Abstract:
The present invention provides a method of optimizing a pressure contour of a pressure adjustable platform system by (a) measuring pressure in a plurality of bladders in the pressure adjustable platform system; (b) assessing whether a change in pressure in one or more of the plurality of bladders occurs; (c) determining whether a subject on the pressure adjustable platform system has adjusted position, moved or tossed; (d) generating an adaptive sleep algorithm; and (e) adjusting the pressure in one or more bladders.
Abstract:
The present invention provides a method of optimizing a pressure contour of a pressure adjustable platform system by (a) measuring pressure in a plurality of bladders in the pressure adjustable platform system; (b) assessing whether a change in pressure in one or more of the plurality of bladders occurs; (c) determining whether a subject on the pressure adjustable platform system has adjusted position, moved or tossed; (d) generating an adaptive sleep algorithm; and (e) adjusting the pressure in one or more bladders.
Abstract:
An apparatus for forming flanged quilted panels from an infed web of quilted material (18) has a panel cutter (14) which receives the web of quilted material (18) and severs it into discrete quilted panels (16). A flanger (34) integrated with the panel cutter (14) has a table (40) which supports individual panels in a fixed position while a trimming and sewing head (60) is moved around the perimeter of the panel to trim the panel to a desired size and to stitch a flange near the trimmed edge. Because the panel is trimmed prior to stitching, precise alignment of the panel on the table is not required. The flanger (34) may further include a cutting head (72) which is movable relative to the table (40) and enables the flanger (34) to cut very thick quilted material without the need for precise holding and guiding of the material.
Abstract:
Ink jet printing is provided on large area substrates such as wide width textile webs. The printheads are driven by linear servo motors across a bridge that extends across the substrate. The timing of the jetting of the ink is coordinated with the motion of the printheads, so that the heads can be rapidly moved and the ink can be jetted while the printheads are accelerating or decelerating as they move on the bridge. Preferably, ultraviolet (UV) light curable ink is jetted and first partially cured with UV light and then subjected to heating to more completely reduce uncured monomers of the ink on the substrate.
Abstract:
An automated method for the manufacture of a coil spring assembly including inserting coil springs having predetermined multiple spring rates into respective individual pockets of a continuous pocket strip in a predetermined order. The predetermined multiple spring rates of at least one coil spring may differ from that of the other coil springs, and each of the multi-rate coils has at least two different spring rates. One or more wires having a substantially uniform thickness are coiled to form the multiple rate coil springs before insertion into the continuous pocket strip. The wire is preferably coiled to produce a coil spring having at least two different diameters and at least two different pitches. The method also includes cutting the spring-filled strip into one or more desired lengths, placing at least two spring-filled lengths adjacent to each other; and attaching adjacent lengths together. A coil spring assembly may thus be provided with one or more firmness zones. Perimeter coil springs may also be inserted into pockets corresponding to the outer perimeter of the coil spring assembly, and border wire may be added for stiffness.
Abstract:
A quilting machine (10, 100, 200, 300, 400, 500, 600) is provided with a printing station (20, 125, 225, 325, 425, 525, 611, 626, 631) and a quilting station (44, 127, 227, 327, 427, 527, 627, 632). The printing station is located either in line and preferably upstream of the quilting station, with a conveyor (520) 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 (90, 135, 235, 335, 435, 535) 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 (32) across the width of a web. Identifying data (40) 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.
Abstract:
Ink jet printing is provided onto fabric using ultraviolet (UV) light curable ink. The ink is first partially cured with UV light and then is subjected to heating to more completely cure the ink and to remove by evaporation or otherwise, the uncured monomers and producing a printed image of ink having an amount of unpolymerized monomers and polymerization reactants and byproducts that is less than a food industry packaging standard of 100 PPM, and as low as 10 PPM. The printing is provided in a quilting machine having a quilting station and a printing station located upstream of the quilting station. Preferably, at the printing station, only a top layer of fabric is printed with a multi-colored design under the control of a programmed controller. UV curable ink is jetted onto the fabric with a dot volume of about 75 picoliters. A conveyor moves the printed fabric from the printing station through a UV curing station where a UV curing light head moves either with the print head or independent of the print head to expose the deposited drops of UV ink with a beam of about 300 watts per linear inch of energy, at a rate that applies about 1 joule per square centimeter. The conveyor then conveys the fabric through a heated drying station or oven where the fabric is heated to about 300° F. for from about 30 seconds up to about three minutes. Forced hot air is preferably used to apply the heat in the oven, but other heating methods such as infrared or other radiant heaters may be used. Before, or preferably after, the heat curing, the fabric is combined with other material layers and a quilted pattern is applied in program controlled coordination with the printed pattern.
Abstract:
A quilting apparatus is provided with a computer controlled presser plate adjusting mechanism. A presser plate rocker shaft is separate from and mechanically connected to a needle rocker shaft and imparts a reciprocating motion to the presser plate. The presser plate rocker shaft is adjustable to vary the range of its output link to the presser plate, thereby changing the endpoints of its reciprocating path of travel. Certain embodiments have an output end of the presser plate rocker shaft adjustable relative to the input end through a coupling to different angular positions relative to an input end in order to change the upper and lower ends of the range of reciprocation of the pressure plate relative to the needle plate. Alternatively, the length of a link between the needle and pressure plate rocker shafts is variable to make the presser plate adjustment. A motor or other actuator changes the coupling or link in response to a signal from a quilting machine controller, which can be made instantly, either manually by an operator at a controller interface terminal, by a batch mode program run by the controller to set the machine to the parameters required by products on a product schedule, or automatically in response to measurements from sensors that are interpreted by the controller in determining optimal pressure plate setting.
Abstract:
A quilting machine includes a base having three bridges; a sewing head secured to the upper bridge; a cylindrically shaped frame slidably and rotatably mounted on the lower two bridges, the frame including first and second end assemblies spaced from each other on the lower bridges, each having a support casting slidably mounted on the base and a ring rotatably mounted on a support casting, each ring including circumferential gear teeth, gears meshing with the gear teeth and extending from the support castings for supporting the rings, a plurality of first and second telescoping rods secured to the first and second end assemblies, at least one first telescoping rod screw-threadedly receiving a second telescoping rod, and at least one first and second telescoping rod rotatably fixed and axially movable with respect to each other, a gear secured to each of the latter in meshing engagement with the gear teeth of the respective rings; a mechanism for rotating the axially movable and rotatably fixed first and second telescoping rods to rotate the rings; an elongation mechanism for rotating one of the first and second screw-threaded telescoping rods to change the length of the frame; a lead screw, belt or chain assembly for axially moving the frame along the lower bridges of the base; clamps secured to the outer circumference of each ring for clamping fabric to the frame; friction rollers having a height substantially even with the rings and driven by the gears on the support castings for guiding the fabric with respect to the sewing head; a clamping assembly extending axially of the frame for clamping the free end of a fabric tensioned on the frame; a painting assembly positioned above the fabric and adjacent the sewing head for painting a pattern on the fabric; and an external control device such as a mouse for manually controlling movement of the frame.
Abstract:
A quilting machine includes a base having three bridges; a sewing head secured to the upper bridge; a cylindrically shaped frame slidably and rotatably mounted on the lower two bridges, the frame including first and second end assemblies spaced from each other on the lower bridges, each having a support casting slidably mounted on the base and a ring rotatably mounted on a support casting, each ring including circumferential gear teeth, gears meshing with the gear teeth and extending from the support castings for supporting the rings, a plurality of first and second telescoping rods secured to the first and second end assemblies, at least one first telescoping rod screw-threadedly receiving a second telescoping rod, and at least one first and second telescoping rod rotatably fixed and axially movable with respect to each other, a gear secured to each of the latter in meshing engagement with the gear teeth of the respective rings; a mechanism for rotating the axially movable and rotatably fixed first and second telescoping rods to rotate the rings; an elongation mechanism for rotating one of the first and second screw-threaded telescoping rods to change the length of the frame; a rack and pinion assembly for axially moving the frame along the lower bridges of the base; clamps secured to the outer circumference of each ring for clamping fabric to the frame; and two piston-cylinder assemblies for closing or opening the clamps during rotation of the rings.