U.S. patent application number 09/918506 was filed with the patent office on 2001-12-06 for machine for and a method of manufacturing a laminate particularly adapted for bedding, padding, upholstering and like applications.
Invention is credited to Antinori, Steven, Fernandez, Manuel, Harp, William.
Application Number | 20010048997 09/918506 |
Document ID | / |
Family ID | 23796543 |
Filed Date | 2001-12-06 |
United States Patent
Application |
20010048997 |
Kind Code |
A1 |
Antinori, Steven ; et
al. |
December 6, 2001 |
Machine for and a method of manufacturing a laminate particularly
adapted for bedding, padding, upholstering and like
applications
Abstract
A method of manufacturing a laminate particularly adapted for
bedding, padding upholstering and like applications by feeding an
indeterminate length of a first material along a predetermined
first path of travel from a source of the first material to a
downstream assembly area. Feeding an indeterminate length of second
material along a predetermined second path of travel from a source
of the second material to the downstream assembly area. Depositing
a multiplicity of substantially yieldable cushioning materials upon
an upper surface of one of the first and second indeterminate
lengths of material during the feeding thereof between the
respective sources and the assembly area. Thereafter, sandwiching
the cushioning materials between the indeterminate lengths of first
and second materials to form a laminate therefrom, and rolling the
laminate into a roll. The cushioning materials are foam latex
and/or down and the first and second lengths of material are
polyester fiber material and/or convoluted foam.
Inventors: |
Antinori, Steven; (Tampa,
FL) ; Fernandez, Manuel; (Tampa, FL) ; Harp,
William; (Seffner, FL) |
Correspondence
Address: |
Vincent L. Ramik
DILLER, RAMIK & WIGHT
Suite 101
7345 McWhorter Place
Annandale
VA
22003
US
|
Family ID: |
23796543 |
Appl. No.: |
09/918506 |
Filed: |
August 1, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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09918506 |
Aug 1, 2001 |
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09452461 |
Dec 2, 1999 |
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|
6290800 |
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Current U.S.
Class: |
428/102 |
Current CPC
Class: |
Y10T 428/24033 20150115;
B32B 5/22 20130101; Y10T 156/1724 20150115; Y10T 156/1727 20150115;
Y10T 156/1741 20150115; B32B 37/24 20130101; Y10T 428/233
20150115 |
Class at
Publication: |
428/102 |
International
Class: |
B32B 003/06 |
Claims
What is claimed is:
1. A machine for manufacturing a laminate particularly adapted for
bedding, padding, upholstering and like applications comprising
first means for feeding an indeterminate length of a first material
along a predetermined first path of travel from a source of the
first material to a downstream assembly area, second means for
feeding an indeterminate length of second material along a
predetermined second path of travel from a source of the second
material to the downstream assembly area, means for depositing a
multiplicity of substantially yieldable cushioning materials upon
an upper surface of one of the first and second indeterminate
lengths of material during the feeding thereof between the
respective sources and the assembly area, means for sandwiching the
cushioning material between the indeterminate lengths of first and
second materials to form a laminate therefrom, and means for
rolling the laminate into a roll.
2. The laminate manufacturing machine as defined in claim 1
including means for storing packaging material adjacent the
assembly area whereby the laminate roll can be packaged in the
packaging material.
3. The laminate manufacturing machine as defined in claim 1
including means for severing the laminate substantially transverse
to the direction of feed of the laminate.
4. The laminate manufacturing machine as defined in claim 1
including means for edge-binding longitudinal edges of the
laminate.
5. The laminate manufacturing machine as defined in claim 1
including means for edge-binding longitudinal edges of the laminate
prior to being rolled into a roll.
6. The laminate manufacturing machine as defined in claim 1
including means for edge-bonding longitudinal edges of the
laminate.
7. The laminate manufacturing machine as defined in claim 1
including means for edge-binding longitudinal edges of the
laminate, and said edge-binding means includes means for applying
an adhesive to a longitudinal edge of at least one of the first and
second indeterminate lengths of material.
8. The laminate manufacturing machine as defined in claim 1
including means for edge-binding longitudinal edges of the
laminate, and said edge-binding means includes means for spraying
an adhesive to a longitudinal edge of at least one of the first and
second indeterminate lengths of material.
9. The laminate manufacturing machine as defined in claim 1
including means for compressing the laminate.
10. The laminate manufacturing machine as defined in claim 1
including means for forming cushioning materials anti-migration
areas between the first and second materials.
11. The laminate manufacturing machine as defined in claim 1
including stitching means for forming cushioning materials
anti-migration areas between the first and second materials.
12. The laminate manufacturing machine as defined in claim 1
including means for edge-binding longitudinal edges of the
laminate, and means for compressing the laminate longitudinal
edges.
13. The laminate manufacturing machine as defined in claim 1
including first roll supporting means for supporting a roll of the
first material, second roll supporting means for supporting a roll
of the second material, the first and second roll supporting means
being located respectively upstream and downstream of said
depositing means, and the first material is fed beneath said
depositing means whereby the cushioning materials are deposited
upon an upper surface of the first material.
14. The laminate manufacturing machine as defined in claim 1
wherein the depositing means includes trough means for housing a
supply of the cushioning material.
15. The laminate manufacturing machine as defined in claim 1
wherein the depositing means includes trough means for housing a
supply of the cushioning material, said trough means being in
substantially transverse spanning relationship to the feeding
direction of the first material, and opening means along said
trough means through which pass the cushioning materials incident
to the depositing thereof upon the first material.
16. The laminate manufacturing machine as defined in claim 1
wherein the depositing means includes trough means for housing a
supply of the cushioning material, said trough means being in
substantially transverse spanning relationship to the feeding
direction of the first material, opening means along said trough
means through which pass the cushioning materials incident to the
depositing thereof upon the first material, and means for
regulating the passage of the cushioning materials through the
opening means.
17. The laminate manufacturing machine as defined in claim 1
wherein the depositing means includes trough means for housing a
supply of the cushioning material, said trough means being in
substantially transverse spanning relationship to the feeding
direction of the first material, opening means along said trough
means through which pass the cushioning materials incident to the
depositing thereof upon the first material, and means for
facilitating the removal of the opening means and the replacement
thereof by different opening means to thereby selectively vary the
deposition of the cushioning materials upon the first material.
18. The laminate manufacturing machine as defined in claim 1
wherein the depositing means includes trough means for housing a
supply of the cushioning material, said trough means being in
substantially transverse spanning relationship to the feeding
direction of the first material, opening means along said trough
means through which pass the cushioning materials incident to the
depositing thereof upon the first material, and rotatable feed
means for regulating the passage of the cushioning materials
through the opening means.
19. The laminate manufacturing machine as defined in claim 1
wherein the depositing means includes trough means for housing a
supply of the cushioning material, said trough means being in
substantially transverse spanning relationship to the feeding
direction of the first material, opening means along said trough
means through which pass the cushioning materials incident to the
depositing thereof upon the first material, and means for
selectively varying the size of said opening means.
20. The laminate manufacturing machine as defined in claim 1
wherein the depositing means includes trough means for housing a
supply of the cushioning material, said trough means being in
substantially transverse spanning relationship to the feeding
direction of the first material, opening means along said trough
means through which pass the cushioning materials incident to the
depositing thereof upon the first material, said opening means
being a slot extending substantially along the length of said
trough means, and means for selectively adjusting the transverse
dimension of said slot to thereby regulate the deposition of the
cushioning materials upon the first material.
21. The laminate manufacturing machine as defined in claim 1
wherein the depositing means includes trough means for housing a
supply of the cushioning material, said trough means being in
substantially transverse spanning relationship to the feeding
direction of the first material, opening means along said trough
means through which pass the cushioning materials incident to the
depositing thereof upon the first material, said opening means
being a slot extending substantially along the length of said
trough means, means for selectively adjusting the transverse
dimension of said slot to thereby regulate the deposition of the
cushioning materials upon the first material, said slot being
defined in part by a movable trough plate having a lower edge in
part defining said slot, and said adjusting means includes means
for moving said trough plate and its lower edge to thereby adjust
the transverse dimension of said slot.
22. The laminate manufacturing machine as defined in claim 1
wherein the depositing means includes trough means for housing a
supply of the cushioning material, said trough means being in
substantially transverse spanning relationship to the feeding
direction of the first material, opening means along said trough
means through which pass the cushioning materials incident to the
depositing thereof upon the first material, said opening means
being a slot extending substantially along the length of said
trough means, means for selectively adjusting the transverse
dimension of said slot to thereby regulate the deposition of the
cushioning materials upon the first material, said slot being
defined in part by a pivotable trough plate having a lower edge in
part defining said slot, and said adjusting means includes means
for pivoting said trough plate and its lower edge to thereby adjust
the transverse dimension of said slot.
23. The laminate manufacturing machine as defined in claim 1
wherein the depositing means includes trough means for housing a
supply of the cushioning material, said trough means being in
substantially transverse spanning relationship to the feeding
direction of the first material, opening means along said trough
means through which pass the cushioning materials incident to the
depositing thereof upon the first material, said opening means
being a slot extending substantially along the length of said
trough means, means for selectively adjusting the transverse
dimension of said slot to thereby regulate the deposition of the
cushioning materials upon the first material, and rotatable feed
means for regulating the passage of the cushioning materials
through the slot.
24. The laminate manufacturing machine as defined in claim 1
wherein the depositing means includes trough means for housing a
supply of the cushioning material, said trough means being in
substantially transverse spanning relationship to the feeding
direction of the first material, opening means along said trough
means through which pass the cushioning materials incident to the
depositing thereof upon the first material, said opening means
being a slot extending substantially along the length of said
trough means, means for selectively adjusting the transverse
dimension of said slot to thereby regulate the deposition of the
cushioning materials upon the first material, said slot being
defined in part by a pivotable trough plate having a lower edge in
part defining said slot, said adjusting means includes means for
pivoting said trough plate and its lower edge to thereby adjust the
transverse dimension of said slot, and rotatable feed means for
regulating the passage of the cushioning materials through the
slot.
25. The laminate manufacturing machine as defined in claim 1
including first roll supporting means for supporting a roll of the
first material, second roll supporting means for supporting a roll
of the second material, the first and second roll supporting means
being located respectively upstream and downstream of said
depositing means, the first material is fed beneath said depositing
means whereby the cushioning materials are deposited upon an upper
surface of the first material, and means for drivingly rotating
said rolling means to thereby automatically draw the first and
second materials toward the assembly area.
26. The laminate manufacturing machine as defined in claim 1
including first roll supporting means for supporting a roll of the
first material, second roll supporting means for supporting a roll
of the second material, the first and second roll supporting means
being located respectively upstream and downstream of said
depositing means, the first material is fed beneath said depositing
means whereby the cushioning materials are deposited upon an upper
surface of the first material, means for drivingly rotating said
rolling means to thereby automatically draw the first and second
materials toward the assembly area, and means for restraining
free-wheeling unrolling of the first material.
27. The laminate manufacturing machine as defined in claim 1
including first roll supporting means for supporting a roll of the
first material, second roll supporting means for supporting a roll
of the second material, the first and second roll supporting means
being located respectively upstream and downstream of said
depositing means, the first material is fed beneath said depositing
means whereby the cushioning materials are deposited upon an upper
surface of the first material, means for drivingly rotating said
rolling means to thereby automatically draw the first and second
materials toward the assembly area, and means for adjustably
braking the unrolling of the first material.
28. The laminate manufacturing machine as defined in claim 1
including first roll supporting means for supporting a roll of the
first material, second roll supporting means for supporting a roll
of the second material, the first and second roll supporting means
being located respectively upstream and downstream of said
depositing means, the first material is fed beneath said depositing
means whereby the cushioning materials are deposited upon an upper
surface of the first material, means for drivingly rotating said
rolling means to thereby automatically draw the first and second
materials toward the assembly area, and means for placing the first
material under tension upstream of the depositing means.
29. The laminate manufacturing machine as defined in claim 1
wherein the depositing means includes a trough disposed in
substantially transverse spanning relationship to the feeding
direction of the first material, opening means along a bottom of
said trough through which pass the cushioning materials incident to
the depositing thereof upon the first material, a chute
substantially surrounding said opening means and extending
downwardly toward the first material, and a lower terminal edge of
said chute being spaced slightly above the first material.
30. The laminate manufacturing machine as defined in claim 1
wherein the depositing means includes a trough disposed in
substantially transverse spanning relationship to the feeding
direction of the first material, opening means along a bottom of
said trough through which pass the cushioning materials incident to
the depositing thereof upon the first material, a chute
substantially surrounding said opening means and extending
downwardly toward the first material, a lower terminal edge of said
chute being spaced slightly above the first material, and means for
maintaining a space between said chute terminal edge and the first
material.
31. The laminate manufacturing machine as defined in claim 1
including first roll supporting means for supporting a roll of the
first material, means for driving said rotating means to thereby
automatically draw the first and second materials through the
assembly area and into a laminate roll, and means for selectively
varying the speed of said driving means.
32. The laminate manufacturing machine as defined in claim 1
including first roll supporting means for supporting a roll of the
first material, means for driving said rotating means to thereby
automatically draw the first and second materials through the
assembly area and into a laminate roll, means for selectively
varying the speed of said driving means, and means for applying
selective varying braking to said first roll supporting means.
33. The laminate manufacturing machine as defined in claim 1
including first roll supporting means for supporting a roll of the
first material, means for driving said rotating means to thereby
automatically draw the first and second materials through the
assembly area and into a laminate roll, means for selectively
varying the speed of said driving means, means for applying
selective varying braking to said first roll supporting means, and
means for placing the first material under tension between said
first roll supporting means and said depositing means.
34. The laminate manufacturing machine as defined in claim 2
including means for edge-binding longitudinal edges of the
laminate.
35. The laminate manufacturing machine as defined in claim 2
including first roll supporting means for supporting a roll of the
first material, second roll supporting means for supporting a roll
of the second material, the first and second roll supporting means
being located respectively upstream and downstream of said
depositing means, and the first material is fed beneath said
depositing means whereby the cushioning materials are deposited
upon an upper surface of the first material.
36. The laminate manufacturing machine as defined in claim 2
wherein the depositing means includes trough means for housing a
supply of the cushioning material, said trough means being in
substantially transverse spanning relationship to the feeding
direction of the first material, opening means along said trough
means through which pass the cushioning materials incident to the
depositing thereof upon the first material, and means for
regulating the passage of the cushioning materials through the
opening means.
37. The laminate manufacturing machine as defined in claim 2
wherein the depositing means includes trough means for housing a
supply of the cushioning material, said trough means being in
substantially transverse spanning relationship to the feeding
direction of the first material, opening means along said trough
means through which pass the cushioning materials incident to the
depositing thereof upon the first material, and means for
facilitating the removal of the opening means and the replacement
thereof by different opening means to thereby selectively vary the
deposition of the cushioning materials upon the first material.
38. The laminate manufacturing machine as defined in claim 2
wherein the depositing means includes trough means for housing a
supply of the cushioning material, said trough means being in
substantially transverse spanning relationship to the feeding
direction of the first material, opening means along said trough
means through which pass the cushioning materials incident to the
depositing thereof upon the first material, said opening means
being a slot extending substantially along the length of said
trough means, means for selectively adjusting the transverse
dimension of said slot to thereby regulate the deposition of the
cushioning materials upon the first material, said slot being
defined in part by a movable trough plate having a lower edge in
part defining said slot, and said adjusting means includes means
for moving said trough plate and its lower edge to thereby adjust
the transverse dimension of said slot.
39. The laminate manufacturing machine as defined in claim 2
wherein the depositing means includes trough means for housing a
supply of the cushioning material, said trough means being in
substantially transverse spanning relationship to the feeding
direction of the first material, opening means along said trough
means through which pass the cushioning materials incident to the
depositing thereof upon the first material, said opening means
being a slot extending substantially along the length of said
trough means, means for selectively adjusting the transverse
dimension of said slot to thereby regulate the deposition of the
cushioning materials upon the first material, said slot being
defined in part by a pivotable trough plate having a lower edge in
part defining said slot, and said adjusting means includes means
for pivoting said trough plate and its lower edge to thereby adjust
the transverse dimension of said slot.
40. The laminate manufacturing machine as defined in claim 2
wherein the depositing means includes trough means for housing a
supply of the cushioning material, said trough means being in
substantially transverse spanning relationship to the feeding
direction of the first material, opening means along said trough
means through which pass the cushioning materials incident to the
depositing thereof upon the first material, said opening means
being a slot extending substantially along the length of said
trough means, means for selectively adjusting the transverse
dimension of said slot to thereby regulate the deposition of the
cushioning materials upon the first material, and rotatable feed
means for regulating the passage of the cushioning materials
through the slot.
41. The laminate manufacturing machine as defined in claim 2
wherein the depositing means includes a trough disposed in
substantially transverse spanning relationship to the feeding
direction of the first material, opening means along a bottom of
said trough through which pass the cushioning materials incident to
the depositing thereof upon the first material, a chute
substantially surrounding said opening means and extending
downwardly toward the first material, and a lower terminal edge of
said chute being spaced slightly about the first material.
42. The laminate manufacturing machine as defined in claim 2
including first roll supporting means for supporting a roll of the
first material, means for driving said rotating means to thereby
automatically draw the first and second materials through the
assembly area and into a laminate roll, and means for selectively
varying the speed of said driving means.
43. The laminate manufacturing machine as defined in claim 2
including first roll supporting means for supporting a roll of the
first material, means for driving said rotating means to thereby
automatically draw the first and second materials through the
assembly area and into a laminate roll, means for selectively
varying the speed of said driving means, and means for applying
selective varying braking to said first roll supporting means.
44. The laminate manufacturing machine as defined in claim 4
including first roll supporting means for supporting a roll of the
first material, second roll supporting means for supporting a roll
of the second material, the first and second roll supporting means
being located respectively upstream and downstream of said
depositing means, and the first material is fed beneath said
depositing means whereby the cushioning materials are deposited
upon an upper surface of the first material.
45. The laminate manufacturing machine as defined in claim 4
wherein the depositing means includes trough means for housing a
supply of the cushioning material, said trough means being in
substantially transverse spanning relationship to the feeding
direction of the first material, opening means along said trough
means through which pass the cushioning materials incident to the
depositing thereof upon the first material, and means for
regulating the passage of the cushioning materials through the
opening means.
46. The laminate manufacturing machine as defined in claim 4
wherein the depositing means includes trough means for housing a
supply of the cushioning material, said trough means being in
substantially transverse spanning relationship to the feeding
direction of the first material, opening means along said trough
means through which pass the cushioning materials incident to the
depositing thereof upon the first material, and means for
facilitating the removal of the opening means and the replacement
thereof by different opening means to thereby selectively vary the
deposition of the cushioning materials upon the first material.
47. The laminate manufacturing machine as defined in claim 4
wherein the depositing means includes trough means for housing a
supply of the cushioning material, said trough means being in
substantially transverse spanning relationship to the feeding
direction of the first material, opening means along said trough
means through which pass the cushioning materials incident to the
depositing thereof upon the first material, said opening means
being a slot extending substantially along the length of said
trough means, means for selectively adjusting the transverse
dimension of said slot to thereby regulate the deposition of the
cushioning materials upon the first material, said slot being
defined in part by a movable trough plate having a lower edge in
part defining said slot, and said adjusting means includes means
for moving said trough plate and its lower edge to thereby adjust
the transverse dimension of said slot.
48. The laminate manufacturing machine as defined in claim 4
wherein the depositing means includes trough means for housing a
supply of the cushioning material, said trough means being in
substantially transverse spanning relationship to the feeding
direction of the first material, opening means along said trough
means through which pass the cushioning materials incident to the
depositing thereof upon the first material, said opening means
being a slot extending substantially along the length of said
trough means, means for selectively adjusting the transverse
dimension of said slot to thereby regulate the deposition of the
cushioning materials upon the first material, said slot being
defined in part by a pivotable trough plate having a lower edge in
part defining said slot, and said adjusting means includes means
for pivoting said trough plate and its lower edge to thereby adjust
the transverse dimension of said slot.
49. The laminate manufacturing machine as defined in claim 4
wherein the depositing means includes trough means for housing a
supply of the cushioning material, said trough means being in
substantially transverse spanning relationship to the feeding
direction of the first material, opening means along said trough
means through which pass the cushioning materials incident to the
depositing thereof upon the first material, said opening means
being a slot extending substantially along the length of said
trough means, means for selectively adjusting the transverse
dimension of said slot to thereby regulate the deposition of the
cushioning materials upon the first material, and rotatable feed
means for regulating the passage of the cushioning materials
through the slot.
50. The laminate manufacturing machine as defined in claim 4
wherein the depositing means includes a trough disposed in
substantially transverse spanning relationship to the feeding
direction of the first material, opening means along a bottom of
said trough through which pass the cushioning materials incident to
the depositing thereof upon the first material, a chute
substantially surrounding said opening means and extending
downwardly toward the first material, and a lower terminal edge of
said chute being spaced slightly about the first material.
51. The laminate manufacturing machine as defined in claim 10
including means for edge-binding longitudinal edges of the
laminate.
52. The laminate manufacturing machine as defined in claim 10
wherein the depositing means includes trough means for housing a
supply of the cushioning material, said trough means being in
substantially transverse spanning relationship to the feeding
direction of the first material, opening means along said trough
means through which pass the cushioning materials incident to the
depositing thereof upon the first material, and means for
regulating the passage of the cushioning materials through the
opening means.
53. The laminate manufacturing machine as defined in claim 10
wherein the depositing means includes trough means for housing a
supply of the cushioning material, said trough means being in
substantially transverse spanning relationship to the feeding
direction of the first material, opening means along said trough
means through which pass the cushioning materials incident to the
depositing thereof upon the first material, said opening means
being a slot extending substantially along the length of said
trough means, and means for selectively adjusting the transverse
dimension of said slot to thereby regulate the deposition of the
cushioning materials upon the first material.
54. The laminate manufacturing machine as defined in claim 11
including means for edge-binding longitudinal edges of the
laminate.
55. The laminate manufacturing machine as defined in claim 11
wherein the depositing means includes trough means for housing a
supply of the cushioning material, said trough means being in
substantially transverse spanning relationship to the feeding
direction of the first material, opening means along said trough
means through which pass the cushioning materials incident to the
depositing thereof upon the first material, and means for
regulating the passage of the cushioning materials through the
opening means.
56. The laminate manufacturing machine as defined in claim 11
wherein the depositing means includes trough means for housing a
supply of the cushioning material, said trough means being in
substantially transverse spanning relationship to the feeding
direction of the first material, opening means along said trough
means through which pass the cushioning materials incident to the
depositing thereof upon the first material, said opening means
being a slot extending substantially along the length of said
trough means, and means for selectively adjusting the transverse
dimension of said slot to thereby regulate the deposition of the
cushioning materials upon the first material.
57. The laminate manufacturing machine as defined in claim 11
wherein the depositing means includes a trough disposed in
substantially transverse spanning relationship to the feeding
direction of the first material, opening means along a bottom of
said trough through which pass the cushioning materials incident to
the depositing thereof upon the first material, a chute
substantially surrounding said opening means and extending
downwardly toward the first material, a lower terminal edge of said
chute being spaced slightly above the first material, and means for
maintaining a space between said chute terminal edge and the first
material.
58. A method of manufacturing a laminate particularly adapted for
bedding, padding upholstering and like applications comprising the
steps of feeding an indeterminate length of a first material along
a predetermined first path of travel from a source of the first
material to a downstream assembly area, feeding an indeterminate
length of second material along a predetermined second path of
travel from a source of the second material to the downstream
assembly area, depositing a multiplicity of substantially yieldable
cushioning materials upon an upper surface of one of the first and
second indeterminate lengths of material during the feeding thereof
between the respective sources and the assembly area, sandwiching
the cushioning materials between the indeterminate lengths of first
and second materials to form a laminate therefrom, and rolling the
laminate into a roll.
59. The laminating method as defined in claim 58 including the step
of storing packaging material adjacent the assembly area whereby
the laminate roll can be packaged in the packaging material.
60. The laminating method as defined in claim 58 including the step
of severing the laminate substantially transverse to the direction
of feed of the laminate.
61. The laminate method as defined in claim 58 including the step
of edge-binding longitudinal edges of the laminate.
62. The laminate method as defined in claim 58 including the step
of edge-binding longitudinal edges of the laminate prior to being
rolled into a roll.
63. The laminate method as defined in claim 58 including the step
of edge-bonding longitudinal edges of the laminate.
64. The laminate method as defined in claim 58 including the step
of edge-binding longitudinal edges of the laminate, and performing
the edge-binding step by applying an adhesive to a longitudinal
edge of at least one of the first and second indeterminate lengths
of material.
65. The laminate method as defined in claim 58 including the step
of edge-binding longitudinal edges of the laminate, and said
edge-binding step by spraying an adhesive to a longitudinal edge of
at least one of the first and second indeterminate lengths of
material.
66. The laminate method as defined in claim 58 including the step
of forming areas between the first and second materials within
which the cushioning materials are confined.
67. The laminate method as defined in claim 58 including the step
of stitching pockets between the first and second materials within
which the cushioning materials are confined.
68. The laminate method as defined in claim 58 including the step
of stitching substantially closed pockets between the first and
second materials within which the cushioning materials are
confined.
69. The laminate method as defined in claim 58 including the step
of creating a plurality of downwardly opening valleys in a lower
surface of the other of the first and second indeterminate lengths
of material which substantially house the cushioning materials
therein incident to performing the sandwiching step.
70. The laminate method as defined in claim 58 including the steps
of supporting a roll of the first material, supporting a roll of
the second material, the first and second roll supporting steps
being performed at locations respectively upstream and downstream
of a point at which the depositing step is performed, and feeding
the first material beneath the depositing point whereby the
cushioning materials are deposited upon an upper surface of the
first material.
71. The laminate method as defined in claim 58 wherein the
depositing step is effected from a trough housing a supply of the
cushioning material.
72. The laminate method as defined in claim 58 wherein the
depositing step is effected from a trough housing a supply of the
cushioning material, the trough being in substantially transverse
spanning relationship to the feeding direction of the first
material, and the trough includes openings through which pass the
cushioning materials incident to the performance of the depositing
step.
73. The laminate method as defined in claim 58 wherein the
depositing step is effected from a trough housing a supply of the
cushioning material, the trough being in substantially transverse
spanning relationship to the feeding direction of the first
material, the trough includes openings through which pass the
cushioning materials incident to the depositing step, and
regulating the passage of the cushioning materials through the
trough openings.
74. The laminate method as defined in claim 58 wherein the
depositing step is effected from a trough housing a supply of the
cushioning material, the trough being in substantially transverse
spanning relationship to the feeding direction of the first
material, the trough includes openings through which pass the
cushioning materials incident to the performance of the depositing
step, and removing the trough openings and replacing the trough
openings with different trough openings to thereby selectively vary
the deposition of the cushioning materials upon the first
material.
75. The laminate method as defined in claim 58 wherein the
depositing step is effected from a trough housing a supply of the
cushioning material, the trough being in substantially transverse
spanning relationship to the feeding direction of the first
material, the trough includes opening through which pass the
cushioning materials incident to the performance of the depositing
step, and selectively varying the size of the trough opening.
76. The laminate method as defined in claim 58 wherein the
depositing step is effected from a trough housing a supply of the
cushioning material, the trough being in substantially transverse
spanning relationship to the feeding direction of the first
material, the trough includes opening through which pass the
cushioning materials incident to the performance of the depositing
step, selectively varying the size of the trough opening, the
trough opening being a slot extending substantially along the
length of said trough, and selectively adjusting the transverse
dimension of the slot to thereby regulate the deposition of the
cushioning materials upon the first material.
77. A method of manufacturing a laminate particularly adapted for
bedding, padding, upholstering and like applications comprising the
steps of feeding an indeterminate length of a first material along
a predetermined first path of travel from a source of the first
material to a downstream assembly area, feeding an indeterminate
length of second material along a predetermined second path of
travel from a source of the second material to the downstream
assembly area, depositing a multiplicity of substantially yieldable
cushioning materials from an upper surface of one of the first and
second indeterminate lengths of material during the feeding thereof
between the respective sources and the assembly area, sandwiching
the cushioning materials between the indeterminate lengths of first
and second materials to form a laminate therefrom, and quilting the
laminate.
78. The laminating method as defined in claim 77 wherein the
quilting step is performed by stitching which substantially reduces
migration of the cushioning materials.
79. The laminating method as defined in claim 77 wherein the
quilting step is performed by stitching substantially closed
pockets between the first and second materials which substantially
reduces migration of the cushioning materials.
80. A method of manufacturing a laminate particularly adapted for
bedding, padding, upholstering and like applications comprising the
steps of feeding an indeterminate length of first material having
opposite surfaces along a predetermined first path of travel from a
source of the first material to a downstream assembly area, feeding
an indeterminate length of second material having opposite surfaces
along a predetermined second path of travel from a source of the
second material to the assembly area, depositing a multiplicity of
substantially yieldable cushioning materials upon an upper surface
of one of the first and second indeterminate length material during
the feeding thereof between the respective sources and the assembly
area prior to sandwiching the cushioning materials between the
upper surface of the one material and a lower surface of another of
the first and second indeterminate length materials, at least one
of the upper and lower surfaces being a convoluted surface defined
by peaks and valleys, and sandwiching the cushioning materials
between the indeterminate lengths of first and second materials to
form a laminate therefrom and during the sandwiching of the first
and second materials confining the cushioning materials in the
valleys.
81. The laminating method as defined in claim 80 wherein the
indeterminate length material having the convoluted surface is
latex.
82. The laminating method as defined in claim 80 wherein the
convoluted surface is the lower surface.
83. The laminating method as defined in claim 80 wherein the
convoluted surface is the upper surface.
84. The laminating method as defined in claim 80 wherein the
convoluted surface is the lower surface of an uppermost of the
first and second indeterminate length materials.
85. The laminating method as defined in claim 80 wherein the
convoluted surface is the upper surface of a lowermost of the first
and second indeterminate length materials.
86. The laminating method as defined in claim 80 wherein the
convoluted surface is the lower surface of an uppermost of the
first and second indeterminate length materials, and the upper
surface is a substantially planar surface of a lowermost of the
first and second indeterminate length materials.
87. The laminating method as defined in claim 80 wherein the
convoluted surface is the upper surface of a lowermost of the first
and second indeterminate length materials, and the lower surface is
a substantially planar surface of an uppermost of the first and
second indeterminate length materials.
88. The laminating method as defined in claim 80 wherein the
convoluted surface is the lower surface of an uppermost of the
first and second indeterminate length materials, the upper surface
is a substantially planar surface of a lowermost of the first and
second indeterminate length materials, and crest portions of the
peaks contact the planar surface.
89. The laminating method as defined in claim 80 wherein the
convoluted surface is the upper surface of a lowermost of the first
and second indeterminate length materials, the lower surface is a
substantially planar surface of an uppermost of the first and
second indeterminate length materials, and crest portions of the
peaks contact the planar surface.
90. The laminating method as defined in claim 80 wherein the volume
of cushioning materials deposited upon the upper surface is
substantially confined in the valleys.
91. The laminating method as defined in claim 80 including the step
of edge-binding longitudinal edges of the laminate.
92. The laminating method as defined in claim 80 including the step
of edge-bonding longitudinal edges of the laminate.
93. The laminating method as defined in claim 80 including the step
of rolling the laminate into a roll.
94. The laminating method as defined in claim 80 wherein the
indeterminate length material having the convoluted surface is
latex, and the cushioning materials are latex.
95. The laminating method as defined in claim 84 wherein the
indeterminate length material having the convoluted surface is
latex, and the cushioning materials are latex.
96. The laminating method as defined in claim 87 wherein the
indeterminate length material having the convoluted surface is
latex, and the cushioning materials are latex.
97. The laminating method as defined in claim 88 wherein the
indeterminate length material having the convoluted surface is
latex, and the cushioning materials are latex.
98. A method of manufacturing a laminate particularly adapted for
bedding, padding, upholstering and like applications comprising the
steps of feeding an indeterminate length of first material having
opposite surfaces along a predetermined first path of travel from a
source of the first material to a downstream assembly area, feeding
an indeterminate length of second material having opposite surfaces
along a predetermined second path of travel from a source of the
second material to the assembly area, depositing a multiplicity of
substantially yieldable cushioning materials upon an upper surface
of one of the first and second indeterminate length materials
during the feeding thereof between the respective sources and the
assembly area prior to sandwiching the cushioning materials between
the upper surface of the one material and a lower surface of
another of the first and second indeterminate length materials, and
the volume of cushioning materials deposited upon the upper surface
is substantially in the range of 0.15-0.50 pound per square
yard.
99. The laminating method as defined in claim 98 wherein the
cushioning materials are latex.
100. The laminating method as defined in claim 98 wherein the
cushioning materials are an admixture of latex and down.
101. The laminating method as defined in claim 98 wherein the
cushioning materials are substantially 50%-50% admixture of down
and latex.
102. The laminating method as defined in claim 98 wherein the
indeterminate length materials are each polyester fiber, and the
cushioning materials are latex.
103. The laminating method as defined in claim 98 wherein one of
the indeterminate length materials is latex and another of the
indeterminate length materials is polyester fiber.
104. The laminating method as defined in claim 98 wherein one of
the indeterminate length materials is latex and another of the
indeterminate length materials is polyester fiber, the one
indeterminate length material includes a convoluted surface defined
by peaks and valleys, and the cushioning materials are housed in
the valleys.
105. A method of manufacturing a laminate particularly adapted for
bedding, padding, upholstering and like applications comprising the
steps of feeding an indeterminate length of first material having
opposite surfaces along a predetermined first path of travel from a
source of the first material to a downstream assembly area, feeding
an indeterminate length of second material having opposite surfaces
along a predetermined second path of travel from a source of the
second material to the assembly area, depositing a multiplicity of
substantially yieldable cushioning materials upon an upper surface
of one of the first and second indeterminate length materials
during the feeding thereof between the respective sources and the
assembly area prior to sandwiching the cushioning materials between
the upper surface of the one material and a lower surface of
another of the first and second indeterminate length materials, and
stitching a plurality of anti-migratory areas between the first and
second indeterminate length materials within which cushioning
materials are confined and substantially precluded from migrating
therefrom.
106. The laminating method as defined in claim 105 wherein the
stitched anti-migratory areas are substantially pockets.
107. The laminating method as defined in claim 105 wherein the
stitched anti-migratory areas are substantially closed pockets.
108. The laminating method as defined in claim 105 wherein the
stitched anti-migratory areas are substantially narrow
channels.
109. The laminating method as defined in claim 105 wherein the
stitched anti-migratory areas are substantially narrow crossing
channels.
110. The laminating method as defined in claim 105 wherein the
stitched anti-migratory areas are substantially narrow sinusoidal
channels.
Description
BACKGROUND OF THE INVENTION
[0001] A mattress normally includes a coil spring unit defined by a
plurality of interconnected coil springs which are united to each
other and to upper and lower polygonal frame wires which impart a
generally rectangular configuration to the coil spring unit. An
upper or top mattress pad and a lower or bottom mattress pad, each
formed of multiple layers or plies of materials stitched together,
and a like narrow peripheral mattress pad, also formed of multiple
plies or layers, are assembled to entirely encapsulate the coil
spring unit and form the mattress.
[0002] The top, bottom and peripheral mattress pads are each formed
as a laminate which might, for example, include a backing material
layer, a foam material layer, a fiber material layer and a ticking
layer, all stitched together by stitching of a conventional "quilt"
pattern or design. The materials of the latter layers, the
thicknesses thereof, etc. all contribute to such characteristics as
softness, breathability, wear, etc. However, irrespective of the
particular layers, it is important that the upper mattress pad and
the lower mattress pad are manufactured as inexpensively as
possible, yet provide the best mattress characteristics possible at
the lowest equitable cost over the longest mattress life
possible.
[0003] A typical conventional mattress corresponding to the
mattress just described is disclosed in U.S. Pat. No. 5,317,768
granted on Jun. 7, 1994. The patent discloses a spring component
and at least a top surface component formed as a laminate with the
outer layer being the ticking or cover fabric, the next inboard
layer being a fiber layer, the third layer being a convoluted foam
layer, and the innermost fourth layer being a cotton layer with
associated stitching holding all four of these layers together to
form a quilted multi-ply mattress pad. The thickness of the fiber
layer and the thickness of the convoluted foam layer are said to be
matters of design choice, though specific examples of weight per
square foot of the polyester fiber and the height of the convoluted
foam layer are specified as being illustrative. However, it is
generally conceded that the best mattresses providing the most
comfort are those which include an appreciably thick layer of
convoluted foam. However, foam material, particularly latex
(natural rubber) foam is extremely expensive and, therefore,
appreciably thick convoluted latex foam layers are found most
exclusively in higher end, more expensive mattresses. It would be
highly desirable to increase the latex foam content in lower end
mattresses (less expensive) if costs could be maintained relatively
low during the manufacture thereof such that as an end result
virtually all qualities of the mattress are appreciably increased
at a moderate or low increase in cost at both the wholesale and
retail levels.
SUMMARY OF THE INVENTION
[0004] In keeping with the foregoing, it is a primary object of the
present invention to provide as an end product a novel mattress
which includes a conventional coil spring unit and at least a top
or upper mattress pad formed of multiple plies or layers including
at least one fiber layer and one convoluted foam latex layer having
conventional peaks and valleys with the valleys being each
substantially filled with a multiplicity of relatively inexpensive,
small, random sized, foam latex pieces/materials which might
otherwise be discarded as scrap, yet possess all of the highly
desirable characteristics of a solid latex foam layer. Since the
relatively small pieces of foam latex are entrapped in the valleys
during lamination, as will be described more specifically herein,
the manufacture of such an upper and/or lower multi-ply mattress
pad is relatively inexpensive and, thus, can be utilized to enhance
all grades of conventional mattresses now being produced, sold and
used throughout the world.
[0005] In further accordance with the present invention, such
relatively small random sized pieces of latex foam material are
also preferably sandwiched between two layers of fiber material,
such as conventional polyester fiber, to form an upper mattress
pad, a lower mattress pad and/or a peripheral mattress pad formed
of three plies, namely, a polyester fiber ply or layer, a layer of
latex foam pieces and another polyester fiber ply or layer. As thus
far described and as opposed to the first laminated mattress pad
herein described, the small individual pieces of latex foam
(hereinafter termed "latex") would tend to shift or move when in
use as part of a mattress, unless otherwise provided for, as is the
case of the present invention in which the two polyester layers are
stitched together by a conventional quilting machine which not only
secures the layers together as a unit, but the stitching confines
or limits the movement or "migration" of the latex when used, for
example, as the upper and/or lower mattress pads of a mattress.
Thus, conventional stitching of the quilting process not only
functions to maintain the two polyester fiber layers (or any other
additional layers) united, but the stitching additionally precludes
undesired latex migration/shifting which essentially maintains
uniform latex thickness and results in a very comfortable yet
inexpensive mattress available at low and moderate prices while
providing moderate to high quality comfort and softness absent
localized "hard" spots, as might otherwise occur with undesired
latex migration.
[0006] In keeping with the foregoing, the last described mattress
pad is formed by a novel laminating machine of the present
invention which provides respective first and second means for
rotatably supporting first and second rolls of polyester fiber
material with an upper surface of a layer or web of the first roll
being fed beneath a trough from which latex/latex pieces are fed.
Downstream of the trough a second layer or web of the second roll
of polyester fiber material is overlayed upon the pieces of latex
at an assembly area during the continuous travel of the polyester
fiber layers toward a roll forming or winding station. The thus
formed laminate (polyester fiber layer/latex pieces/polyester fiber
layer) are then preferably wound into a roll of laminate/laminate
roll, the laminate is cut upstream of the roll, and the laminate
roll is packaged and shipped to a mattress manufacturer for
utilization in the manufacture of a mattress as described earlier
herein. An area is provided for storing packaging material, such as
a roll of transparent polymeric/copolymeric packaging material,
adjacent the roll forming station to use as the packaging material
for the laminate roll. Obviously, the diameter of the laminate roll
and its length will vary dependent upon the thicknesses of the
polyester fiber layers and the amount of latex sandwiched
therebetween. No matter the length, width or diameter of the
laminate roll, preferably a flying shear or flying cutter severs
the laminate normal to the direction of travel in response to
automated or manual controls immediately upon completion of the
roll packaging operation.
[0007] Immediately upon effecting lamination at the lamination or
assembly area, the longitudinal edges of the polyester fiber layers
are subject to an edge-binding operation which is preferably
achieved through spraying a fast drying adhesive therealong which
virtually dries instantaneously under normal temperature ranges
found in factories, but heaters may be used, as necessary. The
adhesive thus sprayed along the longitudinal edges binds all
edge-exposed latex pieces to each other and to the polyester fiber
layers. Alternatively or additionally, compression edge rollers can
be utilized downstream of the adhesive spray applicators,
preferably spray guns, to bring the polyester layers into intimate
adhesive bonding contact, thereby further assuring that the
latex/latex pieces cannot escape the laminate.
[0008] In lieu of immediately forming the laminate into a roll,
cutting the laminate, packaging the laminate roll and shipping the
same to an end user, the laminate may be fed directly into a
quilting machine and conventionally quilted or stitched to not only
provide unification of the layers and the attendant conventional
"quilted" appearance of mattresses, but to also prevent latex
"migration." Conventional quilting machines have multiple
programmable stitching heads and in accordance with the present
invention, such stitching heads are programmed not only to provide
an aesthetic quilt appearance, but to also create essentially a
multiplicity of relatively small "closed" pockets between the
polyester fiber layers defined by the threads of the stitching with
the threads or stitching of each "pocket" confining the latex
therein and substantially preventing latex migration outwardly of
each stitched pocket. The simplest example of the latter is
stitching the laminate prior to rolling or immediately upon being
unrolled at a mattress fabricator by closely spaced rows of
stitching normal and parallel to the direction of travel of the
laminate (rolling direction of the laminate roll) to form
substantially square or polygonal "closed" pockets, each being
relatively "closed" by the stitching associated therewith. Though
such "closed" pockets of stitching are desirable, the stitching
need not define completely "closed" pockets, but the stitching
instead might be configured such as to prevent excessive migration
as, for example, closely adjacent parallel sinusoidal stitching
either lengthwise or widthwise of the laminate which forms narrow
sinusoidal channels which essentially prevent latex migration by
the very curved nature thereof and the relatively narrow width of
each channel.
[0009] The trough which houses the latex preferably includes a
tubular polygonal rubber chute carrying at a lower end a latex
proportioning gate having a plurality of proportioning openings
therein through which pass the latex for deposit upon the upper
surface of the polyester fiber layer being conveyed therebeneath.
The openings in the gate or plate vary in number, size, shape and
orientation depending upon the range of sizes of the particles of
the latex being fed therethrough, the amount of latex which is to
be deposited per square foot/yard (and thus the eventual height
thereof) upon the upper surface of the underlying polyester fiber
layer, the speed of production, etc. Gates varying in opening
numbers, sizes, shapes and configurations are provided in
accordance with the invention for selective utilization to
manufacture virtually any and all end product characteristics, such
as latex height, density, etc.
[0010] The rubber chute or the gate also carries spacers which
engage the upper surface of the polyester fiber layer passing
therebeneath and assures that this upper surface is spaced at all
times a minimum distance from the gate/plate openings. The minimum
distance corresponds to the maximum height of the layer of latex
which is to be applied to the underlying polyester fiber layer.
Since the underlying polyester fiber layer is in continuous motion
as it is conveyed toward the assembly/laminating area, its inherent
resilience evokes up-and-down movement during the conveyance
thereof which, if excessive in an upward direction, will cause the
upper surface of the polyester fiber layer to move undesirably
closer to the gate openings resulting in the height of the latex
being lessened and lessened appreciably beyond that desired. Thus,
by maintaining the gate openings at a predetermined minimum
distance from the upper surface of the underlying polyester fiber
layer during its movement, the thickness/height of the latex is at
all times maintained at a uniform desired maximum height which in
turn results in a laminate of uniform cross-sectional thickness
throughout.
[0011] The trough also includes a pair of trough plates, one fixed
and another which is adjustable, and between the two trough plates
is a vane feed roll or roller which can be rotated at different
speeds dependent upon the desired rate of feed of the latex. Lower
edges of the trough plates define a transverse slot which can be
increased in size by moving the edge of the movable trough plate
away from the fixed trough plate and decreased in size by opposite
motion for varying the rate of feed of the latex in conjunction
with the speed of rotation of the vane feed roll or vane
feeder.
[0012] The laminating machine also includes a drive mechanism for
the take-up roll or roll forming mechanism which is variably
adjustable in rotational speed while shafts supporting the rolls of
polyester fiber layers or webs are under constant tension of a
conventional adjustable brake mechanism. The tension is relatively
slight but sufficient to maintain the upper surface of the
polyester fiber layer passing beneath the trough relatively
horizontally disposed to prevent vertical motion and/or bowing
during travel, and thereby assures maximum uniformity of the height
of the latex deposited thereupon. Thus, by manually or
automatically adjusting the speed of rotation of the shaft upon
which the laminate is being wound to form the laminate roll, the
amount of latex being deposited upon the upper surface of the
underlying polyester fiber layer can be further regulated in
conjunction with the earlier mentioned adjustable trough plate,
adjustable vane feeder, and different proportioning gates.
[0013] The laminating machine can also be utilized to form a
multi-ply or laminated mattress pad defined by a convoluted latex
foam layer having a relatively flat surface and an opposite surface
defining peaks and valleys, latex particles housed within the
valleys, and a polyester fiber layer. The latter-described mattress
pad is manufactured by the laminating machine in the manner just
described with the exception that the downstream roll of polyester
fiber material is not utilized, and in lieu thereof a roll of
convoluted latex foam is supported upon an associated shaft and is
drawn therefrom with its peaks and valleys respectively pointing
toward and opening toward the upper surface of the underlying
polyester fiber layer. In this fashion as the latex particles
deposited upon the upper surface of the lower polyester fiber layer
pass beneath and are united with the convoluted latex foam layer,
the latex particles are entrapped/encapsulated within the valleys
or "pockets" of the convoluted latex foam layer. The laminate thus
formed is rolled into a laminate roll and/or stitched by a
conventional quilting machine, though the quilt pattern need not
provide stitching "pockets," as in the case of the polyester fiber
layer/foam latex particles/polyester fiber layer laminate, because
the valleys are the "pockets" and prevent latex migration.
[0014] With the above and other objects in view that will
hereinafter appear, the nature of the invention will be more
clearly understood by reference to the following detailed
description, the appended claims and the several views illustrated
in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a perspective view of a novel laminating machine
constructed in accordance with this invention, and illustrates foam
latex particles being deposited upon an upper surface of a
polyester fiber layer or web being drawn from a roll, and another
polyester fiber layer being applied thereto forming a laminate
which is formed into a laminate roll and is packaged for delivery
to a mattress manufacturer.
[0016] FIG. 2 is an enlarged cross-sectional view taken generally
along line 2-2 of FIG. 5 through a trough which houses the foam
latex particles, and illustrates a fixed and a movable trough
plate, a vane feeder, and a rubber chute through which the foam
latex pieces moves incident to being deposited upon an upper
surface of the polyester fiber layer passing beneath the
trough.
[0017] FIG. 3 is an enlarged fragmentary cross-sectional view of
the movable and fixed trough plates and the vane feeder
therebetween, and illustrates one of many different relative
positions to achieve desired latex feed therethrough.
[0018] FIG. 4 is a fragmentary enlarged perspective view similar to
FIG. 3, and illustrates another relative position of the fixed and
movable trough plates and the vane feeder which alters the relative
size of the transverse slot, as compared to FIG. 3, and thereby
varies the rate of latex feed.
[0019] FIG. 5 is an enlarged fragmentary cross-sectional view taken
generally along line 5-5 of FIG. 1, and illustrates a drive for the
vane feeder and a portion of a linkage for varying the adjusted
position of the movable trough plate.
[0020] FIG. 6 is a fragmentary top perspective view looking
downwardly into the trough, and illustrates a removable trough end
plate partially removed to provide access to journals and bearings
associated with the movable trough plate and the vane feeder.
[0021] FIG. 7 is a fragmentary top perspective view of the left
side of the trough, as viewed in FIG. 1, and illustrates a handle
and a screw thread received in an internally threaded sleeve of the
linkage for adjusting the position of the movable trough plate.
[0022] FIG. 8 is a bottom perspective view of a spacer assembly,
and illustrates a spacer frame carrying three convex spacer
rods.
[0023] FIG. 9 is a bottom perspective view of a proportional feed
gate or feed plate, and illustrates a plurality of substantially
identically shaped rectangular openings thereof.
[0024] FIG. 10 is a fragmentary bottom perspective view of another
proportional feed gate or feed plate, and illustrates openings of
two different sizes formed therein.
[0025] FIG. 11 is a bottom perspective view of another proportional
feed gate or feed plate, and illustrates a further group of feed
openings formed therein.
[0026] FIG. 12 is a fragmentary longitudinal cross-sectional view
taken generally along line 12-12 of FIG. 1, and illustrates the
proportional feed gate of FIG. 9 and the spacer assembly of FIG. 8
removably secured to a lower terminal edge of the rubber chute with
the convex spacer rods touching an upper surface of the underlying
polyester fiber layer.
[0027] FIG. 13 is a fragmentary longitudinal cross-sectional view
similar to FIG. 12, and illustrates a roll of convoluted foam latex
in lieu of the downstream roll of polyester material of FIG.
12.
[0028] FIG. 14 is an enlarged fragmentary longitudinal
cross-sectional view of the lamination of FIG. 13, and illustrates
a multiplicity of randomly sized latex particles/pieces
substantially filling downwardly opening valleys or pockets of the
convoluted latex foam layer.
[0029] FIG. 15, which appears on the sheet of drawing containing
FIG. 7, is a fragmentary top perspective view of a modification of
the lamination machine of FIG. 1, and illustrates the polyester
fiber layer/latex foam pieces/polyester fiber layer laminate being
fed into a conventional quilting machine and both transverse and
longitudinal sinusoidal stitching forming substantially closed
pockets to prevent latex migration.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] A novel machine for manufacturing a laminate particularly
adapted for use in bedding (mattresses), padding, upholstering and
like applications is fully illustrated in FIG. 1 of the drawings
and is generally designated by the reference numeral 10.
[0031] The laminate manufacturing machine or laminating machine 10
includes first means 11 for feeding an indeterminate length or
layer L1 of first material M1, such as polyester fiber, from a roll
R1 thereof along a first predetermined path of travel P1 (FIGS. 1
and 12) which is from left-to-right in each of the two latter
figures toward a downstream assembly or laminating area A (FIG.
1).
[0032] Second means 12 are provided for feeding another
indeterminate length or layer L2 of second material M2 of polyester
fiber from a roll R2 along a predetermined second path of travel P2
(FIG. 1). The paths of travel P1, P2 are for the most part
substantially in the same direction and are substantially
horizontally disposed.
[0033] Means 13 are provided for depositing a multiplicity of
substantially yieldable cushioning materials L, such as pieces of
foam latex of random sizes, upon an upper surface Us of the
polyester fiber layer L1 of a predetermined height H (FIG. 12) in a
manner to be described more fully hereinafter. The pieces of foam
latex L are deposited upon the upper surface Us of the polyester
fiber layer L1 upstream of the roll R2 of the polyester fiber layer
L2, as is evident from FIGS. 1 and 12 of the drawings. The latex L
is deposited upon the upper surface Us of the polyester fiber layer
L1 in varying amounts depending upon such factors as the quality of
the latex L, whether the mattress to be formed therefrom will be
low, moderate or high priced, etc., but for the most part the latex
L deposited upon the layer L1 will range between 0.15-0.30 pound
per square yard of the layer L1. The range can, of course, be
lessened for less expensive end product production and increased
for higher priced end products, as, for example, the deposited
latex L might be between 0.10-0.50 pounds per square yard. Latex
and down, admixed 50%/50% can also be used as the layer L in the
preferable range of 0.15-0.30 pound per square yard and up to the
broader 0.10-0.50 pound per square yard range.
[0034] Means 15 in the form of identical adhesive spraying
mechanisms are located along opposite longitudinal edges
(unnumbered) of the layers L1, L2 and the eventually formed
laminate Lm which direct an adhesive spray S therealong to
edge-bind/edge-bond the longitudinal edges of the layers L1, L2 to
each other.
[0035] Means 16 in the form of an upper roller 17 and a lower
roller 18 temporarily compress the laminate Lm during the passage
therebetween to effectively close the longitudinal edges of the
layers L1, L2 and preclude the latex L from being dislodged
outwardly of the layers L1, L2.
[0036] Means 20 are provided for rolling the laminate Lm into a
laminate roll Lr.
[0037] When the laminate roll Lr is of a desired size, an operator
or an appropriate conventional microcontroller Mc, such as
Motorolla microcontroller C68HCO5J2P, which contains a variety of
input/output pins that are programmable to effect a multiplicity of
functions including that of appropriately controlling cutting means
22, such as a conventional flying shear or flying cutter, which
cuts the laminate Lm normal to the direction P1, P2 thereby freeing
the laminate roll Lr for subsequent packaging and shipment.
[0038] Means 24 support a roll R3 of packaging material, such as a
roll of polyethylene P, above the roll of laminate Lr. The
polyethylene material P is simply drawn from the roll R3, wound
about the roll of laminate Lr, severed from the roll R3, and
appropriate edge-to-edge sealed to encase, protect, and package the
laminate roll Lr therein for subsequent shipping to a mattress
manufacturer or the like.
[0039] The first feeding means or first feeding mechanism 11
includes opposite uprights 30 of which only one is illustrated in
FIG. 1 and between which is rotatably supported a shaft 31 which is
in intimate frictional engagement with the innermost convolution of
the roll R1. A conventional adjustable brake 32 can be adjusted by
a worker or by the microcontroller Mc to maintain desired drag on
the layer L1 as it is drawn from the roll R1 by the roll forming
mechanism 20 in a manner to be described more fully hereinafter.
The brake or brake means 32, no matter the specifics of the
construction thereof, is relatively conventional and is designed
simply to assure that sufficient pull or tension is applied to the
layer L1 to maintain the same substantially horizontal with little
bow therein during movement along the path P1. The tension is
augmented by a top roller 33 spring biased downwardly which spans
the width of the layer L1, the purpose of which is to take-up any
minute "slack" which might otherwise occur in the layer L1 during
its movement along the path of travel P1.
[0040] The lower layer L1 is preferably freely fed absent lower
support from the point of take-off from the roll R1 until it enters
between the rollers 17, 18. However, a lower surface Ls (FIG. 12)
of the layer L1 may be supported upon an upper surface (unnumbered)
of a relatively smooth glide plate Gp formed of material having an
extremely low co-efficient of friction or coated with such
material, such as synthetic fluorine-containing resins
(Teflon.RTM.). In lieu of the guide plate Gp, a plurality of
transverse conveyor rollers (not shown) may be utilized to assure
that the upper surface Us of the layer L1 is at a fixed height
during the passage thereof through the foam latex depositing means
13.
[0041] The latex depositing means 13 includes a trough 40
conventionally supported by a frame F in transversely spanning
relationship to the layer L1. The trough 40 is defined by an
upstream wall 41 and a downstream wall 42 which converge relative
to each other in a downward direction. The walls 41 and 42 are
welded to a side wall 43 and opposite thereto the walls 41, 42 are
similarly welded to an outboard opposite side wall 44 (FIGS. 5 and
6). A removable inboard side wall 45 (FIGS. 5 and 6), when m seated
in its operative position (FIG. 5), covers and protects housings
and bearings of linkages and shafts to be described more fully
hereinafter. This protects the housings, bearings and shafts, yet
provides ready access thereto for repair or replacement by simply
gripping and pulling the removable inboard side wall 45 upwardly
from the position shown in FIG. 5 to that shown in FIG. 6.
[0042] Lowermost terminal edge portions 51, 52 (FIG. 2) of the
converging walls 41, 42, respectively, are generally in parallel
relationship to each other, and these collectively define with
lower edge portions (unnumbered) of the end walls 43, 45 a
transverse opening 60 above and extending entirely across the layer
L1 as it passes therebeneath.
[0043] Housed within the trough 40 and extending substantially the
entire length of the transverse opening 60 are means 70 for
cooperatively adjustably varying the size of the transverse opening
60 and between which is located rotatable feed means 80 for
regulating the passage of the latex L through the transverse
opening 60.
[0044] The opening size adjusting means 70 include a fixed trough
plate 71 and a movable trough plate 72 (FIGS. 2, 5 and 6). The
fixed trough plate 71 is welded along its entire length to the
downstream wall 42 and to the side wall 43, but not to the
removable inboard side wall 45. The movable trough plate 72 is
welded along its entire length to a shaft 73 which at the end
adjacent the removable inboard side wall 45 passes through a slot
47 thereof (FIG. 6). The shaft 43 passes through a bearing (not
shown) of a bearing housing 74 (FIG. 6) and passes through an
opening (not shown) in the outboard wall 44 (FIG. 7) beyond which
it is connected to a linkage 75 (FIG. 7). The opposite end of the
shaft 73 is received in a bearing and a housing corresponding to
the housing 74 mounted adjacent the side wall 43 (not shown). The
trough plate 72 can thereby pivot selectively and adjustably
relative to the fixed trough plate 71 and the rotatable feed means
80 in the manner diagrammatically depicted in FIGS. 3 and 4 of the
drawings to thereby vary the size of the transverse opening 60 to
selectively vary the rate of feed of the latex L therethrough under
any one particular speed of rotation of the rotatable feed means
80. In other words, though the rotatable feed means 80 can be
varied in its rotational speed, changes in the amount of latex L
discharged through the transverse opening 60 can be altered by
merely pivoting and changing the position of the pivotable trough
plate 72 relative to the rotating feed means 80 and the fixed
trough plate 71.
[0045] The means or mechanism for varying the position of the
trough plate 72 includes trough plate adjusting means 90 (FIG. 7)
in the form of a threaded screw 91 having an unthreaded end 92
jounalled for rotation in a bearing (not shown) fixed to a housing
wall 93 and carrying a handle 94. An internally threaded sleeve 95
forms part of the linkage mechanism 75 (FIGS. 5 and 7) and
threadably receives therein the threaded shaft 91. Links 96, 97
(FIG. 7) are pivotally connected to the sleeve 95 by a pivot pin 98
while opposite ends of the links 96, 97 have fixed thereto the
shaft 73, as by welding, of the trough plate 72. As is readily
apparent from FIG. 7 of the drawings, as the handle 94 of the
trough plate adjusting means 90 is rotated in either of two
directions, the threaded shaft 91 will thread into or out of the
sleeve 95 to pivot the links 96, 97 which in turn rotate the shaft
73 which in turn pivots the movable or pivotable trough plate 72 to
achieve the selected variation in size of the transverse opening 60
(FIGS. 2 through 4).
[0046] The rotatable feed means 80, which also regulates the
passage of the pieces of latex L through the transverse opening 60
through selected speeds of rotation, is defined by a rotatable vane
feeder 81 having a central cylindrical portion 82 and five equally
arcuately spaced radially outwardly directed vanes 83 projecting
therefrom. The cylindrical central portion 82 is reduced in size at
opposite end portions, and one such end portion 84 is illustrated
in FIGS. 5 and 6 of the drawings projecting through a downwardly
opening slot 48 of the removable inboard side wall 45 and being
journalled for rotation in a bearing of a bearing housing 85 (FIG.
5) bolted to the outboard side wall 44. A bearing housing (not
shown) corresponding to the bearing housing 85 secures the opposite
reduced end (not shown) of the cylindrical portion 82 of the
rotatable vane feeder 81 to the side wall 43. The end portion 84
projects through an opening (unnumbered) in the outboard side wall
44 (FIG. 5) and is driven by a conventional right-angle drive 86 of
an electric motor 87 which is controlled in direction of rotation
and speed of rotation by the microcontroller Mc or one of several
conventional manually operated adjustable electric switches, such
as a switch 89 (FIG. 1) fixed to the wall 93 of the trough 40. As
the speed of rotation of the rotatable vane feeder 80 is increased,
more latex L is fed through the transverse opening 60, irrespective
of the size thereof, while a decrease in rotational speed of the
rotatable vane feeder 80 effects the opposite result.
[0047] As the latex L descends vertically downwardly under the
influence of gravity through the transverse opening 60, it passes
through and is guided by guide means 100 in the form of a rubber
guide chute or sleeve having a generally rectangular
cross-sectional configuration, as viewed from above and below, and
terminates in a lower polygonal terminal edge portion 101 spaced
the height H (FIG. 12) above the upper surface Us of the polyester
fiber layer 1. The height H represents the maximum height of the
latex L that will under any circumstances be deposited atop the
upper surface Us of the layer L1.
[0048] Spacer means 110 (FIG. 8) and latex feed proportioning means
120 (FIG. 9) are each carried by the lower terminal edge portion
101 of the guide chute or sleeve 100.
[0049] The latex feed proportioning means 120 is a feed gate or
feed plate of a generally rectangular configuration having an upper
flange 121 of a polygonal configuration whose internal size matches
the exterior size of the terminal end portion 101 of the guide
chute 100. Thus, the terminal end portion 101 of the guide chute
100 can be slipped into the upper flange 121 of the proportional
feed gate 120 and secured thereto by fasteners, such as screws or
clips 122 (FIGS. 12 and 13) passed through openings 119 of the
upper flange 121. A plurality of like sized generally rectangular
identically spaced proportioning openings 123 are formed in the
proportioning plate 120 and it is through the proportioning
openings 123 that the latex L passes before being deposited upon
the upper surface Us of the layer L1. Since the openings 123 are
substantially equally spaced and identically sized, they assure
that no matter the existence of any inconsistencies in content or
volume of the latex L falling through or accumulating in the chute
100, substantially equal amounts of latex L will fall through each
opening 123 to create a substantially uniform and consistent height
H. Different openings 123' (FIG. 10) and 123" (FIG. 11) of
respective proportional feed plates 120', 120" afford effective
dispensing of latex L dependent upon differences in relative sizes
of the pieces of latex L, the height H which must be achieved, the
speed of production, etc. In other words, if the pieces of latex L
are of one size or a specific size range, the proportional feed
gate 120 might be utilized to obtain a desired height H, whereas
should the pieces of latex L be of a different size, range of sizes
or consistency, the proportioning plate 120' or the proportioning
plate 120" might be instead utilized. However, no matter the
particular proportioning plate 120, 120' or 120" which is secured
to the terminal edge portion 101 of the guide chute or sleeve 100,
the selection thereof will assure the exact height H and
consistency of the latex pieces L deposited upon the polyester
fiber layer L1 under all manufacturing protocols, such as the speed
of rotation of the laminate roll Lr, the speed of rotation of the
vane feeder 81, the size of the transverse opening 60, etc.
[0050] The spacing means 110 is a spacer assembly defined by a
polygonal frame 111 having a plurality of openings 112 therein
matching the location of the openings 119, 119', 119" of the
proportional feed plates 120, 120', 120". The internal size of the
frame 111 of the spacer assembly 110 substantially matches the
external size and configuration of the flanges 121, 121', 121 " of
the respective proportional feed plates 120, 120' and 120". The
frame 111 can be telescoped upon and secured to the flanges 121,
121', 121" and/or the terminal edge portion 101 of the chute 100 by
utilizing conventional fasteners, such as the fasteners 122 (FIGS.
12 and 13). Projecting downwardly from the frame 111 in a convex
fashion are three relatively narrow spacer rods 125 which are
parallel to the direction of travel P1 and which contact the upper
surface Us of the layer L1 (FIG. 12) maintaining it at all times
spaced the distance H, thus assuring no matter the vertical
deflection or flexing of the layer L1 during its movement, the
height H of the latex L deposited upon the upper surface Us will
never be less than the height H. Though not illustrated, spacer
assemblies corresponding to the spacer assembly 110 can be provided
as substitutes therefor with the curvature or the spacer bars 125
being lesser or greater than that shown to respectively decrease
and increase the height H to achieve lesser or greater height H
than that illustrated in FIG. 12. In lieu of additional spacing
means, the spacing means 110 may be modified in the manner
illustrated in phantom outline (dashed lines) in FIG. 8 which
illustrates an increase in the overall height of the frame 111 with
additional openings 112 being also shown in phantom outline in
vertical spaced relationship to each other. There are three such
vertical spaced openings shown in the frame 111, and depending upon
which of these are utilized to fasten the frame 111 to the lower
edge portion 101 of the chute 100, the distance of the spacer bars
125 from the upper surface Us of the polyester fiber layer L1 can
be variably adjusted to occupy any one of three positions thus
assuring three different distances for the height H of the latex L
deposited upon the upper surface Us of the polyester fiber layer
L1.
[0051] The means or mechanisms 15 (FIG. 1) for
edge-binding/edge-bonding the layers L1, L2 to each other, along
with the foam latex pieces L sandwiched therebetween, are a pair of
conventional spray nozzles 130 connected by a flexible tube or
conduit 131 and a conventional adjustable valve 132 to an
adhesive-containing reservoir 133. The adhesive (not shown) within
the reservoir 133 is nontoxic, extremely quick drying, and is
preferably controlled in its application through suitably
adjustably controlling the valve 132 through the microcontroller Mc
in a conventional manner. The spray S emitted from the spray
nozzles 130 are applied to the opposite longitudinal edges
(unnumbered) of the layers L1, L2 and any of the latex particles L
exposed therebetween, as is evident from FIG. 1 of the drawings.
The adhesive will bind all of the exposed latex particles L to each
other and to the longitudinal edges of the layers L1, L2, through
preferably prior to the adhesive drying, the layers L1, L2 and L
pass through the rollers 17, 18 of the roller compression mechanism
or means 16 which are preferably spring-biased toward each other in
a conventional manner or through pneumatic fluid cylinders (not
shown) to apply desired pressure to the longitudinal edges
substantially closing the same incident to the adhesive drying such
that the latex L is essentially unexposed after passing beyond the
rollers 17, 18.
[0052] The microcontroller Mc controls the flying cutter or flying
shear 22 to transversely cut the completed laminate Lm after the
laminate roll Lr has been formed to a desired length (diameter)
followed by wrapping the same in the packaging material P for
shipment to a subsequent user, such as a mattress manufacturer.
[0053] The laminate roll Lr is preferably driven by a right-angled
drive 140 selectively driven by an electric motor 141 controlled
manually by an adjustable rheostat 142 or through the
microcontroller Mc. Like conventional control means 143 (FIG. 1)
can be manually adjusted to vary the braking of the roll R1 through
the conventional brake 32 or in lieu thereof, the brake 32 can also
be controlled by the microcontroller or microprocessor Mc.
[0054] In lieu of the edge-binding/edge-bonding means 15, the
utilization of conventional stitching heads (not shown) may be
provided to sew the longitudinal edges of layers L1, L2 to each
other during the performance of the lamination process/method.
[0055] A walkway W (FIG. 1) preferably traverses the paths of
travel P1, P2 between the latex depositing mechanism 13 and the
support means 12 for the roll R2 of polyester fiber material M2 or
the equivalent. The walkway W serves as a substantially central
area or location at which an operator can view the entire
laminating machine 10 and the various components thereof to operate
any of the switches or adjusting means 89, 142, 143 or the
microcontroller Mc, as well as the hand wheel 94 which, though
manually rotated, can as well be power driven in a conventional
manner under the control of the microprocessor or microcontroller
Mc. However, whether under a program control from a personal
computer (PC) associated with the microcontroller Mc (FIG. 1) or
manually, the amount of the latex L deposited upon the layer L1 of
polyester fiber material can be varied to in turn vary the height H
and/or the consistency through a variety of adjustments, as, for
example:
[0056] (1) The driving means 20 can be increased or decreased to
respectively speed up or reduce the speed of the layer L2 which,
with all other factors remaining the same, will respectively
decrease and increase the height H of the latex L.
[0057] (2) Obviously, by increasing or decreasing the speed of the
motor 87 (FIG. 5) the rotation of the vane feeder 81 (FIG. 2) can
be varied to again regulate the height H (FIG. 12) of the latex
material L.
[0058] (3) Manipulating the pivotable trough plate 72 (FIG. 2) to
vary the size of the slot 60 will also selectively vary the height
H of the latex L1 deposited upon the layer L1 (FIG. 12).
[0059] (4) Alternating the particular proportioning plate 120, 120'
and 120" and/or the spacer assembly 110 or its vertical height
relative to the chute 100 via the vertically offset openings 112
can also be utilized to selectively vary the height H of the latex
L deposited upon the layer L1.
[0060] Virtually any combination of adjustments (1) through (4)
above can be utilized to vary the final end product of the laminate
Lm.
[0061] A modification of the laminating machine 10 of FIG. 1 is
shown in FIG. 15 to which attention is now directed, and in this
case the modified laminating machine is designated by the reference
character 10' and includes all of the components of the laminating
machine 10 except for the flying shear or flying cutter 22, and in
lieu thereof is substituted a conventional quilting machine Qm
having a multiplicity of conventional quilting heads (Qh) which
stitch the laminate Lm immediately upon passing beyond the rollers
17, 18 of the compressing means 16 and prior to being formed into a
roll L'r. The laminate roll L'r is generally fed simultaneously
through the quilting machine Qm upon a web of underlying cloth
material Cm drawn from an associated cloth material roll Cmr. The
individual stitching or quilting heads Qh of the quilting machine
Qm can be variably adjusted in a conventional manner for quilting
any one of numerous different stitching patterns or quilting
patterns upon the laminate L'm. However, in keeping with the
present invention, the laminate or laminate material L'm is shown
being stitched therethrough with substantially parallel sinusoidal
longitudinal stitching Ls and substantially sinusoidal parallel
transverse stitching Ts with the stitching Ls and Ts forming
individual narrow sinusoidal longitudinal channels Lc and Tc,
respectively, therebetween. At the crossings of the stitching Ls
and Ts are formed individual substantially closed pockets Cp with
each substantially closed pocket Cp being bounded by portions of
two of the longitudinal lines of stitching Ls and portions of two
of the transverse lines of stitching Ts. The latter described
stitch crossings not only define the substantially closed pockets
Cp, but the stitching and closed pockets Cp prevent excessive
movement or "migration" of the latex L from each of the pockets Cp
which is highly desirable when the laminate material L'm is made
into a mattress, for example. When, for example, a portion of the
laminate L'm is formed as an upper layer of a mattress and a person
lies and moves thereupon for days, months or years at a time, the
latex L will not migrate but instead will remain in each of the
substantially closed pockets Cp and the uniformity and consistency
of the mattress thus manufactured will be maintained substantially
for its entire lifetime.
[0062] While the closed pockets Cp are a preferable form of the
stitching, migration of the latex L of the laminate L'm is
substantially lessened even absent such "closed" pockets. For
example, if the transverse stitching Ts were eliminated, the very
nature of the narrowness and the sinusoidal curvature of the
longitudinal channels Lc would materially preclude migration in the
longitudinal direction and would, of course, totally preclude
migration in the transverse direction. Obviously, the opposite is
true, namely, if the longitudinal stitching Ls were eliminated, the
sinusoidal curvature and the narrowness of the transverse channels
Tc would substantially lessen migration of the latex L in the
transverse direction and, of course, the transverse stitching Tc
would totally preclude migration of the latex L in the longitudinal
direction. Therefore, the stitching of the laminate L'm need only
be such as to define an overall pattern which would substantially
lessen or preclude migration of the latex L between the layers L1,
L2, irrespective of the "closed" or "open" nature thereof, through
substantially "closed" pockets Cp and equivalents thereof are
preferred.
[0063] In further accordance with the present invention, the
machine 10, through described with respect to utilizing polyester
fiber material M1, M2 in association with the respective rolls R1,
R2, can be varied in operation by utilizing other materials, and
one particular modification is illustrated in FIGS. 13 and 14 of
the drawings wherein the roll R2 of polyester fiber material M2 of
FIG. 1 has been eliminated and substituted therefor is a roll R'2
of conventional convoluted foam latex material M'2 defined by a
relatively flat inner/upper surface S'u and a convoluted outer
lower surface S'1, the latter being defined by a plurality of
downwardly/outwardly projecting peaks P' and outwardly/downwardly
opening valleys V'. Latex particles L', corresponding to the latex
particles L of FIG. 1, are deposited upon an upper surface U's of a
lower layer or web L'1 of polyester fiber material M'1 upon which
is superimposed a layer or web L'2 drawn from the roll R'2
resulting in the valleys V' being substantially filled with the
pieces of latex L'. Thus, as is best illustrated in FIG. 14, each
of the valleys V' defines a substantially closed pocket C'p
substantially entirely filled by the latex L' thereby assuring the
absence of migration thereof, just as in the case of the pockets Cp
of FIG. 15, but absent the quilting thereof. However, the
eventually formed laminate L'm can be stitched utilizing the
conventional quilting machine Qm of FIG. 15, but the quilting need
not be specifically utilized to achieve nonmigration of the latex
L'.
[0064] Although a preferred embodiment of the invention has been
specifically illustrated and described herein, it is to be
understood that minor variations may be made in the apparatus
without departing from the spirit and scope of the invention, as
defined the appended claims.
* * * * *