L&p Property Management Company

Ormco Corporation

M Burl White

Richard N Codos

James T Frazer

Thomas J Wells

Steven E Ogle

James F Bondanza

Roland Bulnes

Michael L Shelton

Raymond D Swaney

Russell E Bowman

John Keys

Von Hall, Jr

A quilting machine () is provided with a printing station () and a quilting station (), either on the same or a different production line. Ticking is preprinted with a plurality of different patterns, organized and coordinated by the computer so that a print head can scan the material and print different patterns of different panels (). Identifying data () for matching the panels of a mattress product can be provided in data files and codes can be printed on the fabric. Panels can be matched and assembled into products based on the codes, and quilting, cutting, slitting and other operations can be controlled by printed codes and other data. The quilting and combining of the panels for assembly of a mattress product can be carried out manually or automatically using the data.

Printing and quilting method and apparatus

A quilting machine () is provided with a printing station () and a quilting station (). The printing station is located either in line and preferably upstream of the quilting station, with a conveyor () extending through each of the stations to convey a web of quilting material through the machine, or is off of the quilting line such that the material with a pre-applied pattern thereon is transferred, preferably in web form, to the line of the second station for the application of a pattern in registration with the first applied pattern. At the quilting station, registration longitudinal and transverse registration is measured and skewing or rotation of the material is determined. Opposite transverse sides of the material are differently adjusted to orient and register the material. A master batch controller () assures that the proper combinations of printed and quilted patterns are combined to allow small quantities of different quilted products to be produced automatically along a material web. Ticking is preprinted with a plurality of different patterns, organized and communicated by the computer so that a print head can scan the material and print different patterns of different panels () across the width of a web. Identifying data () for matching the panels of a mattress product can be provided in data files printed on the fabric. Cutting and slitting of the panels from each other and the quilting and combining of the panels for assembly of a mattress product can be carried out manually or automatically using the data.

A quilting machine ( ) is provided with a printing station ( ) and a quilting station ( ). A master batch controller ( ) assures that the proper combinations of printed and quilted patterns are combined to allow small quantities of different quilted products to be produced automatically along a material web. Ticking is preprinted with a plurality of different patterns, organized and communicated by the computer so that a print head can scan the material and print different patterns of different panels ( ) across the width of a web. Identifying data ( ) for matching the panels of a mattress product can be provided in data files printed on the fabric.

Ticking for the production of mattress covers is preprinted with a plurality of different patterns by a computer controlled printer that prints in response to pattern data communicated from a control computer. The pattern data is organized and communicated by the computer so that a print head, for example, can scan the ticking material, such as in rows across the width of a web, and print different patterns. For example, different border panels can be oriented along a web and positioned side-by-side across a web and each printed with a different pattern. Top and bottom panels having corresponding patterns can be printed on the same or a different web. Identifying data for matching the panels of a mattress product can be provided in data files in the same or a different computer or can be printed on the fabric along with the patterns on the panels. The printed data can be manually or machine readable so that cutting and slitting of the panels from each other and the quilting and combining of the panels for assembly of a mattress product can be carried out manually or automatically.

Mattress cover printing and quilting system and method

A quilting system that includes a multiple needle quilting machine is provided with batch processing capability by the addition of a panel cutter in-line with and downstream of the quilting machine. The panel cutter is equipped with a programmed controller that is loaded with batch information for the production, on the quilting machine, of a plurality of quilts by stitching patterns on a multilayered web of fabric. The batch information includes information of a number of quilts to be quilted as well as the patterns to be quilted on each quilt and the composition of the material on which the patterns are to be quilted. Information is derived by the panel cutter controller from sensors on the panel cutter, which information is used to control the quilting machine by adjusting the length of quilted material from the quilter. The panel cutter controller may also operate the quilter to adjust for shrinkage in web length caused by the quilting, and to synchronize splices in the web between different material layer combinations for different quilts of the series to be quilted.

Quilt panel cutter with quilting system batch and panel length control

A quilt manufacturing facility having a plurality of quilting machines is provided with an automated scheduling system which automatically generates and distributes schedules for the making of quilted products listed in input customer orders. The generated schedules are distributed in the form of computer files downloaded to the controllers of the machines. The generation of schedules is carried out by a programmed central scheduling computer which considers stored data identifying each of the machines and their capabilities, the materials available for production of the products and the product specifications, and determines the machine setting and material requirements for each product on the customer order list as well as the required completion times for each of the ordered products. Schedules for each machine are generated so as to schedule each product with other products having similar machine setting or material requirements in a manner that is consistent with the required completion or delivery times for each product. The scheduling optimizes the use of the quilting machines and operator time by reducing the number of machine setups and material changes. Information is collected from each machine which records all downtime of the machines and the reasons therefor and which records a history of the actual performance of the machines for use by the scheduling computer in more accurately evaluating future schedules.

Quilt making automatic scheduling system and method

A method of quilting patterns is provided in which pattern files are generated containing quilting machine control data for use by a controller of a quilting machine to produce different quilted patterns. Product information is generated that identifies pluralities of patterns. In response to the product information, the quilting machine controller sequentially reads the pattern files for each of the patterns of the identified plurality and sequentially quilts the plurality of patterns in the form of sub-patterns on the same panel of multi-layered material to form a combination pattern. A multi-needle quilting apparatus is provided with a controller programmed to carry out the method as part of a quilting system in which pattern and product databases are generated and linked for the production of a variety of individual and combination patterns.

Composite pattern multiple needle quilting method and apparatus

Apparatus including a mattress support for supporting a mattress lying on a first major face or panel thereof and conveying the mattress as a sewing operation, such as an edge sewing and taping operation, is performed with respect to the first major face. A mattress flipping mechanism is provided and may include a pivoting support portion of the mattress support connected to a powered lift mechanism. Mattress elevating units are provided to create slack in the top panel of the mattress for easier grasping by the operator during a sewing operation. A mattress guide arm is provided for holding the mattress down during the sewing operation. A mattress inclining mechanism is provided for selectively moving the mattress from a generally horizontal orientation used for mattress conveying and flipping operations to an inclined orientation used during sewing to gravity feed the mattress into engagement with the sewing machine.

Mattress sewing and handling apparatus

A quilting method and apparatus in which ticking or facing material changes are effected, preferably under the control of a programmed computer or controller, by automatically retrieving, and preferably also splicing onto a web, selected materials from a facing material supply. The controller preferably also controls a quilter in the stitching of selected patterns along a web, and coordinates the positions of the patterns and material splices between the patterns, in response to measurements and calculations of dimensional changes between infeed webs, quilted tensioned web and cut untensioned panels. Storage compartments are provided for a variety of facing materials, preferably rolls thereof. A retrieval mechanism moves webs selected by the programmed controller to a feed position adjacent the quilter. Preferably, the storage compartments are moveable and suspended from an endless conveyor, and the retrieval mechanism also includes a two holder transfer arm that can exchange webs between the conveyor and a quilter feed position. In a fully automated embodiment, the transfer arm includes V-shaped troughs formed of moveable belts that unwind and rewind the ticking supply rolls.

Growing community of inventors

Coral Springs, FL, United States of America

M Burl White