Quilted panel

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Solution Overview

Problem

Existing quilting methods cannot sew together lofted materials like foam without compressing them, leading to the use of expensive adhesives and prolonged curing times in manufacturing processes.

Innovation Solution

A high-speed quilting machine with a sewing assembly powered by servo motors and a feed assembly that moves the material without compressing it, using a combination of needle and looper threads to create chain stitches that join lofted layers without altering their height.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If adhesive is used to join lofted materials, then the materials can be joined together, but manufacturing time increases due to curing requirements

Engineering Contradiction:

Improveability to join lofted materialsVSAvoidmanufacturing time

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The patent replaces the chemical adhesive system with a mechanical sewing system. The sewing machine uses needles and threads to mechanically join lofted materials without requiring chemical curing processes. This substitution eliminates the time-consuming adhesive curing step while maintaining the ability to join lofted materials effectively.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If adhesive is used to join lofted materials, then the materials can be joined together, but manufacturing costs increase

Engineering Contradiction:

Improveability to join lofted materialsVSAvoidmanufacturing cost

Core Design Contradiction:

Ease of manufactureVSQuantity of substance

Solution Approach 1:

The patent employs inexpensive sewing threads and needles as temporary joining elements that can be quickly consumed and replaced. This approach uses low-cost mechanical fastening methods instead of expensive adhesive materials, reducing the quantity of substance cost in manufacturing while maintaining effective joining capability.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Ease of manufacture

If conventional quilting methods are used, then materials can be joined, but the lofted materials are compressed

Engineering Contradiction:

Improveability to join materialsVSAvoidloft of material

Core Design Contradiction:

Ease of manufactureVSShape

Solution Approach 1:

The patent applies local quality by using a specialized feed assembly with controlled pressure zones. The feed rollers apply minimal localized pressure only where necessary to advance the material through the sewing machine, while the majority of the lofted material remains uncompressed. This selective pressure application maintains the overall loft and shape of the materials while enabling the joining process.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS11578441B2Quilted panel

Publication Date: 2023.02.14 L & P PROPERTY MANAGEMENT CO

AI summary

Apparatuses, methods, and computer program products for quilting webs without compressing the webs. A quilting machine includes a needle bar to which needles are attached, needle thread passing through each needle, a looper shaft to which loopers are attached, a looper corresponding to each needle and from which looper thread is provided to form stitches, and a retainer bar to which spreaders are attached to facilitate stitching. A drive pulley powered by a first servo motor rotates cranks to move the needles through a cycle and rotates a belt which rotates an indexer pulley. Rotation of the indexer pulley oscillates the looper shaft and reciprocates the retainer bar. Another drive pulley powered by a second servo motor operates to move an input web through the machine between chain stiches.