Fabric Casket Component Sewing Frame and Clamp
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Solution Overview
Problem
The challenge lies in efficiently and cost-effectively producing fabric components for caskets that provide a tidy and comfortable appearance while covering hardware and edges, as existing methods require multiple layers of different materials, making sewing labor-intensive and prone to errors, leading to increased costs.
Innovation Solution
A method using a frame with clamps and a programmable sewing machine to sew fabric panels together, ensuring accurate alignment and stitching of layers with varying properties, reducing the need for manual labor and minimizing material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple layers of different materials are used to provide comfort and appearance, then the fabric component achieves desired functionality and aesthetic quality, but the sewing process becomes labor-intensive and error-prone
Solution Approach 1:
The patent applies preliminary action by pre-assembling multiple fabric layers onto a rigid frame structure before sewing. The layers are secured with clips and fasteners in predetermined positions, ensuring proper alignment and preventing shifting during the sewing process. This pre-positioning eliminates the need for complex manual alignment during sewing, reducing labor intensity and errors while maintaining the multi-layer construction quality.
2Manufacturing precision
If hand-sewing is used to adjust and reposition layers, then manufacturing flexibility and quality control are improved, but production time and labor costs increase
Solution Approach 1:
The patent replaces the manual mechanical system of hand-sewing with an automated programmable sewing machine. The rigid frame structure with pre-positioned layers and standardized clip/fastener systems enables the sewing machine to automatically guide needles and threads through multiple layers with consistent precision. This automation maintains the alignment quality previously achieved only through skilled hand-sewing while dramatically increasing production speed and reducing labor requirements.
3Adaptability or versatility
If conventional sewing methods are used for multi-layer fabric components, then material flexibility and comfort are maintained, but material waste and production costs increase
Solution Approach 1:
The patent applies preliminary action by precisely pre-positioning fabric layers on a rigid frame with predetermined cut patterns. The frame structure guides the sewing machine to stitch only where needed, minimizing excess fabric and reducing material waste. The standardized assembly process allows for optimized cutting patterns that reduce offcuts while maintaining the flexibility and multi-layer construction required for comfort and adaptability in casket applications.
Data Source
AI summary
A method of making a fabric component includes arranging panels of fabric on a frame such that a first panel is in direct contact with the frame and a second panel is positioned on a side of the first panel opposite the frame. The method includes arranging the panels on the frame to cover an opening of the frame and a clamping surface of the frame that surrounds a perimeter of the opening. The method includes rotating a clamp about an axis from an open position to a closed position to hold the panels directly interposed between the clamp and the clamping surface. The method includes arranging the opening in an operating area of a programmable sewing machine, and operating the sewing machine to sew the panels together within the opening such that the panels form the fabric component. The method includes removing the fabric component from the frame.