-WO threaded aperture in first cross member plate 350. Similarly, a Vacuum cassette 356b is secured to second cross member plate 352 by a fastener extending though a boss 388 in second region 366 and is threadedly received within a threaded aperture in cross member plate 352. Referring to FIG 25 first upper roller 358 is secured to vacuum cassette 356 with an end adjustment plate 390. A pair of fasteners 392 secure end adjustment plate 390 to a side plate 394 to allow for adjustment of first upper roller 358 relative to vacuum cassette 356. In one implementation a second pair of fasteners secure a second end adjustment plate to a second side plate 395 to allow for additional adjustment of first upper roller 358. In one implementation fasteners 392 extend through both first side plate 394 and second side plate 395.

[0143] A gap 396 is provided by design between a leading edge of end adjustment plate 390 and side plate 394 to allow for movement of first upper roller 358 along a direction parallel to or along the longitudinal axis and within a plane (XY plane) perpendicular to the direction of gravity when vacuum cassette 356 and system 110 are in an installed position. Adjustment of first upper roller 358 allows a user to make adjustments to the movement of belt 124 about cavity 398. In one implementation first upper roller 358 has a crowned surface where the center of first upper roller 358 has a diameter that is greater than the diameter at the portions proximate side plates 394, 395. In one implementation each side plate 394, 395 includes an opening 400 into first region 364 allowing fluid communication between first regions 364 of adjacent vacuum cassettes 356. A leading vacuum cassette 356 is connected to one of first duct 216 and first duct 217 so that each first region 364 of each vacuum cassette 356 is connected to the vacuum system. Bottom plate 374 opposite top plate 368 includes an opening in fluid communication with one of first duct 216 and first duct 217 and first region 364. First duct 216 and second duct 218 travels with gantry 116 as gantry 116 moves longitudinally along longitudinal axis 118 of system 110 and moves in a direction perpendicular to longitudinal axis 118 as base member 250 moves along the longitudinal axis of gantry 116. A flexible hose 402 connected to a first duct 216 and first duct 217 is connected to a vacuum source outside of system 110. In one implementation first duct 216 and first duct 217 are connected to first region 364 of a respective vacuum cassettes 356a and 356b one a first side of frame.Atty. Dkt. No. F160-106-WO The first side of the frame is the side of the frame identified by an operator facing the frame with first longitudinal end 146 on their left and second longitudinal end 148 on their right. The second side of the frame is the side opposite the first side of the frame in the positive Y direction. In one implementation first duct 216 and first duct 217 are also operatively connected to the first region 364 of the pair of cassettes that are closest to the second side of the frame. In this manner vacuum is applied to the first region 364 of both sides of the line of multiple cassettes 356a and 356b.

[0144] Referring to Fig 26, a cavity 404 is substantially rectangular, this shape is in contrast to the triangle shape of cavity 162 discussed herein above. Cavity 404 has a longitudinal opening 406 that allows a processing device to extend from above a material being processed to a region within cavity 404. The width 408 of longitudinal opening 406 along a direction parallel to the longitudinal axis of system 110 in one implementation is between 20 mm and 40 mm. In one implementation the width 410 of cavity 404 below lower plate 374 and base plate 354 in a direction parallel to longitudinal axis 118 of system 110 is between 200 and 400 mm. Stated another way the width 408 is between less than 50% of width 410. Ine one implementation longitudinal opening 406 is 30mm and width 410 is 200mm. In one implementation the height of cavity 404 from base plate 354 to bottom plate 374 of vacuum cassette 356 is less than width 410. In one implementation vacuum cassette 356 may be designed to have an opening greater or less than 40mm depending on the tools being used.

[0145] Referring to FIG 25 and FIG 26 a front member 412 includes a ledge 414 that supports and guides a peripheral edge of horizontal belt 126. Stated another way a first peripheral edge 127a is supported on ledge 414a if vacuum cassette 356a and a second peripheral edge 127b is supported on ledge 414b of vacuum cassette 356b.

[0146] Referring to FIG 24 and FIG 25 a vacuum is applied through first region 364 and is not applied to cavity 398. Further in one implementation, a vacuum is only applied to the portion of belts 124 directly above top plate 368 of vacuum cassette 356. Referring to FIG 1 and FIG 24 Stated another way system 110 is free of vacuum between the terminal ends 146 and 148 of system 110 along longitudinal axis 118Atty. Dkt. No. F160-106-WO except for the region above the top plates 368 of vacuum cassettes 356 that are immediately adjacent to longitudinal opening 406 of cavity 404.

[0147] Note that all other aspects of system 110 discussed herein above operate in a similar manner with vacuum cassettes 356 and vacuum cavity 404 as with cavity 162 illustrated in FIGS 1-11. Note that cavity 162 has a general triangular shape with the base of the triangle having a width parallel to longitudinal axis 118 that is greater than the cavity opening. Cavity 404 has a generally rectangular shape with the width parallel to longitudinal axis 118 being substantially the same from the base plate toward a region proximate the cavity opening. Note that the path of belt 124 through vacuum cassette 356a includes a portion that extends from the first roller toward the second roller in a direction generally opposite the direction of the belt path from first longitudinal end 146 toward the first roller. In one implementation Vacuum cassette 356 has two rollers to provide a triangular cavity shape with the base being larger than the cavity opening. In one implementation vacuum cassette 356 has more than 3 rollers. The term material as used herein may be a single material, or two or more stacked materials.

[0148] The term a material treatment system as used herein includes any of the cutting (including but not limited to laser, oscillating blades, routing, wire), joining (including but not limited to sewing, ultrasonic welding), creasing, grommet insertion, metal snap insertion, routing, embossing, and printing modules and systems discussed herein. The term surface treatment system as used herein includes any of the aforementioned modules that affect a surface of a material.

[0149] Vacuum system discussed herein provides a hold down force of the materials being processed or treated adjacent to the cavity openings. Note that in FIG 26 the vacuum path 372 is identified with arrows extending through first region 364 and out of the plurality of apertures 370. Note that vacuum will operate to move air in the opposite directions of the arrows illustrated in FIG 26. Stated another way the vacuum applied will move air through the materials being processed through plurality of apertures 370 and through first region 364 into one of first duct 216 and second duct 218.Atty. Dkt. No. F160-106-WO

[0150] Referring to FIGS 28 - 30, in one embodiment vacuum system 214 includes a duct 510 that is in fluid communication with a vacuum source and a plurality of separate cassettes 512. Each cassettes 512 is in fluid communication with duct 510 through a hollow connector 514. Hollow connector 514 includes at least one open end 516 that is in fluid communication with the vacuum source. The vacuum source may be supported on gantry 116 or may be connected to a vacuum source secured to or separate from frame 114 with flexible hoses. Referring to FIG 10 vacuum system 214 includes first duct 216 and second duct 218 that are secured to a first duct 510 on one side of cavity opening closer to first longitudinal end 146 and a second duct 510 on the other side of cavity opening closer to second longitudinal end 148. In one embodiment duct 510 includes two open ends that are in fluid communication with vacuum system 214. A first end closer to a first longitudinal gantry support members 140 and a second end closer to the second longitudinal gantry support members 140 that is spaced from and parallel to the first longitudinal gantry support members 140. In this manner a vacuum source is applied to each open 516 end of each duct 510.

[0151] Plurality of separate cassettes 512 include an upper housing member 518 that is not in fluid communication with a second portion 520 that has a longitudinal axis that is perpendicular to the housing member longitudinal axis. Upper housing member 518 has a solid bottom and side walls that are fluidly separate from the other components of plurality of separate cassettes 512 with the exception of cover plate 522 that has apertures 524. Upper housing member 518 includes an opening 524 that is in fluid communication with duct 510 through hollow connector 514. Additionally, each cassette 512 is not in fluid communication with any other cassette 512 except through duct 510. In one implementation each plurality of separate cassettes 512 may be removed from the gantry 116 without the need to remove duct 510.

[0152] Referring to FIG 31, each cassette 512 along with a second cassette 512 positioned on the opposite side of the cavity opening supports and directs a separate belt 124 about the belt path generally illustrated in FIG 24. Similar to the cassettes 356 discussed herein and illustrated in FIG 24, plurality of separate cassettes 512 includes a small diameter roller 526, a second roller 528 with a diameter larger than the first roller and a third roller 530. In implementation second roller 528 and thirdAtty. Dkt. No. F160-106-WO roller 530 are supported by roller bearings 532 to provide a low friction path for belt 124.

[0153] Referring to FIG 28 and FIG 29 plurality of separate cassettes 512 includes a pair of side brackets 534 generally L shaped with a first generally horizontal portion 536 (extending along the x axis) supporting upper housing member 518 a second generally vertical portion (having a longitudinal axis along the z axis). Upper housing member 518 is not in fluid communication with a portion of the plurality of separate cassettes 512 defined by the vertical portion.

[0154] Referring to FIG 25, the vacuum was applied to vacuum cassette 356 through an opening in first region 364 in a side of vacuum cassette 356 that was in fluid communication with each adjacent vacuum cassette 356 also through the side opening. In contrast referring to FIG 28 the vacuum is applied to each cassette 512 through an opening 524 in a direction that is perpendicular to the side opening of vacuum cassette 356. Stated another way opening 524 faces either first longitudinal end 146 or second longitudinal end 148 depending on whether plurality of separate cassettes 512 is on the first side of the cavity opening or the second side of the cavity opening. This frontward or rearward opening of hollow connector 514 allows for duct 510 to be free of the terminal ends or sides of the end most cassettes 512.

[0155] Referring to FIGS 32 – 37 a keder application system 600 includes a guide 610 that directs a keder member to be automatically sewn to a material. The material 612 may be a single layer material or a multiple layers. Material 612 may have a printed side a reverse side, or may have two printed sides. Keders 610 are used for many purposes such as in tents, awnings, soft signage, marine covers, sails. Keders 610 create a strong connection between a flexible material 612 to a rigid frame or structure. Keders 610 are normally sewn to the fabric or textile along the edges. Keders 610 are typically made from pvc or silicone and comes in many sizes and strength. There are also Keders 610 made from recycled polyester. In the graphics industry, graphics with keders attached thereto are called a silicone edged graphics (or short: SEG Graphics).

[0156] The keder application system 600 can be integrated with sewing system 130. In implementation, keder application system 600 includes a roll of keder materialAtty. Dkt. No. F160-106-WO supported by gantry 116 that is automatically placed onto the material being sewn a few mm in front of the needle position, a keder (typically 1.3mm thick, 14mm wide) is automatically rolled out (dispensed / presented) and then sewn to the fabric below.

[0157] Keder application system 600 includes a dispenser shoe 614 that guides keder 610 through a guide channel 626 onto the surface of the material to which it will be sewn. Many sewing machines use a shoe to ensure the retracting needle does not pull the fabric up too far.

[0158] The dispenser shoe 614 includes a plate 616 has a small hole 618 (such as 1 mm) for the needle to move up and down in (same as all other sewing machines). Dispenser shoe 614 has a built-in channel (1.5mm high x 14mm wide) which guides the keder material coming vertically down from a large keder roll (50 m) hanging above the FS system. In one implementation dispenser shoe 614 directs the keder 610 to a horizontal direction parallel with the material 612. However, in other implementations shoe may direct keder 610 in any desired sewing direction including directions that are not parallel with the material.

[0159] In one implementation keder 610 is automatically fed through dispenser shoe 614 with a motor or actuator including a drive source that operatively rotates a drive member 620 including but not limited to belts or wheels. Drive member 620 drives keders 610 at exactly the same speed as the sewing head with needle and bobbin to ensure that material to which the keder is being sewn does not buckle. Stated another way the keder 610 is moved to be synchronized with the sewing of the keder to the material.

[0160] In one implementation drive member 620 is a tractor wheel or wheeled sprocket 621 having sprockets 622 that engages apertures 624 preformed within in the keders 610. The distance between adjacent apertures 624 in one implementation is the distance between stiches, in this manner the needle in the sewing system does not need to puncture the keder but merely to extend through the aperture so that the thread may be engaged with the bobbin in the cavity below the top surface of the material. Wheeled sprocket 621 extends through an opening (not shown) in a wall 628 of dispenser shoe 614.Atty. Dkt. No. F160-106-WO

[0161] In one implementation drive member 620 includes a power belt having the same width as the keder strip. In one implementation belts on both sides pull and / or push the keder towards the dispenser opening and needle position. In one implementation perforated holes are not used either in the keder strip or in the drive mechanism. In one implementation a small power drive belt(s) inside the dispenser unit securely presses the keder forward with sufficient accuracy. In one implementation to verify the accuracy of the positioning of the keder before cutting round dots are printed on the keder which are read by the camera mounted above. The reading of the dots can be used to both determine the speed in which the keder is being fed as well as to ensure that the cutting device does not cut into the keder itself which is only a few mm from the edge of the material to be cut.

[0162] In one implementation movement of keders 610 through dispenser shoe 614 is assisted with two small pulleys which pulls the keder material out of the guide channel 626 within dispenser shoe 614. In this manner a leading edge of the keder 610 is presented directly under the needle, so it is ready to be sewn into the fabric below. In one implementation a motor drives a first gear 630 which operatively drives 621 with a pully or gear train. In one implementation a first belt on the top of the keder and a second belt on the bottom of the keder is used to accurately dispense the keder underneath the needle.

[0163] The pulley rotation speed is servo motor controlled, so the speed of rotation of the wheeled sprocket 621 and / or the speed of the pulleys are synchronized with the sewing speed at all times. In other words, the dispensing of the keder must match the speed which the sewing action if moving across the fabric.

[0164] Referring to FIG 33 when the sewing head reaches the end of one side of the graphic, the sewing stops and the keder 610 is automatically and cut with a small knife or scissor action (similar to a thread cutter used in most sewing machines). The small knife or blade is robotically controlled and part of the keder application system 600.

[0165] Once the keder has been applied to one side of a printed image and cut dispenser shoe 614 is robotically turned tangentially between 100 and -110 degrees (moved by motor) so the sewing and dispensing can start on the next side of theAtty. Dkt. No. F160-106-WO graphic. This allows the sewing on fabric where the images are not 100 percent parallel with the machine axis. In one implementation where the image on the fabric is aligned with the axis of the machine, dispenser shoe 614 is turned 90 degrees to change directions along a horizontal and vertical attachment. When each side is completed, the dispenser heads turn yet again until all four sides of the graphic is attached with keder material.

[0166] In one implementation dispenser shoe 614 is limited from rotating a full 360dg to avoid the keder strip coming from above would get tangled up with the sewing heads, its mounting brackets and hinder a frictionless dispensing of the keder. In one implementation the rotation of dispenser shoe 614 is limited to 180 dg or less and in one implementation the rotation of dispenser shoe 614 is limited to 270 dg or less. In one implementation a keder 610 is attached all four sides are of a rectangular or square material by changing sewing direction, the missing side to be done simply by moving in the opposite sewing direction. In one implementation keder is cut and separated from adjacent keders on the material.

[0167] As some SEG graphics are not rectangular, the above solution will also be able to dispense in any angle only limited by the stiffness of the Keder (keders are normally very flexible and bends easily in all directions). So with this method, SEG graphic with rounded corner, or contoured shapes can be SEG sewn. The aluminum frame or structure to which the keder 610 will be attached must have a matching contour for the keder / graphic to fit into.

[0168] In one implementation prior to cutting (or during cutting) the vision camera above will the check that the distance between the keder edge and cutting path is 1mm or more to prevent the laser or blade to cut into the keder and disrupt (push, move) the cutting or destroy the graphic. To ensure an accurate registration of the keder position, the keder is printed with a repeating pattern of black dots (e.g.5mm od) repeated every 20 or 40mm. The camera will perform move over the sewn keder before proceeding to do the cutting a few mm from the keder edges.

[0169] After all the sides of graphics have been keder sewn, system 110 switches to a cutting mode and then cuts the edges precisely a few mm away from the keder. The cutting can be done by an oscillating knife, rotary knife or a laser. The cutting couldAtty. Dkt. No. F160-106-WO also take place before sewing. As the fabric is secured with vacuum during all the production steps, there is little risk the sewing or cutting getting out of registration.

[0170] After the keder sewing and cutting have both been completed, the FS conveyer belts move the finished SEG graphics forward and out of the machine while new fabric is pulled in from a roll to be sewn and cut.

[0171] The above method will also apply to dispensing and sewing of electrical wires used in industrial heating jackets, heated seats / furniture, and more. It can also apply to sewing antenna wires or low voltage wires used into smart clothing (aka textile cables). Or even sewing of small flexible cooling tubes into clothing used in hot areas. Additionally, the system can be used to sew in flexible zippers as they also come in rolls. Carbon fiber strips can be sewn in using keder application system 600 and sewing system 130 to enhance the strength of tarps, tents, sails and kites.

[0172] In one implementation the graphic on material 612 may be face down facing belts 124 and / or material 112 includes registration marks on the side of material 612 facing downward. A camera may be placed within cavity 162 that obtains images of the material 612 through an aperture or window in horizontal belt 126. The keder application system 600, sewing system 130 and system 110 could be synchronized to begin sewing the keder to the material at the correct location and orientation based identification of the material orientation by images processed from the camera.

[0173] Referring to FIGs 38-41 keder application system 600 includes a support 632 operative secured to the gantry 116 adjacent to sewing system 130. A dispenser shoe 614 is supported by support 632 and feeds keder 610 below 616 so that sewing system 130 can secure keder 610 to a material. In one implementation a motor 634 secured to dispenser shoe 614 drives a drive gear 636 that drives a belt 638 along a belt path. Belt 638 has a first side adjacent drive gear 636 and a second side that contacts keder keder 610. Adjacent the belt path is a first gear 640 on the second side of belt 638 that presses keder 610 against belt 638 to avoid slipping of keder 610 as it is being driven through dispenser shoe 614. Adjacent the belt path is a third gear or roller 642 and a third gear 644 both adjacent to the first side of belt 638. In one implementation at least one of gears 636, 640, 642 and 644 are adjustable to provide proper tension on belt 638. In one implementation a spring 648 biases drive gear 636 and fourth gearAtty. Dkt. No. F160-106-WO 644 to ensure continuous tension on belt 638. In one implementation keder 610 enters dispenser shoe 614 through an aperture 650 and is fed between drive gear 636 and a roller 646. Keder 610 exits keder 610 via an exit aperture 652 proximate the plate 616,

[0174] Motor 634 is controlled by same the motion control system as that which controls The XY movements of sewing system 130. In this way keder is fed at the same rate and movement as the sewing system so that the speed of the keder feed rate is coordinated with the speed of the stitches are applied by sewing system 130. In one implementation the controller provides instructions to flexible strip feeder. The flexible strip feeder will be referred to herein as a keder feeder 804 to feed keder strip 816 as a function of the stitch length and stitching motion. However as discussed below the flexible strip feeder may feed a variety of flexible strip materials to be secured to a material on material joining system 600, 800 with a sewing system 130.

[0175] In one implementation belt is a timing belt and at least one of the pulleys is a timing pulley including teeth and pockets that match pitch on the timing belt. In one implementation the first side of the timing belt includes ribs having the same pitch as the timing pulley and the second side being smooth to interface with keder 610.

[0176] In one implementation belt 638 is a small power belt(s) to push the keder strip forward inside the dispenser head. There may be one or two small power belts (one of top of the keder strip and potentially one below it. The belt(s) are motorized and can drive the keder strip without the use of sprocket wheels and perforated keder strips and may be used to drive a keder strip without any perforations or apertures.

[0177] In one implementation the keder strips are marked with printed dots (5 mm diameter) placed every 20 – 40 mm. The dots are detected and read by the camera mounted on the top head after the sewing is completed. The purpose is to detect any misalignment of the keder strip after sewing, so the cutting laser or knife never touches the keder and disrupts the keder placement - and damages the material (seg graphic). The cutting will typically take place 2 – 3mm outside the keder strip, so the accuracy of the keder sewing and the cutting must be within + / - 1mm.

[0178] In one implementation where the graphics are printed on so called blackout materials (solid black backside so the image on the front is not showing thru anyAtty. Dkt. No. F160-106-WO support structures on the backside – except if the image is backlit with LEDs), a camera is mounted below mounted in the cavity. The images are always sewn / cut with the image downwards, so the camera below will read the register marks pointed downwards. This system provides a moving camera that resides below the surface and reads upwards. This read up camera is in contrast to other vision cameras that are positioned facing the top of the material as it rests on the belts or cameras that are located at a position distal from where the material is being sewn and / or cut.

[0179] Referring to FIG 42, a material processing system 700 using the mobile cavity technology (“MCT”) includes a frame 702, a gantry 704, and a waterjet cutter device 706. While FIG 42 illustrates a schematic of a waterjet cutter a commercially available waterjet cutting system known in the art may be used. A belt system similar to the belt system described herein with respect to system 110 includes a plurality of belts that follow a belt path about a cavity 162 allowing a material to be cut in a stationary while cavity 162 is moved relative to the longitudinal axis 118 of system 110 and move relative to the material being cut. In one implementation, no sewing takes place and a water jet spray device 706 applies a water spray with sufficient velocity to cut through a material above the cavity. Cutting a material with a water jet is well known in the art and there are many commercial waterjet cutting devices available.

[0180] In one implementation a cavity 708 includes a trough or container 710 having an upper opening slit 712. The waterjet spray is sprayed through slit 712 extending in a direction perpendicular to longitudinal axis 118 and is received in container 710. The fluid from the waterjet spray is collected within container 710 and processed and disposed of or recycled as is known in the waterjet cutting industry. In one implementation An extraction tube and pump removes the liquid (e.g. water) from the container 710 which is enclosed on all 3 sides and with the narrow slit 712 at the top.

[0181] In one implementation the width of the container along longitudinal axis 118 is greater than the width of. In one implementation the width of slit 712 is between 1 and 2 mm. Though it is contemplated that other widths are possible. The narrow slit 712 helps to minimize any liquid from spraying back up through slit 712 and on to the surface of the material being cut or on to an upper surface of material processingAtty. Dkt. No. F160-106-WO system 700.Material processing system 700 allows for a user to cut roll-goods such as felt, foam, plastics. Referring to FIG 43A and FIG 43B roll materials 714 and are automatically pulled into the system from a roll-off device. The cut-out parts are automatically pushed out of the system when finished to a tray, robot or another conveyer belt. The belts 716 will not be touched or damaged by the water jet and move freely and protected under the container 710. The use of the narrow container 710 eliminates the need for “bathtub” surface with pins to support the materials being cut. In contrast to the large cavity 162 of system 110 discussed herein above cavity 708 can be narrower as there are no moving parts inside cavity 708 except the container 710 which collects the waterjet spray fluid. Since slit 712 is narrow cut out waste parts will not fall into container 710 to be fished out, but are easily removed between the cut parts of the material being cut.

[0182] Referring to FIG 44, FIG 45 and FIG 46 material processing system 700 includes a cross frame belt 718 that moves about container 710, such that the portion of cross frame belt 718 adjacent to the water jet nozzle moves in in the Y direction along with movement of the water jet nozzle on gantry 704. Cross frame belt 718 has small round moving hole 720 (1mm –2mm) which is dynamically re-positioned below right below the water spray from the waterjet nozzle. Similar to the sewing / laser hole discussed herein the water jet nozzle moves in the X and Y direction cutting parts and the moving hole 720 moves with it. Note in one implementation there are no moving parts inside the container 710. The only moving part is cross frame belt 718 with small round moving hole 720. Cross frame belt 718 is actuated by a servo motor mounted outside (protected from) the container 710. In this implementation the risk of any water spray bouncing back up will be extremely limited as there is only a small 2mm hole and no long open slit in cross frame belt 718. In one implementation smaller rollers may be installed on cross frame belt 718 to reduce any friction between the materials being cut and cross frame belt 718. In one implementation only three rollers are required to direct belts 716 around container 710. In one implementation a single roller 722 is positioned below container 710 to direct belts 716 about the bottom of container 710.Atty. Dkt. No. F160-106-WO

[0183] Referring to FIG 47, belts 716 are replaced with thin metal such as stainless steel cables 724 instead of belts to add strength and support heavier materials such as metals. Using steel wires 724 under proper tension minimizes backlash. In one implementation where the belts are in the form of cables there is no cross belt 718.

[0184] As with the systems described herein material processing system 700 can be used to cut through multiple materials simultaneously.

[0185] Referring to FIG 48, FIG 49, FIG 50, FIG 51, FIG 51A and 51B material joining system 800 includes the MCT technology as described herein in which a belt system similar to the belt system described herein with respect to systems that includes a plurality of belts following a belt path about cavity 162, or cavity 404, or cavity 708 or any other cavity allowing a material 850 to be cut in a stationary position while the cavity is moved relative to the longitudinal axis 118 of system 110 and moved relative to the material 850 being cut. Material joining system 800 includes a keder application system 802 that can be used in conjunction with any of the implementations described herein.

[0186] Keder application system 802 includes a keder feeder 804 that moves along a keder feeder guide 806 about a center point 807 through which needle 208 of sewing system 130 extends. Stated another way center point 807 is a point along the longitudinal axis of needle 208 of sewing system 130. In one implementation keder feeder guide 806 includes a curved rail having a radius about center point 807. In one implementation keder feeder guide 806 extends about a longitudinal axis of the joining system 13045 degrees or greater. Where the joining system is a sewing system with a needle the longitudinal axis of the joining system is the longitudinal axis of the needle.

[0187] Keder feeder 804 and keder feeder guide 806 are operatively secured to gantry 116 with a bracket 808. A second bracket portion 809 is operatively connected to bracket 808 and a track portion of keder feeder guide 806, In one implementation, bracket 808 is secured to gantry 116 to a support 810 that also supports sewing system 130 such that movement of keder application system 802 along the longitudinal axis of gantry 116 is the same as movement of sewing system 130 along the longitudinalAtty. Dkt. No. F160-106-WO axis of gantry 116. In one implementation keder application system 802 also includes a cutting system 134 as described herein.

[0188] Keder feeder 804 includes a first actuator 814 to feed a keder strip 816 through keder feeder 804 to a plate 209 of sewing system 130. In one implementation plate 209 has an upwardly concave shape with an aperture allowing needle 208 to extend therethrough. Keder strip 816 is positioned between material 850 to which the keder is to be sewn and the bottom of plate 209.

[0189] Referring to FIG 52 first actuator that includes a motor 818 that drives a drive wheel 820 that in turn moves a drive belt 822 about a belt path. In one implementation drive belt includes splines on a first side of the drive belt 822 that engage with splines on drive wheel 820. Drive belt 822 is moved from keder application system 802 toward and about a lower splined wheel 824. A second side of drive belt 822 extends over a wheel 826 and guides drive belt 822 over a spring biased idler wheel 828 to provide proper tension on drive belt 822. Keder strip 816 is pressed against drive belt 822 by a pair of wheels 830 that contacts a first side of keder 816 pressing the opposite second side of keder strip 816 against drive belt 822. In this manner movement of drive belt 822 results in movement of 816 from the entrance to the exit of keder feeder 804.

[0190] Keder feeder 804 includes an exit guide 828 at centers keder strip 816 as the portion of keder strip 816 exits exit guide 832 that aligns the longitudinal edges of keder strip 816 as keder strip 816 is presented to sewing system 130. The internal channel of exits exit guide 832 has tapered walls to align keder strip 816 to align keder strip 816 as it exits keder feeder 804. Since keder strips 816 come in various widths and thicknesses, exit guide 832 is removable from keder feeder 804 and may be replaced with another exit guide that has the proper dimensions for the particular keder strip 816 being applied to material 850 on material joining system 800.

[0191] Keder feeder 804 is moved along keder feeder guide 806 by an actuator having a motor keder feeder 834 that is positioned on keder feeder 804. The following is a list of non-limiting illustrative embodiments disclosed herein. An engagement portion 836 of keder feeder 804 engages with and rides on keder feeder guide 806. Motor keder feeder 834 moves keder feeder 804 between a first positionAtty. Dkt. No. F160-106-WO on keder feeder guide 806 adjacent bracket 808 and a second position on keder feeder guide 806 adjacent second bracket portion 809. In all positions between the first position and the second position along the track of keder feeder guide 806 keder feeder 804 is positioned about center point 807 such that keder strip 816 as it exits keder feeder 804 is aligned with center point 807 such that keder strip 816 is positioned in a preselected orientation with respect to needle 208 of sewing system 130. In one implementation an offset actuator moves keder feeder 804 a determined distance from a line defined by center point 807 and a longitudinal center line 838 of keder strip 816. In certain applications it is desired to secured keder strip 816 to material 850 not along the longitudinal center line of keder strip 816 for a set distance from the longitudinal center line 838 of keder strip 816.

[0192] In one implementation Keder feeder 804 includes a third actuator having a motor 840 to actuate a cutter to cut keder strip 816 once keder strip 816 has been secured to material 850.

[0193] Referring to FIG 53 a user interface 854 is provided that allows a user to set the locations and order in which keder strip 816 is to be applied to material 850 on material joining system 800. In one implementation four keder strips 816 are secured to a material 850 with two pairs of spaced keder strips 816 where each pair is perpendicular to the other pair. For description purposes keder strips 816 are labeled 816a, 816b, 816c and 816d in the order in which they are sewn to the material. A user inputs the location and length of each keder strip 816 on the user interface and the order in which each keder strip 816 is to be secured to the material 850. A controller automatically positions keder application system 802 relative to the material 850. In one implementation material 850 has a pattern, image or text and the keder strips 816 need to be applied in a certain orientation with respect to the pattern, image or text. In one implementation a vision registration system as described herein identifies the location of the pattern, image or text on the material with respect to gantry 116 and aligns the keder feeder and sewing system 130 with respect to the pattern, image or text. If the material pattern, image or text is aligned such that the application of the keder strips 816 follow the X and Y coordinates the keder feeder is moved from a first position aligned with the Y coordinate system to apply the keder strips along the YAtty. Dkt. No. F160-106-WO axis and the keder feeder is moved on keder feeder guide 806 to a second position in which the keder strips are applied along the X axis of the system . However, if the material pattern, image or text is offset from the XY coordinate system keder feeder 804 is moved along keder feeder guide 806 to compensate for the offset. Referring to FIG 51, longitudinal center line 838 of keder feeder 804 is shown aligned with the Y axis of material joining system 800. Keder feeder guide 806 allows for movement of keder feeder 804 over 90 degrees about the longitudinal axis of the needle when the joining system is a sewing system, where the needle longitudinal axis extends though center point 807. In one implementation keder feeder guide 806 allows for movement between 90 and 95 degrees about 807. In one implementation keder feeder guide 806 allows for movement over 90 degrees about center point 807. In another implementation keder feeder guide 806 allow for movement between 95 and 105 degrees about center point 807.

[0194] As noted above, the Keder feeder 804 is automatically positioned on keder feeder guide 806 in the proper orientation with respect to the material 850 based on information provided via user interface 854.

[0195] Referring to FIG 54, FIG 55 and FIG 56 in a first step keder feeder 804 is moved to a first position on keder feeder guide 806. Ine one example when the material pattern, image or text is aligned with the XY coordinate system of material joining system 800 then longitudinal center line 838 of keder feeder 804 is aligned with the Y axis of material joining system 800. The exit of keder feeder 804 is positioned a predetermined distance from center point 807 at a first sewing point 856 The controller then provides instructions to the actuators on gantry 116 to move sewing system 130 and keder feeder 804 along a first sewing path in the positive Y direction, that is a direction generally away from sewing system 130. The controller provides instructions to first actuator 814 to feed keder strip 816 at the rate in which sewing system 130 and keder feeder 804 are moving as sewing system 130 sews keder strip 816 to the material 850 until the predetermined length of the first keder strip 816 is secured to the material 850. The controller then provides instructions to the cutter actuator to cut the keder strip 816 within keder feeder 804.Atty. Dkt. No. F160-106-WO

[0196] The controller then moves the gantry along the longitudinal axis 118 in the positive X direction of material joining system 800 and provides instructions to sew a second keder strip 816b of the first pair of keder strips 816 as outlined above with respect to keder strip 816a beginning a point 857. Once the first pair of keder strips 816a and 816b have been sewn to the material 850 the controller provides instructions to move keder feeder 804 via the track actuator motor 818 to a second position in which longitudinal center line 838 of keder feeder 804 is parallel to or aligned with the X axis of material joining system 800. The controller then provides instructions to first actuator 814 and sewing system 130 to sew and cut the first keder strip 816c of the second pair of keder strips in that order to the material 850 beginning at point 858. Finally, the second keder strip 816d of the second pair of keder strips is sewn to the material 850 and cut beginning at point 859. All of the positioning of keder feeder 804, sewing and cutting steps are performed automatically by the controller. In one implementation, the controller includes a processor and memory holding instructions to execute user commands through a user interface to perform the functions of moving keder feeder 804 with respect to keder feeder guide 806, automatically feeding keder strips 816 to sewing system 130 and sewing 816 to a material 850 in a particular pattern and finally automatically cutting the keder strip 816 once the identified length of keder strip 816 has been sewn the material 850.

[0197] Where the material pattern, image or text is aligned with the XY coordinate system of material joining system 800 the keder strips applied parallel to the Y axis is accomplished by the controller providing instructions moving keder application system 802 and longitudinal members 136 along the longitudinal axis of gantry 116. However if the material pattern, image or text is not aligned with the Y axis the controller provides instructions to position keder feeder 804 on keder feeder guide 806 in the direction that the keder strip is to be applied and movement of keder application system 802 and longitudinal members 136 is accomplished by movement along gantry 116 and by movement of gantry 116 along the X axis of material joining system 800.

[0198] Referring to Fig 56, once the keder strips 816 are sewn to the material 850 the controller automatically moves cutting system 134 to cut an outer boarder 852 ofAtty. Dkt. No. F160-106-WO material 850. In this manner the placement, sewing and cutting of keder strip 816 to material 850 and the cutting of material 850 is fully automatic.

[0199] In one implementation the keder strips are applied in a linear manner and separated / cut. In one implementation the strips are applied in a non-linear manner forming an arcuate shape as the flexible strip is secured to the material. In this implementation, the gantry is moved along the longitudinal axis of the table and the feeding and joining system are moved along the longitudinal axis of the gantry in a direction perpendicular to the longitudinal axis of the table and keder feeder 804 is moved along keder feeder guide 806 simultaneously to provide the arcuate joining of the flexible strip to the material.

[0200] Referring to FIG 57, in one implementation, keder feeder 804 includes a lateral actuator 860 that moves at least a top portion 862 of keder feeder 804 with respect to a bottom portion 864 of keder feeder 804 that is engaged with and moves with respect to keder feeder guide 80. Lateral actuator 860 actuated to offset the longitudinal axis of keder strip 816 as the keder strip 816 exits exit guide 832 a predetermined distance from center point 807. Motor keder feeder 834 moves along with motor keder feeder 834 of keder feeder 804. Lateral actuator 860 includes a motor or pneumatic actuator 866 that moves a lateral slider plate 868 with respect to a base member 870 that is part of bottom portion 864 of keder feeder 804. When lateral actuator 860 is in a neutral position the longitudinal center line axis 838 of keder strip 816 as it exits exit guide 832 is in line with center point 807. However in a displaced position longitudinal center line 838 is offset from center point 807 such that keder strip 816 will be stitched to the material off set from longitudinal center line 838.

[0201] In this manner the operator through user interface 854 can move the line of stitches applied to keder strip 816 in a position that is not along the longitudinal axis of keder strip 816 but rather offset therefrom. In one implementation where the keder strip 816 is 14mm wide the offset is 3mm from center point 807 such that stitches are applied 4mm from the edge of keder strip 816. The offset allows fabricators of signage to press the textile / material w keder sewn thereto into the aluminum profile when installing the graphic. In one implementation the lateral actuator system including motor or pneumatic actuator 866 and lateral slider plate 868 moves topAtty. Dkt. No. F160-106-WO portion 862 of keder feeder 80410mm with respect to engagement portion 836 of keder feeder 804. However, other distances between 0 and 10 mm are contemplated. In one implementation the lateral distance of the lateral acatuar system is 10mm or greater.

[0202] Although keder application system 802 has been described in feeding and sewing a keder strip 116 it is also contemplated that keder application system 802 can be used for any flexible material including but not limited to edge banding edge banding used to strength an edge of sewn / cut fabrics. Edge banding is used for sealing stitched fabrics from water penetration (that is used when sewing energy floats / life boats for example). Instead of keder, it could be a hook and loop (Velcro) material banding or zippers. In another application, instead of a keder material, material joining system 800 could be used to dispense and secure wires to produce industrial heating blankets (we met a prospect yesterday asking us to sew large heating blankets with electric wires or 10mm narrow fabric bands with a wire centered in the middle. These heating blankets are used for repairs wind turbine blades or keeping oil / chemical drums above freezing temp. Other types of flexible banding is also contemplated.

[0203] Although material joining system 800 has been described with sewing system 130 other joining systems described herein such as ultrasonic welding may also be used. The longitudinal axis of needle 208 is the vertical longitudinal axis in the Z direction as illustrated in FIG 48. The longitudinal axis of other joining systems described herein is the vertical Z axis at the point in which the joining system acts on the flexible strip and material. Material joining system 800 described may include the various features described herein above such as the secondary belt extending in the Y direction.

[0204] Referring to FIG 58 and FIG 58B a keder material 900 includes a series of spaced physical locators 902. Keder material 900 can be used with any of the moving cavity technology (MCT) systems described herein. Keder material 900 similar to the keder materials described herein is typically provided on a spool and fed to the joining system 128 to be adhered to material 850. In one implementation joining system 128 is a sewing system in which keder material 900 is sewn to material 850 on the MCTAtty. Dkt. No. F160-106-WO systems described herein. Keder material 900 includes a first face 904, an opposing second face 906, a first edge 908 and a second edge 910. The perpendicular distance between first face 904 and opposing second face 906 defines the thickness of keder material 900. A keder longitudinal axis 912 is defined as the axis that extends along the length of keder material 900 intermediate the first edge 908 and second edge 910 of keder material 900. The width of keder material 900 is defined as the perpendicular distance between first edge 908 and second edge 910.

[0205] In one implementation keder material 900 has a width that is greater than its thickness. In one implementation spaced physical locators 902 are depressions extending into the first face toward the second face. The term depression as used herein refers to a cavity or divot having an opening on the first face and not extending through the second face. The shape of the depressions may be one of a cylinder, cylindrical oval, tapered cylinder, star shape, or other linear or non-linear shapes. In one non-limiting example spaced physical locators 902 are semi-spherical having a diameter between 2 mm and 3 mm and a depth of 1 mm. However other geometrical shapes are also contemplated, such as but not limited to a rectangular shape, cylindrical shape having an arcuate shape such as a circle or oval. In one implementation spaced physical locators 902 protrude from the first face of keder material 900 away from the second face of keder material 900. In another Implementation spaced physical locators 902 may be spaced in a pattern that is non- linear, such as zig zag pattern about the longitudinal axis of the keder, or in a pattern in which there are groups physical locators that are spaced from one another.

[0206] Referring to FIG 59 keder material 900 is fed through keder feeder 804. In one implementation keder feeder 804 includes a drive member 914 such as a drive wheel having radial projections 916 that engage the spaced physical locators 902. In one implementation radial projections 916 have a complementary geometry to the spaced physical locators 902. For example, if the spaced physical locators 902 are semi-spherical depressions, radial projections 916 have semi-spherical protrusions that fit within the semi-spherical depressions within keder material 900.

[0207] Referring to FIG 60 keder feeder 804 includes a belt 918 having protrusions 920 that engage the spaced physical locators 902 of keder material 900. The beltAtty. Dkt. No. F160-106-WO protrusions 920 remain engaged with the spaced physical locators 902 of with another drive for driving the keder material of FIG 58. In one non-limiting more than one protrusion 920 is engaged with a spaced physical locator 902 as keder material 900 is fed through keder feeder 804.

[0208] Keder material 900 with spaced physical locators 902 provide for accurate dispensing from keder application system 802. Keder material is used on numerous applications where an edging or banding are required to attach fabric to a frame or other type of rigid structure. Applications range from boats, truck tarps, tents and in our case printed fabrics being stretched in frame to create a retail display, sign or exhibition display. Keder material is sold commercially by Keder Solutions. See https: / / kedersolutions.com.

[0209] Material joining system 800 includes a keder application system 802 which pushes out an exact length of keder material 900 precisely coordinated with the stitching steps of sewing system 130. In one implementation. As discussed herein keder application system 802 provides an accurate synchronization of the speed and length of keder material dispensed to match the stitch length and speed of sewing system 130. Without this accurate synchronization the fabric will start to curl due to undesired tension at the edges as the keder material is stitched to the fabric material 850.

[0210] The sewing and keder speeds vary continuously with the acceleration and deacceleration based on commands from a control system. To prevent any inaccuracy in the keder dispensing speed, keder material 900 includes spaced physical locators 902 embossed into the keder at regular intervals spaced in one implementation at 5mm between each indentation. The indentations are placed in the middle of the keder and only on one side. Figure 1. However other spacing distances and location of the spaced physical locators 902

[0211] In one implementation spaced physical locators 902 are spaced at 5mm intervals, measure 2mm in diameter and be 1mm deep. The indentation creates half globe shapes placed in the keder surface. Keder typically used in connection with graphic textile typically measure 3mm x 14mm or 2mm x 12mm. However other keder dimensions that are known in the art are also contemplated. Keder material 900Atty. Dkt. No. F160-106-WO in one implementation is a flat keder have a rectangular cross section, however spaced physical locators 902 can be applied to other keder materials having different cross sections including but not limited to materials having an arcuate cross section.

[0212] In one implementation a matching sprocket wheel 914 or belt 918 with protruding pins 916 are placed every 5mm and measuring the same 1mm in depth and having 2mm in diameter will drive keder material 900 accurately forward to ensure highly accurate placement of a give keder length matching the stitching length at any given speed. The motor driving the wheel or belt is driven from a control system which also controls the sewing speed and stitch length.

[0213] Keder feeder 804 of keder application system 802 and sewing motions from sewing system 130 are able start / stop / start and then turn 90 degrees at corners or at other angles of material 850 as the design requires. It may also be possible to sew and dispense in nonlinear shapes and contours, but the radius of such contours are limited by the rigidity of the keder in the flat plane. Typically, the keder will not allow smaller radiuses than 1m – 2m or the rigidity of the keder (in the flat plane) will cause tension in the sewn fabric causing wrinkles which are undesired or may worst case will flip the fabric edge over during sewing and cutting and also make installation into the alu tension frames difficult.

[0214] There are several types of keder made from e.g. Silicon, PVC, TPE or Polyester. The most flexible keder is made from silicone and can create the tightest radius of curvature of approx.1m. The least flexible type of keder is made from polyester and has a much larger minimum radius of curvature of 2m or higher. The term “keder” as used herein is broadly defined as a flexible strip of material. The term keder as used herein can be substituted with the phrase flexible strip of material. In certain industries and geographical locations elongate strips of material used to join one fabric to another component such as a frame may be referred to as a gasket. Hook and loop fasteners often referred to as Velcro is an elongate strip of material. It is contemplated that the keder attachment systems described herein include the joining of a hook and loop fastener to a material. The systems described herein can also be used to secure a wire secured to a flexible strip to a cushion material for a heated seat or to a blanket for a heated blanket. Keder materials as described herein can also beAtty. Dkt. No. F160-106-WO joined to a material for use in furniture so that the material can be secured to the furniture to secure the cushion or fabric to a frame to minimize movement of the cushion or fabric relative to the furniture frame. Keders are also used on sails for sailboats. It is contemplated that the systems described herein could be used to join a sail keder to a sail material.

[0215] It is desirable to create a system and method of automatic sewing of the keder so that radius of curvature can be made tighter (smaller than 1m) so the sewn graphics can include more contoured details following the contour of an image showing the item which are being promoted with the display. When the keder is secured to material 850 along a non-linear path one longitudinal edge is compressed while the other longitudinal edge is stretched. Stated another way when the radius of curvature is greater has a non-zero value one longitudinal edge is stretched while the other longitudinal edge is compressed. Using a more flexible keder will also allow dispending and sewing of curved shapes such as an arc, a rounded hole and other nonlinear design elements in the final fabric graphic.

[0216] Referring to FIG 61 in one implementation keder feeder 804 includes a punch mechanism 930 to make the keder more flexible in a the flat plane when keder 900 is secured to material 850 in an arcuate path. Punch mechanism 930 includes an actuator 932 to move a punch 934 through keder material 900 from first face 904 through opposing second face 906 along one of first edge 908 and second edge 910 is to punch out (remove) small parts along the edges forming a notches 936.

[0217] The contours of the keder sewn fabric must closely match the contoured frame which the sewn keder is mounted into (by pressing the keder edge into a slit in the tension frame). When the contoured frame has a longitudinal axis that is non-linear the longitudinal axis of the keder that is secured to the material 850 must closely match the longitudinal axis of the contoured frame.

[0218] In one implementation punch mechanism 930 is integrated into keder application system 802 either within keder feeder 804 or as a separate device located closely adjacent to keder feeder 804. In one implementation keder feeder 804 is positioned intermediate punch mechanism 930 and sewing system 130. Stated another way keder material 900 includes a series of notches 936 prior to enteringAtty. Dkt. No. F160-106-WO keder feeder 804. As the punching takes place prior to the sewing when the keder material exits the keder feeder 804, the control system provides sends signals to the punching mechanism at the right time (distance) before the turning starts a few so that when the keder material 900 is being secured to material 850 with sewing system 130 along an arcuate path keder material 900 includes an edge with notches 936 along one of first edge 908 and second edge 910. Since in one implementation punch mechanism 930 punches out the material along an edge of keder material 900 a distance from when keder material 900 is actually applied to material 850, punch mechanism 930 punches out notches 936 in advance of when keder application system 802 provides keder material 900 to sewing system 130. In one implementation punch mechanism 930 only provides notches 936 along one of first edge 908 and second edge 910 for the region in which keder material 900 is being secured to material 850 in a non-linear manner. Stated another way the region of keder material 900 secured to material 850 in a linear manner is free of notches 936, while the region of keder material 900 secured to material 850 in an arcuate path includes notches 936.

[0219] In one implementation the distance between notches 936 can be varied by the control system as a function of the radius of the bend in which keder material 900 is being secured to material 850. Stated another varying the distance between adjacent notches 936 can be made more (or less) bendable.

[0220] In addition to varying the distance between adjacent notches 936, it is also contemplated to vary the size of the notches being formed by punch mechanism 930 be varied by changing the location of punch to one of first edge 908 and second edge 910. The size of the notches 936 may be a function of one or more of the inherent rigidity the keder material, the width of the keder material, and the thickness of the keder material. For example, a keder formed of silicone keder will need less material removed than a keder material formed from polyester.

[0221] When keder material 900 is dispended and sewn in a straight line the punching stops to ensure a stable and durable keder edge to mount into the alu tension frame.

[0222] The punching mechanism 930 can also be placed outside keder feeder 804 as long as the punching data is transmitted at the correct time (distance) before theAtty. Dkt. No. F160-106-WO turning of the sewing is initiated. This may be more practical as there will be more space available and the waste from the punching (removal) can be collected in a bag or box (and potentially be recycled) hung outside the moving sewing head where space is limited. It may also be possible to laser cut the small triangles, provided the material is laser friendly.

[0223] In one implementation, punch 934 of punch mechanism 930 is movable with respect to keder material 900 not only in a direction perpendicular to first face 904 of keder material 900 but movable in a cross keder direction along a direction perpendicular to both first edge 908 and second edge 910. In this manner punch 934 may punch notches 936 adjacent to one of first edge 908 and second edge 910. Referring to FIG 62A notches 936 are formed on keder material 900 adjacent to first edge 908 when keder material 900 is attached to material 850 in an arcuate path curing to the right (a direction away from second edge 910 ) with first edge 908 having a concave shape and closer to the center of curvature of the arcuate region of keder material 900 than second edge 910. Notches 936 allows keder material 900 to have a longitudinal axis following an arcuate path with a small radius of curvature than would otherwise be possible without notches 936. In one implementation notches 936 are provided on one of first edge 908 and second edge 910. Depending on whether keder material 900 is being curved to the right or left as it is being secured to material 850.

[0224] Referring to FIG 62B when keder material 900 is attached to material 850 in arcuate shape curving to the left (a direction away from first edge 908) when attached to material 850.

[0225] It is believed that the keder material 900 has the first edge 908 and second edge 910 has the ability to stretch a greater distance than compress. Accordingly, in one implementation notches 936 are formed only on one of first edge 908 and second edge 910. However, depending on the material in one implementation where notches are provided on first edge 908 a series of slits 938 are provided on second edge 910. Referring to FIG 62C punch mechanism 930 includes a blade that automatically creates slits 938 on second edge 910 extending through the entire thickness of kederAtty. Dkt. No. F160-106-WO material 900 extending through first face 904 and opposing second face 906. Slits 938 extend from second edge 910 a predetermined distance toward first edge 908.

[0226] Slits 938 are only provided by a bade along second edge 910 along the length of keder material 900 that will be secured to material 850 in an arcuate path. Each slit defines a first face 940 and a second face 942 that are adjacent to one another when the longitudinal axis of keder material 900 is linear. As keder material 900 is secured to material 850 in a non-linear path, one implementation the material adjacent each slit 938 remains in close contact in a region of keder material 900 that is secured to material 850 along a linear path. The material adjacent the slit is spaced from one another forming a v shape in a second region of keder material 900 that is secured to material 850 in an arcuate path in a direction away from the edge with the slits. Referring to FIG 62D in one implementation a keder material 900 includes notches 936 along first longitudinal edge 908 and slits 938 spaced from one another adjacent the second longitudinal edge 910. In one implementation the slits and notches are offset from spaced physical locators 902. In one implementation the slits 938 and notches 936 are offset from spaced physical locators 902 and from one another. Notches 936 are placed on the longitudinal edge that is closer to the center of the radius of curvature than the other longitudinal edge. Each notch 936 is defined by a first edge 944, a second edge 946. Where the notch is a V shape the first edge 444 forms one line of the V shape and the second edge 946 forms the second line of the V shape, where the first edge and the second edge intersect at the bottom of the V. The distal end of first edge 944 is adjacent the first longitudinal edge 908 and a second end of 944 is adjacent to the intersection of a second end of the second edge 946. The distal end of the second edge being spaced from the distal end of the fist notch edge and adjacent the first longitudinal edge when the notch is fully open.

[0227] Referring to FIG 62D in one implementation notches 936 folds upon itself such that first edge 944 and second edge 946 are close to each other in the region where the longitudinal axis of keder material 900 is moved from a linear orientation to an arcuate orientation. In a similar manner first face 940 and second face 942 of slits 938 are moved away from one another in the region where the longitudinal axis ofAtty. Dkt. No. F160-106-WO keder material 900 is moved from a linear orientation to an arcuate orientation. This occurs where first edge 908 is closer to the center of radius C than second edge 910.

[0228] The use of one of notches and slits allow for keder material 900 to have a smaller non-zero radius of curvature when attached to material 850 that would not be available without one of the notches and slits. Similarly the use of both of notches and slits allow for keder material 900 to have a smaller non-zero radius of curvature when attached to material 850 that would otherwise be available without both the notches and slits.

[0229] Referring to FIG 32 and FIG 33 a keder 610 or keder 900 may have a series of through holes that extend through both first face 904 and opposing second face 906 of the keder material. In one implementation keder 900 includes printed markings instead of spaced physical locators 902. A vision system tracks the printed markings to adjust the speed of the keder feeder to synchronously match the joining system operation.

[0230] In one implementation keder material 900 may include one or more in any combination of spaced physical locators 902, notches 936, and slits 938. Stated another way in one implementation keder material 900 includes spaced physical locators 902 and is free of notches 936 and slits 938, In another implementation, keder material 900 includes spaced physical locators 902 and notches 936 and is free of slits 938. In another implementation keder material 900 includes spaced physical locators 902 and slits 938 and is free of notches 936. In one implementation, keder material 900 is free of spaced physical locators 902 and includes one or both of notches 936 and slits 938.

[0231] In one implementation, keder 900 is joined to material 850 while material 850 remains stationary with respect to frame 114. In one implementation material 850 remains stationary with respect to frame 114 with the assistance of a vacuum while gantry 116 moves along first longitudinal belt system 122. Belts 124 move about cavity 160 and the other cavities described herein as gantry 116 moves along first longitudinal belt system 122. Keder material 900 is applied to an upper surface of material 850 (the surface facing away from belts 124).Atty. Dkt. No. F160-106-WO

[0232] Referring to FIG 63D In one implementation, keder material 900 is secured to material 850 with a sewing stitch that is parallel to keder longitudinal axis 912 is that is located 1 / 3 the distance from one of first edge 908 and second edge 910. In one implementation spaced physical locators 902 are located along keder longitudinal axis 912. Notches 936 and slits 938 are positioned such that they do not extend across the stitch line 948 securing keder material 900 to material 850.

[0233] In one implementation cutting system 134 cuts material 850 closely adjacent to an outer boundary defined by keder material 900 secured to material 850. Cutting system 134 cuts material 850 while material 850 remains stationary with respect to frame 114. In one implementation cutting system 134 cuts material 850 such that a tap protrudes from the outer boundary defined by the keder material 900 to provide a user from removing material 850 with keder material 900 once it is secured to a frame. In one implementation material 850 and keder material 900 cut from the larger bolt of material is inserted into a frame such that the longitudinal edge of keder material 900 closest to the line of stitches is inserted first into a frame.

[0234] Referring to FIG 63A in one implementation a keder feeder guide 950 extends about a longitudinal axis of the joining system 130180 degrees or greater. Where the joining system is a sewing system with a needle the longitudinal axis of the joining system is the longitudinal axis of the needle. In one implementation the keder feeder guide 950 is positioned above keder feeder 804. In one implementation keder feeder guide 950 and sewing system 130 are secured to a bracket 952 that moves along gantry 116 as discussed herein with respect to bracket In one implementation keder feeder guide 950 may be secured to the bottom of the gantry cross rail to allow for movement of the keder feeder guide up to 360 degrees about the center point of the needle. In one implementation keder feeder guide 806 extends between 180 degrees and 190 degrees about center point 807. Since the bracket that secures keder feeder 804 to keder feeder guide 950 may not allow keder feeder 804 to present keder material 900180 degrees about center point 807 if keder feeder guide 950 extended only 180 degrees about center point 807, keder feeder guide 950 extends greater than 180 degrees so that keder feeder 804 is able to move about keder feeder guide 950 andAtty. Dkt. No. F160-106-WO still present keder material 900 to center point 807 along all possible direction of movement of sewing system 130 with respect to material joining system 800.

[0235] Referring to FIG 63A-63G material joining system 800 can join a keder material 900 to material 850 (not shown) in an arcuate path that extends up to 360 degrees. Referring to FIG 63A keder feeder 804 is positioned substantially parallel to gantry 116 such that keder material 900 is fed to a point A (807). Sewing system 130 and keder feeder 804 are moved together along gantry 116 and along material joining system 800 on rails longitudinal gantry support members 140. Referring to FIGS 63B and 63C Keder feeder 804 moves about keder feeder guide 950 such that keder material 900 is fed toward center point 807 in a vector direction of movement of sewing system 130 until keder material 900 is joined to material 850 at a point B. In this manner a length of keder material 900 is secured to material 850 in an arcuate path extending 180 degrees about a center point. Referring to FIGS 63D - 63F to complete the 360 degree arcuate path, sewing system 130 and keder feeder 804 is then moved by gantry 116 to a position adjacent to point A and a second length of keder material 900 is secured to material 850 completing a 360 degree arcuate path. Referring to FIG 63G in one implementation the arcuate path is a circle, however other arcuate paths are contemplated such as in a non-limiting example an oval. Based on the method described herein keder material 900 is attached to material 850 as two sperate pieces to form a circular path. It is contemplated that keder material 900 may be secured to material 850 in two or more separate pieces to form an arcuate shape.

[0236] The systems described herein can produce full 360 degree circles. SEG graphics with round corners and pretty much any kind of seg shapes to match arcuate frame profiles.

[0237] In one Implementation a graphic or other material 850 is moved to a first portion of system 110 and then held stationary by a vacuum system. Gantry 116 is automatically moved along the longitudinal axis 118 as joining system 130 and keder application system 802 are moved along the cross system axis of system 110 to join keder 900 to material 850 along predetermined path. As described herein belt 124 remain fixed relative to roller bars 152a, 152b, 150a, and 150b. Center portions of belt 124 however move about cavity as gantry 116 moves along theAtty. Dkt. No. F160-106-WO longitudinal axis (X axis) of 110. As a result, material 850 in one mode of operation is stationary with respect to frame 114 of system 110 as keder 900 is joined to material 850.

[0238] As described herein when combined with the punching and or slitting, it is possible to automatically secure keder material 900 to match any curves of a graphic. In this manner it is possible to automatically crate seg graphics matching the contoured shape of logos or product outlines. Note that keder 900 is also referred to herein as keder material, these terms are used interchangeably.

[0239] The following is a list of non-limiting illustrative embodiments disclosed herein:

[0240] Illustrative Embodiment 1. An automated material processing system including: a frame having a longitudinal axis; a gantry movable along the longitudinal axis of the frame; a first belt extending along the longitudinal axis and moving about a cavity having a cavity opening within the gantry; a second belt supported by the gantry extending across the frame in a cross-frame direction perpendicular to the longitudinal axis and covering at least a portion of the cavity opening; a material treatment system to treat a material extending across at least a portion of the first belt and a portion of the second belt; and a vacuum system movable with the gantry and operatively connected to a manifold adjacent to both sides of the cavity opening.

[0241] Illustrative embodiment 2. The automated material processing system of illustrative embodiment 1, wherein the material treatment system includes a first portion outside of the cavity and a second portion within the cavity.

[0242] Illustrative embodiment 3. The automated material processing system of illustrative embodiments 1-2, wherein the cavity has a rectangular shape with a pair of side walls a base supporting a portion of the material treatment system; and a cavity opening.

[0243] Illustrative embodiment 4. The automated material processing system of any one of illustrative embodiments 1-3, wherein a cavity opening adjacent a supporting surface for supporting a material being processed has a cavity opening width that is less than a cavity width between the cavity opening and a cavity base member.Atty. Dkt. No. F160-106-WO

[0244] Illustrative embodiment 5. The automated material processing system of any one of illustrative embodiment 1-4, wherein the second belt has a belt path that extends substantially over an entire length of the gantry in a direction perpendicular to the longitudinal axis of the frame; the second belt extending above the cavity about a first pair of rollers on a first side of the frame, below the cavity and below the first belt portion that extends about the cavity, and about a second pair of rollers on a second side of the frame.

[0245] Illustrative embodiment 6. The automated material processing system of any one of illustrative embodiments 1-5, wherein the first belt has a belt path about the frame and cavity that extends from a first end of the frame on first longitudinal side of the cavity opening about a first roller adjacent the first longitudinal side of the cavity opening, over a second roller that is closer to a first end of the frame than the first roller, over a third roller that is further from the first roller than the second roller, under the cavity and over a fourth roller positioned further from the first end of the frame than the third roller, over a fifth roller closer to the cavity opening than the fourth roller, over a sixth roller adjacent a second longitudinal side of the cavity opening.

[0246] Illustrative embodiment 7. The automated material processing system of any one of illustrative embodiments 1-6, wherein the first belt has a first surface having a first coefficient of friction that supports a material to be treated and a second opposing surface having a second coefficient of friction less than the first coefficient of friction.

[0247] Illustrative embodiment 8. The automated material processing system of illustrative embodiment 7, wherein the second belt has a first surface facing the material to be treated having a coefficient of friction that is less than the first coefficient of friction of the first side of the first belt.

[0248] Illustrative embodiment 9. The automated material processing system of any one of illustrative embodiments 1-8, wherein the manifold adjacent to both sides of the cavity opening has a plurality of openings facing a material being treated, wherein the manifold provides a vacuum force attracting the material being treated toward the manifold, wherein the manifold extends a predetermined distance away from the cavity opening.Atty. Dkt. No. F160-106-WO

[0249] Illustrative embodiment 10. The automated material processing system of illustrative embodiment 9, wherein the cavity is vacuum free.

[0250] Illustrative embodiment 11. The automated material processing system of any one of illustrative embodiment 1-10, wherein the vacuum system includes a plurality of pairs of vacuum cassettes operatively connected to a vacuum source.

[0251] Illustrative embodiment 12. The automated material processing system of illustrative embodiment 11, wherein each vacuum cassette includes a first region in fluid communication with the vacuum source and a second region including at least two rollers.

[0252] Illustrative embodiment 13. The automated material processing system of illustrative embodiment 12, wherein each vacuum cassette includes a top plate having a plurality of apertures therethrough in fluid communication with the first region.

[0253] Illustrative embodiment 14. The automated material processing system of any one of illustrative embodiments 1 -13, wherein the vacuum system includes a plurality of pairs of vacuum cassettes, wherein one vacuum cassette of each pair of vacuum cassettes includes the first roller, the second roller and the third roller, and the other of the vacuum cassette in each pair of vacuum cassettes includes the fourth roller, the fifth roller and the sixth roller.

[0254] Illustrative embodiment 15. The automated material processing system of illustrative embodiment 13, wherein each cassette includes a notch receiving one longitudinal edge of the second belt proximate a bottom side of the second belt, wherein a top side of the second belt that faces the material being treated is parallel with the top plate of the vacuum cassette.

[0255] I Illustrative embodiment 16. The automated material processing system of any one of illustrative embodiment 2-15, wherein the material treatment system is a laser system including a laser nozzle located in the first portion and a laser dump device in the second portion within the cavity.

[0256] Illustrative embodiment 17. The automated material processing system of illustrative embodiment 16, wherein the laser dump device includes a light sensor detecting laser scattered from a reflecting surface.Atty. Dkt. No. F160-106-WO

[0257] Illustrative embodiment 18. The automated material processing system of illustrative embodiment 17, including a controller receiving a signal from the light sensor and providing instructions to the laser nozzle adjusting the laser energy emitted from the laser nozzle as a function of the signal from the light sensor.

[0258] Illustrative embodiment 19. The automated material processing system of illustrative embodiment 18, wherein the controller provides instructions to a first actuator driving the gantry along the longitudinal axis of the frame and to a second actuator moving the material treatment system along a longitudinal axis of the gantry.

[0259] Illustrative embodiment 20. The automated material processing system of any one of illustrative embodiments 1-19, wherein the material treatment system includes a joining system supported by the gantry and movable along a cross-frame axis perpendicular to the longitudinal axis to join at least two materials together.

[0260] Illustrative embodiment 21. The automated material processing system of any one of illustrative embodiments 1-20, wherein the material treatment system includes a cutting system supported by the gantry and movable along the cross-frame axis to cut the material together in more than one direction within a plane defined by the longitudinal axis and the cross-frame axis.

[0261] Illustrative embodiment 22. The automated material processing system of any one of illustrative embodiments 2-20, wherein the material treatment system includes a creasing module including a first module positioned outside the cavity a second lower member positioned within the cavity, wherein the first member and the second member are on opposite sides of the material being creased.

[0262] Illustrative embodiment 23. The automated material processing system of any one of illustrative embodiments 2-20, wherein the material treatment system includes a grommet insertion module including a first member positioned outside the cavity a second lower member positioned within the cavity, wherein the first member and the second member are on opposite sides of the material which the grommet is being inserted.

[0263] Illustrative embodiment 24. The automated material processing system of any one of illustrative embodiments 2-20, wherein the material treatment system includes a button insertion module including a first member positioned outside the cavity aAtty. Dkt. No. F160-106-WO second lower member positioned within the cavity, wherein the first member and the second member are on opposite sides of the material which the button is being attached.

[0264] Illustrative embodiment 25. The automated material processing system of any one of illustrative embodiments 2-20, wherein the material treatment system includes a routing tool module including a first member positioned outside the cavity holding a first end of a router bit and a second lower member positioned within the cavity having a member guiding a portion of the router bit within the cavity.

[0265] Illustrative embodiment 26. The automated material processing system of any one of illustrative embodiments 2-20, wherein the material treatment system includes an oscillating blade module including a first member positioned outside the cavity driving a first end of the oscillating blade and a second lower member positioned within the cavity having a member guiding a portion of the oscillating blade within the cavity.

[0266] Illustrative embodiment 27. An automated system for joining and cutting flexible materials including: a frame having a longitudinal axis; a gantry movable along the longitudinal axis; a belt system extending along the longitudinal axis and moving through a cavity within the gantry; a joining system supported by the gantry and movable along a cross-frame axis perpendicular to the longitudinal axis to join at least two materials together; a cutting system supported by the gantry and movable along the cross-frame axis to cut the material together in more than one direction within a plane defined by the longitudinal axis and the cross-frame axis a vacuum system movable with the gantry and operatively connected to a manifold on both sides of the cavity opening.

[0267] Illustrative embodiment 28. An automated system for joining and cutting flexible materials including: a frame having a longitudinal axis; a gantry movable along the longitudinal axis; a vacuum system having a duct movable with and along a cross-frame axis perpendicular to the longitudinal axis of the gantry; a belt system extending along the longitudinal axis and moving through a cavity within the gantry; and a material treatment system movably supported by and along the gantry configured to treat a material supported by the belt system.Atty. Dkt. No. F160-106-WO

[0268] Illustrative embodiment 29. An automated material processing system includes a frame having a longitudinal axis; a gantry movable along the longitudinal axis of the frame; a first belt extending along the longitudinal axis and moving about a cavity having a cavity opening within the gantry; a second belt supported by the gantry extending across the frame in a cross-frame direction perpendicular to the longitudinal axis and covering at least a portion of the cavity opening; a material treatment system to treat a material extending across at least a portion of the first belt and a portion of the second belt; and a vacuum system movable with the gantry and operatively connected to a manifold adjacent to both sides of the cavity opening, wherein the vacuum system is in fluid communication with the manifold from a position facing a first longitudinal end or second longitudinal end of the frame.

[0269] Illustrative embodiment 30. An automated system for joining and cutting flexible materials includes a frame having a longitudinal axis; a gantry movable along the longitudinal axis; a belt system extending along the longitudinal axis and moving through a cavity within the gantry; a joining system supported by the gantry and movable along a cross-frame axis perpendicular to the longitudinal axis to join at least two materials together; a keder application system supported by the gantry and movable along the cross-frame axis to robotically present a keder to be joined to the material by the joining system.

[0270] Illustrative embodiment 31. An automated system for cutting materials includes a frame having a longitudinal axis; a gantry movable along the longitudinal axis; a belt system extending along the longitudinal axis and moving through a cavity within the gantry; a waterjet system spraying a stream of liquid to cut through at least one material; and a container located within the cavity receiving the liquid from the waterjet.

[0271] Illustrative embodiment 32, The automated system of illustrative embodiment 30 wherein the material being cut is flexible.

[0272] Illustrative embodiment 33, The automated system of illustrative embodiment 30 further including a pump to extract liquid material that falls into the container.Atty. Dkt. No. F160-106-WO

[0273] Illustrative embodiment 34. The automated system of illustrative embodiment 31, further including a motor driving a cross-belt in a direction perpendicular to the longitudinal axis is positioned outside or below the container.

[0274] Illustrative embodiment 35. An automated material processing system comprising: a frame having a longitudinal axis; a gantry movable along the longitudinal axis of the frame; a first belt extending along the longitudinal axis and moving about a cavity having a cavity opening within the gantry; wherein the cavity opening moves along the longitudinal axis of the frame as the gantry is moved along the longitudinal axis of the frame, a material joining system supported on the gantry and including a flexible strip feeding system and a joining system; the flexible strip feeding system feeding a portion of a flexible strip between a material supported on the first belt and an upper portion of the joining system as the joining system secures the flexible strip to the material.

[0275] Illustrative embodiment 36. The automated material processing system of illustrative embodiment 35 wherein the flexible strip feeding system includes a flexible strip feeder that is moveable about a curved feeder track about the longitudinal axis of a joining tool of the joining system.

[0276] Illustrative embodiment 37. The automated processing system of illustrative embodiment 36, wherein the flexible strip feeding system includes a lateral actuator moving a feeding actuator of the flexible feeder to offset a longitudinal axis of the flexible strip from the longitudinal axis of joining tool.

[0277] Illustrative embodiment 38. The automated processing system of any one of illustrative embodiment 35-37, wherein the flexible strip feeder is movable at least 45 degrees about the longitudinal axis of the joining tool.

[0278] Illustrative embodiment 39 The automated processing system of any one of illustrative embodiment 35-37, wherein the flexible strip feeder is movable at least 90 degrees about the longitudinal axis of the joining tool.

[0279] Illustrative embodiment 40. The automated processing system of any one of illustrative embodiments 35-37, wherein the flexible strip feeder is movable at between 95 degrees and 270 degrees about the longitudinal axis of the joining tool.Atty. Dkt. No. F160-106-WO

[0280] Illustrative embodiment 41. The automated processing system of illustrative embodiment 36, wherein the joining system is a sewing system having a needle, and wherein the flexible strip feeder includes flexible strip feeder actuator that automatically feeds the flexible strip material toward the needle as a function of a stitch length and a stitching motion.

[0281] Illustrative embodiment 42. The automated processing system of any one of illustrative embodiments 36-41, wherein the flexible strip feeder includes a cutting actuator having a blade that automatically cuts the flexible strip once a pre-determined length of the flexible strip has been sewn to the material.

[0282] Illustrative embodiment 43. The automated processing system of any one of illustrative embodiments 36-42, including a flexible strip location actuator that automatically moves the flexible strip feeder about the flexible strip track to align the flexible strip upon an orientation of an image on the material.

[0283] Illustrative embodiment 44. The automated processing system of any one of illustrative embodiments 36-43, wherein the flexible strip feeder includes an interchangeable exit guide having an opening that corresponds with a width of the flexible strip.

[0284] Illustrative embodiment 45. The flexible strip feeding system of any one of illustrative embodiments 35-43, wherein the flexible strip is a keder material between the widths of 5 mm and 50 mm and having a thickness between .1 mm and 20 mm.

[0285] Illustrative embodiment 46. An automated flexible strip feeding system, comprising: a flexible strip feeder automatically feeding a flexible strip material; a curved flexible strip track supporting a first portion of the flexible strip feeder; and a track actuator moving the flexible strip feeder on the curved flexible strip about a pre- determined longitudinal axis.

[0286] Illustrative embodiment 47. The automated flexible strip feeding system of illustrative embodiment 46 further including a feeder actuator automatically feeding the flexible strip to an exit of the flexible strip feeder.

[0287] Illustrative embodiment 48. The automated flexible strip feeding system of illustrative embodiment 46, wherein the flexible strip feeder includes flexible strip feeder actuator automatically feeding the flexible strip material toward a needle of aAtty. Dkt. No. F160-106-WO sewing system as a function of the stitch length and stitching motion, wherein predetermined longitudinal axis is a longitudinal axis of the needle.

[0288] Illustrative embodiment 49. The automated flexible strip feeding system of illustrative embodiment 46 further including a lateral actuator moving at least a second portion of the feeder laterally with respect to a first portion of the feeder offsetting a longitudinal axis of the flexible strip as it exits the feeder from the fixed longitudinal axis.

[0289] Illustrative embodiment 50. The automated flexible strip feeding system of illustrative embodiment 46, wherein the flexible strip feeder includes a cutting actuator having a blade that automatically cuts the flexible strip once a pre-determined length of the flexible strip has been fed through the flexible strip feeder.

[0290] Illustrative embodiment 51. The automated flexible strip feeding system of illustrative embodiment 46, including a flexible strip location actuator that automatically moves the flexible strip feeder about the flexible strip track to align the flexible strip upon a desired orientation on the material.

[0291] Illustrative embodiment 52. The automated processing system of illustrative embodiment 46, wherein the flexible strip feeder includes an interchangeable exit guide having an opening that corresponds with a width of the flexible strip.

[0292] Illustrative embodiment 53. An automated material joining system, comprising: a keder application system including: a flexible strip feeder automatically feeding a flexible strip material; a curved flexible strip track supporting a first portion of the flexible strip feeder; and a track actuator moving the flexible strip feeder on the curved flexible strip about a pre-determined longitudinal axis; a sewing system including a needle having a longitudinal axis co-linear with the pre-determined longitudinal axis; a controller automatically providing instructions to the sewing system to sew the flexible strip to a material with a pre-determined stitch and stich motion and to feed the flexible strip material toward the needle as a function of the stitch length and stitching motion.

[0293] Illustrative embodiment 54. A system for joining a keder to a material: a frame having a longitudinal axis; a gantry movable along the longitudinal axis; a belt system extending along the longitudinal axis and moving through a cavity within the gantry;Atty. Dkt. No. F160-106-WO a joining system and movable along a cross-frame axis perpendicular to the longitudinal axis; and a keder application system to automatically feed a keder material to be joined to a first material by the joining system.

[0294] Illustrative embodiment 55. The system of illustrative embodiment 54, wherein the joining system and the keder application system are supported by the gantry.

[0295] Illustrative embodiment 56. The system of any of illustrative embodiments 54-55, wherein the keder application system is moveable by an actuator along the cross-frame axis.

[0296] Illustrative embodiment 57. The system of any of any of illustrative embodiments 54-56, wherein the keder application system is automatically moveable along the cross-frame axis synchronously with the joining system.

[0297] Illustrative embodiment 58. The system of illustrative any of illustrative embodiments 54-57, further including a cutting system supported by and movable along the gantry.

[0298] Illustrative embodiment 59. The system of any of illustrative embodiments 54- 58, wherein the keder application system includes a guide track and an actuator moving a keder feeder along the guide track at least 45 degrees about a joining axis.

[0299] Illustrative embodiment 60. The system of any of illustrative embodiments 54- 58, wherein the keder application system includes a guide track and an actuator moving a keder feeder along the guide track about a joining axis greater than 90 degrees.

[0300] Illustrative embodiment 61. The system of any of illustrative embodiments 54- 60, wherein the keder application system includes a keder feeder automatically positioned on a guide track to feed the keder material in a direction that the keder material opposite a movement of the joining system.

[0301] Illustrative embodiment 62. The system of any of illustrative embodiments 54- 61, wherein the keder application system includes a feeder that feeds the keder material synchronously with a movement of the joining system joining the keder material to the first material.Atty. Dkt. No. F160-106-WO

[0302] Illustrative embodiment 63. The system of any of illustrative embodiments 54, including a controller sending providing instructions to the keder application system to automatically move a keder feeder along a keder guide track and to automatically feed the keder material and to the joining system to join the keder material to the first material in along a non-linear path.

[0303] Illustrative embodiment 64, The system of any of illustrative embodiments 54- 63, further including a punch system including a punch punching notches along a first portion of one longitudinal side of the keder material.

[0304] Illustrative embodiment 65. The system of illustrative embodiment 64, wherein the notches of the first portion have a first shape when punched and a second shape when the punched portion is secured to the material in a non-linear path.

[0305] Illustrative embodiment 66. The system of illustrative embodiments 54-64 A keder material including a first face, an opposing second face spaced from the first face, a first longitudinal side and a second opposing longitudinal side, the first face having spaced physical locators.

[0306] Illustrative embodiment 67. The keder material of illustrative embodiment 66, wherein the physical locators are a depression extending into the first face toward the second face.

[0307] Illustrative embodiment 68. The keder material of illustrative embodiment 66, wherein the physical locators are through holes.

[0308] Illustrative embodiment 69. The keder material of illustrative embodiment 66, wherein the physical locators are a protrusion extending from the first face in a direction away from the second face.

[0309] Illustrative embodiment 70. The system of illustrative embodiment 66, wherein the keder application system includes a keder feeder having a drive mechanism with a drive member with mating features that engage a series of physical locators of a keder material as the keder drive moves the keder material through the drive.

[0310] Illustrative embodiment 71. The system of any of the illustrative embodiments 54-70, wherein the joining system is a sewing system to sew the keder material to the first material, and including a controller automatically providing instructions to theAtty. Dkt. No. F160-106-WO sewing system to sew the keder to a material with a pre-determined stitch and stich motion and to feed the keder material toward a needle of the sewing system as a function of a stitch pattern and stitching motion.

[0311] Illustrative embodiment 72. The system of any of the illustrative embodiments 54-71, further including a slit system including a cutting tool to create slits along a portion of one longitudinal sides of the keder material.

[0312] Illustrative embodiment 73. The system of illustrative embodiment 62 further including a lateral actuator moving at least a second portion of keder feeder laterally with respect to a first portion of the keder feeder offsetting a longitudinal axis of the keder material as it exits the keder feeder from a keder feeder longitudinal axis.

[0313] Illustrative embodiment 74. The system of illustrative embodiment 62, wherein the keder application system includes a cutting actuator having a blade that automatically cuts the keder material once a pre-determined length of the keder material has been fed through by the keder feeder.

[0314] Illustrative embodiment 75. A keder material comprising a first face, an opposing second faced spaced from the first face, a first longitudinal side and a second opposing longitudinal side, the first face having a spaced physical locators along a longitudinal axis of the keder material.

[0315] Illustrative embodiment 76. The keder material of illustrative embodiment 75, wherein the physical locators are a depression extending into the first face a fixed distance toward the second face, and having a depression bottom between the first face and the second face.

[0316] Illustrative embodiment 77. The keder material of illustrative embodiment 76, wherein the depression is semi-spherical.

[0317] Illustrative embodiment 78. The keder material of illustrative embodiment 75, wherein the physical locators are through holes.

[0318] Illustrative embodiment 79. The keder material of illustrative embodiment 75, wherein the physical locators are a protrusion extending from the first face in a direction away from the second face.Atty. Dkt. No. F160-106-WO

[0319] Illustrative embodiment 80. The keder material of illustrative embodiment 75 wherein the physical locators have a center which is offset from the longitudinal axis of the keder material.

[0320] Illustrative embodiment 81. An automated flexible strip feeding system, comprising: a flexible strip feeder automatically feeding a flexible strip material; a curved track supporting a first portion of the flexible strip feeder; and a track actuator moving the flexible strip feeder on the curved flexible strip about a pre-determined longitudinal axis.

[0321] Illustrative embodiment 82. The automated flexible strip feeding system of illustrative embodiment 81, further including a feeder actuator automatically feeding the flexible strip to an exit of the flexible strip feeder.

[0322] Illustrative embodiment 83. The automated flexible strip feeding system of illustrative embodiment 82, wherein the flexible strip feeder includes flexible strip feeder actuator automatically feeding the flexible strip material toward a needle of a sewing system as a function of the stitch pattern and stitching motion, wherein predetermined longitudinal axis is a longitudinal axis of the needle.

[0323] Illustrative embodiment 84. The automated flexible strip feeding system of illustrative embodiment 83 further including a lateral actuator moving at least a second portion of feeder laterally with respect to a first portion of the feeder offsetting a longitudinal axis of the flexible strip as it exits the feeder from the a longitudinal axis of the joining system.

[0324] Illustrative embodiment 85. The automated flexible strip feeding system of illustrative embodiment 81, wherein the flexible strip feeder includes a cutting actuator having a blade that automatically cuts the flexible strip once a pre-determined length of the flexible strip has been fed through the flexible strip feeder.

[0325] Illustrative embodiment 86. The automated flexible strip feeding system of illustrative embodiment 81, including a flexible strip location actuator that automatically moves the flexible strip feeder about the flexible strip track to align the flexible strip upon a desired orientation on the material.

[0326] Illustrative embodiment 87. The automated flexible strip feeding system of illustrative embodiment 81, wherein the flexible strip feeder includes anAtty. Dkt. No. F160-106-WO interchangeable exit guide having an opening that corresponds with a width of the flexible strip.

[0327] Illustrative embodiment 88. An automated material joining system, comprising: a flexible strip application system including: a flexible strip feeder automatically feeding a flexible strip; a curved flexible strip track supporting a first portion of the flexible strip feeder; and a track actuator moving the flexible strip feeder on the curved flexible strip about a pre-determined longitudinal axis; a sewing system including a needle having a longitudinal axis co-linear with the pre- determined longitudinal axis; and a controller providing instructions to the sewing system to sew the flexible strip to a material with a pre-determined stitch and stich motion and to automatically feed the flexible strip material toward the needle as a function of the stitching motion.

[0328] Illustrative embodiment 60. The system of any of illustrative embodiments 54- 58, wherein the keder application system includes a guide track and an actuator moving a keder feeder along the guide track about a joining axis ate least 180 degrees.

[0329] Note the joining axis is the longitudinal axis of the joining system perpendicular to the plane defined by the graphic (the x-y plane). Stated another way the joining axis is the axis parallel to the direction of gravity when system 110 is in use where there is a gravitational field such as on earth. Where the joining system is a sewing system the longitudinal axis of the joining system is the longitudinal axis of the needle.

[0330] Although the present disclosure has been described with reference to example embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the defined subject matter. For example, although different example embodiments may have been described as including one or more features providing one or more benefits, it is contemplated that the described features may be interchanged with one another or alternatively be combined with one another in the described example embodiments or in other alternative embodiments. Because the technology of the present disclosure is relatively complex, not all changes in the technology are foreseeable. The present disclosure described is manifestly intended to be as broad as possible. For example,Atty. Dkt. No. F160-106-WO unless specifically otherwise noted, the definitions reciting a single particular element also encompass a plurality of such particular elements.

Claims

Atty. Dkt. No. F160-106-WO WHAT IS CLAIMED IS:

1. A system for joining a keder to a material: a frame having a longitudinal axis; a gantry movable along the longitudinal axis; a belt system extending along the longitudinal axis and moving through a cavity within the gantry; a joining system and movable along a cross-frame axis perpendicular to the longitudinal axis; and a keder application system to automatically feed a keder material to be joined to a first material by the joining system.

2. The system of claim 1, wherein the joining system and the keder application system are supported by the gantry.

3. The system of claim 1, wherein the keder application system is moveable by an actuator along the cross-frame axis.

4. The system of claim 1, wherein the keder application system is automatically moveable along the cross-frame axis synchronously with the joining system.

5. The system of claim 1, further including a cutting system supported by and movable along the gantry.

6. The system of claim 1, wherein the keder application system includes a guide track and an actuator moving a keder feeder along the guide track at least 45 degrees about a joining axis.

7. The system of claim 1, wherein the keder application system includes a guide track and an actuator moving a keder feeder along the guide track about a joining axis greater than 90 degrees.Atty. Dkt. No. F160-106-WO 8. The system of claim 1, wherein the keder application system includes a keder feeder automatically positioned on a guide track to feed the keder material in a direction that the keder material opposite a movement of the joining system.

9. The system of claim 1, wherein the keder application system includes a feeder that feeds the keder material synchronously with a movement of the joining system joining the keder material to the first material.

10. The system of claim 1, including a controller sending providing instructions to the keder application system to automatically move a keder feeder along a keder guide track and to automatically feed the keder material and to the joining system to join the keder material to the first material in along a non-linear path.

11. The system of claim 1, further including a punch system including a punch punching notches along a first portion of one longitudinal side of the keder material.

12. The system of claim 11, wherein the notches of the first portion have a first shape when punched and a second shape when the punched portion is secured to the material in a non-linear path.

13. The system of claim 1, wherein the keder material includes a first face, an opposing second face spaced from the first face, a first longitudinal side and a second opposing longitudinal side, the first face having a spaced physical locators.

14. The keder material of claim 13, wherein the physical locators are a depression extending into the first face toward the second face.

15. The keder material of claim 13, wherein the physical locators are through holes.Atty. Dkt. No. F160-106-WO 16. The keder material of claim 13, wherein the physical locators are a protrusion extending from the first face in a direction away from the second face.

17. The system of claim 13, wherein the keder application system includes a keder feeder having a drive mechanism with a drive member with mating features that engage a series of physical locators of a keder material as the keder drive moves the keder material through the drive.

18. The system of claim 1, wherein the joining system is a sewing system to sew the keder material to the first material, and including a controller automatically providing instructions to the sewing system to sew the keder to a material with a pre-determined stitch and stich motion and to feed the keder material toward a needle of the sewing system as a function of a stitch pattern and stitching motion.

19. The system of claim 1, further including a slit system including a cutting tool to create slits along a portion of one longitudinal sides of the keder material.

20. The system of claim 8, further including a lateral actuator moving at least a second portion of keder feeder laterally with respect to a first portion of the keder feeder offsetting a longitudinal axis of the keder material as it exits the keder feeder from a keder feeder longitudinal axis.

21. The system of claim 8, wherein the keder application system includes a cutting actuator having a blade that automatically cuts the keder material once a pre- determined length of the keder material has been fed through by the keder feeder.

22. A keder material comprising a first face, an opposing second faced spaced from the first face, a first longitudinal side and a second opposing longitudinal side, the first face having a spaced physical locators along a longitudinal axis of the keder material.Atty. Dkt. No. F160-106-WO 23. The keder material of claim 22, wherein the physical locators are a depression extending into the first face a fixed distance toward the second face, and having a depression bottom between the first face and the second face.

24. The keder material of claim 23, wherein the depression is semi-spherical.

25. The keder material of claim 22, wherein the physical locators are through holes.

26. The keder material of claim 22, wherein the physical locators are a protrusion extending from the first face in a direction away from the second face.

27. The keder material of claim 23 wherein the physical locators have a center which is offset from the longitudinal axis of the keder material.

28. An automated flexible strip feeding system, comprising: a flexible strip feeder automatically feeding a flexible strip material; a curved track supporting a first portion of the flexible strip feeder; and a track actuator moving the flexible strip feeder on the curved flexible strip about a pre-determined longitudinal axis.

29. The automated flexible strip feeding system of claim 28, further including a feeder actuator automatically feeding the flexible strip to an exit of the flexible strip feeder.

30. The automated flexible strip feeding system of claim 29, wherein the flexible strip feeder includes flexible strip feeder actuator automatically feeding the flexible strip material toward a needle of a sewing system as a function of a stitch pattern and stitching motion of the sewing system, wherein predetermined longitudinal axis is a longitudinal axis of the needle.

31. The automated flexible strip feeding system of claim 30 further including a lateral actuator moving at least a second portion of feeder laterally with respect to a firstAtty. Dkt. No. F160-106-WO portion of the feeder offsetting a longitudinal axis of the flexible strip as it exits the feeder from a longitudinal axis of the joining system.

32. The automated flexible strip feeding system of claim 28, wherein the flexible strip feeder includes a cutting actuator having a blade that automatically cuts the flexible strip once a pre-determined length of the flexible strip has been fed through the flexible strip feeder.

33. The automated flexible strip feeding system of claim 28, including a flexible strip location actuator that automatically moves the flexible strip feeder about the flexible strip track to align the flexible strip upon a desired orientation on the material.

34. The automated flexible strip feeding system of claim 28, wherein the flexible strip feeder includes an interchangeable exit guide having an opening that corresponds with a width of the flexible strip.

35. An automated material joining system, comprising: a flexible strip application system including: a flexible strip feeder automatically feeding a flexible strip; a curved flexible strip track supporting a first portion of the flexible strip feeder; and a track actuator moving the flexible strip feeder on the curved flexible strip about a pre-determined longitudinal axis; a sewing system including a needle having a longitudinal axis co-linear with the pre-determined longitudinal axis; and a controller providing instructions to the sewing system to sew the flexible strip to a material with a pre-determined stitch and stich motion and to automatically feed the flexible strip material toward the needle as a function of the stitching motion.

36. The system of claim 1, wherein the keder application system includes a guide track and an actuator moving a keder feeder along the guide track about a joining axis at least 180 degrees.

Images