Abstract: This invention relates to a dual clamping system for a sewing machine. The dual clamp system comprises a first clamp and a second clamp which may be used to clamp a first workpiece and a second workpiece, respectively, at a sewing station of the sewing machine. The first and second clamps are preferably of different shapes and dimensions so that different shaped workpieces can be clamped at the sewing station. In the preferred embodiment, the first and second clamps are adjustable inner clamps for clamping an inner portion of the first and second workpieces, respectively. The dual clamping system also comprises a peripheral clamp for clamping at least a portion of the periphery of either or both of the first and second workpieces at the sewing station. The dual clamping system permits an operator to either separately or simultaneously clamp and sew a plurality of workpieces having the same or different shapes.

Abstract: An adjustable clamp for use in a sewing machine is disclosed. The adjustable clamp comprises a template clamp which is slidably and adjustably fastened to a plurality of pins extending from a clamp support. The clamp support and template clamp have a first template and a second template, respectively. The adjustable clamp permits the distance between the first and second templates to be slidably adjusted to a predetermined distance, for example, in order to accommodate a change in the distance between a first predetermined stitch pattern and a second predetermined stitch pattern. In another embodiment, the clamp comprises spacer clamps which may be mounted onto the pins to provide a third template. The spacer clamps may also be provided in predetermined shapes so that, when they are mounted between the clamp support and template clamp, they cooperate to define a fourth template.

Abstract: A clamp is provided for use in a sewing machine. The clamp includes a frame and at least one adjustable presser member associated with the frame. The adjustable presser member applies a preselected amount of pressure to a workpiece located in a sewing machine and the clamp is adapted to be used with workpieces having varying thicknesses.

Abstract: A workpiece pallet for transporting and holding one or more workpieces to be sewn in a programmable sewing machine. The workpiece pallet comprises a frame member having a locator which can be removably secured to the frame member. In a preferred embodiment, the locator comprises a base plate having a plurality of flanges which cooperate with mating flanges on the frame member so that the base plate is detachably supported therein. The base plate has a plurality of posts which facilitate locating one or more workpieces in the workpiece pallet. The workpiece pallet also comprises a universal coupler for permitting a plurality of sets of plates to be pivotally and detachably coupled to the frame member. The universal coupler comprises a plurality of first connecting members located on the frame member and a plurality of second mating connecting members which are located on each plates of the sets of plurality of plates.

Abstract: A method and apparatus is provided for fusing tabs of a hook or loop fastener material to opposing ends of an elongated band of cooperating hook or loop fastener material. The tabs are fed from two sources of a first material on opposing sides of a bonding station. The band is formed from a supply of a second material which is first fed to a transfer device having first and second grippers. The grippers transfer the band of material to the bonding station in a direction transverse to the transfer of the tabs to the bonding station, and the ends of the band are placed in overlapping relationship with the tabs. Subsequently, a pair of ultrasonic welding horns are moved into contact with the overlapping material to fuse the band of material to the tabs. The apparatus operates under the control of a programmable controller and the length of the band may be varied by altering a length of the second material fed between the grippers of the transfer mechanism.

Abstract: A clamping device for use in a sewing machine. The clamping device includes a clamping plate having a downwardly facing clamping surface for clamping a first workpiece to a sewing surface of a sewing machine wherein the clamping plate is supported for vertical movement beneath a sewing head for the sewing machine. The clamping plate is provided with a vacuum aperture which is in fluid connection with a vacuum source wherein the vacuum source draws a second workpiece into engagement with the clamping plate. A support plate is provided for supporting the second workpiece beneath the clamping plate and a feed mechanism is provided for feeding the second workpiece onto the support plate.

Abstract: A sewing station is disclosed including a workpiece clamp shuttle for loading and shuttling a bulky workpiece to be sewn to a sewing location of a sewing machine. The workpiece clamp shuttle includes a support surface for supporting a bulky workpiece and a clamp for clamping the bulky workpiece to the support surface at a loading station wherein the bulky workpiece may be easily loaded onto the support surface. The sewing machine includes apparatus for driving the clamp and the support surface from the loading station to the sewing location where the bulky workpiece can be sewn. In addition, a method for sewing a bulky workpiece in a sewing station is disclosed including the steps of preclamping the bulky workpiece at a loading location, and transferring the preclamped bulky workpiece from the loading location to a sewing location where the workpiece may be clamped and sewn.

Abstract: A method and apparatus for inverting and flattening an air bag including an inverter for inverting the air bag and an actuator for actuating the air bag to cause it to flatten. The inverter includes a plunger moveable in a vertical direction through an aperture in a conveyor table to cause a face panel of the air bag to pass through an aperture formed in a main panel of the air bag. The actuator includes a spin disk for causing an inertial force to be applied to the air bag whereby outer portions of the air bag are caused to move radially outwardly relative to a central gripped portion. After the air bag is flattened, it is dropped down onto belts running along the conveyor table and the belts are actuated to convey the bag out of the apparatus. In addition, a load table is provided for automatically moving air bags into alignment with the inverter in preparation for an inversion and flattening cycle.

Abstract: A modular air bag construction system is disclosed wherein an airbag is constructed by providing a main panel, attaching reinforcing material to predetermined locations on the main panel and forming holes through the main panel at the predetermined locations, and subsequently attaching a face panel to the main panel and trimming the face and main panels to a desired rounded configuration. The present system uses substantially rectangular panels whereby conveying and accurate placement of the panels is facilitated. The present system is conducive for implementation as an automated system and eliminates expensive and time consuming precutting of the air bag components.

Abstract: A rotatable presser foot for use in a sewing machine having a sewing station. The rotatable presser foot comprises a foot member and a coupler for detachably and adjustably coupling the foot member to a needle bar in the sewing machine so that the foot member can be rotatably adjusted about a center axis of the needle bar. The coupler comprises a bracket which is adjustably fastened to the needle bar and a foot support on which the foot member can be adjustably secured. The coupler also comprises a resilient coupling located between the foot support and bracket so as to permit the foot member to be resiliently biased towards a sewing surface at the sewing station. The rotatable presser foot can be rotated to any predetermined location about the axis of the needle bar, thereby facilitating sewing workpieces of different shapes and configurations.

Abstract: A material handling system for forming an air bag in a plurality of workstations. The system includes a pallet for holding a workpiece in a predetermined orientation and a locator for locating the pallet in a plurality of workstations for performing different operations on the workpiece. The pallet is provided with structure for aligning the pallet in at least two workstations for performing different operations on the workpiece. The workstations preferably include a sewing station and a punch press station wherein the pallet is adapted to be accurately aligned in each of the stations for performance of respective sewing and hole cutting operations. The locator is operable for moving the pallet from a loading station to the sewing station and then to the punch press station. Further, the locator is operable to subsequently move the pallet to an unloading station or to a further workstation.

Abstract: A side-by-side material feed system is provided for feeding two dissimilar strips of material. The material is fed along parallel feed paths by first and second drive mechanisms which move the material toward respective cutters. The operation of the feed mechanisms and the cutters is controlled by a programmable controller which permits each of the material strips to be fed and cut to form pieces of predetermined length which may be removed by an operator or conveyed to a subsequent station for further processing.

Abstract: A clamp is provided for use in a sewing machine. The clamp includes a frame and at least one adjustable presser member associated with the frame. The adjustable presser member applies a preselected amount of pressure to a workpiece located in a sewing machine and the clamp is adapted to be used with workpieces having varying thicknesses.

Abstract: A side-by-side material feed system is provided for feeding two dissimilar strips of material. The material is fed along parallel feed paths by first and second material feeders which move the material toward respective cutters. The operation of the feeders and the cutters is controlled by a programmable controller which permits each of the material strips to be fed and cut to form pieces of predetermined length which may be removed by an operator or conveyed to a subsequent station for further processing. In a further embodiment of the invention, the feeders are supported on an ergonomic arm mounted to a portable cart whereby the feeders may be used at different sewing stations and the ergonomic arm may be positioned at an optimum location for each of the sewing stations.

Abstract: A modular air bag construction system is disclosed wherein an air bag is constructed by providing a main panel, attaching reinforcing material to predetermined locations on the main panel and forming holes through the main panel at the predetermined locations, and subsequently attaching a face panel to the main panel and trimming the face and main panels to a desired rounded configuration. The present system uses substantially rectangular panels whereby conveying and accurate placement of the panels is facilitated. The present system is conducive for implementation as an automated system and eliminates expensive and time consuming precutting of the air bag components.

Abstract: This invention relates to a dual clamping system for a sewing machine. The dual clamp system comprises a first clamp and a second clamp which may be used to clamp a first workpiece and a second workpiece, respectively, at a sewing station of the sewing machine. The first and second clamps are preferably of different shapes and dimensions so that different shaped workpieces can be clamped at the sewing station. In the preferred embodiment, the first and second clamps are adjustable inner clamps for clamping an inner portion of the first and second workpieces, respectively. The dual clamping system also comprises a peripheral clamp for clamping at least a portion of the periphery of either or both of the first and second workpieces at the sewing station. The dual clamping system permits an operator to either separately or simultaneously clamp and sew a plurality of workpieces having the same or different shapes.

Abstract: An interchangeable clamp having a plurality of interchangeable members which can be secured together to provide a clamp frame having a predetermined configuration. The predetermined configuration and clamp area of the clamp frame can be changed by substituting the interchangeable members with other interchangeable members having different shapes or sizes. The interchangeable members may be selected from a set of interchangeable members which make it easy for a user to change the configuration of the interchangeable clamp.

Abstract: A sewing station is disclosed including a workpiece clamp shuttle for loading and shuttling a bulky workpiece to be sewn to a sewing location of a sewing machine. The workpiece clasp shuttle includes a support surface for supporting a bulky workpiece and a clamp for clamping the bulky workpiece to the support surface at a loading station wherein the bulky workpiece may be easily loaded onto the support surface. The sewing machine includes apparatus for driving the clamp and the support surface from the loading station to the sewing location where the bulky workpiece can be sewn. In addition, a method for sewing a bulky workpiece in a sewing station is disclosed including the steps of preclamping the bulky workpiece at a loading location, and transferring the preclamped bulky workpiece from the loading location to a sewing location where the workpiece may be clamped and sewn.

Abstract: A workpiece pallet for transporting and holding a workpiece to be sewn in a programmable sewing machine. The workpiece pallet has a first frame member and a second frame member which is pivotally secured to the first frame member. The workpiece pallet also includes a detachable workpiece holder having a first template member and a second template member which can be detachably mounted to the first and second frame members, respectively. In one embodiment, the first template member has a seat and the second template member has a flange which cooperates with the seat in order to removably retain the workpiece in a mounted position in the workpiece holder so that the programmable sewing machine can sew a predetermined stitch pattern on the workpiece. In another embodiment, a support member is used in place of the second template member. The support member has a plurality of fingers which force the workpiece against the seat of the first template member.

Abstract: A workpiece pallet for transporting and holding one or more workpieces to be sewn in a programmable sewing machine. The workpiece pallet comprises a frame member having a locator which can be removably secured to the frame member. In a preferred embodiment, the locator comprises a base plate having a plurality of flanges which cooperate with mating flanges on the frame member so that the base plate is detachably supported therein. The base plate has a plurality of posts which facilitate locating one or more workpieces in the workpiece pallet. The workpiece pallet also comprises a universal coupler for permitting a plurality of sets of plates to be pivotally and detachably coupled to the frame member. The universal coupler comprises a plurality of first connecting members located on the frame member and a plurality of second mating connecting members which are located on each plates of the sets of plurality of plates.