Sewing – Special machines – Upholstery
Reexamination Certificate
2001-12-21
2004-04-13
Izaguirre, Ismael (Department: 3765)
Sewing
Special machines
Upholstery
C112S080010, C112S113000
Reexamination Certificate
active
06718894
ABSTRACT:
TECHNICAL FIELD
This invention relates to an improved method for the automatic tufting of mattresses, futons, cushions and the like. The invention also relates to a device for carrying out the method.
BACKGROUND OF THE INVENTION
Mattresses and futons have long been held together by means of tufts. The tuft also serves to stabilise the outer layers of materials, tickings and fillings.
In the art, the word ‘tuft’ is generally understood to comprise two elements (hereinafter known as ‘tuft elements’) located outside each principal face of the mattress, and held together by means of a cord, strip or similar device (hereinafter referred to as a ‘retaining link’), attached to each tuft element. Hereinafter the word ‘tuft’ when used alone will be used to describe the complete arrangement of tuft element, retaining link and further features.
One particular type of tuft known in the art is the “tape tuft”
22
illustrated in FIG.
1
. This tuft comprises a strip
12
of flexible material (typically nylon, although polyethylene, polypropylene, rayon and other materials may also be used) which interacts at either end with tuft elements
14
a
,
14
b
of harder material (polymers such as nylon, polyethylene and polypropylene being preferred, although other materials such as metal and wood may also be used). Similar tufts are described in, for example, UK Patent 814651, although the tuft elements described in this patent are made of different material.
Tape tufts may advantageously be produced by moulding. As illustrated in
FIG. 1
, a string
10
of tufts
22
,
24
,
26
joined in series and comprising a continuous strip
12
interacting with tuft elements
14
a
,
14
b
,
14
c
,
14
d
,
14
e
, may be produced. The string of tufts may typically be provided on a reel or the like: the tufts are separated by cutting the strip between the tuft elements. Alternatively, the string could be supplied pre-cut into individual tufts which are then loaded into a magazine or the like.
Typically, such tape tufts are attached to the mattress using a needle, such as a ting or ejector needle, the structure of which is well known to those skilled in the art. An example of a tufting needle is given in UK Patent 903464, the contents of which are incorporated herein by reference thereto.
The mattress is first compressed to a thickness less than the length of the tape tuft to be used. One of the tuft elements is inserted into a recess in the tufting needle, leaving the other end free. The tufting needle, carrying the first tuft element, is then passed through both faces of the mattress, the second (free) tuft element being unable to pass through the hole made by the needle and consequently remaining outside the mattress. When the tufting needle exits the mattress, the first tuft element is released so that both tuft elements are located on the outside faces of the mattress. The tufting needle may further be provided with elastic means, such as a spring-loaded plunger, which ejects or otherwise aids release of the first tuft element from the tufting needle. Once the tufting process is complete, the mattress is decompressed.
Many manufacturers use a support, such as a washer, in connection with the tape tuft; a support may be provided on either or both faces of the mattress. The function of such supports is to prevent the tuft element from being pulled through the mattress ticking and to make the tuft more comfortable to sit or lie on. Such supports may be made from felt, cardboard, foam, leather or plastic. A first washer may be fitted to the proximal face of the mattress (ie the face the needle enters) by attaching it to the free tuft element, the washer being unable to pass through the mattress. When the needle emerges from the distal face of the mattress, its point may engage a second washer so that when the first tuft element is released from the tufting needle, the washer need only be disengaged from the needle point to be in the correct position. Alternatively, the second washer may be placed on the tuft element after it has been ejected from the tufting needle, before the mattress is decompressed.
The tufting method described hereinabove has traditionally been carried out manually. The operator may have to apply a considerable amount of force to drive the tufting needle through the mattress. This makes the process slow and inefficient, and repeatedly applying such forces over a long period of time may be detrimental to the health of the operator.
It would therefore be desirable to increase automation of the tufting process making the process faster and more efficient, and less reliant on manual effort.
Machines which allow the tufting needle to engage with driving means, such as a pneumatic piston or mechanical jack, are known in the art. The first tuft element is engaged with a recess on the tufting needle as described hereinabove, and the needle is then connected to, or forms part of, means which drive the needle through the mattress. An example of such a machine is described in UK Patent 910253.
However, while such machines automate some steps of the tufting process, a significant amount of manual input is still required in particular, it remains necessary to load the tuft element manually. It would therefore be desirable to provide a device and method which minimises manual input.
In particular, it would be advantageous to provide a device capable of tufting a mattress using the string of tufts described above, without the operator having to stop the device after fitting a tuft to separate the next tuft from the string.
It would further be advantageous to provide a device which aids the release of the tuft element from the tufting needle.
In addition, it would be desirable to provide a device capable of automatically placing the supports (such as washers) in their correct positions.
SUMMARY OF THE INVENTION
With the above objectives in mind, there is provided according to the invention a device for the automatic tufting of upholstery units using tufts comprising a retaining link with a tuft element at either end and associated with further such tufts, said device including:
engagement means for a tuft;
means for separating the engaged tuft from the associated tufts;
means for driving the engagement means, together with one tuft element and the retaining link of the engaged tuft, through an upholstery unit and withdrawing the engagement means once the tuft is released; and
means for automatically reloading the engagement means with a further tuft.
The device may further include means for aiding the release of the engaged tuft from the engagement means.
Preferably, the device may also comprise means for engaging and correctly placing in its supporting position at least one support (such as a washer). For example, such means could take the form of feed means arranged for cooperation with the automatic tufting device.
There is also provided according to the invention a method for the automatic tufting of upholstery units, said method including the following steps:
providing a tuft, said tuft comprising a retaining link with a tuft element at either end and associated with further such tufts;
engaging the tuft in engagement means;
separating the engaged tuft from the associated tufts;
driving the engagement means, together with one tuft element and the retaining link of the engaged tuft through an upholstery unit;
releasing the engaged tuft;
withdrawing the engagement means; and
automatically reloading the engagement means with a further tuft.
The tuft used in the device and method according to the present invention is associated with further such tufts. It is preferred that the tuft is connected to a string of tufts, as described and illustrated below. In this case, the tuft may advantageously be separated from the string by cutting; for example, by means of one or more appropriately positioned blades. However, the tuft may also be associated with individual pre-cut tufts in a magazine or the like, the storage and loading of such tufts being readily apparent to those skilled in the art.
The upholstery
Dorsey & Whitney LLP
Izaguirre Ismael
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