Attachment gusset with ruffled corners and system for automated manufacture of same

• US 6,834,603 B1
• Filed: 08/15/2002
• Issued: 12/28/2004
• Est. Priority Date: 03/05/2002
• Status: Expired due to Term

• Current Assignee: Atlanta Attachment Company
• Original Assignee: Atlanta Attachment Company
• Inventors: Price, Elvin C., Murphy, Danny V., Dasher, Preston B., Nguyen, Van H., Chamlee, John S., Price, George A., Ruderman, Stephen S.
• Primary Examiner(s): Calvert, John
• Assistant Examiner(s): KAUFFMAN, BRIAN K
• Application Number:
  US10/219,837
• Time in Patent Office: 866 Days
• Field of Search: 112/470.07, 112/427, 112/18, 112/20, 112/120, 112/470.05, 112/176
• US Class Current: 112/470.07
• CPC Class Codes: D05B 11/005 for sewing the edges of mattresses
• CPC Class Codes: D05B 35/06 for attaching bands, ribbons, strips, or tapes or for binding

Abstract

An apparatus for attaching a gusset to a panel includes a gusset folder that receives and folds a gusset material to form the gusset. The panel is supported by a sewing table. A sewing machine is positioned relative to the sewing table so as to be able to sew the gusset to the panel. A gusset guides the gusset toward a selected edge of the panel so that the gusset is held in substantial alignment with the edge of the panel. An edge detector detects when a next edge of the panel is approaching the sewing machine. A turning mechanism is positioned along the sewing table and is moveable into engagement with the panel. The turning mechanism turns the panel relative to the sewing machine when the edge detector detects the next edge of the panel is approaching the sewing machine.

Claims

1. An apparatus for attaching a gusset to a panel, comprising:

a. a gusset folder that receives and folds a gusset material to form the gusset for attachment to the panel;

b. a sewing table on which the panel is received and supported for sewing;

c. a sewing machine positioned relative to the sewing table so as to be able to sew the gusset to the panel;

d. a gusset guide for guiding the gusset fed to the sewing machine toward a selected edge of the panel so that the gusset is held in substantial alignment with the edge of the panel;

e. an edge detector that detects when a next edge of the panel is approaching the sewing machine;

f. a pleat generator that selectively forms a pleat in a portion of a gusset as the gusset is being sewn to the panel by the sewing machine; and

g. a turning mechanism positioned along the sewing table and moveable into engagement with the panel to turn the panel relative to the sewing the when the edge detector detects the next edge of the panel is approaching the sewing machine.

2. The apparatus of claim 1, wherein the pleat generator comprises a pleat formation blade moveable in timed relation to the sewing of the gusset to engage and form at least one pleat in the gusset as the panel is turned by the turning mechanism to form a ruffed gusset corner on the panel.

3. The apparatus of claim 1, further comprising a material conveyor that engages the gusset on the panel and advances the gusset and panel together past the sewing machine as the sewing machine sews the gusset to the panel.

4. The apparatus of claim 3 wherein the material conveyor comprises a rotationally driven belt that engages the gusset material in position upon the panel.

5. The apparatus of claim 1, wherein the sewing table comprises a surface upon which the panel may rest and at least one air chamber into which air is forced and from which air flows trough a plurality of holes defined by the surface of the table.

6. The apparatus of claim 5, further comprising a plurality of directional air jets that direct air parallel to the sewing table so as to move the panel in a predetermined direction.

7. The apparatus of claim 6, further comprising an air jet air flow controller that turns on the directional air jets when assistance is needed to move the panel and that turns off the directional air jets when no assistance is needed.

8. The apparatus of claim 5, further comprising an air flow controller that controls airflow through the plurality of holes.

9. The apparatus of claim 8, wherein the air flow controller is programmable so as to cause an increase in air flow as the panel becomes heavier as gusset material is being sewn thereto.

10. The apparatus of claim 8, wherein the air flow controller is programmable so as to increase air flow for more porous panel materials.

11. The apparatus of claim 8, wherein the air flow controller is programmable so as to increase air flow for heavier panel materials.

12. The apparatus of claim 1, wherein the pleat generator includes:

a. a pleat formation blade that is coupled to the sewing machine so as to have a position and a spaced apart second position and so that a pleat is formed in the gusset when the pleat formation blade moves from the fist position to the second position; and

b. an actuator that selectively moves the pleat formation blade from the first position to the second position.

13. The apparatus of claim 12, wherein the pleat generator further comprises:

a. a sewing machine state sensor that generates a signal indicative of a position of the sewing needle;

b. a ruffler controller that causes the actuator to move the pleat formation blade to the second position when the sewing machine state sensor indicates that the sewing needle is moving to an upward position.

14. The apparatus of claim 13, wherein the sewing machine comprises an external rotor that rotates as the sewing needle moves and wherein the sewing machine state sensor comprises:

a. an optical sensor directed to the external rotor; and

b. a reflective material disposed on a predetermined position on the external rotor and positioned so that as the external rotor moves to a predetermined position, the optical sensor will sense movement of the reflective material.

15. The apparatus of claim 13, wherein the sewing machine is controlled by a sewing machine controller that is coupled to the ruffler controller that causes the sewing machine to operate at a relatively fast rate when the pleat generator is not operating and that causes the sewing machine to operate at a relatively slow rate when the pleat generator is operating.

16. The apparatus of claim 1, further comprising a gusset tensioning device that is capable of controlling tension on the gusset as the gusset is being sewn to the panel so that the tension on the gusset is within a desired range for a characteristic of the gusset.

17. The apparatus of claim 16, wherein the characteristic of the gusset comprises ability of the gusset material to stretch.

18. The apparatus of claim 16, wherein the characteristic of the gusset comprises direction of sewing relative to the panel.

19. The apparatus of claim 1, wherein the edge detector comprises:

a. a piece of reflective material disposed at a predetermined location on the table; and

b. an optical sensor that senses when the piece of reflective material is uncovered.

20. The apparatus of claim 1, further comprising a movable knife that is capable of cutting the gusset material after the gusset has been sewn to the panel.

21. An apparatus for attaching a gusset to a panel, comprising:

a. an accumulator that draws out the gusset material from a source along a path having a predetermined length, the predetermined length being sufficient for the first purpose;

b. a detector that generates a signal that indicates that there is insufficient gusset material in the accumulator for the first purpose;

c. a gusset folder that receives and folds a gusset material to form the gusset for attachment to the panel;

a sewing table on which the panel is received and supported for sewing;

e. a sewing machine positioned relative to the sewing table so as to be able to sew the gusset to the panel;

f. a gusset guide for guiding the gusset fed to the sewing machine toward a selected edge of the panel so that the gusset is held in substantial alignment with the edge of the panel;

g. an edge detector that detects when a next edge of the panel is approaching the sewing machine; and

h. A turning mechanism positioned along the sewing table and moveable into engagement with the panel to turn the panel relative to the sewing machine when the edge detector detects the next edge of the panel is approaching the sewing machine.

22. The apparatus of claim 21 wherein the path has a first end adjacent the source and an opposite second end and wherein the detector generates the signal when there is no gusset material at the first end of the path.

23. The apparatus of claim 21, wherein the accumulator includes indicia that indicate when there is enough gusset material sufficient for a second purpose, different from the first purpose.

24. The apparatus of claim 21, wherein the accumulator comprises:

a. a first plurality of rollers that are evenly spaced apart;

b. a second plurality of rollers evenly spaced apart;

c. a mechanism that moves the second plurality of rollers from a first position, in which the second plurality of rollers arm interleaved with fist plurality of rollers, to a second position in which the second plurality of rollers is spaced apart from the first plurality of rollers,

so that when the gusset material is interleaved between the first plurality of rollers and the second plurality of rollers, and when the second plurality of rollers is moved from the fist position to the second position, a length of the gusset material is drawn from the supply.

25. The apparatus of claim 24, wherein the detector comprises:

a. a reflective material disposed adjacent the source of the gusset material; and

b. an optical sensor disposed so as to be able to detect when the reflective material is covered by the gusset material.

26. The apparatus of claim 25, further comprising a clamp disposed adjacent to a selected roller of the first plurality of rollers, the clamp capable of holding the gusset material against the selected roller while the second plurality of rollers moves to the second position.

27. A method of sewing a gusset to a panel, comprising the steps of:

a. sewing, with a sewing machine, the gusset to the panel along a first substantially linear path;

b. detecting a corner of the panel;

c. turning the panel when the corner of the panel approaches the sewing machine so that the gusset follows a curved path adjacent the corner of the panel;

d. creating at least one pleat in the gusset in a region that is adjacent to the corner of the panel;

e. sewing the pleat onto the panel; and

f. sewing the gusset to the panel along a second substantially linear path, angularly divergent from the from the first substantially linear path after the gusset has been sewn around the corner of the panel.

28. The method of claim 27 and wherein the step of creating at least one pleat comprises detecting movement of a needle of the sewing machine toward a raised position, engaging the gusset with a pleat formation blade as the needle is in its raised position and forming the pleat in the gusset, and moving the pleat formation blade away form engagement with the gusset as the needle is moved into engagement with the pleat.

29. The method of claim 27, wherein the step of sewing the gusset to the panel comprises sewing at a first desired rate of sewing, and varying the rate of sewing as the panel is turned.

30. The method of claim 29, further comprising the step of reducing the rate of sewing of the gusset to the panel as at least one pleat is formed in the gusset.

31. The method of claim 27 further comprising the step of accumulating a predetermined length of gusset material sufficient to form a gusseted panel of a desired size.

32. A system for attaching a gusset to a panel, comprising:

a. a gusset forming station for automatically forming the gusset from a strip of gusset material;

b. a sewing table having an upper surface supporting the panel as the gusset is attached thereto;

c. a sewing machine adjacent the upper surface of the sewing table, positioned along sewing path for the panel, for attaching the gusset to the panel;

d. a pleat generator for forming at least one pleat in the gusset at a desired location about the panel, said pleat generator operated in timed relation with said sewing machine, sewing the gusset to the panel; and

e. a system controller controlling a sewing operation for attaching the gusset to the panel, wherein said system control can control the sewing of the gusset to the panel at varying rates to enable high speed sewing of the gusset to the panel and sewing at a different rate for generation of the pleats in the gusset as needed.

33. The system of claim 32, further comprising a clamp arm for engaging and turning the panel upon detection of the approach of an edge of the panel to said sewing machine.

34. The system of claim 32, wherein ad sewing table includes a plurality of ports formed in said upper surface thereof for providing an air flow to the panel moving over said upper surface.

35. The system of claim 32, wherein said sewing table further includes at least one directional air jet for applying a directional air flow to the panel.

36. The system of claim 32, wherein said gusset forming station includes an accumulator for accumulating predetermined lengths of gusset material from a supply, a folder for folding the gusset material, and a sewing machine for sewing the folded gusset material and attaching a flange material to form a flanged gusset.

37. A system for attaching a gusset to a panel, comprising:

a. a gusset forming station for forming the gusset from a strip of gusset material;

b. a sewing table having a table surface for supporting the panel as the gusset is attached thereto;

c. a sewing machine adjacent the table surface, positioned along a sewing path for the panel, for attaching the gusset thereto;

d. a system controller controlling a sewing operation for attaching the gusset to the panel, the system control including programming for controlling the sewing of the gusset to the panel at varying rates for sewing the gusset to the panel and enabling generation of pleats in the gusset during sewing as needed; and

e. wherein the sewing machine table includes a series of ports formed in the table surface thereof for supplying an air flow to the panel supported on the sewing table, the air flow being variable by the system controller to accommodate variations in the size, weight or material of the panel being sewn.

38. A gusset for attachment to a panel, having at least one first corner, the gusset comprising a strip of gusset material having a first edge and a second edge, the strip of gusset material being folded substantially along a centerline, the first edge of the gusset material being sewn to the first panel, the gusset defining at least one pleat that uses the gusset material to change direction, the at least one pleat being placed adjacent to the first corner.

39. The gusset of claim 38, wherein the at least one pleat extends partially across a width of the gusset material.

40. The gusset of claim 38, further comprising a plurality of pleats forming a ruffled corner, whereby the direction of the gusset material is altered by substantially ninety degrees.

41. The gusset of claim 38, further comprising a plurality of pleats that are substantially evenly spaced.

42. The gusset of claim 38, wherein the gusset material is continuous about a perimeter of the panel.

43. The gusset of claim 38, wherein the at least one pleat does not extend across an entire width of the gusset material.

44. The gusset of claim 38, further comprising a mattress, the first panel being attached to the mattress.

45. The gusset of claim 38, wherein the gusset material is made of mattress upholstery material.

46. An apparatus for attaching a gusset to a panel comprising:

a. a gusset folder that receives and folds a gusset material to form the gusset for attachment to the panel;

b. a sewing table on which the panel is received and supported for sewing;

c. a sewing machine positioned relative to the sewing table so as to be able to sew the gusset to the panel;

d. a gusset guide for guiding the gusset fed to the sewing machine toward a selected edge of the panel so that the gusset is held in substantial alignment with the edge of the panel;

e. an edge detector that detects when a next edge of the panel is approaching the sewing machine; and

f. a turning mechanism having a swing frame positioned along the sewing table, a clamp am moveable into engagement with the panel, and a drive mechanism for moving the clamp arm about an arcuate path to turn the panel relative to the sewing machine when the edge detector detect the next edge of the panel is approaching the sewing machine.

47. The apparatus of claim 46, wherein the clamp arm has an angular configuration and engages the panel proximate to a corner of the panel.

48. An apparatus for attaching a gusset to a panel, comprising:

a gusset folder that receives and folds a gusset material to form the gusset for attachment to the panel;

b. a sewing table on which the panel is received and supported for sewing;

c. a sewing machine positioned relative to the sewing table so as to be able to sew the gusset to the panel;

d. a gusset guide for guiding the gusset fed to the sewing machine toward a selected edge of the panel so that the gusset is held in substantial alignment with the edge of the panel;

e. an edge detector that detects when a next edge of the panel is approaching the sewing machine;

f. a turning mechanism positioned along the sewing table and moveable into engagement with the panel to turn the panel relative to the sewing machine when the edge detector detects the next edge of the panel is approaching the sewing machine; and

g. a movable knife capable of cutting the gusset material after the gusset has been sewn to the panel;

wherein the knife has an extended position and a retracted position and wherein the table includes a door portion hingedly attached to the table, and defining a door opening suitable for an operator to access the sewing machine, and a controllable actuator that raises the door portion when the knife is in its extended position, thereby blocking the door opening.