Quilted Panel Sewing Machine for Lofted Material Without Compression
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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 increased manufacturing time.
Innovation Solution
A high-speed quilting machine with a sewing assembly powered by a servo motor and a feed assembly also powered by a servo motor, which allows for the sewing of lofted materials without compressing them, eliminating the need for adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If chain-stitch sewing heads are used to join lofted materials, then the materials can be sewn together, but the lofted materials are compressed during the process
Solution Approach 1:
The feed assembly dynamically adjusts its operation to move the lofted material web in coordination with the needle movement. The material is advanced between stitches rather than being held stationary and compressed, allowing the needle to penetrate and form stitches without sustained compression pressure on the lofted material.
Solution Approach 2:
The quilting process is segmented into discrete stitching operations separated by material advancement phases. Rather than continuous compression, the system performs individual stitches with the material fed forward between them, allowing each stitch to be formed without compressing the lofted material structure.
2Shape
If adhesive is used to join lofted materials, then the materials can be joined without compression, but manufacturing time increases due to curing requirements
Solution Approach 1:
The invention replaces the chemical bonding mechanism of adhesive with a mechanical stitching mechanism. The needle and thread system mechanically joins the lofted material layers through chain-stitch sewing, eliminating the need for adhesive curing time while avoiding compression of the material.
Solution Approach 2:
The adhesive joining step is completely removed from the manufacturing process. The system extracts the joining function and implements it through mechanical sewing alone, eliminating the time-consuming curing phase inherent in adhesive applications.
3Ease of manufacture
If adhesive is used to join lofted materials, then joining is possible, but manufacturing cost increases due to adhesive expense
Solution Approach 1:
The invention replaces expensive adhesive materials with inexpensive thread and a mechanical sewing system. The thread-based chain-stitch method uses low-cost consumables compared to industrial adhesives, significantly reducing material costs while maintaining the ability to join lofted materials.
Data Source
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Figure 1A
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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.