| JP09241955 | RED-BLACK-AND-WHITE PAPER STRINGS TO BE BONDED BY TAPE |
| JP10096152 | BORED APPLIQUE |
| JP2005329543 | ADHESION METHOD FOR EMBROIDERED OBJECT |
White, Burl M. (484 Osceola Avenue, Jacksonville Beach, FL, 32250, US)
Bowman, Russell E. (16283 Northwest 14th Court, Penbrook Pines, FL, 33028, US)
Codos, Richard N. (34 Casale Drive South, Warren, NJ, 07059, US)
White, Burl M. (484 Osceola Avenue, Jacksonville Beach, FL, 32250, US)
Bowman, Russell E. (16283 Northwest 14th Court, Penbrook Pines, FL, 33028, US)
| 1. | A method of forming a patterned quilted product comprising: digitally applying a printed onamentation to one or more textile substrates, said ornamentation including at least one of a plurality of patterns for each of a plurality of panels that are to for adjacent panels of the same textile product, with a controller, controllin the applying ot'ihe printed ornamentation so that the alignment of the patterns on the different panels is coordinated among the panels of the product when the panels are joined to form the product. |
| 2. | The method of claim 1 wherein: the ornamentation inctudes a pattern for a top pane ! and a pattern for a side panel of the same mattress cover ; and the controlling includes controlling the applying of the printed ornamentation so thatapattern on the top panel aligns with a pattern on the side panel when the panels are joined to form a mattress cover. |
| 3. | The method of c ! aiml wherein : the ornamentation includes patterns for at least two panels of the same garment ; and the controlling includes controlling the applyin of the printed ornamentation so that a pattern on one of said panels aligns with a pattern of another of said panels when the panels are joined to form a garment. |
| 4. | The method of claim 1 wherein : the ornamentation includes ornamentation for a) least two panels of the same garment : and the controlling includes controlling the applying of the printed ornamentation so that ornamentation on one of said panels is coordinated with ornamentation of another of said panels when the pane ! s are joined to form a garment. |
| 5. | The method of claim 1 wherein: the ornamentation includes a simulated Jacquard pattern that matches a woven Jacquard pattern of a mattress cover top panel ; and the controlling includes controlling the applying of the printed ornamentation so that a side panel has a simulated Jacquard printed pattern that matches a woven Jacqnard pattern of a top panel when the panels are joined to form a mattress cover. |
| 6. | A method of limiting inventory of ticking material in bedding manufacture comprising: stocking pane ! ticking materia ! havinga woven pattern therein ; printing generic ticking material with a printed pattern simuluting said woven pattern : and forming a mattress cover by joining a pane ! having the printed pattern with the pane ! having the woven pattern. |
| 7. | A method of forming a patterned quitted product comprising : digita) ! y applying printed ornamentation to one or more substrates, said ornamentation inc ! uding patterns for each of a p ! ura ! ity of products, including at least one quilted textile product; controlling the appllying of the printed ornamentation to applly a printed pattern to a textile and quilting the textile to form a quitted textile having the printed ornamentation ; and controlling the applying of printed ornamentation to at least one other substrate to apply a printed pattern matching the printed pattern apphed to the texti ! e product and is of the same or a different scale. |
| 8. | Amethodofformingapatternedquihedproductcomprising : digitaHy app ! ying printed ornamentation to one or more substrates, said ornamentation including a pattern for at least one quilted textile product that is to be quilted with a sewn pattern ; controlling the app ! ying of the printed pattern and sewn patterns such that one is scaled in rotation to the other in one or more dimensions to compensate tor the shrinkage during the qui ! ting of the quitted product. |
| 9. | A method of forming a patterned mattress cover comprising : digitally applying printed ornamentation to a ticking material substrate ; controlling the applying of the printed ornamentation to arrange a top panel with a plurality of adjacent integral side pane ! s having the printed ornamentation coordinated thereon. |
| 10. | A method of forming a quilted product comprising: establishing the dimensions of features of a product to be quilted from a muftilayered material ; and with a controller, controlling the application of tension the mutti ! ayered quitted material to control the quitting induced shrinkage of the material to maintain the established dimensions of the features of the product after quitting. |
| 11. | A method of quitting a multilayered materia ! that includes a facing material having a pattern thereon, the method comprising : feeding the facing material into a yuilting machine ; adjusting the facing material to eliminate the skewing thereof by differentially applying force to opposite side edges of the facing material as it is being fed by controlling servo motors or brakes linked to elements engaging the side edges of said facing nr,tterial. |
| 12. | Amethodofmanufacturingaprintedandquittedproductcomprising : digitally applying onto a layer of textile material printed ornamentatiom and printed machine readable codes; and reading information from the machine readab ! e codes and in response thereto controHing a subsequent process in the manufacture of the quitted product. |
| 13. | The metllod of claim 12 wherein: the controlling of the subsequent process includes registering the apllication of quilted pattern in response to the reading of the machine readable codes. |
| 14. | The method of claim 13 wherein : the controlling of the subsequent process includes adjusting the angular orientation of the material during quitting in response to the reading of the machine readab ! e codes. |
| 15. | The methodof claim 12 wherein : the controlling of the subsequent process includes controlling the application of a quilted pattern in response to the reading of the machine readable codes. |
| 16. | The method of claim 12 wherein : the controlling of the subsequent process includes assembling the quilted product in response information from the reading of the machine readable codes. |
| 17. | The method of claim 12 wherein : the contlollillg of the subsequent process includes identifying the bedding product or its properties or associating the product with an order in response !') the reading of the machine readable codes. |
| 18. | A method of manufacturing a printed and quitted product comprising : digitally applying onto a layezoui textile material printed ornamentation on a printing machine ; and printing a material content tabe ! on said layer of textile material while the material is on said printing operation. |
Patent Application Serial No. 09/250,352, filed February 16, 1999, now U.S. Patent No. 6, 012, 403, which is a Continuation-fn-Part of U. S. Patent Application Seria ! No. 09/070, 948, filed May 1, 1998, now U. S. Patent No. 5,873,315, all of which are hereby expressly incorporated by reference herein.
This is also a Continuation-In-Part of the copending and commonly assigned PCT application PCT/US01/00596, filed January 9, 2001, which claims priority to U. S. Patent Application Serial No. 09/649. 471. filed August 28,2000 and U. S. Patent Application Serial No. 09/480, 094, filed January 10, 2000, now U. S. Patent No. 6,158,366, and also hereby expressty incorporated by reference herein.
Field ot the Invention : The present invention relates to quitting, and particularly to the quitting of pattern bearing products such as mattress covers. The invention further relates to the manufacture of quitted materials that bear printed patterns The invention is particularly useful where the quitting is performed on mutti-needte quitting machines, where the quitting and printing are applied to rott fed or web material or where differing products are produced in small quantities and in batches.
Background of the Invention : Quilting is a special art in the general fietd of sewing in which patterns are stitched through a plurality of layers of material over a two dimensional area of the material. The multiple layers of material normally include at least three layers, one a woven primary or facing sheet that witt have a decorative finished quahty, one a usually woven backing sheet that may or may not be of a finished quality, and one or more internal layers of thick filler material, usually of randomly oriented fibers. The stitched patterns maintain the physical relationship of the layers of material to each other as well as provide ornamental qualities. In quilting, two different approaches, are generally used.
Single needle quitters of the type illustrated and described in U. S. patents nos. 5,640,916 and 5, 685, 250, and those patents cited and otherwise referred to therein are customarily used for the stitching of most comforters. some bedspreads and other products from pre-formed or pre-cut rectangular panels. Some single needle quitters are used to quitt patterns on fabric that carries a pre-woven or printed pattern, with the quitting adding to or enhancing the appearance of the pattern. Such quitters requ ire that pre-patterned material be manual ty positioned in the quitting <BR> <BR> apparatus so that the quitting can he registered with the pre applied pattern or a complicated visual positioning system be used. With such systems, border quitting or coarse pattern quitting can be achieved but high quality outline quilting around the pre applied patterns or the quilting of pattern details of a fraction of an inch in scale are difficult to achieve, particularly automatically. Single needle quilters are usually lock stitch machines.
Large scale quitting operations have been used for many years in the production of bedding products.
Mattress covers, which enclose and add padding to inner spring, foam or other resilient core structure, provide functional as well as ornementa) features to a mattress. Mattress covers are typically made up of quilted top and bottom panels, which contribute to the support and comfortcharacteristics of a mattress, and an elongated side panel.
which surrounds the periphery of the mattress to join the top and bottom panels around their edges to enclose the inner spring unit or other mattress interior.
Mattresses are made in a small variety of standard sizes and a much larger variety of combinations of interiors and covers to provide a wide range ot support and comfort features and to cover a wide range of product prices. To provide variety of support and comfort requirements, the top and bottom panels of mattress covers are quilted using an assortment of fills and a selection ot quitted patterns. To accommodate different mattress thicknesses, border panels of different widths are required with variations in the fitt for border pane) s being less common. Border panels as weft as top and bottom panels are usually made in different sizes to accommodate all of the standard mattress sizes.
Mattress covers are usually quilted on web-fed multi-needle quilters. Only one side of the quilted product need be finished for a mattress cover, so one layer ot ornamental top goods or ticking is usually combineed with fill and backing materia ! to produce the mattress cover products on a chain stitch quitting machine which can use large spools of thread and qnitt on webs of material suppliecl em rolls. Multiple needle yuilters of the type illustrated in U. S. Patents Nos.5,154,130 and 5,544,599 are customarrily used for the stitching of mattress covers, some bedspreads and other such products which are commonly formed from multi-layered web fed material. These multi-needle ynilters include I, anks of mechanically ganged needles that sew multiple copies of a recurring pattern on the fabric.
With such mntti-need ! e machines, the combining of quitting with pre-apphed printed or woven patterns in the fabric which would require registration of the quilting with the pre-applied patterns is usually not attempted. Multi-needle quitters are usually chain stitch machines. Such quitters include banks of mechanically ganged needles that sew multiple copies of a recurring pattern.
The ornamental characteristics of the ticking that form the outer surface of a mattress are regarded as important in the marketing of bedding products. Bedding manufacturers stock a variety of ticking materials of different colors and types, many having different sewn or printed patterns. Maintaining an adequate inventory of ticking requires the stocking of different widths of materials of different colors and patterns. The cost of such an inventory as well as the storage and handling of such an inventory contributes substantially to the manufacturing cost of bedding products.
Some of these quilted patterns are highly ornate and contribute materially to the appearance of the quitted products, particularly those that are of higher quality and cost, and which are made in smaller quantities. With such high-end products the combining of quitting with pre-apptied printed or woven patterns in the fabric may call for registration of the quilting with the pre-applied patterns, which is difficult to achieve with multi-needle machines.
But other quitted products, such as those with simple zig-zag quitted patterns, are more tunctionai, and rety on the varieties of the ticking material for the visual distinctiveness of the product. The varieties of ticking materials include those sewn or printed with different patterns. For such products, printed patterns are usually applied by the ticking supplier and rolls of ticking of each pattern are invenltoried by the mattress cover manufacturer.
Other quitting machines and methods employing some of the characteristics of both single needle p. lel type quitters and web fed multi-needle quilters are disclosed in U.S. patent application serial no. 08/831,060 of Jeff Kaetterhenry, et al. filed April 1, 1997 ancl entitled Web-fecl Chain-stitch Single-needle Mattress Cover Quilter with Needle Deflection Compensation, now U. S. patent no. 5, 832, S49 and U. S. patent application serial no : 09/189, 656 <BR> <BR> of Bondanza etat., fifed November tO, 1998 and entitled Web-fed Chain-stitch Singte-needte Mattress Cover Quitter with Needle Deflection Compensation, both hereby expressly incorporated by reference herein. Such a machine uses one or more separately controllable single needle heads that apply chain stitches to panels or webs.
The production ofquitts by off-tine processes, that is those involving both printing and quitting processes performed on different production tines, has included specialty product production involving the outlining or other coordinated stitching onto material on which patterns have been preprinted. Stitching in such processes is traditionally carried out with manually guided single needle quitting machines. Proposed automated systems using vision systems to follow a preprinted pattern or other schemes to automatically stitch on the preprinted materia ! have been proposed but have not proven successful. Registration of pattern stitching with preprinted patterns has been
a problem. White efforts to align printing and stitching longitudinally or transversely have been made, angular orientation of the printed web and the angular alignment printed patterns with the quitting head has been ignored.
Correction for misalignment of quilted and printed patterns by repositioning of a quilting or printing head is inadequate if multi-needle yuilters are to be used, particularly where angutar mis-orientation is present.
Application of registration techniques to roll fecl materials, where printing and quitting are performed on the material webs. presents additional problems. Registration errors that are minor where patterns are applied to individual panels produce cumulative errors when patterns are applied to webs. This is particularly true where angular orientation errors resutt due to skewing of the web as it is fecl into the subsequent pattern applying machine after removed from a machine in which the first pattern has been applied.
With off-line processes for applying one pattern and then another in registration with the first, one by printing and one by quilting, production of quilts in small batches of pattern combinations is particularly a problem.
Each batch can include one or a few quilted products of a common design made up of a printed pattern and a quilted pattern in combination, with the products of different batches, preferably to be consecutively made on the same machinery, being made up of a different printed patter !) in combination with a different quitted pattern. As a result, the matching of the second pattern to be applied with the correct pre-applied pattern as the partially completed products are moved from a first machine or production line to a second is critical and a potential source of error as weft as production delay.
For example, the outer tayer of material used for mattress covers that is referred to as ticking is supplied in a variety of colors and preprinted or dyed patterns. Generally, mattress manufacturers who are the customers of the quitted mattress cover manufacturers or quitting machinery manufacturers require a wide variety of ticking material patterns to produce a variety of bedding products. Frequently, small quantities of each of the variety of products must be made to supply their customers'requirements, requiring the maintenance of inventories of a targe number of different patterns of ticking material, which involves substantial cost. Further, the need to constantly match patterns as well as to change ticking supply rotts when manufacturing suet) a variety of products in small quantities can be a major factor in reducing the throughput of a mattress making process and delaying production.
These and related problems continually exist in the manufacture of bedspreads, comforters and other quitted products where a variety of products in smatt quantities is desired.
Other off-tine processes may involve the loading of rolls of ticking materials commonly bearing a pre- applied pattern onto the quitting machines. Lower cost mattresses are often made by sewing generic quitted patterns onto printed pattern material. However, frequent changing of the ticking material to produce products having a variety of appearances, requires interruption of the operation of the quitting machine for manual replacement and splicing of the material. This adds to labor costs and lowers equipment productivity. Further, the spliced area of the material web which must he cut from the quitted material is wasted. Furthermore, since mattress top and bottom panels are often thicker, and vary in thickness more than border panels, border panels are sometimes quitted on quitting tines that are separate from those used to spilt the top and bottom panels. Since border panels are usually preferred to match the top and bottom panels, the changing of ticking on the top and bottom panel line is almost always accompanied by a similar change of ticking niuerial on the border panel line. Coordination of the two production tines, as we ! t as the matching of border panels with the top and bottom panels, requires well executed control procedures and can lead to assembly errors or production delays.
There exists a need in mattress cover manufacturing for a capability of efficiently producing small quantities of quitted fabric such as mattress covers, comforters, bedspreads and the tike where different pre-apptied patterns on the product are desired to be enhanced by combining the pre-apptied and quitted patterns, particularly where combinations of quitted patterns and printed or other pre-apptied patterns must vary with each or every few products.
Further, there is a need in mattress cover manufacturing to improve the productivity and efficiency of making quitted products, particularty mattress covers, having a variety of designs without increasing, or white reducing, production costs.
Summary of the Invention : An objective of the present invention is o provide quitt manufacturers, particularly mattress cover manufacturers, with the ability to produce quitted products having a wide variety of patterns that include both quitting and printed or other images or designs efficiently and economicatty. A particular objective of the invention is to provide such ability without the need to inventory material in a targe number of different pre-appiied designs.
A further objective of the invention is to provide for the intricate outhne or other coordinated quitting of designs or patterns on multi-layered materials in a highly efficient, economical, high speed and automated manner, particularly by both applying the printed design or pattern and quitting the outline or other coordinated quilted enhancement of the printed design or pattern in sequence on the same manufacturing line.
Another objective of the present invention is to efficiently provide for customizable printed and quitted patterns on mattress covers, bedspreads and the like, which can be varied on all individual piece basis or with among items produced in snrill quuntities. It is a particular objective of the present invention to provide flexibility in the production of mattress ticking and quitted mattress covers having patterns that can differ from product to product.
A further objective of the present invention is to reduce quitting downtime due to the need to make ticking or other material changes, pattern changes or machine adjustments. A more particular objective of the present invention is to provide a quitting method and apparatus with which quitted patterns and printed patterns may be applied in registration and varied on a quilting machine.
A particular objective of the present invention is to aid the production of quitted materia) by combining both printed patterns and quitted patterns wherein multiple copies of the quitted patterns can be simultaneously applied using. mnlti-neeedle cpilter. An additional particular objective of the present invention is to facilitate accurate coordinated application of patterns by printing and quitting to web or roll fed material. Another particular objective of the present invention is to assist in the automatic coordination of printed and quitted patterns of products produced successively in smatt batches of different products. These objectives are most particularly sought in systems in which a first pattern, such as a printed pattern, is applied off-tine from the machine on which the second pattern, such as a quitted pattern, is to be applied in registration with the first pattern.
An additional objective of the present invention is to provide for the efficient arrangement of top. bottom and border panels of different printed patterns on one or more webs or sections of a fabric. A further objective of the invention is to coordinate the matching and assembly of the different panels that make up each of a plurality of differently.
According to principles of the present invention, a quitting method and apparatus are provided for the manufacture of a quitted product by a combination of printed pattern application and quitting. The process provided includes the application of the printed pattern and the application of a quitted pattern with the pattern that is applied second being applied in registration with the first. Preferably the printed pattern is applied first. Both the primed and the quitted patterns are printed from electronic source fifes. The printing is carried out by a process referred to as Direct Digital Printing, which is defined in the industry as commercial-quality printing in which the electronic source fifes are processed directly on the printing press or printing system, rather than through analog steps such as film imagesetting and ptatemaking. Even though the included printing may be from electronic source fifes that are may not be literally "digital" and the excluded image setting and plate-making may could be literally digitally rather than analog as the terms digital and analog are used in the electronics arts. Direct digital printing systems may be based on lithographic offset technology or laser/ioner technology. In the preferred embodiment of the invention, the printing is carried out by ink-jet printing processes. Further, in accordance with preferred embodiments of the invention, the printing is applied directly to the substrate without the use of all offset or transfer process.
According to the various embodiments of the present invention, the principles set forth above are achieved by applying printed designs and coordinated quitted patterns to muttitayered material on either the same production tine, on separate production lines, or under the control of a common machine and pattern controller. On a single line system, multiple layers of the material for the forming a quilt ure supported on a frame on which a printing head and a quitting head are also mounted. A mechanism is provided to impart relative movement of the supported material
elative to the quilting and printing heads. Such a mechanism can include a material conveyor that moves the material with respect to the frame, and/or head transport mechanisms that move the heads to and from the material when it is fixed relative to the frame. Either the supported material or the heads or both are moved rotative to each other under the control of a programmed computer control to apply printed designs and quilted patterns to the material in mutual registration. Preferably, the printed designs are applied first onto the top layer or facing material. then a pattern is quitted in registration with the printed designs. Alternatively, printed designs can be applied after the patterns are quitted.
According to certain embodiments, a quitting apparatus is provided with a supply of multiple layers of material to be quitted and printed with a combination printed design and quilt pattern. An outer or top layer is fed, preferably as a continuous web, through a series of stations. At one station, a printed design is app) ied to the top or facing layer of material. At another station, preferably downstream of the printing station, a quilted pattern is app) ied to the multiple layered fabric of material including the facing material layer and filter and backing material layers, Whichever pattern or design is applied second, preferably the quitted pattern, it is applied in registration with the pattern or design that has been applied first to the fabric under the control of a programmed controller. A curing station or oven may be further provided downstream or as part of the printing station to cure the dye or ink applied at the printing station.
In certain machines according to the invention, a printing station is provided on a frame and quitting station is located on the frame, preferably downstream from the printing apparatus. A material conveyer is provided that brings fabric printed at the printing station into the quitting station with the location of the printed pattern known so that one or more quilting heads at the quilting station can be registered with the printed pattern.
According to one preferred embodiment of the invention, the printing station includes one or more ink-jet printing or dye transfer heads moveabte under computer control over the outer or facing layer of material. Additional layers of material are combined with the outer layer, preferably downstream of the printing station and after a printed pattern is applied to the outer layer at the printing station. In this embodiment, the quilted pattern is then quilted onto the material in registration with the printed pattern. Registration may be achieved by maintaining information in a controller of the location of the printed pattern on a facing material and of the relative location of the heads with respect to the facing material.
In embodiments where the material is moved on a conveyor successively through the printing and quilting stations, information of the location of the design or pattern on the facing material and of the material on the conveyor is maintained by the controtter. The matterial may be fed in separate precut panel sections, as continuous patterns and designs along a web or in discrete panel sections along a continuous web. Where the printed design is applied before the quilting, which is preferred, information of the exact location of the design on the facing material is maintained as the material moves from the printing station, as the filler and backing layers of material are brought into contact with the outer layer or facing material, and as the material is fed to the quitting station. For example, outline quilting the pattern in computer controlled registration with the printed pattern can be carried out, or some other quilting pattern can be applied, based on the maintained registration information ot the pattern on the web moving through the apparatus. fit one preferred embodiment, exact registration between the design that is printed onto the material and the pattern that is quitted on the material is maintained by holding a panel section of the multi-layered material onto which the pattern is printed in some securing structure at and between the printing and quitting stations. The panel section can be a separate panel or a portion of a web of material, and may be secured in place on a conveyor, In such an embodiment, the registration may be maintained throughout the entire printing and quilting operation by side securements such as, for example, a pin-tentering material transport that keeps the material fixed relative to the conveyor or securing structure through the printing process and the quitting process. A programmed or process controller controls the relative movement of the fabric and printing and quilting heads, and coordinates the movement in synchronization with printing head control and quilting head control so that the printed and quitted patterns are applied in precise registration.
Iii other embodiments, the pattern is applied off-line, preferably the printing process. The printed pattern may include a machine identifiable mark or other reference, such as may be achieved by the printing of selvage edge registration marks on the material that are uniquely positioned relative to the printed pattern. The printed material is then transferred to I quitting tine at which a quilted pattern is applied in registration with the printed pattern.
Preferably, machine readable registration information is produced on the material at more than one transversely spaced points on the material, such as on opposite selvages or side edges of the material. Separate determinations are made from the plural marks as to the relative alignment at two places on the material, such as at both of the opposite side edges. Thus, two such marks can be located when the second pattern is registered to the first, and determination can be made of the skewing or rotation of the material carrying the first or pre-applied pattern.
Adjustment to eliminate skewing or rotation of the fabric, and thereby to achieve registration of the second pattern with the first at transversely spaced locations on the material, is provided by side-to-side material position adjustment. Preferably, adjustment is provided by a split feed ro ft, with separately rotatable right and left components that are separately controlled in response to separate determinations of the registration of the right and left sides of the material. Separate servo drives or separately controlled particle brakes can be used to control the feed rolls to steer the web. Feed rolls at the upstream end of the quilter may be controlled with brakes to affect the tension of the web through the quilting station with driven feed rollers at the downstream end of the station, thereby controlling shrinkage or stretch of the web longitudinally.
In the preferred embodiments, linear servos motors are provided to drive the print heads, at least transversely, over the substrate. Linear motors are easier to tune, require little service, and have better acceleration and deceleration than belt or other drive systems. Such servos provide accuracy that enables printing to be carried out while the heads are accelerating or decelerating. Programmed compensation is made for the variable head speed by the timing of the jetting of the ink. Thus, areas of the substrate having no printing can be skipped at high speed, greatly improving the speed and efficiency of the print operation by minimizing the time during which the print head is not depositing ink on the substrate.
Preferably, the patterns are apphed to webs of material on which different products are to be quilted along the length of the material prior to the panels being separated from the web. Multi-needle quilting machines are also preferably used. Where the printing is apphed to the web off-hue, side-to-side registration that overcomes the effects of skewing or mis-orientation of the web achieves equally good registration of the different pattern copies being stitched simultaneously by the multiple needles and overcomes cumulative registration errors as the web is fed.
In certain other embodiments, vision systems may be employed to determine or verify the location of the printed pattern and to enhance or provide registration of the quitting with the printing. Such a vision system may be employed in addition or in the alternative to the computer control of the material transport.
Printed patterns or designs and the quitted patterns may be programmed or stored in memory and, in a programmed or operator selected manner, printed designs and quilted patterns may be combined in different combinations to produce a wide variety of composite printed and quilted patterns.
In alternative embodiments, the material may be held stationary, rather than moved relative to a fixed frame, and the printing and quilting heads of the respective printing and quitting stations may move relative to the frame and the material fixed Oil the frame, under the coordination of a controller, to bring a printing head or a quitting head into position over the portion of the material on which a pattern is to be applied. In most applications, quilting a pattern after applying a printed design is preferred. However, aspects of the invention can be utilized to print designs onto material after quilting the material Preferably also, a batch control automated system keeps track of the products moving through the process.
Where one pattern applying process is off-tine, such as where printing is carried out on a line separate from the quilting line on which the stitched pattern is applied, the control matches the quilted pattern and the printed patterns required by each product or batch of products. This can be carried out by maintaining information in a control system memory that Will allow for the following of the product through the system or can be assisted by automatically identifying the product on the second hue. such as by reading a code, such as a bar code. applied to the product
previously and correlated with the pattern that was printed onto the panei or product. Batch control systems are described in U. S. patent no. 5,544,599 and in U. S. patent applications seria) nos. 09/301,653, filed April 28, 1999, and 09/359. 539, filed July 22, 1999.
In the munufucture of mattress covers, printecl ancl quilted top and bottom panels can be produced along with strips of border fabric that are to cover the border, including the sides and the head and foot, of a mattress. Such border panels can be produced with coordinated printed designs and patterns that match or correspond to the top and bottom panels. This can be achieved according to one embodiment of the invention by printing and quitting a strip of fabric along a width of the same web material of which the top and bottom panels are being made. The border panel printing and quilting are carried out under the control of a programmed controller, preferably the same controller that coorclinates the ipplicati « n of the printed designs and quitted patterns on the top and bottom panels.
The border panels so made are then cut or slit from the web that carries the top and bottom panels.
As an alternative to forming border panels out of the same web as the top and bottom panels, a separate but smallel machine having separate quilting and printing stations may be provided adjacent and hnked to the main machine on which the mattress top and bottom panefs can be apphed. The separate machine is supplied with material for forming the border pane ! s that is narrower than, but matches, the material supplied to the main machine for forming the top and bottom panels. Both machines are controlled by the same controller or a controllers that are in <BR> <BR> communication with each other to coordinate the making of the mattresscover units or batches of units with matching or coordinated top, bottom and border panels. Border panels are of different widths, corresponding to mattresses of different thicknesses, and are of a length equal to the periphery of the mattress rather than the length of the mattress.
In addition, border panels have thinner fill layers, being in the range of from 1/4 to'/2 inches thick, where the top and bottom panels are usually from ½ inch to 3 or 4 inches thick. For these reasons, the embodiment using the separate border panel machine is preferred in that it provides for more efficient use of different lengths of materiat and provides less process complexity.
According to certain other principles of the present invention, webs of ticking or units of other fabric are printed with patterns under the control of a computer controlled printer. Such printers are typically digital printers and may be referred to as digital printers, and inclucle ink jet printers, continuous and dot-on-demand printers, and other printers that print images by dispensing ink or other printing medium in response to pattern information, which can uauully vary from opy to copy, rather than from a physica ! mat, p) ate or mechanical transfer surface such as those commonly used for printing multiple copies of the same image.
In the preferred application of such principles, an ink jet printer scans a web of ticking material transversely and prints on the web in response to signals from a programmed computer. In one preferred embodiment of the invention, each scun row need not necessarily print only on the same panel, but can print one or more lines of each of several panels that are arranged transversely across the web of material. Each panel can be printed with me same pattern, each with a different pattern or some with the same pattern and others with one or more different patterns.
Top and bottom panels that match or correspond to each of the border panels can be printed on different parts of the same or a different web.
Patterns on different panels of the same product, such as on adjacent top and side panels of a mattress cover. can be printed so as to be coordinated such that the patterns or pattern parts ahgn when the mattress cover is assembled, integrated panels can atso be produced, with the side and top panels, for example, of a mattress cover attached at their common seams, with the patterns on each panel varied in size. shape and orientation as is appropriate For the respective panel. In addition, material can be printed to produce visually coordinated products, such as sheets, piHow cases, drapes and other products, with the patterns on the different products printed to different scales as are appropriate for the respective products. Such different products can then be arranged and printed on the same material in the most materia ! efficient arrangement, with the print head scanning different ones of the products across the web. On qui ! ted products, the printed patterns can be automatically scaled to accommodate shrinkage due to quilting, which can be based on either measured or calculated information.
After printing, the webs of ticking are usually quilted to one or more layers of fill material and usually a layer of hacking material. The quilting may be applied to qui) t different patterns on different panels or different sections of web containing more than one pane !, or an entire web or length of web may be quitted with a generic pattern.
According to one aspect of the invention, Jacquard material (in which ornate patterns are woven into an otherwise plane material, are simulated by printing patterns on the same p ! ane materia ! background. In one application, for example, greige goods of the same background as the Jacquard material, can be printed to match the Jacquard material, with the actual Jacquard material providing the top and bottom panels of a mattress cover and the simulated material providing the border pane ! s. In this way, the less noticeable border panels need not be made up in each and every Jacquard materia), but a sing) e print hue can be set up to make, on demand, matching border panels in small lots to corresponcl to each pruduct order.
After the printing and after the quitting, where applicable, different panels are separated from adjacent panels of the web by longitudinal slitting or transverse cutting. The cut panels are subsequently matched with other corresponding panels to form a mattress cover, which is matched with a spring interior unit and one or more layers of padding for assembly into a bedding product.
Each panel is preferably identified with a particular bedding product and maybe identified with a particular item of a particular customer order. The identification ancl/or infornunipn relating to the properties of the pane) can be contained in a computer fi le that is synchronized to each panel on the fabric. Such information can a) so be printed or coded on the fabric, on or adjacent a pane), preferably in the same printing operation that apphes the printed pane) s to the material, which coding can be in the form of either manually readable information, machine readable information or a combination of manua)) y readab) e and machine readab) e information. Such information can be manually read for control of the qui) ting, the cutting and shtting and the machine of panels and assembly into bedding products. Preferably, the information is automatical read and signals are then generated in response to the information to control tle yuilting of the printed material, the cutting and slittingof the panels from the web, and the matching of corresponding panels for assembly into bedding products.
Product labels such as those identifying the manufacturer, a retai) er or a bedding product type or model as well as describing the product, can be printed on the fabric in the same operation as the printing of a panel with a pattern. Further, the government reyuired tag, callecl a law-tau, can be printed onto the substrate and the content of the tag can be derived from information in the system controller as to the content of the product being produced.
The present invention provides great flexibility in producing products of a wide variety of appearances and greatly reduces the ticking inventories of a mattress manufacturer.
The present invention a) so provides the abihty to change printed patterns in the course of a quihing run. and to change both printed and quitted patterns to produce quitted products in a wide variety of composite patterns.
With the invention, the number of base c) oth supphes required to provide pattern variety is greatly reduced, saving substantial costs to the quilted product manufacturer. With the invention, the appearance of the outer) ayer can be <BR> <BR> embellished to provide variety and detail, and outline quitting can be carried out in high quality and in close proximity to the printed design. Further, with the invention, these advantages are avai) ab) e with both single needle and multiple needle quilters.
These and other objects of the present invention will be more readily apparent from the followin_ detailed description of the drawings.
Brie) Description of the Drawings : Fig. 1 is a diagrammatic perspective view of a one embodiment of a web-fed mattress cover quilting machine embodying principles of the present invention.
Fig. IA is a diagrammatic perspective view of a portion the machine of Fig. 1 illustrating one emhodiment of the printing station thereof.
Fig. 2 is a diagrammatic perspective view of a discrete panel quitting machine which is an alternative embodiment to the machine of Fig. 1 that is more suitab) e for the production of comforters.
Fig. 3 is a top view of an alternative embodiment of the web-fed mattress cover quitting machine of Fig. 1 that includes structure for making coordinated top and bottom panels and border panels for mattress covers.
Fig. 3A is a diagram illustrating one manner of coordinating patterns between top, bottom and border pane ! s of a mattress cover using various embodiments of the invention.
Fig. 3B is another diagram illustrating another manner of arranging patterns on side and bottom panels of a mattress cover and forming the panels out of a contiguous piece of materiaL Fig. 4 is a diagrammatic perspective view of an alternative embodiment to the machine of Fig. 3.
Fig. 4A is a diagram illustrating one embodiment of a method according to certain principles of the present invention.
Fig. 5 is a diagrammatic perspective view of an off-hue alternative embodiment to the machine of Fig. 1.
Fig. 5A is a perspective view of an alternative embodiment of the feed roll portion of the machine of Fig. 5.
Fig. 6 is a diagram of one embodiment of a mattress cover quilting system embodying other principles of the present invention.
Fig. 6A is a perspective view of a pattern printing portion of the system of Fig. 6.
Fig. 7 is a fragmentary plan view of a web of ticking being printed at the print Hue of the system of Fig. 1 showing the transverse arrangement of a set of border panels bearing different patterns.
Fig. 7A is a fragmentary plan view of a web of ticking being printed at the print line of the system of Fig. 6 showing the printing of a bedding manufactturer's label along with the printing of a pattern on a top pane ! of a mattress cover.
Detailed Description ot the Preferred Embodiment: Fig 1 illustrates a combination printing and quitting machine 500 having a stationary frame 5 t t with a longitudinal extent represented by arrow 512 and a transverse extent represented by arrow 5) 3. The machine 500 has a front end 514 into which is advanced a ticking or icing material 515. The facing material SIS is. in the Htustrated embodiment of the machine 500, in the form of a web that is fed into the front end 5) 4 of the machine 500 from a supply roll 516, which is rotatably mounted to the frame 5 11. A backing material 517 and one or more layers of fitter materia) 5 t8 are also supplied to the machine 500, preferably in web form from supply rolls thvt ire also rotatabiv mounted to the frame 51 !. The layers of material are di rected around a plurality of rollers (not shown) onto a conveyor or conveyor system 520, each at various points along the conveyor 520. The conveyor system 520 includes machine elements that engage and advance the materials through the machine 500, and control the position of the material so that other machine elements that operate on the material (print heads, quilting heads, cutters, etc.) can be located relative to the materia ! or to features on the material, including edges or pattern components previously applied to the material by printing, sewing or otherwise.
In the embodiment shown in Fig. 1, the conveyor system 520 includes, for example, pairs of opposed pin tentering belt sets 521 which may alone or in cooperation with other elements extend the conveyor system 520 through the machine 500. In the machine 500, the outer layer 515 of facing material is fed to the belts 521 at the front end 5 14 of the machine 500. The belt sets 52l retain the web 5 15 in a precisely known longitudinal position thereon as the belt sets 52 ! carry. the web 5 ! 5 along the longitudinal extent of the machine 500, preferably with an accuracy of 0 to 1/4 inch. The longitudinal movement of the conveyor system 520 is controlled by a conveyor drive 522. The conveyor 520 may include alternative forms of elemems, including but not limited to opposed cog belt side securements, longitudinally moveable positive side c ! amps that engage and tension the materia ! of the web 5 ! 5, pin tentering elements or other securing structure for holding the facing materia) web 515 in a controlled or fixed position relative to the conveyor 520.
Along the conveyor system 520 are provided a plurality of stations, including a printing station 525, a drying station 526, a quilting station 527 and a pane ! cutting station 528. The backing material 517 and filler material 518 are brought into contact with the top layer 515 between the drying station 526 and the quilting station 527 to form a mufti-layered material 529 for quitting at the quitting station 527. The layers 517 and 5 18 are, in the embodiment shown, not engaged by the be ! t sets 52 1 of the conveyor system 520 but rather are brought into contact with the
bottom of the web of facing material 515 at the @ip of a pair ol rolls 543 upstream of the quiking station 527 and extended through the quilting station 527 and between a pair of pinch rollers 544 at the downstream end of the quilting station 527. The rollers 543 and 544 are elements of the conveyor system 520 and controlled to operate in synchronism with the belt sets 521 and pull the webs 517 and 518 through the machine 500 with the web 515. The rollers 543 and 544 may be mechanically linked to the conveyor drive 522 or may be driven independently through differentinl ! drives or motors 523. The drives 522 and 523 and the machine elements 521, 543 and 544 are preferaNy provided with sensing devices or encoders for providing control information feedback as to the location of the material in the machine.
The printing station 525 includes one or more printing heads 530 that are transversely moveable across the frame 511 and may also be longitudinally moveable on the frame 531 under the power of a transverse drive 531 and an optional longitudinal drive 532. Alternatively, the head 530 may extend across the width of the web 515 and be configured to print an entire transverse hue of points simuhaneousiy onto the weh 515. The head 530 is provided with controls that aNow for the se ! ective operation of the head 530 to selectively print two dimensional designs 534 of one or more co ! ors onto the top layer web 515. The drive 522 for the conveyor 520, the drives 531 and 532 for the print heads 530 and the operation of the head 530 are program controlled by a controller 535 to print patterns at locations on the web 515 that are preferaloly known in advunce or will be remembered by the program of the controller 535. The controller 535 includes a memory 536 for storing such information and for storing pattern <BR> programs, machine control programs and rea) time data regarding the nature and longitudinal and transverse location of printed designs on the web 515 and the relative longitudinal position of the web 515 in the machine 500.
The drying station 526 is positioned re ! ative to the conveyor system to dry the printed design 534 as the web 5 15 is conveyed longitudinally. In the embodiment shown, the drying station is fixed to the frame 511. The drying station may he of whatever configuration is suitable to effectively dry the ink or dye being applied at the printing station 525. It may operate continuously or be selectively controHed in accordance with the pattern, as is appropriate.
The print head 530 is preferably a digital dot printer or ink jet printer with which the coordinates of each dot of the image printed is capable of being precisely located on the web 515 and relative to the conveyor 520. Ahernatively. screen printed, roll printed or other types of printed images may be used while still realizing some of the advantages of the invention. Where a print head 530 such as an ink jet print head is used, the head may be moved transversely of the material by a carriage moveable on a transverse bridge with belts or chains driven by transverse drive servo 53 with the transversely extending bridge being moveable longitudinally on the frame 511 by a longitudinal drive servo 532.
In preferred embodiments, the heads 5 i0 include inkjet print heads having at least one multiple jet head for each of a plurality of, for example four, colors. The drives 531 and 532, and particularly the transverse drive 531, are preferably linear servo motors 531a, as illustrated in Fig. 1A. A transverse linear servo or servo motor 531a would include, for example, a stator 56) that is fixed to and extends across the bridge 560. On the staror 561 travels a transversely hnear ! y moveabie armature 562 to which is fixed a print head carriage 563 on which the print head 530 is mounted. The stator 561 includes a row of magllets illustlated as an arlay of electromagnets 564 that are actuated by signa ! s from the controller 535. Magnets 565 of the armature 562 exert forces on the armature 562 to move the carriage 563 and the print head 530 quickly and precisely among various transverse dot positions across the substrate 5 15.
Linear motors such as the servo 53 la are easier to tune, require little service, and have better acceleration and dece ! eration than belt or other drive systems. Because of their accuracy, printing can be carried out white the heads are accelerating or dece ! erating. with programmed compensation in the timing of the jetting of the ink being made by the controller 535. This greatly improves the speed and efficiency of the print operatiom hy allowing the print head 530 to skip across areas of the substrate 5 t5 that are to have no printing to areas at which ink is to be deposited, minimizing the time during which the print head is not depositing ink on the substrate. Accordingly, hnear servo motors, at) east to transversely move the print heads across the bridge, are preferred for the machine 500 and for the print head drives of the other embodiments described below.
The quitting station 527 is. in this illustrated embodiment, a single needle quitting station such as is described in U. S. Patent No. 5,832,849. Other suitable single need ! e type quitting machines with which the present invention may be used are disclosed in U. S. Patents Nos. 5,640,916 and 5,685,250. The quilting station 527 may alternatively include a mutti-needte quitting structure such as that disclosed in U. S. Patent No. 5,154,130. With such multi-needle machines, often the needles are fixed in the transverse and longitudinal directions of the material. reciprocating only perpendicular to the plane of the material, with the material being shifted transversely and/or longitudinally relative to the frame 5 11 under the control of the controller 535 to stitch patterns. In Fig. 1, a single need ! e quitting head 538 is illustrated which is transversely moveabte on a carriage 539 which is longitudinally moveable on the frame 5 I 1 so that the head 538 can stitch 360° patterns on the mufti-layered material 529. With 360" pattern forming on multi-needle machines, the drives 522.523 would be capable of reversing the material in the longitudinal direction.
The controller 535 controls the position of head 538 relative to the mufti-layered material 529, which is maintained at a precisely known position by the oper. oion of the drive 522,523 and conveyor 520 by the controtter 535 and through the storage and retrieval of positioning information in the memory 536 of the controller 535. tn the quitting station 527. the quitting head 538 quilts a stitched pattern in registration with the printed pattern 534 to produce a combined or composite printed and quitted pattern 540 on the multi-layered web 529. The precise locations of me printed images on the material and the material relative to the frame of the machine are tracked in the memory 536, and this information is used by the controller 535 to relatively position the material and needles of the quilt head 538 to quilt in registration with the printing. This may be achieved, as in the illustrated embodiment, by holding the assembled web 529 stationary in the quitting station 527 while the head 538 moves both transversely, under the power of a transverse t i near servo drive 541. and longitudinal ty on the frame 5 1 t, under the power of a longitudinal servo drive 542, to stitch the 360° pattern by driving the servos 541 and 542 in rotation to the known position of the patter !) 534 by the controller 535 based on information in its memory 536.
Alternatively, the needles of a single or mutti-needte quitting head may be moved relative to the web 529 by moving the quitting head 538 only transversely rotative to the frame 511 white moving the web 529 longitudinally relative to the quilting station 527, under the power of conveyor drive 522, which can be made to reversibly operate the <BR> <BR> conveyor 520 under the control of the controtter 535. Further, the quitting head, for example one contain ing a mutti- needle array, may also he fixed transversely with the material being shifted transversely as weft as moved longitudinally relative to the needles and thetrame5tt.
In certain applications, the order ot the printing and quilting stations 525 and 527 can be reversed, with the printing station 525 located downstream of the quitting station 527, for example the station 550 as illustrated by phantom tines in Fig. 1. When at station 550, the printing is registered with the quitting previously applied at the <BR> <BR> quitting station 527. t !) such an arrangement, the function of the curing station 526 would also be relocated to a point downstream of both the quitting station 527 and downstream of the printing station 550 or be included in the printing station550.
The cutoff station 528 is located downstream of the quitting and printing stations at the downstream end of the conveyor 520. The cutoff station 528 is also controlled by the controller 535 in synchronism with the quitting station 527 and the conveyor 520. The cut-off station 528 may be controlled in a manner that witt compensate for shrinkage of the multi-layered material web 529 during quilting at the quilting station 527, or in such other manner as described and illustrated in U. S. Patent No. 5.544,599 entitled Program Controlled Quilter and Panel Cutter System with Automatic Shrinkage Compensation. Information regarding the shrinkage of the fabric during quitting, which is due to the gathering of material that results when thick filled multi-layer material is quilted, can be taken into account by the controller 535 when quitting in registration with the printed pattern 534. For example, the dimensions of a quilted pattern or pattern component may be selectively reduced, and the spacing of pattern components may be similarly altered, in relation to the dimensions and spacings of components of the corresponding printed pattern, so that exact correspondence and registration between the quitted and printed patterns is attained.
The panel cutter 528 separates indivicluai printed amd quilted panels 545 from the web 538. each bearing a composite printed and quitted pattern 540. The cut panels 545 are removed from the output end of the machine by an out-feed conveyor 546, which also operates under the control of the controller 535.
Fig. 2 illustrates an embodiment 100 of the invention that which employs a single-needle, frame-supported, discrete-panel quilting machine such as those described in U. S. patent no. 5,832,849. Other machines of that type are disc ! osed in U. S. patents nos. 5,640.9 ! 6 and 5, 685, 250. These single needle quitting machines apply patterns to panels 129 that are often precut. Such machines are useful for manufacturing comforters, for examp ! e. The machine 100 has an operator accessible stack I t6 of preformed panels from which the panel 129 is taken and loaded into the machine) 00. A conveyor or conveyor system 120 moves a set of panel supporting edge clamps or other edge securements 121 to bring the panel i29 into a fixed position for application of a combination pattern by printing onto the outer top layer 115 of the multilayered fabric 129 and by quilting the multilayered fabric 129.
In the embodiment 100, a printing station 125, which in this embodiment includes a combined drying station 126 and a quilting station 127, is provided on moveabie tracks i 19 that are fixed relative to die machine frame tit. The printing station t25 includes one or more printing heacls 130 that are transversely moveab ! e across tile frame 111 under the power of a transverse drive 132 and is longitudinally moveable under the power of a longitudinal drive 131. As with the embodiment 500 above, the drives t3 i and 132 may be linear servo drives or other linear motors, such as those illustrated in Fig. 1A. The head 130 is controllable so as to allow for the selective operation of the head 130 to selectively print two dimensional designs 134 of one or more colors onto the top layer 115. The drive 122 for the conveyor 120, the drives 131 and 132 for the print head 130 and the operation of the head 130 are program controlled to print designs or patterns at known locations on the facing material 115 by a controller 135. which includes a memory 136 for storing programmed patterns, machine control programs and real time data regarding the nature and longitudinal and transverse location of printed designs on the material L LS and the relative position of the panel 129 in the mwchine 100. The drying station 126 may be moveable with the printing station 125, independently moveable on the frame 111, or fixed to the frame I I I in a position at which it can operate to cure the print medium applied by the printing head 130 without interfering with the printing station 125 or quitting station 127.
The quitting station 127, in this embodiment 100, is preferably a single needle quilting station such as is described in U. S. patent no. 5, 832,849. The quitting station 127 has a single needle quilting head 138 which is transversely moveabie on a carriage t39 which is longitudinally moveabie on the frame 111 so that the head 138 can stitch 360° patterns on the multi-layered material 129. This is achieved, in the embodiment 100. by holding the panel 129 stationary while the quilting head 138 moves both transversely, under the power of a transverse servodrive 142. and the station 127 moves longitudinally on the frame 111, under the power of a longitudinal drive 141. The drives 141 and 142 may be a linear servo drive motors. The servos can be operated to stitch a 360'pattern. Alternatively. the head may be stationary and the pane ! moved both transversely and longitudinally to stitch a 360"pattern, or one drive may he employed to move the head in one direction with the panel moveable in the other perpendicylar direction.
The controller 135 coordinates the motion and operation of the printing station i25 and the quilung station 125 to that one applies a pattern or design to panel 129 and then the other applies a coordinated pattern or design in registration. The machine 100 can apply either the printed design first and then register the quilted pattern to it. which is the preferred order, or can apply the quitted patter)) first and then register the printed design to the quitted patter)). The controller t35 controls the operation of these stations.
Fig. 3 illustrates all emhoclimenr 200 that is similar in certun respects to the machine 500 of Fig. 1, but which further includes the capability to apply combination patterns to different areas of ticking material 215 on a wide muttitayered fabric 229 to produce top or bottom panels 25 t with matching or otherwise corresponding border panels 252 of a mattress cover, tn the preferred arrangement, a web of ticking or facing material 215 from a roll 216 is printed in an efficient arrangement of panels on the facing material 2t5. The machine 200 is provided with a supply 217 of backing material and supplies 218 and 2) 9of fitter material, which is preferably, for this embodiment,
of different thicknesses at different positions across the width of the facing material 125, to form the multi-layered fabric 229, on which the arrangement of panels is then quihed at a quitting station 227 in a way that spatiaHy corresponds to the printed patterns. The machine 200 is also provided with ashtting station 253 adjacent cutoff station 228, to slit the border panels 252 from the top and bottom panels 251, and to otherwise cut the panels from the web of multi-layered fabric 229. The printing, quilting, cutting and slitting of the material as well is the movement of the material by operation of a drive 222 is controlled by a machine controller 235, which may be similar to those discussed previously.
The patterns on the fabric 229 may be coordinated in such a way that, when the mattress covers are assembled, the patterns align. This is illustrated in Fig. 3A, in which severed top and bottom panels 251 a, 251b and a continuous border panel 252 are illustrated. laid f ! at in the left side of the figure and folded for joining together as a mattress cover in the right side of the figure. The top and bottom panels 25 ! a, 25 ! b have pattern features 261-264 <BR> <BR> thereon white the side pane ! 252 has features 265-568 thereon. The features 261-268 maybe printed, quitted or both.
The features 265 are positioned on the side panel 252 so as to align with the features 261 on the top and bottom panels 251a, 251b when the panels are assembled into a mattress cover 269. Similarly, the features 266-268 are positioned on the side panel 252 to align with the features 262-264 respectively on the top and bottom panels 25 la, 25 ! b when the panels are assembled into the mattress cover 269. Coordination of the panels 251 and 252 and assembly of the mattress covers 269 may be carried out as described in connection with the system 10 of Fig. 6, described below The other embodiments described herein may be operated ancl controlled to produce mattress covers having the characteristics of mattress cover 269 of Fig. 3A.
Fig. 3B illustrates a mattress cover 270 having integral top and side pane ! s 27 !-275 with pattern features 276-279 similar to features 261-268 of Fig. 3A printed uncl/or quilted onto ticking material 215a. Mattress cover 270 is particularly suitable for single sided mattresses, which are finished and padded on the tops hut not on the bottoms. and which are not intended to be turned.. Such mattress covers 270 are trimmed from a multi-layered printed and/or qui ! ted web or panel, folded and sewn over a spring interior assembly to form the mattress cover 270.
Fig. 4 illustrates an alternative embodiment 300 for producing matching top and bottom panels and border paneLs for mattress covers. The embodiment 300 inc ! udes a machine 310a of the type similar to the machine 500 described in connection with Fig. 1 above in combination with a machine 310b, which is simi ! ar to but a narrower version of machine 310a. The machine 3 ! 0a produces the top and bottom panels from multilayered fabric 329a that is dimensioned according to the specification for such panels, incluling a relatively thick filler layer I 18a of mattress size width and ! ength. The machine 310b produces the minching or coordinated border panels from multilayered 329b that is dimensioned according to the specification for horder pamels, including a relatively thin filler layer I 18h and narrower width that corresponds to the thickness of a mattress but greater ! ength that corresponds to the perimeter of the border of the mattress. The matching of the combination patterns applied to the fabric 329a, 329b is controlled either by a single controller, by a master-controller 335 (as illustrated) which controls separate similar machine controllers 335a, 335b of respective machines 310a, 310b, or through other controller architecture. The separate controNers of the machines 3t0a. 3 ! 0b may be hnked together such that they work in unison or such that the controller of one mmchine 310u, 310b conrmls the other. Alternatively, the machines 310a and 310b may be controlled separately, in response to batch data, for example, which may be generated by a coordinated plant scheduling system. Where separately controlled, the output of the machines 310a and 310b may be tracked through computers that follow each mattress cover component of each product and order through the plant, relying on coordinated data fi ! es or indicia printed on the panels or both. as. for example, described in connection wit !) the system 10 of Fig. 6, described below.
In Fig. 4. the controller 335a controls the operation of the machine 310a to produce combination printed designs and quilted patterns on the top and bottom panels of a mattress with printing head 325a and qui ! ting head 327a, respectively, as with the machine 500 described above. Controller 335b controls the operation of the <BR> <BR> machine 3 tOb to produce matching combination printed designs and quitted patterns on border panels for the same mattress with printing head 325b and quitting head 327b, respectivety. Master controHer 335 coordinates the
operation of the two controllers 335aand 335 b. Siniitarty, each of the machines 3 tOaand 3 10b can be separated onto two production Hues, one a print ! ine containing a respective one of the printers 325a, 325b and one a quilt line containing a respective one of the quilters 327a. 327b. As with the machines 310a, 310b, the print hues and the quilt lines of each of the machines may be separately controlled or controlled together. The coordinating of the operations of the different machines and production lines and the coordination, batching and scheduling of the product components, may utilize features of system 10 of Fig. 6, clescribed helow.
The system 300 of Fig. 4 can be controlled to produce the coordinated panels 25 t. 252 wit)) the coordinated <BR> <BR> pattern features 26)-268 illustrated in Fig. 3A To produce the mattress cover 269, machine 310h would be controlled to produce the border panel 252 having the pattern features 265-268 white machine 310a would he controlled to produce the top and bottom panels 251a, 251b having the pattern features 261-264.
An efficient use of the system 300 of Fig. 4 is illustrated in and described in connection with Fig. 4A. ! n Fig. 4A. a mattress cover production facility 600 is furnished with an inventory of different rolls of textile material 601-603, each being, for example, a Jacquard material in which different decorative Jacquard patterns 604-606 are respectively woven into the fabric 601-603. In the manufacture of mattress covers by the facility 600, a process is implemented, which may cause the printing of various printed patterns onto the Jacquard fabric 60 !-603. For example, patterns 610 may be printed onto materia) 602 with ink jet printing equipment 611 of the types described elsewhere herein. The patterns 610 may be located on the fabric 602 to coincide with or bear a spatial relationship to the Jacquard patterns 605 on the fabric 602. With the batch controls described elsewhere herein, printed patterns may be changed from panel to panel along the fabric 602, with one pane) 613 of the fabric 602 imprinted wit)) a pattern 6) 2 and a following pane) 6) 3 printed wit)) the pattern 610. The web containing the printed panels 613 are then transferred to a quitting tine 6) 5 on which a quitted pattern 616 is applied to the prinlted panels 613. Similurly, patterns 620 may be printed. onto materia) 603 with printer 611 in spatial relationship with the Jacquard patterns 606. and the web containing the printing then transferred or fed directly to quitting tine 615 at which a quitted pattern 62) may be applied at a quitting station 627.
In the facility 600 of Fig. 4A. the different supplies of Jacquard material 601-603 have their respective woven patterns 604-606 applied to the same background material 609. The background material 609 may be completely untreated greige goods, or gray goods, or may be material that is partially treated so as to be in zut print condition. The inventory of the facility 600 is also made to contain a supply of border panel material 625 of a background materia) 609 having the same appearance as the background of Jacquard material 60t-603. The border panel material 625 is subjected to a preliminary printing process in which simulated Jacquard patterns 604a-606a. resembling the woven Jacquard patterns 604-606, are printed onto the background or greige good materia) 625 to produce a border panel supply that has the appearance of any of the Jacquard materials 601-603. The border panel material printed to contain the different simulated Jacquarcl patterns 604a-606a is then transPerred to a print line at which it is printed by a printer 631 simitar to the printers 611 with any decorative pattern, including the patterns 610, 612 and 620. Alternatively, the simulated patterns 604a-606a and the decorative patterns 611, 612, 620 may be applied at the same print station in one or more print head passes to apply combined printed patterns under the control of a programmed controller. The printed border panels are then sent to a quilting station 632 similar to the qui ft tine 615 at which the border panels are quilted.
The process depicted in Fig. 4A has advantages of reducing inventory requirements and material handling in the mattress cover production facility 600. The method may be integrated into the methods described elsewhere herein, particularly those in connection with Fig. 6 described below.
In the embodiment of Fig. 5, a printing and quilting system 400 is provided that includes separate print and quilting lines, such as print line 401 and quilt tine 402. Quilt line 402 is preferably a multi-needle quilting machine such as that described in U. S. Patent Nos. 5.154.130 or 5.544.599. The print line 401 includes a printing station 425. preferably of the jet printing type, and a curing or drying station 426, usually an oven but which may be a UV light curing station or such other station as wilt cure the type of ink being used. Mattress ticking materia) or some other facing sheet of material 416 is provided, preferably in web form. and fed successively through the printing station
425 and curing station 426. The printing station 425 applies patterns to the web of material 416 6 in accordance with pattern programs controlled by a print line controller 431. For the printing of top and bottom mattress cover panels, for example, patterns are printed on one or more successive panel lengths 432 along the web. The patterns may be changed from panel to panel in accordance with a schedule executed by a batch controller 435, which supplies product information to the print Hue controller 431. The print tine 40) produces a plurality of printed panels preferably on a web 429 of the facing material from the supply 416.
In one preferred embodiment of the system 400, the printing performed on the print line 401 prints, in addition to a series of panel patterns, a series of registration or reference marks 450. The registration marks 450 are preferably printed on the opposite selvages or side edges of web 429 and are configured, for example in a Z-shape or such other shape that, when detected, can provide both longitudinal and transverse positioning references at each of the respective side edges of the web 429. The opposite marks 450 are preferably aligned with each other and include one opposed pair of marks for each panel, although more than one pair per panel may be used for added accuracy. The marks 450 are printed in a predetermined relationship to the location of the pattern being printed on the web 429, and data of this retationship is maintained in data files available to the controller 431 and to subsequent controllers, such as quilt line controller 437, for use in accurately positioning subsequent operations on the web 429, such as the application of a quilted pattern on the panels 450.
Further, associated with each panel there may be printed on the web 429 coded information that can be automatically read by a sensor and provided to a subsequent controller, such as controller 437 of quilting the 402, to identify a pane) or bedding product component, to describe properties of the bedding product component, or to corre ! ate with information in data files accessible to such controller that will provide process control or product information. Examples of the use of such data are set forth in the description of the system 10 iHustrated in Fig. 6.
After printing, the web of preprinted material 429 is preferably re-rolled and transported, or otherwise directed, to the quilting machine or quilt line 402 into which it is loaded and on which it is combined with a backing liner web 417 and one or more filler material webs 418. The combined webs 429, 417 and 418 are engaged by front feed rolls 460 from which they are advanced through a quilting station 427 of the multi-needle type at which a plurality of pattern components are quilted onto the previously printed web 429 in registration with the patterns printed thereon.
The quilting machine 402 has, immediately upstream of the quilting station 427, a pair of sensors 451, one over the right edge of the web 429 and one over the left edge of the web 429. The sensors 451 may be photo electric detectors that are capable of sensing the respective positions of the marks 450 so that a controller 437 of the quilting machine 402 call calculate the positions of the opposite edges of the web 429. The controller 437 is programmed to determine the longitudinal and transverse positions of the marks 450 and to derive therefrom the location of the printed patterns so that quitted patterns can be registered with the printed patterns. The program of the controller 437 also calculates any rotation of the panel or skewing of the web 429 relative to the coordinates of the machine 402.
The controller 437 can then use the rotation information to adjust the angular orientation of it quitted pattern in it it the tile substrate in registration with the printed pattern and properly oriented on the panels 450. Such adjustment of the pattern is practical when the quitting station 427 is a single needle quilter. Alternatively, the angular orientation information is used to reorient the material 429. The reorientation of the material 429 is particularly more practical where the quilting station is a multi-needle quilting station.
According to the embodiment of Fig. 5, the quilting machine 402 is provided with a split feed roll 460 upstream of the quilting station 427. The split feed roll 460 includes a left half 460a and a right half 460b, each of which is separately controlled by an active or passive controllable element 461 a, 461b such as a servo motor or brake.
The controller 437 may, for example, differently drive servo motors 461a, 461b in response to skewing of the web 429 that is calculated as a result of the analysis by the controller 437 of the outputs of the sensors 451 so as to adjust the orientation of the web 429 as it advances through the line 402 and so as to affect the transverse position of the web 429 eliminating the skew. As a result, a quilted pattern can be applied in angular registration with the printed pattern. Multiple needles of the quilting station can maintain equal alignments with their respectively
correspond ing printed patterns. The skew correction, which may also be combined with a longitudinal and transverse adjustment of the web 429, results in high accuracy registration of the plurality of quitting needles with a plurality of components of, or location on, the printed patterns. The elements 461 can be used to control longitudinal tension on the web 429 entering the quitting station 427. and for this purpose, servo motors, or preferably brakes may be used to cause such tension to be applied, as explained further below.
In lieu of split feed rol Is 460, other types of separately controllahle feed elements that can feed or otherwise move the material in a way that wi ! t rotate or redirect the material to adjust the skew of the materia ! can be used. For example, in system 500 of Fig. 1, the edge feecl conveyor belts 521 can be configured in a series of flights, with a short flight downstream of the printing and drying stations 525 and 526 and upstream of the quitting station 527.
The short flights of the conveyor betts 521 on each side of the web 529 can be separately controlled by the controller 535 based on information provided to the controller 5 35 oftheactua ! orientation and position of the web 529 entering the quitting station 527. This orientation may be determined by registration marks such as the marks 450 of Fig. 5, from other sensing of the actua ! position and orientation of the web 529 or otherwise.
White Fig. 5 shows a split feed roll 460 having two halves 460a,460b that can be differently controlled the feed elements can be divided into more than two separatety operable sections across the width of the web 429.
For example, in Fig. 5A, a spht feed rott 470 is illustrated that is divided into four sections, 470a-470d. The roH sections 470a and 470d affect the opposite edges of the web 429 and are driven by separate ! y controlled drives 47 ta and 471d, respectively. Central sections of the rot ! 470, namely sections 470b and 470c, may be made to idle so that the web between the rotts 470a and 470d can freely adjust its position. and orientation, or the rolls 470b and 470c can be geared in relation to the end sections of the rott 470a and 470d to conform to motion intermediate that of roH sections 470a and 470d in proportion to their distances from the respective end sections. Alternatively, the intermediate rott sections 470b and 470c can be separately or differentially driven by separate motors 471 iiid 471c that are independently controlled by the controller 437.
In addition, as Fig. 5A illustrates, the separaate sections 470a-470d of roll 470 can be provided with relative transverse position adjustments, driven by contrpller controlled servos 472a and 472b, for example, to affect the transverse stretch or tension on the web 429. Such transverse adjustment can be coordinated with transverse tension applied to the web 429 by side securements (not shown) at the quilting station. Additionnlly, the feed roll 470 can be shifted transversely to generally center the web 429 entering the qui ! ting station 427 to generally align the printed pattern on the fabric with the quilting head.
An alternative configuration of the embodiment 400 of Fig. 5 employs magnetic particle brakes for the controllable elements 46) in p ! ace of servo motors. With such brakes, differentia ! tension is applied on the opposite side edges of the web 429 as the web is pulled by drive rolls 420 upstream of the quilting station 427. The unequal tension on the opposite side edges of the web 429 affects the skew adjustment. Further, bv locating the split feed roll 460 upstream of a set of rolls (not shown) at which the backing and fill layer webs 417 and 418 are joined to the facing web 429, shrinkage of the facing layer 429 bearing the printed pattern can be controlled and limited, so that tile printed pattern can be, in effect, lengthened relative to qnihed pattern. Typically, the longitudinal scale of the printed pattern at the printing station 425 takes into account predicted shrinkage due to the gathering of material during quilting. Sometimes dimensional changes occur that result in a longitudinal shortening of the web 429 after it is printed and before it is fed to the quitting line 402. Controlling longitudinal tension of the web 29 can reduce the shrinkage from that predicted and can bring the ! ongitudina ! sca ! e of the printed pattern and the quitted pattern into better correspondence. Alternatively, the quilted pattern could be electronically scaled at the quilting station 427 by the controller 437, but suet) scahng is not always aesthetically acceptable and, where the quitting station 427 employs a mufti-bar mutti-needte array is not always practical. Further, panel centric designs that must correspond to standard panel dimensions cannot be so freely scalecl. Therefore, the ability to control the amount of shrinkage to either increase or decrease the panel width (which ties in the longitudinal direction on the web) is desirable. This ability eliminates the need to provide extra material between the longitudinally spaced panels to accommodate variations in shrinkage, which extra material woulcl have to be removed by trimming, thus producing waste.
Fig 6 illustrates a mattress cover manufacturing system tO according to other aspects of the present invention. The system 10 can he divided into four subsystems or production lines, including at least one print line 11. at least one, and preferably two or more, quoting lines t2. illustrated as two quilting Iines 12a and 12b, a mattress cover combining line 13 and a mattress assembly line 14. These production lines 11-14 may be located at a single bedding manufacturing facility or distributed among different facilities of the same or different companies.
The printing line 11 includes an ink jet printing station 20 illustrated in more detail in Fig. 6A. The printing station 20 is operable to print an image from a memory, or otherwise in accordance with a programmed controHer, onto mattress cover material. By so printing, the image can be controlled and varied from product to product along the material or from one portion of the material to another. Such printing may be referred to as digital or custom <BR> <BR> printing, although the contro ! signals need not necessarily be, but preferably wi)) be, digital signals. that determine the patterns and images to be printed.
At the printing station 20, a print head carriage 2t is preferably provided having one or more print heads 22 thereon. The carriage 21 is moveable transversely on a bridge 23, which is rigidly mounted to a frame 26 and spans tile width of the printing ! ine t t, which is wide enough to accommodate a print head path that traverses the width of the widest expected web 24 of mattress ticking, which may be nominally wider than the width of the king size mattress, which is 80 inches. The carriage 2t is preferably driven by a Hnear motor 27, which, along with the operation of the print heads 22, are controlled by a print line controller 25 to selectively print a dot pattern image on the web 24. The print heads, in the illustrated embodiment, scan individual lines across the entire transverse extent of the web 24 to print line-by-line along the length of the web 24. although the print heads 22 may be controlled to scan in different x-y paths to also print patterns in area-by-area or otherwise.
The printine station may inclucle a UV curing station 26, at which UV curable ink is cured with ultraviolet light and/or a drying oven 28, which can further cure or dry UV inks or solvent based inks A suitable printing station and method are described in the commonly assigned and copending U.S. Patent Application Serial No. 09/390.571. tiled September 3, 1999, hereby expressly incorporated herein by reference.
The print ! ine controller 25 includes a digital memory in which may be stored a plurality of pattern data files. Pattern and other data from these files, and/or from a master system controller or computer 90, call be printed at selected locations on tile web 24. Tile master controller 90. in certain preferred embodiments, sends commands to the print line controller 25 to coorclinute the printing of different mattress cover patterns onto the web 24 that are grouped together in batches that wit ! be quitted in the most efficient sequence on the same quitting line 12 with a <BR> <BR> minimum of needle changes, material changes or other adjustments or operator interventions. Typicatty. this woutd mean that the top and bottom panels of a mattress cover would be grouped separate from the border panels because the top and bottom panels are usually thicker, having more fill, than the border panels. Furthermore, top and bottom panels vary more in thickness from one mattress product to another whi ! e border panels often are of the same thicknesses for many different mattress products.
In Fig. 6, for example, patterns for a series of king size top and bottom panels 30 are shown printed along a length 24a of the web 24. These include : two panels 30a. a top panel and a bottom panel of a first printed pattern ; two panels 30b, a top panel and a bottom panel of a second printed pattern to be printed ; and a pane ! 30c of the next pattern to be printed. These patterns are shown as changing from one product to another for illustration purposes.
More typically, several products of each pattern wit ! be printed in succession according to an order schedule. These patterns 30 are printed under the batch control of the master controller 90 according to a schedule that assigns orders for products bearing the patterns of panels 30a-c tea particLnar print tine tt, or toaparticutar series to be printed on the web section 24a. The grouping of the products to be made of the pane 30a-c to the same section of web 24a is assigned by the master controller 90 making the determination that these panels are to be quitted with simitar quitted patterns and with the same fill components, so that they can be run on the same quilt line 12 without interruption to make machine adjustments or material or needle changes, for example. When all panels 30 that are to be quitted consecutively on the same quilting line 12 are printed on the web section 24a, the web section 24a is preferably cut and separately wound in a roll 31 for transfer to a quitting line 12a for quilting.
The controller 90 then batches border panels 32 for printing. These border panels 32 maybe printed on the same or a different print line 1 I owlhich the top and bottom panels 30 were printed. The border panels are ! ong nlilrrow strips typicully 10 to 20 inches wide. but winch may be wider or narrower, and usua ! ! y in the range of from 18 to 27 feet long in order to surround the perimeter of a mattress, although they may be formed in shorter strips and later, sewn together. The border panels 32 will be printed to match the top and bottom panels 30 that are printed onto the web section 24a and rolled in the roll 31. The border panels 32 may include, for example, a border pane ! 32a. which is printed of the same pattern as, or one matching, the pattern of the panel 30a. Similarlyl border panels 32b may be printed with patterns corresponding to the pattern printed for the panels 30b, and border panels 32c may be printed with patterns corresponding to the pattern printed for panels 30c. The corresponding patterns can be printed in the same or a different orientatiom or size. These border panels 32 are printed on a web section 24b to be rolled into a roll 33 for transfer to the yuilting line L2b, which is set up for the quitting of border paneis.
In the quitting of border panels 32. the long narrow panels 32 are arranged to most efficiently use the area of the web section 24b. For example, five i6 inch border pane ! strips can be printed across the width of an 80 inch web section 24bs as illustr. ued in Fig. 7. For this arrangement, the print head 22 is controlled by the print line controller 25 to swn the entire transverse width of the web, line-by-line, to print one row of dots of the different patterns of each of the five panels across the width of the web section 24b, then to print another row of dots, alid so forth, until each consecutive row of dots is printed similarly as the web section 24 advances in one direction through the printing station 20. Alternatively, the print heads 22 call be moveable in a plane relative to the material and can be controlled to print selected areas of different patterns in various orders, as may be convenient. The patterns on the border panels across the width of the web 24b may be the same or each may be different, as i) iustrated. Cut hues 29 may also be printed to indicate where the panels 32 are to be slit or trnnsverseiy cut from one another.
The arrangement of the patterns are printed on the web groups of the panels such that those having similar quitting parameters are grouped together. Panels having the same quilted patterns and that call for the same needle settings can be arranged contiguously on the material. Border panels, for example, of different products usually, but not necessarily, have the same fill characteristics. Panels of similar characteristics can be grouped together, and particularly if they have the same quiit patterns, can be arranged side-by-side. Where possible, the arrangements of the printed patterns on the material is carried out to minimize material waste and production inefficiency. Pattern arrangements can be made automatically by a batch mode controller or scheduling computer that is programmed to implement some arranging criteria. fn addition to border pane ! s 32, top and bottom paneLs 30d can also be arranged on the web section 24b which may be desirable where such top and bottom pane ! s are to be quitted to the same thickness as that of the border pane ! s 32. in such a case. a top or bottom pane) 30d, for example, of a full rather than king size mattress, may be printed with the matching border panel 32d for the same mattress fit in along side of the top and bottom panels 30d.
Further, manufacturer or retailer ! abe ! s, such as a retailer label 78, can be printed directly on the bedding products by the print heads 21 at the printing station 20, as illustrated in Fig. 7A. Heretofore, labels have been sewn onto bedding products. The retailer's lahel 78 can, instead, be printed a ! ong with the pattern on the print line 11 at, for example, the corner or edge of top pane ! 30a, as the carriage 21 scans the print head 22 across the web 24 to print the pattern for the pane ! 30a of a mattress identified to a specific order. Where a bedding manufacturer makes bedding for a number of retailers, labels can be customized to designate different store brands or product models.
Even individual retail customer names can he applied for custom mattress orders. This can be done on a batch or piece-by-piece basis, as products for various retailers are batched for quilting. Such labels can be printed on a panel along with the pattern at the printing station 20. The ! abe ! s can include machine readabte information such as bar code encoded information identifying or describing the product, customer or order.
With the batch mode scheduling provided by the controller 90, provision is made for the communication of information to the quitting lines i2. the combining line 13 and the assembly line 14 so that the top and bottom panels 30 are correctly matched with border panels 32 and the resuming mattress cover is matched with the correct inner spring unit. This may be carried out by generating information records, whch can be done in any of several
ways. One method of coordinating information, and one of the more reliable, is by attaching information records to the mattress cover panels. This can be achieved by printing product codes at the printing station 20 along with the printing of the patterns on panels 30 and 32. Such printed records can be in the form of bar codes or other machine readable records.
Bar code labels are illustrated as areas 40 and 41 in the drawings. The codes 40 are, for example, shown in Fig. 6 as codes 40a-d, which contain information identifying the products for which top and bottom panels 30a-d belong, with bar codes 4ta-d identifying the products to which border panels 32a-d belong These codes are then read by sensors at subsequent stations so that subsequent operations can be automatically carried out that are appropriate for the prticular products. In addition, or in the alternative, to the printing of machine readable indicia or codes, the printer can also print manually readable information that can be used by a quoting machine operator. by those manually matching components in a mattress cover or mattress assembly, or by others in subsequent operations.
In addition, a government required iabe ! or so-called"taw tag", which discloses the content of a bedding product, can he calculated bv the controller and printed at the time that the product is being manufactured. Such a tag can, for example, be printed at the time of the priming of the tabeis 4ic or 78. Such a tag 79 can be permanently printed on the product, as iilustrated in Fig. 7A. The text of such a tag 79 can vary with the content of the particular product, and can be calculated by information made available to the print line controller from the product or batch control information data files.
R. ither than employ codes 40, 41 printed on the material to identify the patterns, electronic files containing identifying information can be synchronized among the controllers of the various lines through the master computer 90. For example, the printing of patterns at the print line I I can cause informWtion us to where and what was printed to be passed by the print line controller 25 to the master controller 90. The master controller 90 then transmits the printed pattern information along with information tracking the location of the printed patterns through the system 10 to the various controllers of the tines) 12 t3, 14 controlling and keeping track of each product component in the flow through tile system 10.
For the quitting part of the operation, the i-oll 3 1 the top and bottom printed panels 30 on the web 24a of ticking is loaded onto the quitting hue) 2a, where the web 24a is combined with, for example, two tavers of fill 36, 37 and one web of backing material 38. The layers are advanced through a quitting station 44a at which the layers are quitted together with. for example, a generic quitted pattern, such as a plurality of side-by-side continuous <BR> <BR> zig-zag patterns. Typical patterns, as weft as a muhi-needte quitting machine suitable for use as the quitting station 44a, are illustrated and described in U.S. Patent No. 5.154.130, hereby expressly incorporated by reference herein.
The quitting station 44a is controlled by a controller 45a which controls the quilting of the patterns under the control of the master controller 90 which selects the proper pattern for the product to which the patterns of the panels 30 relate. Coordination between the printed and quitted patterns may be accomplished, for example, by a sensor 46a which reads the printed codes 40, or by signals from the controller 90, communicated to the quitting station controller 45 ; 1 The quilting line 12a also includes a panel cutting station 50a, which may also be operated by the quitting station controller 45a era controller on the pane ! cutter in response to coordinating signals from a master controller, the quilting station controller or from codes read from the product such as by independently reading a bar code on the product. The cutter at the cutting station 50a uses coordination information from the controller 45a, which may include information read from the product, to determine where to sever the individual panels 30. Different panels may be cut to different lengths in accordance with product size information from batch control product parameter data through the controller 90. The cutting of the panels may be controlled to accommodate for"shrinkage"that occurs as the materia ! dimensions change in the quitting process. The cutting produces completed individual rectangular top and bottom mattress cover panels 51. which include, for example, one pair of top and bottom panels 5 la bearing the printed patterns 30a, one pair of panels 5 t b bearing the printed patterns 30b and a series of panels S lc bearing the printed patterns 30c. Panel cutters are illustrated and described in U. S. Patent No. 5. 544. 599
and in U. S. Patent Application Serial No. 09/359, 535, fHed. tuty22. t999. Thesecutpanetsare then placed in a stack 52a and transferred to an area. referred to as a matching subsystem 59 of the combining line t3. at which the corresponding top and bottom panels are matched with corresponding border panets to make up the mattress cover sets 53 for each of the products. The matching may be coordinated manually or with the batch mode control by the system controller 90, directly, or through a separate matching controller or computer 55.
Similarly, the roll 33 bearing the printed border panels 32 on the web 24b of ticking is loaded onto the quilting line 12h, where the web 24b is combined with, for example, one) ayer of fitt 47 and one web of backing material 48. The layers are advanced through a quitting station 44b at which the layers are quitted together with, for example, the same generic quitted pattern or patterns as applied at the quilting station 44a of the line 12a. The quitting station 44b is also controlled by a controller 45b which also controls the quitting of the patterns under the control of the master controller 90 which selects the proper pattern for the product to which the patterns of the panels 32 relate. Coordination between the printed and quitted patterns at the quilting line 12b may be accomplished, for example, by a sensor 46b which reads the printed codes 40. or by signals from the controller 90. communicated to the quitting station controller 45b.
The quilting line 12b also includes a panel cutting station 50b, which is also operated by the quilting station controller 45b, and is similar to the cutting station 50a of the quitting tine t2a. The cutting station 50h can he controlled by the quitting tine controller, through a master controller or independently by reading codes, such as bar codes, printed on the panels with the pattern. The cutter at the cutting station 50b uses coordination information from the controllel 45b to determine where to transversely sever one set of transversely adjacent horde !' panels 32 from another set. This transverse cutting may take place before or after the individual border panels are slit to separate one border pane ! from another. The cutting and slitting processes produce completed individual rectangular border panel strips. The border panels 61, which include, for example, one panel 61a bearing the printed patterns 30a, panel 61b bearing the printed patterns 30b, and panels 61c bearing the printed patterns 30c, are similarly cut from the material. These cut panels are then placed in a stack 52b and transferred to the matching subsystem 13 for matching with corresponding top and bottom panels as described above.
Provision for the slitting of transversely arranged panels is made by equipping one or all of the quilting lines 12 with a slitting station 60 for longitudinally separating panels 30, 32 or other panels one from mother, or to trim the selvage or other material from the edges. Suet) a slitting station is illustrated in the quitting line 12b where it is shown located between the quitting station 44b and the cutting station 5n. The slitting station 60 has a plurality of transversely adjustable and selectively operable slitting or trimming elements or knife assemblies (not shown), which can be positioned and operated to selectively slit the web 24b. In the embodiment shown, the knives can be operated to longitudinally sht the web 24b in four places to separate the five border panels 32 from each other. The completed border panels 61. so separated by stittins and transverse cutting, are then set in stack 52b for transfer to the matching station t3. The separate individual rectangular border panel strips 6t include, for example, border panel 6ta bearing the printed patterns matching top and bottom panels 51a, border panel 61b bearing the printed paterns matching top and bottom panel 51b, and border panels 61c bearing the printed patterns matching top and bottom panels 51c. These cut panels are then placed in a stack 52b and transferred to the matching subsystem t3 for matching with corresponding top and bottom panels as described above.
Trimming knife assemblies may be made selectively operable and transversely moveabte by motors or actuators under control of the quilting line controller 45b. Registration of the cutting and slitting station elements with the printed patterns is carried out at the quitting tines 12 or can be carried out on independent cutting lines on which the printed and quitted material is placed for cutting and trimming. Information for activating and/or positioning the trimming knives, as well as the transverse cutting knives, may be communicated via electronic files from the master controller 90 to the quilting an cuttin « line controllers 45a, 45b) or may be contained in coded information and/or separation tines 29 printed on the ticking with the patterns at the print tine 11. The registration techniques and web alignment techniques of the parent applications identified above for registering the quitted and printed patterns may also be used for registering and aligning the cutting and stitting operations with the patterns.
printed on the web of ticking material. In locating the cuts and slits automatically, direct sensing of printed cut lines or calculated shrinkage compensation along with precise tracking of the material through the system should be employed.
After matching of the completed border panels 61 with the top and bottom panels 51 at the matching subsystem 59 of the combining line 13, the components of a mattress cover set 53 are assembled onto an inner spring unit 65 in a conventional numner on the nrUtress assemloly line 14 to form the finished mattress products 70. The matching of the mattress cover sets 53 with the proper inner spring units 65 are a ! so carried out under the control of the master controller 90. For proper matching, the inner spring units 65 as well as the mattress cover sets 53 may be provided with sensor readuble coded labels or mmy be coordinated with electronic files by controller 90. The resulting products 70 may then include mattresses having covers and inner springs specified by product description parameters in data fiies processed by computer 90. Examples of such fi ! es are described in U. S. Patent Application Serial No. 09/301, 653, filed April 28, 1999.
The coordination of printed patterns from component to component of a given product does not only combine components having identical patterns, but can combine products having scaled patterns varying primarily in size but otherwise match ing, patterns varying in orientation, varying in coior. orotberwi. se forming complementary components of an overall design. For example border panel features may be scaled reductions of features printed in ! arger scale on the top and bottom panels. Further, different product components may be printed on the same material with the patterns oriented differently.
The above embodiments are described in the context of mattress cover or bedding product manufacturing. but certain features of the invention have additional applications. For example, white described in the context of a mattress manufacturing, the certain aspects of the method of arranging the printing of different patterns on mattress covers can be used for other applications where fabrics are printed, such as in the production of upholstery. bedspreads and comforters, and other textile and patterned fabric production.
The production of home furnishings, in general, can benefit from the coordinated manufacture of different articles having complementary printed patterns. Soft goods such as bedspreads, comforters, curtains and draperies, sheets and pi ! tow cases, bed skirts or dust ruffles, table cloths and napkins and f urn itureshp covers can be efficiently made using various aspects of the equipment and methods set forth above. Doing so can avoid the need for a ici,to carry several different widths of fabrics, for example, by arranging and printing the different products from the same material sheet or web. A printing controller can, for example, carry a single data fi le of a given pattern or set of patterns with a sca ! e factor stored in the product descriptions files for coordinated products. For example, a large print for bed coverings and small prints of the same patterns can be used for drapes, curtains, dust ruffles, pillow shams and other products. The various complementary products can be printed across the width of a wide material and arranged and oriented on the materia ! to make most efficient use of the c ! oth. By using data of one or more selected reference points on each product, the printing controller can scale uncd orient or otherwise modify each pattern so that the patterns appear correct ! y on each product as the print head scans across the textile or fabric.
Fig. 7B illustrates such a printing scheme for the printing of large, medium and small floral patterns 681-683 on a bedspread 684. pillow cases 685 and a dust ruffle 686 on a common web of material 680.
Further, the principles involved in the coordination of printed patterns among the various pane ! sot a mattress cover as described in connection with Fig. 3A above can be applied to the manufacture of apparel. For example., the sleeves and body panels of a shirt can be arranged efficiently on a single piece of fabric and the fabric can be printed with patterns differ from panel to panel or that are differently oriented from panel to panel, but that are placed on the different panels so that, when the panels are cut and sewn together the pattern parts form part of acoordinated design. This is illustratecl, For example, in Fig. 3B.
While the above description is representative of certain preferred embodiments of the invention, those skilled in the art will appreciate that various changes and additions may be made to the embodiments described above without departing from the principles of the present invention.
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