Abstract: An automated quilting and tufting system for application of tufts at selected locations along a web of material, including a sewing head receiving a series of tufts or rosettes from a supply. The tufts are removed from their supply and are placed at selected locations on the web of material for attachment to the web of material by the sewing head. Thereafter, the web of material can be cut to form a panel of a desired size.

Abstract: A method for coupling together at least two layers of a mattress includes the steps of aligning each layer in its proper position in relation to the other layers of the mattress and, after the alignment step, inserting a plastic fastener through the layers. A fastener dispensing tool is provided for inserting plastic fasteners through the layers of the mattress. In one embodiment, the fastener dispensing tool includes a housing, a hollow sharpened needle fixedly coupled to the housing, an ejection mechanism for advancing a cross-bar of the plastic fastener through the hollow needle and a needle stop slidably coupled to the housing for limiting the degree of penetration of the hollow needle through the layers of the mattress. The needle stop is adapted to be releasably fixed in place by a locking member which is internally spring biased.

Abstract: A stitched pile surface structure and a process and apparatus for producing and finishing the same is disclosed. The stitched pile surface structure includes a backing having a thickness T. A plurality of parallel lines of stitches extends longitudinally along the backing. Each stitch has a predetermined stitch length dimension S. A plurality of rows of pile elements (either as loop pile or cut pile) is formed from one or more pile yarn(s) having an effective predetermined yarn diameter D. The total weight of the yarn used to form the pile loop elements is G grams. Substantially all of the stitches have a thread length DKL that satisfies the relationship: DKL<=D·(1+?/2)+(2·T)+(2·S) A mass of binder material having a weight of less than G grams is disposed on the pile surface structure.

Abstract: An apparatus for inserting tuft assemblies through a mattress, with retention disks, comprising a mattress locking structure composed of: two walls, flat and parallel with a space for accommodating the mattress for compression; a first carriage, supported by one of the walls with a first disk feeder and a tuft insertion device; a second carriage, supported by the second wall supporting a second disk feeder; an actuator for the carriages; each one of the feeders for disks comprises a disk magazine that is supported on a respective carriage and contains disks arranged in stack acted upon by a pusher in order to keep a front disk of the stack in a pick-up position; and pick-up elements each with a transfer element, supported by a carriage.

Abstract: An apparatus for inserting through a mattress tufting straps having a frame for locking said mattress, a device for inserting the tufting straps through the mattress, supported by the frame, and actuators for actuating the device to move above the mattress. The inserting device includes a magazine for tufting straps, a needle with a tip receptacle for receiving and transferring a clip through the mattress, a transfer element, with a seat for receiving the clip, and a pusher, movable transversely to the needle for engaging the clip and inserting the clip in the tip receptacle.