Quilted Panel Sewing Without Compression of Lofted Materials
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Solution Overview
Problem
Existing quilting processes cannot sew together lofted materials like foam without compressing them, requiring expensive adhesives and increasing manufacturing time due to adhesive curing processes.
Innovation Solution
A quilting machine with a sewing assembly and feed assembly powered by servo motors, allowing for the sewing of lofted materials without compression, using a combination of servo motor operations and a unique stitch formation process that includes chain stitches with specific thread configurations.
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 requirements
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 penetration and thread interlocking, eliminating the need for chemical curing processes. This mechanical substitution allows immediate joining without waiting for adhesive to set, directly resolving the time-consuming curing issue while maintaining the ability to join lofted materials.
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 and needle components in the sewing system that can be easily replaced. The thread, while consumable, is far cheaper than adhesive materials and equipment. The mechanical sewing components (needles, presser feet) are simple, durable parts that can be replaced without specialized tooling. This approach reduces material costs and eliminates expensive adhesive application equipment, directly addressing the cost increase issue.
3Ease of manufacture
If chain-stitch sewing is used on lofted materials, then the materials can be joined, but the lofted materials get compressed
Solution Approach 1:
The patent employs a dynamic feed system where the feed dogs and presser foot move in coordination with the needle cycle. The presser foot applies minimal downward pressure just enough to hold layers together during needle penetration, then releases pressure to allow lofted material to rebound. The feed dogs advance material between stitches with controlled pressure. This dynamic, rhythmic pressure application and release prevents permanent compression while maintaining the joining function during the sewing process.
Solution Approach 2:
The sewing mechanism uses periodic needle penetration and presser foot pressure application synchronized with the stitching cycle. Pressure is applied only during the brief moment of needle penetration and thread interlocking, then released during the needle retraction and thread formation phase. This periodic pressure pattern allows the lofted material to maintain its shape between stitches while still being joined during the active sewing moments, resolving the compression issue.
Data Source
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 (160), a looper shaft (188) to which loopers (282) are attached, a looper (282) corresponding to each needle (160) 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.