Quilted Panel Sewing Without Compressing Lofted Foam Materials
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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
Engineering Contradiction Analysis
1Ease of manufacture
If adhesive is used to join lofted materials, then the materials can be joined together, but the manufacturing time increases due to curing time and energy consumption
Solution Approach 1:
The patent replaces the chemical adhesive system with a mechanical sewing system. The chain-stitch sewing mechanism physically joins lofted materials through needle and looper threads that interlock layers without requiring chemical bonding or curing time, thus eliminating the time and energy consumption associated with adhesive curing while maintaining the ability to join lofted materials effectively
2Ease of manufacture
If adhesive is used to join lofted materials, then the materials can be joined together, but the manufacturing cost increases
Solution Approach 1:
The patent employs inexpensive thread materials in the form of chain stitches that can be quickly consumed and replaced. The sewing process uses readily available, low-cost thread spools that feed through the sewing mechanism, eliminating the need for expensive adhesive materials while maintaining effective joining capability for lofted materials
Solution Approach 2:
The patent replaces the chemical adhesive system with a mechanical sewing system. The chain-stitch sewing mechanism physically joins lofted materials through needle and looper threads that interlock layers without requiring chemical bonding or curing time, thus eliminating the time and energy consumption associated with adhesive curing while maintaining the ability to join lofted materials effectively
3Productivity
If conventional quilting machines are used, then sewing can be performed, but the lofted materials are compressed during the process
Solution Approach 1:
The patent employs dynamic, independently controlled feed rollers that adjust their rotation speeds and positions during the sewing process. This dynamic control allows the material to be fed at variable rates, creating tension-free conditions that prevent compression of lofted materials while maintaining continuous sewing operation, thus preserving material loft without sacrificing productivity
Solution Approach 2:
The patent changes the operational parameters of the feed mechanism by using independently variable speed motors on feed rollers. This allows precise control over material feed rate and tension, enabling the sewing process to proceed without compressing lofted materials while maintaining high productivity through optimized sewing speeds and feed coordination
Data Source
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 stitches.