Sewing Material Supply Device for Mattress Panel Production
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Solution Overview
Problem
Existing supply devices for sewing large area products, such as mattress panels, require significant time for changing layers of sewing material, leading to inefficiencies and risks of damaging the material during thread cutting.
Innovation Solution
A supply device with rotatably supported material rolls in holders allows for seamless switching between sewing material layers, enabling continuous operation and reducing setup time by allowing layers to be connected and fed alternately, thus enhancing flexibility and production speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If material rolls are horizontally arranged one behind the other with separate guiding assemblies, then each material roll can be placed and guided individually, but the setup time for changing layers of sewing material remains significant and manual handling of heavy material rolls is required
Solution Approach 1:
The patent combines multiple material rolls onto a single conveyor belt within one guiding assembly, allowing simultaneous transport of multiple layers. This merging approach reduces the number of separate guiding assemblies needed and enables more efficient material changeover by having all layers ready on one belt for quick transfer to the sewing machine.
Solution Approach 2:
The patent prepares multiple material rolls in advance by arranging them all on a single conveyor belt before the changing process begins. This preliminary arrangement ensures that when a layer needs to be changed, multiple replacement layers are already positioned and ready for immediate transfer, significantly reducing setup time compared to retrieving rolls one at a time.
2Ease of manufacture
If a separate guiding assembly is provided for each material roll, then individual placement and guidance is possible, but the device complexity increases and manual handling becomes more cumbersome
Solution Approach 1:
The patent merges the function of multiple separate guiding assemblies into a single integrated guiding assembly that handles multiple material rolls simultaneously on one conveyor belt. This consolidation reduces the total number of guiding assemblies needed, simplifies the overall device structure, and makes the system easier to manufacture and maintain while improving operational efficiency.
Data Source
AI summary
The invention relates to a supply device (32) for sewing material layers (16, 18, 20) of a large area sewing product such as mattress panels for example, comprising several sewing material layers (16, 18, 20), particularly at least three, preferably one sewing material layer of elastic material, for example foamed material, and one sewing material layer intended as a top layer, which layers are to be stitched together using a sewing machine (14) with at least one sewing unit, in particular a multiple-needle sewing machine, wherein said supply device consists of at least one roll receiver (34) capable of receiving at least two material rolls (24, 26, 28, 36, 38, 40), each material roll (24, 26, 28, 36, 38, 40) being rotatably supported in a holder (42) of the roll receiver (34), and wherein sewing material layers (16, 18, 20) can be removed from the material rolls (24, 26, 28, 36, 38, 40) arranged in a roll receiver (34) and fed to the sewing unit, wherein the sewing material layers (16, 18, 20) from a roll receiver (34) can be alternatively fed to the sewing unit.