US2274929A - Upholstery - Google Patents

Upholstery Download PDF

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Publication number
US2274929A
US2274929A US264476A US26447639A US2274929A US 2274929 A US2274929 A US 2274929A US 264476 A US264476 A US 264476A US 26447639 A US26447639 A US 26447639A US 2274929 A US2274929 A US 2274929A
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Prior art keywords
batts
upholstery
fabric
sheeting
band
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US264476A
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John R Millar
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National Automotive Fibres Inc
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National Automotive Fibres Inc
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Priority to US264476A priority Critical patent/US2274929A/en
Priority to US331047A priority patent/US2282425A/en
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B68SADDLERY; UPHOLSTERY
    • B68GMETHODS, EQUIPMENT, OR MACHINES FOR USE IN UPHOLSTERING; UPHOLSTERY NOT OTHERWISE PROVIDED FOR
    • B68G7/00Making upholstery
    • B68G7/02Making upholstery from waddings, fleeces, mats, or the like
    • B68G7/04Making upholstery from waddings, fleeces, mats, or the like by conveyor-line methods
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/17Surface bonding means and/or assemblymeans with work feeding or handling means
    • Y10T156/1702For plural parts or plural areas of single part
    • Y10T156/1712Indefinite or running length work
    • Y10T156/1734Means bringing articles into association with web

Definitions

  • the present invention relates to upholstery material and more particularly to the novel method of making decorated padded upholstery material.
  • the vulcanized seam offers a number of substantial advantages over the sewed seam referred to.
  • the cloth is not weakened by sewing.
  • the seam resulting from vulcanization of the upholstery material to sheeting is substantially permanent and in fact will outlast portions of the cushion not included in the vulcanized ,area.
  • Figure 2 is a diagrammatic view illustrating the complete assembly of the apparatus
  • Figure 3 is an enlarged sectional view of the mechanism for restraining padding material
  • Figure 4 is a section on the line 44, Figure 3;
  • Figure 5 is a section on the line 5--5, Figure 3;
  • Figure 6 is a section on the line 6-6, Figure 3;
  • Figure 7 is a section on the line 'l-1, Figure 3; and
  • Figure 8 is a fragmentary perspective illustrating upholstery material made according to the present disclosure.
  • FIG. 2 which illustrates the complete layout of apparatus employed, I have illustrated at iii a casing having a surmounting table M on which precut cover fabrics are positioned by the operator or over which a continuous cover fabric maybe advanced if desired.
  • a casing. is next provided which is associated with forming means subsequently to be described. At this station the upholstery material is formed over ridges to provide pleat fullness for subsequent operation.
  • the casing is located at a station where the formed upholstery fabric is brought into contact with a sheet or a plurality of batts of padding material and is further brought into contact with the strip of uncured rubber and an uppermost permanently bonded along lines corresponding to seams of conventional pleated upholstery material.
  • a final station 90 may be employed for performing a final sewing operation. This last station and its function may be omitted if desired.
  • FIGS 1A, 1B and 1C are enlarged views of the apparatus illustrated diagrammatically in Figure 2.
  • the casing i is provided with a foraminous belt H which is adapted to pass over a suction box 62 associated with suitable producing means connected to a conduit I3.
  • the arrangement is such that as the upholstery fabric is advanced by the belt ll it is firmly retained against displacement by the suction means referred to.
  • Partly supported by the frame of the casing H! is a table it on which the operator positions individual precut cover fabrics, if such are employed.
  • a support l5 may be provided for the convenience of the operator upon which are located a supply of individual cover fabrics indicated at Hi.
  • a pusher assembly indicated at H is carried by the casing H5 and is adapted to advance accurately positioned fabric it into closely contiguous relation to the preceding cover fabric.
  • a plurality of resilient pusher elements I8 are provided which are adapted to engage fabrics it upon movement of pusher assembly H to the right of Figure 1A.
  • FIG. IE I have illustrated in somewhat enlarged scale a casing 30 which carries a foraminous belt-3!, a suction box 32 which is connected to a suitable suction supply source, such as'a conduit 3-3 or the like.
  • a suitable suction supply source such as'a conduit 3-3 or the like.
  • a plurality of forming bars 3d are provided.
  • Suitable actuating mechanism 35 which forms no part of the present invention is provided to control motion of the forming bars 3d.
  • the relationship of parts is such that in timed relation to the advance of the upholstery material the formingvbars 3d are moved vertically downward to form the upholstery material over ridge members 35 having a cross-section such for example as shown in Figure 4.
  • formation of the fabric over these ridge members by the forming bars 36 provides a predetermined amount of fullness in the upholstery fabric for a purpose which will presently be described.
  • the forming bars 3 3 after being moved vertically downward are advanced to the right at the same rate as the advancing upholstery material for a predetermined distance. They are then raised to a position to clear the upholstery material and return to their initial position.
  • the upholstery material It is now brought into association with a padding material 55., such as cotton, strips of uncured rubber 55, and a continuous web of sheeting 56.
  • a padding material 55 such as cotton, strips of uncured rubber 55, and a continuous web of sheeting 56.
  • the fibrous padding material is preferably in the form of individual substantially cylindrical batts of cotton which are led downwardly over a roller 5'! and an apron 58 into contact with the upholstery material.
  • the arrangement is such that one or more batts of cotton is led into accurate registering relation with the pleat fullness provided by theforming bars 3% previously referred to.
  • one or more batts of cotton may be necessary to fiH the pipe, depending upon the lateral spacing of the seams.
  • the fibrous material 58 passes through a breaker comprising a pair of breaker rolls 58 and 6t.
  • Suitable automatic mechanism is provided for timing operation of the breaker mechanism, and rotation of the rolls 59 is interrupted momentarily while the rolls (it) continue to rotate. This breaks the cotton batts intermediate the rolls 59 and 6E! and rotation of the rolls 59 is delayed for an interval corresponding to the spacing between adjacent cover fabric. This not only serves to sever the padding material intermediate adjacent cushions, which would otherwise have to be performed as a separate operation, but also serves the separate function of effecting a substantial saving in padding material.
  • the strips of rubber are led from a roll 6! to a point intermediate the upholstery fabric it and the continuous strip of sheeting 56.
  • the fibrous material is definitely excluded from encroaching upon the rubber at this time.
  • the assembly advances to the continuous vulcanizing unit 'il which comprises a rotating drum if over which the assembly is adapted to advance.
  • the drum H is provided with heating means which may take any convenient form, such for example as electric resistance elements.
  • the upholstery assembly is brought into contact with the rotating drum H such that the sheeting it directly contacts the drum.
  • the outermost surface of the upholstery material at this time is the upholstery fabric 86.
  • a forming band 12- which is adapted to engage the outer or dress face of the fabric. Suitable means (not shown) areprovided for applying a predetermined tensicn to the band l2.
  • band 72 may take many forms. If, for example. it is desired to impart straight beads as a form of decoration to the vulcanized zone, the band or bands "i2 may be straight metal bands. If, however, it is desired to impart an arbitrary or fanciful decorative efiect of the type indicated in Figure 8, the band 72 will be correspondingly formed. In the latter case it is often found desirable to reduce the tension on the forming band I2 to a minimum, in which case it is sometimes necessary to provide additional pressure by means of a second pressure band I3.
  • the band 13 will normally be of metal and of sufficient strength to withstand relatively high tension.
  • the bands 12 and 13 are guided around suitable rollers 14 and, as will be evident, advance in accurately timed relation with the drum H.
  • the action of the forming band or forming and pressure band, if used, at this time may well be described.
  • the strip of rubber 55 which is ulncoated on both sides, is brought into direct contact with the upholstery material l6 and the sheeting 56.
  • the rubber is preferably of excellent quality and a quick curing rubber.
  • the forming band I2 applies pressure to the dress face of the upholstery fabric, the pressure being sufiicient to deform the rubber.
  • the forming band I2 is in the form of a straight unmodified continuous band, the rubber will be deformed from beneath the band to provide a straight groove having at the side thereof an upstanding rubber riser formed of rubber displaced from beneath the forming bar.
  • the rubber will be displaced from beneath imperforate portions of the forming band into spaces underlying perforations therein and will also be displaced laterally to form upstanding ridges at the sides of the band.
  • the drum H is rotated at a speed sufficient to cause substantially complete vulcanization of the rubber strip 55 during its contact with the drum II. This will also depend upon the characteristics of the rubber and on the temperature available on the drum. Due to the fact that pressure is simultaneously applied, the bond between the sheeting and the fabric I formed by the vulcanization of the thin rubber strip 55 is exceptionally firm. It has been found in tests that the vulcanized bond is of sufficient strength such that rupture of the fabric precedes destruction of the bond. It has furthermore been found that the bond resulting from this vulcanization is substantially permanent and further is unaffected by moisture or cleaning fluids common in use.
  • a stripping blade is provided which is adapted to insure separation of the vulcanized upholstery material from the drum, and suitable guiding means 18 are arranged to lead the up- .1.
  • the upholster material then advances with the bands 12 and 13 to the upper righthand roll 14 at which time it passes downwardly over an apron 16 to the sewing mechanism indicated generally at 90.
  • this upholstery material as it leaves the vulcanizing station H1 is completed.
  • the bond imparted, as previously stated, is not only substantially stronger than previously known sewed bonds but further adds a highly desirable decorative effect to the upholstery material as a whole.
  • the vulcanized bond may be desirable to supplement the vulcanized bond with a sewed seam.
  • the sewed seam may cooperate with the vulcanized bond to create a novel, decorative effect. It also may cooperate therewith to form a reinforcement, although it is again emphasized that the vulcanized bond is itself stronger than the sewed seam.
  • the vulcanized bond in combination with the sewed seams exhibits different characteristics. In the first place, the vulcanized bond is characterized by its flexibility, and in som instances the rubber forming the bond may supplement the sewed seam, preventing undue strain upon the seam and further preventing failure of the seam as a whole upon breakage of the sewing thread.
  • the mechanism indicated at 90 in Figure 10 may be employed.
  • the casing 90 is provided with a foraminous b'elt 9i which is adapted to cooperate with an open top suction box 92 connected by a conduit 93 with a suitable source of suction.
  • the arrangement is such that the upholstery material as it is advanced by the foraminous belt 9
  • the sewed seam shall be definitely located with respect to the vulcanized seam and decorative design.
  • a plurality of sewing heads indicated generally at 94 are positioned to sew seams in the advancing upholstery fabric Sewing heads 94 are preferably laterally adjustable and may be clamped in desired position.
  • guides indicated generally at 95 for receiving the vulcanized design and for guiding it in accurately located relation past sewing heads 94.
  • the exact arrangement of the guides 95 will depend upon the character of the decorated vulcanized design. For example, where the vulcanized design comprises a pair of spaced parallel upstanding beads, the guides 95 will have correspondingly formed recesses to receive the beads. Preferably these recesses will be flared in the direction from which the upholstery material advances so as to permit positioning of the decorated design definitely relative to the sewing heads.
  • FIG. 3 Ihave illustrated the breaker rolls 59 and 60 as carried by a suitable frame element 62.
  • the fibrous. padding material 54 passes downwardly between a pair of rolls t9 and 69 as previously described.
  • the block 62 at its lower portion is provided with a channel or recess 63, best seen in Figure '7, guidingly receiving the strip 55 of rubber.
  • the sheeting 5% passes over the upper surface of th lower end of the block 62.
  • Secured to or integral with the lower end of the block 62 I provide a pair of forwardly extending plates E i which are well illustrated in the sectional views of Figures 4 and 5.
  • a roller 55 is carried b the frame of the machine and is adapted to present the sheeting 5B and the rubber 55 into contact with the lower portion of the block 52, all as well illustrated in Figure 8.
  • the upholstery material i6 is advanced over the plurality of ridge members 35, thus providing pleat fullness for the reception of the padding material.
  • Ihis arrangement of parts is well illustrated in Figure 4 in which the cover fabric 55 is shown as formed upwardly over the ridge members 35 and abutting the lower edge of the plates 6d.
  • the rubber 55 as seen in this figure, is thus retained in an enclosed chamber defined on two sides by the plates fi l, on the bottom by the cover fabric l6, and on top by the sheeting 56.
  • the plates M are formed around the roll 66 and terminate as close as possible to the point of tangency between the roll $6 and heated drum H.
  • the sheeting tit is at this time still in contact with the upper surface of the plates 6
  • the forming band I2 presses the upholstery fabric firmly against the heating roll ll as soon as permitted to do so by the termination of the plates at.
  • the plates 6% terminate substantially at the point where the forming band l2 forces the fabric it and the rubber against the roll. It also, as will be readily apparent, forces the rubber firmly into contact with the sheeting 56.
  • the complete cushion 89 is illustrated in Figure 8, in which the upholstery fabric is provided with a sheeting ill and intermediate padding material, such for example as cotton 82.
  • a sheeting ill and intermediate padding material such for example as cotton 82.
  • the upholstery fabric is thus vulcanized to the sheeting 8! throughout a substantial width and entirely across the completed cushion.
  • This design comprises a pair of lines of beads, and in this figure I have also indicated a line of sewing symmetrically located with respect to the beads. This line of sewing may or may not be provided.
  • Apparatus for forming stuffed pleated upholstery which comprises a heated roll, a pres sure band engaging said roll and movable therewith throughout less than its complete circum" ferenoe, means for assembling and continuously advancing upholstery material including sheeting, fabric, laterally spaced batts and an intermediate band of thermal setting material, said pressure band adapted to press said upholstery against said heated roll along the line of said thermal setting material.
  • Apparatus for forming stuffed pleated upholstery which comprises a heated roll, a pressure band engaging said roll and movable therewith throughout less than its complete circumference, means for assembling and continuously advancing upholstery material including sheeting, fabric, laterally spaced batts and an intermediate band of thermal setting material, said pressure band adapted to press said upholstery against said heated roll along the line of said thermal setting material, and a fixed separator member intermediate said batts and adjacent said fabric for retaining said batts separated substantially until engagement with said band.
  • Apparatus for forming stuffed pleated upholstery which comprises a heated roll, a pressure band engaging said roll and movable therewith throughout less than its complete circumference, means for assembling and continuously advancing upholstery material including sheeting, fabric, laterally spaced batts and an intermediate band of thermal setting material, said pressure band adapted to press said upholstery against said heated roll along the line of said thermal setting material, and a fxed separator member intermediate said batts and adjacent said fabric for retaining said batts separated substantially until engagement with said band, said member arranged to apply said thermal setting material between said laterally spaced batts.
  • Apparatus for forming stuffed pleated upholstery which comprises a heated roll, a pressure band engaging said roll and movable therewith throughout less than its complete circumference, means for assembling and continuously ad- While I have illustrated throughout a vancing upholstery material including sheeting, fabric, laterally spaced batts and an intermediate band of thermal setting material, said pressure band adapted to press said upholstery against said heated roll along the line of said thermal setting material, and a fixed separator member intermediate said batts and adjacent said fabric for retaining said batts separated substantially until engagement with said band, said member arranged to apply said thermal setting material between said laterally spaced batts, said thermal setting material comprising a strip of uncured rubber, and said separator member being provided with a groove for guidingly receiving said strip.
  • Apparatus for forming stuffed pleated upholstery which comprises a heated roll. a pres' sure band engaging said roll and movable therewith throughout less than its complete circumference, means for assembling and continuously advancing upholstery material including sheeting, fabric, laterally spaced batts and an intermediate band of thermal setting material, said pressure band adapted to press said upholstery against said heated roll along the line of said thermal setting material, and a fixed separator member intermediate said batts and adjacent said fabric for retaining said batts separated substantially until engagement with said band, said separator member including a pair of spaced parallel plates of reduced height in the direction of advance and terminating substantially adjacent the point of engagement of said upholstery with said heated roll.
  • a machine for forming stuffed pleated upholstery means for assembling and continuously advancing a sheeting and cover fabric with interleaved laterally spaced batts and strips of uncured rubber stock intermediate said batts, separator means to retain said batts separated, presser means to compress said sheeting and fabric along said strips, said separator means extending substantially to said presser means, said separator means comprising an elongated member having a groove therein for guidingly receiving said strip of rubber stock.
  • Apparatus for making stuffed pleated upholstery which comprises means for advancing a cover fabric having laterally spaced batts against one surface thereof, stationary means intermediate said batts and adjacent said cover fabric for retaining said batts laterally spaced, means for advancing a strip of securing material, said stationary means being formed to guide said securing material into the space between said batts, and means for advancing sheeting into assembled relation with said fabric, batts, and securing material to position said batts and securing material between said sheeting and said fabric.
  • Apparatus for making stuffed pleated upholstery which comprises means for advancing a cover fabric having laterally spaced batts against one surface thereof, stationary means intermediate said batts and adjacent said cover fabric for retaining said batts laterally spaced, means for advancing a strip of securing material, said stationary means being formed to guide said securing material into the space between said batts, and means for advancing sheeting into assembled relation with said fabric, batts, and securing material to position said batts'and securing material between said sheeting and said fabric, said stationary means comprising a block grooved to receive said strip of securing material.
  • Apparatus for making stuffed pleated upholstery which comprises means for advancing a cover fabric having laterally spaced batts against one surface thereof, stationary means intermediate said batts and adjacent said cover fabric for retaining said batts laterally spaced, means for advancing a strip of securing material, said stationary means being formed to guide said securing material into the space between said batts, and means for advancing sheeting into assembled relation with said fabric, .batts, and securing material to position said batts and securing material between said sheeting and said fabric, said stationary means comprising a block grooved to receive said strip of securing material and terminating in a pair of spaced plates adapted to receive said securing material therebetween.
  • Apparatus for making stuffed pleated upholstery which comprises means for advancing a cover fabric having laterally spaced batts against one surface thereof, stationary means intermediate said batts and adjacent said cover fabric for retaining said batts laterally spaced, means for advancing a strip of securing material, said stationary means being formed to guide saidsecuring material into the space between said batts, and means for advancing sheeting into assembled relation with said fabric, batts, and securing material to position said batts and securing material between said sheeting and said fabric, said stationary means comprising a block grooved to receive said strip of securing material and terminating in a pair of spaced plates adapted to receive said securing material therebetween, and means for compressing said sheeting and fabric directly against said securing material.
  • Apparatus for making stuffed pleated upholstery which comprises means for advancing a cover fabric having laterally spaced batts against one surface thereof, stationary means intermediate said batts and adjacent said cover fabric for retaining said batts laterally spaced, means for advancing a strip of securing material, said stationary means being formed to guide said securing material into the space between said batts, and means for advancing sheeting into assembled relation with said fabric, batts,
  • said stationary means comprising a block grooved to receive said strip of securing material and terminating in a pair of spaced plates adapted to receive said securing material therebetween, and means adjacent the end of said plates for compressing said sheeting and fabric directly against said securing material.
  • Apparatus for making stuffed pleated upholstery which comprises means for advancing a cover fabric having laterally spaced batts against one surface thereof, stationary means intermediate said batts and adjacent said cover fabric for retaining said batts laterally spaced, means for advancing a strip of securing material, said stationary means being formed to guide said securing material into the space between said batts, and means for advancing sheeting into assembled relation with said fabric, batts, and securing material to position said batts and securing material between said sheeting and said fabric, said stationary means comprising a block grooved to receive said strip of securing material and terminating in a pair of spaced plates adapted to receive said securing material therebetween, and a travelling pressure band for compressing said sheeting and fabric directly against said securing material.
  • Apparatus for making stuffed pleated upholstery which comprises means for advancing a cover fabric having laterally spaced batts against one surface thereof, stationary means intermediate said batts and adjacent said cover fabric for retaining said batts laterally spaced, means for advancing a strip of securing material, said stationary means being formed to guide said securing material into the space between said batts, and means for advancing sheeting into assembled relation with said fabric, batts, and securing material to position said batts and securing material between said sheeting and said fabric, said stationary means comprising a block grooved to receive said strip of securing material and terminating in a pair of spaced parallel plates of gradually reduced height in the direction of advance adapted to receive said securing material therebetween.
  • a machine for forming stuffed, pleated upholstery means for assembling and continuously advancing a sheeting and cover fabric with interleaved batts of padding material and strips of uncured rubber stock, said batts and strips being arranged alternately and spaced transversely of the path of advance thereof, elongated separator elements intermediate adjacent batts, said elements having longitudinally extending channels for the reception of said strips of rubber stock, presser means adapted to press said cover fabric toward said sheeting along lines overlying said strips of rubber, said separator elements extending substantially to said presser means to prevent encroachment of said padding material on said strips of rubber.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Description

March 3, 1942. J. R. MlL LAR UPHOLSTEHY Filed March 27, 1939 FIG] 3 Sheets-Sheet l 4 INVENTOR.
A TTORNEYS March 3, 1942. J. R. MILLAR UPHOLSTERY Filed March 27, 1939 '3 Sheets-Sheet 2' INVENTOIR.
JOHN R. 1%
ATTORNEYS Patented Mar. 3, 1942 r UPHOLSTERY John R. Millar, Reno, Nev., assignor to National Automotive Fibres, Inc., Detroit, Mich, a corporation of Delaware Application March 27, 1939, Serial No. 264,476
14 Claims.
The present invention relates to upholstery material and more particularly to the novel method of making decorated padded upholstery material.
In'the past it has been proposed to form up-. holstery material by a continuous process in which individual precut upholstery fabric covers are combined with padding material and sheeting and are sewed along lines parallel to the advance of the assembly. Certain disadvantages of upholstery material made by this method have long been recognized. In the first place the method just described is far from flexible and it is impossible to apply any substantial amount of decoration to the completed product. In the second place the sewing of the seams referred to tends to weaken the fabric, and it has been found that oftentimes the sewed upholstery becomes useless due to tearing at'the seams long before the fabric itself exhibits substantial Wear. It has also been found that the sewingof the seams is not entirely satisfactory for the reason that threads employed break either in the sewing operation or in subsequent use.
It has been proposed to substitute a vulcanized seam for a sewed seam. The vulcanized seam offers a number of substantial advantages over the sewed seam referred to. In the, first place, the cloth is not weakened by sewing. In the second place, it has been found that the seam resulting from vulcanization of the upholstery material to sheeting is substantially permanent and in fact will outlast portions of the cushion not included in the vulcanized ,area. More important, it has been found that by employing a vulcanized seam, of substantial width it is possible to combine decoration with the completed upholstery material. This decoration may take theform of straight beads, circular beads, or in fact any arbitrary or fanciful design which is desired.
In order to manufacture upholstery material by providing a vulcanized bond between sheeting and'the upholstery fabric, it is desirable to positively exclude the introduction of padding material, such as cotton or the,like,, between the cover fabric and the sheeting throughout the zone of vulcanization. In the present disclosed method this is accomplished by the provision of spaced plates over which the assembly advances, the plates serving to hold the padding, material apart ;until pressure means may be applied to bring the upholstery material and the sheeting into abutting relation with a strip of rubber.
With the foregoing somewhat general description in mind, it is accordingly an object of the present invention to provide a novel method and apparatus for continuously manufacturing a vulcanized decorated upholstery material.
It is a further object of the present invention to provide a novel method and apparatus for positively preventing appearance of padding material between the sheeting or the upholstery material and the strip of rubber.
It is a further object of the-present invention to provide automatic mechanism for providing a vulcanized seam of the type disclosed.
Itis a further object of the present invention to provide a method and apparatus for forming a vulcanized seam in combination with a cooperating sewed seam. r
Other objects of the invention will be apparent as the description proceeds, and when taken in conjunction with the accompanying drawings wherein p Figures 1A, 1B and 1C are side elevations of the apparatus employed in the continuous manufacture of upholstery material;
Figure 2 is a diagrammatic view illustrating the complete assembly of the apparatus;
Figure 3 is an enlarged sectional view of the mechanism for restraining padding material;
Figure 4 is a section on the line 44, Figure 3; Figure 5 is a section on the line 5--5, Figure 3; Figure 6 is a section on the line 6-6, Figure 3; Figure 7 is a section on the line 'l-1, Figure 3; and
Figure 8 is a fragmentary perspective illustrating upholstery material made according to the present disclosure.
Referring briefly to Figure 2 which illustrates the complete layout of apparatus employed, I have illustrated at iii a casing having a surmounting table M on which precut cover fabrics are positioned by the operator or over which a continuous cover fabric maybe advanced if desired. A casing. is next provided which is associated with forming means subsequently to be described. At this station the upholstery material is formed over ridges to provide pleat fullness for subsequent operation.
The casing is located at a station where the formed upholstery fabric is brought into contact with a sheet or a plurality of batts of padding material and is further brought into contact with the strip of uncured rubber and an uppermost permanently bonded along lines corresponding to seams of conventional pleated upholstery material. If desired, a final station 90 may be employed for performing a final sewing operation. This last station and its function may be omitted if desired.
Figures 1A, 1B and 1C are enlarged views of the apparatus illustrated diagrammatically in Figure 2. In Figure 1A the casing i is provided with a foraminous belt H which is adapted to pass over a suction box 62 associated with suitable producing means connected to a conduit I3. The arrangement is such that as the upholstery fabric is advanced by the belt ll it is firmly retained against displacement by the suction means referred to. Partly supported by the frame of the casing H! is a table it on which the operator positions individual precut cover fabrics, if such are employed. A support l5 may be provided for the convenience of the operator upon which are located a supply of individual cover fabrics indicated at Hi. A pusher assembly indicated at H is carried by the casing H5 and is adapted to advance accurately positioned fabric it into closely contiguous relation to the preceding cover fabric. For this purpose a plurality of resilient pusher elements I8 are provided which are adapted to engage fabrics it upon movement of pusher assembly H to the right of Figure 1A.
The details of the mechanism for actuating the pusher assembly form no part of the present invention. It is sufficient to say here that the arrangement is such that the operator is given a substantial interval of time to accurately position a cover fabric 1 6 relative to suitable markers or guides carried by the table M. During this interval the preceding cover fabric is slowly advanced by the foraminous belt 5 i in timed relation. The pusher assembly I! moves to the right to quickly advance the cover fabric it to close position behind the preceding cover fabric.
In Figure IE I have illustrated in somewhat enlarged scale a casing 30 which carries a foraminous belt-3!, a suction box 32 which is connected to a suitable suction supply source, such as'a conduit 3-3 or the like. The arrangement is such that as the cover fabrics are advanced by the belt 3i they are firmly retained against casual or accidental displacement.
I At this station a plurality of forming bars 3d are provided. Suitable actuating mechanism 35 which forms no part of the present invention is provided to control motion of the forming bars 3d. The relationship of parts is such that in timed relation to the advance of the upholstery material the formingvbars 3d are moved vertically downward to form the upholstery material over ridge members 35 having a cross-section such for example as shown in Figure 4. As will be evident, formation of the fabric over these ridge members by the forming bars 36 provides a predetermined amount of fullness in the upholstery fabric for a purpose which will presently be described. Preferably the forming bars 3 3 after being moved vertically downward are advanced to the right at the same rate as the advancing upholstery material for a predetermined distance. They are then raised to a position to clear the upholstery material and return to their initial position.
The next operation is performed at the station 59 indicated in part in Figures 13 and 10. At this station third foraminous belt ii is provided and is associated with an upwardly open suction box 52 connected to a suitable source of suction as by the conduit 53 or the like. Again the arrangement is such that the advanced upholstery material is firmly retained against casual or accidental displacement.
Referring more particularly now to Figure 10, the upholstery material It is now brought into association with a padding material 55., such as cotton, strips of uncured rubber 55, and a continuous web of sheeting 56.
The fibrous padding material is preferably in the form of individual substantially cylindrical batts of cotton which are led downwardly over a roller 5'! and an apron 58 into contact with the upholstery material. The arrangement is such that one or more batts of cotton is led into accurate registering relation with the pleat fullness provided by theforming bars 3% previously referred to. As will be understood one or more batts of cotton may be necessary to fiH the pipe, depending upon the lateral spacing of the seams.
As will be subsequently described in detail,
mechanism is provided for positively preventing the batting material 541 from encroaching upon the rubberous material 55. Preferably the fibrous material 58 passes through a breaker comprising a pair of breaker rolls 58 and 6t. Suitable automatic mechanism is provided for timing operation of the breaker mechanism, and rotation of the rolls 59 is interrupted momentarily while the rolls (it) continue to rotate. This breaks the cotton batts intermediate the rolls 59 and 6E! and rotation of the rolls 59 is delayed for an interval corresponding to the spacing between adjacent cover fabric. This not only serves to sever the padding material intermediate adjacent cushions, which would otherwise have to be performed as a separate operation, but also serves the separate function of effecting a substantial saving in padding material.
The strips of rubber are led from a roll 6! to a point intermediate the upholstery fabric it and the continuous strip of sheeting 56. As previously stated, the fibrous material is definitely excluded from encroaching upon the rubber at this time.
From this station the assembly advances to the continuous vulcanizing unit 'il which comprises a rotating drum if over which the assembly is adapted to advance. The drum H is provided with heating means which may take any convenient form, such for example as electric resistance elements. As will be apparent from a consideration of Figure 1C, the upholstery assembly is brought into contact with the rotating drum H such that the sheeting it directly contacts the drum. The outermost surface of the upholstery material at this time is the upholstery fabric 86.
In order to provide a firm vulcanized bond between the sheeting and the fabric and to simultaneously impart a decorative effect along the vulcanized zone, I employ a forming band 12- which is adapted to engage the outer or dress face of the fabric. Suitable means (not shown) areprovided for applying a predetermined tensicn to the band l2. As will be apparent, the
band 72 may take many forms. If, for example. it is desired to impart straight beads as a form of decoration to the vulcanized zone, the band or bands "i2 may be straight metal bands. If, however, it is desired to impart an arbitrary or fanciful decorative efiect of the type indicated in Figure 8, the band 72 will be correspondingly formed. In the latter case it is often found desirable to reduce the tension on the forming band I2 to a minimum, in which case it is sometimes necessary to provide additional pressure by means of a second pressure band I3. The band 13 will normally be of metal and of sufficient strength to withstand relatively high tension. The bands 12 and 13 are guided around suitable rollers 14 and, as will be evident, advance in accurately timed relation with the drum H.
The action of the forming band or forming and pressure band, if used, at this time may well be described. The strip of rubber 55, which is ulncoated on both sides, is brought into direct contact with the upholstery material l6 and the sheeting 56. The rubber is preferably of excellent quality and a quick curing rubber. When the assembly comes into contact with the heated drum 1| the rubber initially is soft. The forming band I2 applies pressure to the dress face of the upholstery fabric, the pressure being sufiicient to deform the rubber. Thus for example, if the forming band I2 is in the form of a straight unmodified continuous band, the rubber will be deformed from beneath the band to provide a straight groove having at the side thereof an upstanding rubber riser formed of rubber displaced from beneath the forming bar.
In the event that an arbitrary design, such as indicated in Figure 8 is employed, the rubber will be displaced from beneath imperforate portions of the forming band into spaces underlying perforations therein and will also be displaced laterally to form upstanding ridges at the sides of the band.
The drum H is rotated at a speed sufficient to cause substantially complete vulcanization of the rubber strip 55 during its contact with the drum II. This will also depend upon the characteristics of the rubber and on the temperature available on the drum. Due to the fact that pressure is simultaneously applied, the bond between the sheeting and the fabric I formed by the vulcanization of the thin rubber strip 55 is exceptionally firm. It has been found in tests that the vulcanized bond is of sufficient strength such that rupture of the fabric precedes destruction of the bond. It has furthermore been found that the bond resulting from this vulcanization is substantially permanent and further is unaffected by moisture or cleaning fluids common in use.
A stripping blade is provided which is adapted to insure separation of the vulcanized upholstery material from the drum, and suitable guiding means 18 are arranged to lead the up- .1.
holstery material around the upper lefthand roller '14. The upholster material then advances with the bands 12 and 13 to the upper righthand roll 14 at which time it passes downwardly over an apron 16 to the sewing mechanism indicated generally at 90.
It is to be generally understood that if desired this upholstery material as it leaves the vulcanizing station H1 is completed. The bond imparted, as previously stated, is not only substantially stronger than previously known sewed bonds but further adds a highly desirable decorative effect to the upholstery material as a whole.
In some instances, however, it may be desirable to supplement the vulcanized bond with a sewed seam. The sewed seam may cooperate with the vulcanized bond to create a novel, decorative effect. It also may cooperate therewith to form a reinforcement, although it is again emphasized that the vulcanized bond is itself stronger than the sewed seam. However, the vulcanized bond in combination with the sewed seams exhibits different characteristics. In the first place, the vulcanized bond is characterized by its flexibility, and in som instances the rubber forming the bond may supplement the sewed seam, preventing undue strain upon the seam and further preventing failure of the seam as a whole upon breakage of the sewing thread.
At all events, if it is desirable to supplement thevulcanized seam with the sewed seam, the mechanism indicated at 90 in Figure 10 may be employed. The casing 90 is provided with a foraminous b'elt 9i which is adapted to cooperate with an open top suction box 92 connected by a conduit 93 with a suitable source of suction. The arrangement is such that the upholstery material as it is advanced by the foraminous belt 9| is firmly retained against accidental displacement relativ thereto. This is particularly important at this point for the reason that the decoration is now permanently imparted to the upholstery material, and in order to obtain a pleasing. effect it is essential that the sewed seam shall be definitely located with respect to the vulcanized seam and decorative design. Preferably. the sewed seam and the decorative design will be arranged symmetrically, but this, of course, is a matter of design. A plurality of sewing heads indicated generally at 94 are positioned to sew seams in the advancing upholstery fabric Sewing heads 94 are preferably laterally adjustable and may be clamped in desired position. In some instances it may be desirable to provide guides indicated generally at 95 for receiving the vulcanized design and for guiding it in accurately located relation past sewing heads 94. The exact arrangement of the guides 95 will depend upon the character of the decorated vulcanized design. For example, where the vulcanized design comprises a pair of spaced parallel upstanding beads, the guides 95 will have correspondingly formed recesses to receive the beads. Preferably these recesses will be flared in the direction from which the upholstery material advances so as to permit positioning of the decorated design definitely relative to the sewing heads.
.The operation of my apparatus and the method has now been described from start to finish and it remains only to describe in detail the mechanism which I emplo to insure positive separation of the-padding material at the point where the rubber strips are brought into contact with the sheeting 56 and the upholstery material l6.
Referring now. more particularly to Figure 3, Ihave illustrated the breaker rolls 59 and 60 as carried by a suitable frame element 62. The fibrous. padding material 54 passes downwardly between a pair of rolls t9 and 69 as previously described. The block 62 at its lower portion is provided with a channel or recess 63, best seen in Figure '7, guidingly receiving the strip 55 of rubber. The sheeting 5% passes over the upper surface of th lower end of the block 62. Secured to or integral with the lower end of the block 62 I provide a pair of forwardly extending plates E i which are well illustrated in the sectional views of Figures 4 and 5.
A roller 55 is carried b the frame of the machine and is adapted to present the sheeting 5B and the rubber 55 into contact with the lower portion of the block 52, all as well illustrated in Figure 8.
The upholstery material i6 is advanced over the plurality of ridge members 35, thus providing pleat fullness for the reception of the padding material. Ihis arrangement of parts is well illustrated in Figure 4 in which the cover fabric 55 is shown as formed upwardly over the ridge members 35 and abutting the lower edge of the plates 6d. The rubber 55, as seen in this figure, is thus retained in an enclosed chamber defined on two sides by the plates fi l, on the bottom by the cover fabric l6, and on top by the sheeting 56. The plates M are formed around the roll 66 and terminate as close as possible to the point of tangency between the roll $6 and heated drum H.
In Figure I have illustrated the relationship of parts on the section line 55, Figure 3. It will be noted that the forming band It has come into contact with the cover fabric i i and has pressed the cover fabric against the rubber 55.
The sheeting tit is at this time still in contact with the upper surface of the plates 6 The forming band I2 presses the upholstery fabric firmly against the heating roll ll as soon as permitted to do so by the termination of the plates at. The plates 6% terminate substantially at the point where the forming band l2 forces the fabric it and the rubber against the roll. It also, as will be readily apparent, forces the rubber firmly into contact with the sheeting 56. As indicated in Figure 6, as soon as the forming band has insured intimate contact between the cover it, the sheeting 56, and the rubber 55 it is no longer necessary to mechanicall prevent the padding material 5 from moving toward the zone to be occupied by the vulcanized seam. In fact it is desirable that the fibrous material be permitted to completely fill the pipes between adjacent seams.
In Figure 6 I have illustrated the pipe when the forming band l2 applies its pressure to the deformable material 55. As best seen in this figure, the deformable material, such as rubber, is largely displaced from beneath the forming band 12 and is caused to form into risers adjacent thereto. In this figure I have illustrated the use of a single simple forming band, although as previously stated the forming band may be of widely differing ornamental designs. Due to the pressure applied by the forming band, the vulcanized bond directly beneath the band is of a high tensile strength, and at the same time the pressureof the band displaces rubber or other material, if employed, to a sumcient extent to form relatively high riser portions at the sides of the forming bands.
The complete cushion 89 is illustrated in Figure 8, in which the upholstery fabric is provided with a sheeting ill and intermediate padding material, such for example as cotton 82. In place of the conventional sewed seam-s, I secure the upholstery fabric to the sheeting 8| by means of a vulcanized bond, produced through the medium of a thin strip of rubber $3. The upholstery fabric is thus vulcanized to the sheeting 8! throughout a substantial width and entirely across the completed cushion. At as I have shown one design which can be formed by the present method. This design comprises a pair of lines of beads, and in this figure I have also indicated a line of sewing symmetrically located with respect to the beads. This line of sewing may or may not be provided.
At 85 I have indicated a somewhat different design comprising a single row of elongated beads extending generally transversely across the vulcanized seam. In this instance it will be noted that two rows of sewed seams are provided. At 68 I have indicated a somewhat different design in which the vulcanized seam is decorated by means of a continuous zigzag raised portion. As will be understood, in any of the foregoing cases the sewing may, if desired, be combined with the vulcanized seam or, if preferred, may be omitted.
apparatus described herein lends itself particularly well to the practice of the novel method herein disclosed, for the continuous, rapid and economical manufacture of upholstery material characterized by the use of vulcanized seams. substantially completely automatic mechanism for carrying out my process, it will be appreciated that the process itself may be carried out with widely different apparatus or, if desired, may be practiced largely by hand or by manually controlled mechanism.
While I have illustrated and described several specific embodiments of my invention, it will be apparent to those skilled in the art that various additions, modifications, omissions, combinations and substitutions may be made which will be within the spirit and scope of my invention as defined by the appended claims.
What I claim as my invention is:
1. Apparatus for forming stuffed pleated upholstery which comprises a heated roll, a pres sure band engaging said roll and movable therewith throughout less than its complete circum" ferenoe, means for assembling and continuously advancing upholstery material including sheeting, fabric, laterally spaced batts and an intermediate band of thermal setting material, said pressure band adapted to press said upholstery against said heated roll along the line of said thermal setting material.
2. Apparatus for forming stuffed pleated upholstery which comprises a heated roll, a pressure band engaging said roll and movable therewith throughout less than its complete circumference, means for assembling and continuously advancing upholstery material including sheeting, fabric, laterally spaced batts and an intermediate band of thermal setting material, said pressure band adapted to press said upholstery against said heated roll along the line of said thermal setting material, and a fixed separator member intermediate said batts and adjacent said fabric for retaining said batts separated substantially until engagement with said band.
3. Apparatus for forming stuffed pleated upholstery which comprises a heated roll, a pressure band engaging said roll and movable therewith throughout less than its complete circumference, means for assembling and continuously advancing upholstery material including sheeting, fabric, laterally spaced batts and an intermediate band of thermal setting material, said pressure band adapted to press said upholstery against said heated roll along the line of said thermal setting material, and a fxed separator member intermediate said batts and adjacent said fabric for retaining said batts separated substantially until engagement with said band, said member arranged to apply said thermal setting material between said laterally spaced batts.
l. Apparatus for forming stuffed pleated upholstery which comprises a heated roll, a pressure band engaging said roll and movable therewith throughout less than its complete circumference, means for assembling and continuously ad- While I have illustrated throughout a vancing upholstery material including sheeting, fabric, laterally spaced batts and an intermediate band of thermal setting material, said pressure band adapted to press said upholstery against said heated roll along the line of said thermal setting material, and a fixed separator member intermediate said batts and adjacent said fabric for retaining said batts separated substantially until engagement with said band, said member arranged to apply said thermal setting material between said laterally spaced batts, said thermal setting material comprising a strip of uncured rubber, and said separator member being provided with a groove for guidingly receiving said strip.
5. Apparatus for forming stuffed pleated upholstery which comprises a heated roll. a pres' sure band engaging said roll and movable therewith throughout less than its complete circumference, means for assembling and continuously advancing upholstery material including sheeting, fabric, laterally spaced batts and an intermediate band of thermal setting material, said pressure band adapted to press said upholstery against said heated roll along the line of said thermal setting material, and a fixed separator member intermediate said batts and adjacent said fabric for retaining said batts separated substantially until engagement with said band, said separator member including a pair of spaced parallel plates of reduced height in the direction of advance and terminating substantially adjacent the point of engagement of said upholstery with said heated roll.
6. In a machine for forming stuffed pleated upholstery, means for assembling and continuously advancing a sheeting and cover fabric with interleaved laterally spaced batts and strips of uncured rubber stock intermediate said batts, separator means to retain said batts separated, presser means to compress said sheeting and fabric along said strips, said separator means extending substantially to said presser means, said separator means comprising an elongated member having a groove therein for guidingly receiving said strip of rubber stock.
7. Apparatus for making stuffed pleated upholstery which comprises means for advancing a cover fabric having laterally spaced batts against one surface thereof, stationary means intermediate said batts and adjacent said cover fabric for retaining said batts laterally spaced, means for advancing a strip of securing material, said stationary means being formed to guide said securing material into the space between said batts, and means for advancing sheeting into assembled relation with said fabric, batts, and securing material to position said batts and securing material between said sheeting and said fabric.
8. Apparatus for making stuffed pleated upholstery which comprises means for advancing a cover fabric having laterally spaced batts against one surface thereof, stationary means intermediate said batts and adjacent said cover fabric for retaining said batts laterally spaced, means for advancing a strip of securing material, said stationary means being formed to guide said securing material into the space between said batts, and means for advancing sheeting into assembled relation with said fabric, batts, and securing material to position said batts'and securing material between said sheeting and said fabric, said stationary means comprising a block grooved to receive said strip of securing material.
9. Apparatus for making stuffed pleated upholstery which comprises means for advancing a cover fabric having laterally spaced batts against one surface thereof, stationary means intermediate said batts and adjacent said cover fabric for retaining said batts laterally spaced, means for advancing a strip of securing material, said stationary means being formed to guide said securing material into the space between said batts, and means for advancing sheeting into assembled relation with said fabric, .batts, and securing material to position said batts and securing material between said sheeting and said fabric, said stationary means comprising a block grooved to receive said strip of securing material and terminating in a pair of spaced plates adapted to receive said securing material therebetween.
10. Apparatus for making stuffed pleated upholstery which comprises means for advancing a cover fabric having laterally spaced batts against one surface thereof, stationary means intermediate said batts and adjacent said cover fabric for retaining said batts laterally spaced, means for advancing a strip of securing material, said stationary means being formed to guide saidsecuring material into the space between said batts, and means for advancing sheeting into assembled relation with said fabric, batts, and securing material to position said batts and securing material between said sheeting and said fabric, said stationary means comprising a block grooved to receive said strip of securing material and terminating in a pair of spaced plates adapted to receive said securing material therebetween, and means for compressing said sheeting and fabric directly against said securing material.
11. Apparatus for making stuffed pleated upholstery which comprises means for advancing a cover fabric having laterally spaced batts against one surface thereof, stationary means intermediate said batts and adjacent said cover fabric for retaining said batts laterally spaced, means for advancing a strip of securing material, said stationary means being formed to guide said securing material into the space between said batts, and means for advancing sheeting into assembled relation with said fabric, batts,
and securing material to position said batts and securing material between said sheeting and said fabric, said stationary means comprising a block grooved to receive said strip of securing material and terminating in a pair of spaced plates adapted to receive said securing material therebetween, and means adjacent the end of said plates for compressing said sheeting and fabric directly against said securing material.
12. Apparatus for making stuffed pleated upholstery which comprises means for advancing a cover fabric having laterally spaced batts against one surface thereof, stationary means intermediate said batts and adjacent said cover fabric for retaining said batts laterally spaced, means for advancing a strip of securing material, said stationary means being formed to guide said securing material into the space between said batts, and means for advancing sheeting into assembled relation with said fabric, batts, and securing material to position said batts and securing material between said sheeting and said fabric, said stationary means comprising a block grooved to receive said strip of securing material and terminating in a pair of spaced plates adapted to receive said securing material therebetween, and a travelling pressure band for compressing said sheeting and fabric directly against said securing material.
13. Apparatus for making stuffed pleated upholstery which comprises means for advancing a cover fabric having laterally spaced batts against one surface thereof, stationary means intermediate said batts and adjacent said cover fabric for retaining said batts laterally spaced, means for advancing a strip of securing material, said stationary means being formed to guide said securing material into the space between said batts, and means for advancing sheeting into assembled relation with said fabric, batts, and securing material to position said batts and securing material between said sheeting and said fabric, said stationary means comprising a block grooved to receive said strip of securing material and terminating in a pair of spaced parallel plates of gradually reduced height in the direction of advance adapted to receive said securing material therebetween.
14. In a machine for forming stuffed, pleated upholstery, means for assembling and continuously advancing a sheeting and cover fabric with interleaved batts of padding material and strips of uncured rubber stock, said batts and strips being arranged alternately and spaced transversely of the path of advance thereof, elongated separator elements intermediate adjacent batts, said elements having longitudinally extending channels for the reception of said strips of rubber stock, presser means adapted to press said cover fabric toward said sheeting along lines overlying said strips of rubber, said separator elements extending substantially to said presser means to prevent encroachment of said padding material on said strips of rubber.
- JOHN R. MILLAR.
US264476A 1939-03-27 1939-03-27 Upholstery Expired - Lifetime US2274929A (en)

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2012028218A1 (en) * 2010-08-30 2012-03-08 Johnson Controls Gmbh Vehicle seat cover
US20180334064A1 (en) * 2017-05-18 2018-11-22 Lear Corporation Method of manufacturing a seat back cushion assembly and cushion assembly made thereby

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2012028218A1 (en) * 2010-08-30 2012-03-08 Johnson Controls Gmbh Vehicle seat cover
US9340134B2 (en) 2010-08-30 2016-05-17 Johnson Controls Technology Company Vehicle seat cover
US20180334064A1 (en) * 2017-05-18 2018-11-22 Lear Corporation Method of manufacturing a seat back cushion assembly and cushion assembly made thereby
US10576853B2 (en) * 2017-05-18 2020-03-03 Lear Corporation Method of manufacturing a seat back cushion assembly

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