Multi-Needle Quilting Machine for Sewing Lofted Foam Without Compression

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Solution Overview

Problem

Existing quilting machines cannot sew together lofted materials like foam without compressing them, necessitating the use of adhesive, which is costly and time-consuming due to curing requirements.

Innovation Solution

A high-speed quilting machine with a multi-needle configuration that forms chain stitches to sew together lofted materials without compression, using a feed assembly, sewing assembly, and indexer assembly to synchronize needle and looper movements, enabling efficient stitching of multiple layers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If adhesive is used to join lofted materials, then the lofted characteristics are preserved, but manufacturing cost increases and curing time is required

Engineering Contradiction:

Improvejoining strengthVSAvoidcuring time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent replaces the chemical adhesive system with a mechanical sewing system. The needle and looper mechanism creates chain stitches that mechanically interlock the lofted materials, eliminating the need for adhesive application and curing time while maintaining strong joining between layers

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the joining method from chemical (adhesive) to mechanical (sewing). By using a specialized needle and looper configuration with specific stitch patterns, the system achieves reliable joining of lofted materials through mechanical interlocking rather than chemical bonding, thereby eliminating curing time requirements

Inventive Principle:

Principle #35Parameter changes

2Reliability

If adhesive is used to join lofted materials, then the lofted characteristics are preserved, but manufacturing cost increases

Engineering Contradiction:

Improvejoining strengthVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses thread as a inexpensive joining medium compared to adhesive. The thread-based chain stitch system provides a low-cost alternative to expensive adhesive materials, achieving reliable joining at reduced material cost

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Productivity

If conventional single-needle sewing is used, then the machine structure is simple, but the quilting speed is slow

Engineering Contradiction:

Improvequilting speedVSAvoidmachine structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent merges multiple needles and loopers into a single integrated sewing head assembly. This allows simultaneous formation of multiple stitch lines across the quilt width, dramatically increasing quilting speed while keeping the overall machine structure manageable through consolidation of components

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent divides the quilting function into multiple independent needle-looper units operating in parallel. Each unit can form stitches independently, allowing the system to process multiple lines simultaneously and achieve high-speed quilting through segmented parallel operation

Inventive Principle:

Principle #1Segmentation

4Ease of manufacture

If lofted materials are compressed during sewing, then the stitching process is simpler, but the lofted characteristics are lost

Engineering Contradiction:

Improvestitching processVSAvoidlofted characteristics

Core Design Contradiction:

Ease of manufactureVSShape

Solution Approach 1:

The patent uses a dynamic needle and looper motion system that adapts to the lofted material thickness. The needle penetrates the lofted material without requiring compression, and the looper captures the thread loop at the optimal point, maintaining the three-dimensional lofted characteristics while achieving secure stitching

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent introduces a specialized looper as an intermediary element between the needle and the lofted material. The looper captures the needle thread and forms chain stitches that wrap around the lofted layers, joining them mechanically without compressing the material structure

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentEP4579020B1Quilting machine

Publication Date: 2025.12.31 L & P PROPERTY MANAGEMENT CO

Figure 1
Figure 1A
Figure 2A

AI summary

Apparatuses, methods, and computer program products for quilting webs without compressing the webs. A quilting machine (10, 10a) includes a needle bar (160) to which needles (120) are attached, needle thread (284) passing through each needle (120), a looper shaft (188) to which loopers (282) are attached, a looper (282) corresponding to each needle (120) and from which looper thread (288) is provided to form stitches (530, 532), and a retainer bar (190) to which spreaders (191) are attached to facilitate stitching. A drive pulley (132) powered by a first servo motor (130) rotates cranks (156) to move the needles (120) through a cycle and rotates a belt (166) which rotates an indexer pulley (168). Rotation of the indexer pulley (168) oscillates the looper shaft (188) and reciprocates the retainer bar (190). Another drive pulley (48) powered by a second servo motor (40) operates to move an input web (22) through the machine (10, 10a) between chain stiches.