Abstract: Ink jet printing is provided onto fabric using ultraviolet (UV) light curable ink. The ink is first partially cured with UV light and then is subjected to heating to more completely cure the ink and to remove by evaporation or otherwise, the uncured monomers and producing a printed image of ink having an amount of unpolymerized monomers and polymerization reactants and byproducts that is less than a food industry packaging standard of 100 PPM, and as low as 10 PPM. The printing is provided in a quilting machine having a quilting station and a printing station located upstream of the quilting station. Preferably, at the printing station, only a top layer of fabric is printed with a multi-colored design under the control of a programmed controller. UV curable ink is jetted onto the fabric with a dot volume of about 75 picoliters.

Abstract: A quilting machine (10,100, 200, 300, 400, 500, 600) is provided with a printing station (20, 125, 225, 325, 425, 525, 611, 626, 631) and a quilting station (44, 127, 227, 327, 427, 527, 627, 632). A master batch controller (90, 135, 235, 335, 435, 535) assures that the proper combinations of printed and quilted patterns are combined to allow small quantities of different quilted products to be produced automatically along a material web. Ticking is preprinted with a plurality of different patterns, organized and communicated by the computer so that a print head can scan the material and print different patterns of different panels (32) across the width of a web. Identifying data (40) for matching the panels of a mattress product can be provided in data files printed on the fabric.

Abstract: Ink jet printing is provided using ultraviolet (UV) light or other curable composition or stable or other printable substance having a dye-component therein. The ink is jetted onto a substrate, the composition is cured, then heated to set the dye. Sublimation dye-based UV ink printing onto polyester is preferred.

Abstract: Inkjet printing is provided onto rigid panels such as office partitions, which have surfaces that are contoured, textured or made of another three-dimensional material, or are otherwise differently spaced from the plane of the panel such that the distance between a printing element and the point on the surface on which ink is to be deposited is not always the same or exactly predictable. Preferably, three dimensional covered panels are printed using ink jet printing, preferably using ultraviolet (UV) light curable ink, which is first, at least partially cured with UV light and then subjected to heating to more completely cure and dry the ink to remove, by evaporation, further curing or otherwise, the uncured monomers. The panel surface may be contoured by quilting or molding processes. Print head to panel spacing is adjustable to maintain a predetermined constant distance from the printing element to the surface of the panel where the ink is to be applied.

Abstract: Ink jet printing is provided on large area substrates such as wide width textile webs. The printheads are driven by linear servo motors across a bridge that extends across the substrate. The timing of the jetting of the ink is coordinated with the motion of the printheads, so that the heads can be rapidly moved and the ink can be jetted while the printheads are accelerating or decelerating as they move on the bridge. Preferably, ultraviolet (UV) light curable ink is jetted and first partially cured with UV light and then subjected to heating to more completely reduce uncured monomers of the ink on the substrate.

Abstract: A quilting machine (10, 100, 200, 300, 400, 500, 600) is provided with a printing station (20, 125, 225, 325, 425, 525, 611, 626, 631) and a quilting station (44, 127, 227, 327, 427, 527, 627, 632). The printing station is located either in line and preferably upstream of the quilting station, with a conveyor (520) extending through each of the stations to convey a web of quilting material through the machine, or is off of the quilting line such that the material with a pre-applied pattern thereon is transferred, preferably in web form, to the line of the second station for the application of a pattern in registration with the first applied pattern. At the quilting station, registration longitudinal and transverse registration is measured and skewing or rotation of the material is determined. Opposite transverse sides of the material are differently adjusted to orient and register the material.

Abstract: Ink jet printing is provided onto fabric using ultraviolet (UV) light curable ink. The ink is first partially cured with UV light and then is subjected to heating to more completely cure the ink and to remove by evaporation or otherwise, the uncured monomers and producing a printed image of ink having an amount of unpolymerized monomers and polymerization reactants and byproducts that is less than a food industry packaging standard of 100 PPM, and as low as 10 PPM. The printing is provided in a quilting machine having a quilting station and a printing station located upstream of the quilting station. Preferably, at the printing station, only a top layer of fabric is printed with a multi-colored design under the control of a programmed controller. UV curable ink is jetted onto the fabric with a dot volume of about 75 picoliters.

Abstract: Ink jet printing is provided onto fabric using ultraviolet (UV) light curable ink. The ink is first cured with UV light to about a 90-97% cure, and then is subjected to heating to more completely cure the ink and to remove by evaporation or otherwise, the uncured monomers and producing a printed image of ink having less than 100 PPM of uncured monomers, and as low as 10 PPM of uncured monomers. The printing is provided in a quilting machine having a quilting station and a printing station located upstream of the quilting station. Preferably, at the printing station, only a top layer of fabric is printed with a multicolored design under the control of a programmed controller. UV curable ink is jetted at a dot density of about 180×254 dots or more per inch per color, each dot of about 80 picoliters.

Abstract: Ticking for the production of mattress covers is preprinted with a plurality of different patterns by a computer controlled printer that prints in response to pattern data communicated from a control computer. The pattern data is organized and communicated by the computer so that a print head, for example, can scan the ticking material, such as in rows across the width of a web, and print different patterns. For example, different border panels can be oriented along a web and positioned side-by-side across a web and each printed with a different pattern. Top and bottom panels having corresponding patterns can be printed on the same or a different web. Identifying data for matching the panels of a mattress product can be provided in data files in the same or a different computer or can be printed on the fabric along with the patterns on the panels.

Abstract: A quilting apparatus is provided with a computer controlled presser plate adjusting mechanism. A presser plate rocker shaft is separate from and mechanically connected to a needle rocker shaft and imparts a reciprocating motion to the presser plate. The presser plate rocker shaft is adjustable to vary the range of its output link to the presser plate, thereby changing the endpoints of its reciprocating path of travel. Certain embodiments have an output end of the presser plate rocker shaft adjustable relative to the input end through a coupling to different angular positions relative to an input end in order to change the upper and lower ends of the range of reciprocation of the pressure plate relative to the needle plate. Alternatively, the length of a link between the needle and pressure plate rocker shafts is variable to make the presser plate adjustment.

Abstract: A quilting machine is provided having a first station and a second station, one being a printing station and one being a quilting station. The printing station is located either in line and preferably upstream of the quilting station, with a conveyor extending through each of the stations to convey a web of quilting material through the machine, or is off of the quilting line such that the material with a pre-applied pattern thereon is transferred, preferably in web form, to the line of the second station for the application of a pattern in registration with the first applied pattern. At the second station, for example, registration of a plurality of transversely spaced points is detected to determine longitudinal and transverse registration as well as skewing or rotation of the material, and the opposite transverse sides of the material are differently adjusted to orient and register the material.

Abstract: An apparatus for stitching fabric to produce a quilted fabric having a needle plate for supporting the fabric, a presser plate located at a first position above the needle plate and a needle located above the presser plate. A needle rocker shaft is mechanically connected to the needle and imparts a reciprocating motion to the needle in response to the angular displacements of the needle rocker shaft. Further, a presser plate rocker shaft is mechanically connected to the needle rocker shaft and imparts a reciprocating motion to the presser plate in response to the angular displacements of the presser plate rocker shaft. The presser plate rocker has an output shaft movable to a different relative angular positions with respect to an input shaft in order to locate the presser plate at a second position with respect to the needle plate.

Abstract: A quilting machine is provided having a quilting station and a printing station located upstream of the quilting station, with a conveyor extending through each of the stations to convey a web of quilting material through the machine. At the printing station a top layer is printed with a multi-colored design under the control of a programmed controller, which may vary the design from section to section of the web so that individual or small quantities of panel sections of the web may be decorated with a different pattern. The conveyor preferably moves the quilting material relative to stationary heads, but the conveyor may alternatively stop at various stations and the printing or quilting heads moved relative to the stationary web on the conveyor. Precise longitudinal position information is maintained of the location of the printed pattern. The conveyor then conveys the top patterned layer web through a drying station.

Abstract: A quilting machine is provided having a quilting station and a printing station located upstream of the quilting station, with a conveyor extending through each of the stations to convey a web of quilting material through the machine. At the printing station a top layer is printed with a multi-colored design under the control of a programmed controller, which may vary the design from section to section of the web so that individual or small quantities of panel sections of the web may be decorated with a different pattern. The conveyor maintains precise longitudinal position information of the location of the printed pattern and conveys the top patterned layer web through a drying station. Then, after combining the top layer web with webs of filler and backing material, it conveys the multi-layered web to the quilting station where a quilted pattern is caused by the controller to be sewn on the printed pattern bearing material in registration with the printed pattern.

Abstract: An automated method for the manufacture of a coil spring assembly including inserting coil springs having predetermined multiple spring rates into respective individual pockets of a continuous pocket strip in a predetermined order. The predetermined multiple spring rates of at least one coil spring may differ from that of the other coil springs, and each of the multi-rate coils has at least two different spring rates. One or more wires having a substantially uniform thickness are coiled to form the multiple rate coil springs before insertion into the continuous pocket strip. The wire is preferably coiled to produce a coil spring having at least two different diameters and at least two different pitches. The method also includes cutting the spring-filled strip into one or more desired lengths, placing at least two spring-filled lengths adjacent to each other; and attaching adjacent lengths together. A coil spring assembly may thus be provided with one or more firmness zones.

Abstract: A process for producing a painted, cord-bordered design on a comforter, includes the steps of superimposing a facing sheet of material on a layer of batting material which is on a backing sheet, positioning a cording material on the facing sheet in a predetermined pattern by use of a quilting machine, stitching the cording material immediately after positioning, the stitching going through all the layers of the comforter, removing the work piece from the quilting machine and painting those areas of the desired design which are bordered by the cording material.

Abstract: A quilting machine includes a base having three bridges; a sewing head secured to the upper bridge; a cylindrically shaped frame slidably and rotatably mounted on the lower two bridges, the frame including first and second end assemblies spaced from each other on the lower bridges, each having a support casting slidably mounted on the base and a ring rotatably mounted on a support casting, each ring including circumferential gear teeth, gears meshing with the gear teeth and extending from the support castings for supporting the rings, a plurality of first and second telescoping rods secured to the first and second end assemblies, at least one first telescoping rod screw-threadedly receiving a second telescoping rod, and at least one first and second telescoping rod rotatably fixed and axially movable with respect to each other, a gear secured to each of the latter in meshing engagement with the gear teeth of the respective rings; a mechanism for rotating the axially movable and rotatably fixed first and secon

Abstract: A quilting machine includes a base having three bridges; a sewing head secured to the upper bridge; a cylindrically shaped frame slidably and rotatably mounted on the lower two bridges, the frame including first and second end assemblies spaced from each other on the lower bridges, each having a support casting slidably mounted on the base and a ring rotatably mounted on a support casting, each ring including circumferential gear teeth, gears meshing with the gear teeth and extending from the support castings for supporting the rings, a plurality of first and second telescoping rods secured to the first and second end assemblies, at least one first telescoping rod screw-threadedly receiving a second telescoping rod, and at least one first and second telescoping rod rotatably fixed and axially movable with respect to each other, a gear secured to each of the latter in meshing engagement with the gear teeth of the respective rings; a mechanism for rotating the axially movable and rotatably fixed first and secon