MATERIAL SHEET ATTACHMENT DEVICE AND METHODS

Abstract

A device for attaching a fabric layer of a quilt to a leader that, in turn, attaches to a rail on a quilting machine so that the quilt may be pulled allowing the quilting machine to stitch the entire quilt.

Description

BACKGROUND

1. Technical Field

The present disclosure generally relates to attachment devices for use in securing multiple sheets of material together, and more particularly relates to devices and related methods for securing a material sheet to a leader, wherein the leader is secured to a rail of a quilting system.

2. Related Art

Creating decorative quilts by hand has become a popular avocation. A typical quilt is comprised of at least three fabric layers which are stacked and stitched together. Generally the quilt is comprised of a top or cover layer, a bottom or backing layer, and sometimes an intermediate or batting layer. The top layer is typically decorative and is produced as a consequence of the creative and artistic effort of the quilt maker. The backing layer is usually simple and aesthetically compatible with the top. The batting layer generally provides bulk and insulation. The specific process of sewing the sandwich of the three planar layers together is generally referred to as “quilting”. The quilting process usually consists of forming long continuous patterns of stitches which extend through and secure the top, backing, and batting layers together.

Quilting traditionally has been performed by hand without the aid of a sewing machine. However, hand quilting is a labor-intensive process which can require many months of effort by a practiced person to create a single quilt. Hence, there is greater current use of machines to assist in the quilting process to allow most of the quilter's effort to be directed toward the creative and artistic aspects of the top layer.

Machine quilting can be performed in a variety of ways. For example, a user can operate a substantially conventional sewing machine in a “free motion” mode. Machine quilting can also be performed by using a wide range of specialized hand- or computer-guided quilting systems. The characteristics and features of such systems are well documented. There are typically categories of such systems; i.e., (1) Table top set-ups, (2) Shortarm systems, and (3) Longarm systems. These categories are generally characterized by a rack assembly that includes a frame and a carriage assembly that supports a sewing machine or other sewing apparatus. The frame includes rails upon which the quilt layers are rolled up so as to enable a portion of the layered stack to be exposed for stitching while the remaining layer portions are stored on the rails. The carriage assembly typically includes two carriages; one sitting upon the other. One carriage moves in a longitudinal direction, and the other carriage moves upon the first carriage in a transverse direction. The sewing machine rests on the upper carriage thereby allowing movement of the sewing machine in two dimensions relative to the frame and the fabric to be quilted.

For machine quilting to occur, the layers of the quilt must be attached to the quilt machine in a process typically referred to as loading or mounting the quilt. Generally, the frame holds one or more payout rails onto which fabric (i.e., the top, bottom and intermediate layers) is rolled, and a take-up rail onto which the sewed quilt is rolled.

The quilt top and backing are typically not directly attached to the rails, but instead to a leader which, in turn, is attached to a rail. In some instances, the quilt is also attached to a leader that is attached to a rail. A leader typically consists of a fabric material, generally heavy and durable in nature since it is used over time for a large number of quilts. There are several methods for attaching a quilt top or backing to the leader. Such methods include, for example, using pins to directly secure a sheet of material (e.g., the quilt top, backing, or stitched quilt) to the leader. FIG. 10 illustrates a first side edge 19 of a fabric sheet 18 secured to a side edge 90 of a leader 86 with a plurality of pins 98. The fabric sheet 18 is rolled upon a rail 42 (e.g., one of the payout rails 42, 44) and the leader 86 is rolled upon a rail 40 (e.g., the quilt rail 40). Pinning the quilt top or backing directly to the leader has the disadvantage of being physically demanding on and time-consuming for the user. Additionally, pinning can result in discomfort for the user due to pin pricks especially given that the leader is typically comprised of a heavy material necessitating greater force to insert the pins through it.

In another example, a sewing machine is used to apply a large stitch to the sheet of material (e.g., the quilt top, backing, or stitched quilt) and the leader to baste the sheet of material onto the leader. “Basting” is defined as to sew with long, loose stitches, as in temporarily tacking together two pieces of cloth.

In a further example, the sheet of material (e.g., the quilt top, backing, or stitched quilt) and leader are secured to each other via a zipper or hook and loop structure (e.g., Velcro®). FIG. 11 illustrates a first side edge 19 of fabric sheet 18 having a strip of hook material 21, and a side edge 90 of leader 86 having a strip of loop material 92. In another arrangement, the feature 21 is a first length of zipper and the feature 92 is a second length of zipper that is configured to releaseably connect with the feature 21. The zipper or hook and loop structure must be secured to the sheet of material and the leader in advance of securing the sheet of material and leader to each other.

Once the layers of the quilt (or the stitched quilt in some arrangements) have been attached to the leaders, they are stretched sufficiently taut so that the layers are smooth over the quilting area for stitching. The quilting area is typically defined as the stretched region of fabric that spans between the take-up rail and the payout rails and is the area over which the fabric layers are sewn together into the finished quilt product. If the quilting area is not sufficiently flat and smooth, defects (e.g., the stitching can become distorted, the edge can become puffy, or the quilt edge may become damaged) can occur. By rotating the take-up rail, a new region of the quilt advances from the payout rails to the stretched area so that the quilting area can be quilted. This process continues until the entire quilt has been stitched at which point the layers of the quilt are disconnected from the leaders.

SUMMARY

According to at least one aspect of the present disclosure, a material sheet attachment device includes a channel member and at least one retaining member. The channel member defines an outer channel surface and a channel cavity having an inner channel surface. The channel member is mounted to a fabric leader along at least a portion of the outer channel surface. The channel cavity is sized to receive a portion of a material sheet such as a fabric sheet that is formed into a quilt. At least one retaining member is configured to releaseably mount to the channel member. When each retaining member is mounted to the channel member, a first portion of the retaining member is positioned in the channel cavity in engagement with the material sheet to retain the material sheet between the inner channel surface and the first portion of the retaining member. A second portion of the retaining member is positioned outside the channel cavity and configured for grasping by a user to insert and remove the retaining member relative to the channel member's cavity.

The material sheet attachment device can further include at least one insert member sized to fit within the channel cavity between the first portion of the retaining member and the material sheet. In some arrangements, the channel member has a C-shaped cross-section and the retaining member comprises a spring construction. Other features and aspects of the material sheet attachment device are possible, including a plurality of insert members each having an elongate construction, the retaining member having a generally U-shape construction, and providing a fastener or adhesive configured to secure the leader to the outer surface of the channel member.

Another aspect of the present disclosure relates to a quilting system that includes a quilting machine, a quilting rack assembly, and a sheet attachment device. The quilting rack assembly is configured to support the quilting machine and includes at least one fabric rail. The sheet attachment device includes a channel member, a fabric leader, a retaining member, and optionally an insert member. The channel member defines a channel cavity and an outer surface, wherein the channel cavity is sized to receive a portion of a fabric sheet. The fabric leader is secured along one edge to at least one fabric rail and secured along an opposite edge to the outer surface of the channel member. The retaining member is configured to releaseably mount to the channel cavity. When the retaining member is mounted to the channel, a first portion of the retaining member is positioned in the channel cavity to secure the fabric sheet to the channel member, and a second portion of the retaining member is positioned outside of the channel cavity for engagement by a user to remove the retaining member from the channel member.

A further aspect of the present disclosure relates to a method of securing a fabric sheet to a quilting machine rail with a material sheet attachment system. The material sheet attachment system includes a channel member, a retaining member, and optionally an insert member. The method can include the steps of securing a fabric leader to the quilting machine rail along a first edge of the fabric leader, and securing the fabric leader to an outer surface of the channel member along an opposite edge of the fabric leader. The method can also include positioning a portion of the fabric sheet within a channel cavity defined by the channel member, and positioning a portion of the retaining member within the channel cavity to secure the fabric sheet to the channel member.

Other aspects of an example method include removeably positioning a first portion of the retaining member within the channel cavity while maintaining a second portion of the retaining member outside the channel cavity for grasping by a user. A further method step includes securing the opposite edge of the fabric leader to the outer surface of the channel member by applying an adhesive or fastener between the outer surface of the channel member and the opposite edge of the fabric leader. Another example method step includes operatively positioning an insert member within the channel cavity between the fabric sheet and the aforementioned first portion of the retaining member. In one example arrangement, the channel member includes a C-shaped cross-section that defines a C-shaped channel cavity, and the retaining member comprises a spring construction, wherein positioning a portion of the retaining member within the channel cavity includes compressing the retaining member to fit the portion of the retaining member within an opening into the C-shaped channel cavity. In yet another example, an opening into the channel cavity is positioned along a top side of the channel member and the fabric leader is secured to a bottom side of the channel member.

A further aspect of the present disclosure relates to a method of securing a fabric sheet directly to a quilting machine rail with a material sheet attachment system. The material sheet attachment system includes a channel member, a retaining member, and optionally an insert member. The method can include the steps of securing the channel member directly to the quilting machine rail. The method can also include positioning a portion of the fabric sheet within a channel cavity defined by the channel member, and positioning a portion of the retaining member within the channel cavity to secure the fabric sheet to the channel member. The method can also include positioning the insert member in the channel cavity between the retaining member and the fabric sheet.

Features from any of the above-mentioned embodiments may be used in combination with one another in accordance with the general principles described herein. These and other embodiments, features, and advantages will be more fully understood upon reading the following detailed description in conjunction with the accompanying drawings and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate a number of exemplary embodiments and are a part of the specification. Together with the following descriptions, these drawings demonstrate and explain various principles of the instant disclosure.

FIG. 1 is a schematic perspective view of an example quilting system that includes a quilting machine and a quilting rack assembly.

FIG. 2 is a schematic partial side view of the quilting system shown in FIG. 1 and further including a sheet attachment assembly in accordance with principles of the present disclosure.

FIG. 3 is a schematic perspective view of another sheet attachment assembly in accordance with principles of the present disclosure.

FIG. 4 is a schematic cross-sectional side view of a portion of the sheet attachment assembly shown in FIG. 3.

FIG. 5 is a schematic cross-sectional side view of another sheet attachment assembly according to principles of the present disclosure.

FIG. 6 is a schematic cross-sectional side view of another sheet attachment assembly according to principles of the present disclosure mounted directly to a rail.

FIG. 7 is a perspective view of the sheet attachment assembly shown in FIG. 3 with the retaining member arranged in the channel member and aligned longitudinally.

FIG. 8 is a perspective view of the sheet attachment assembly shown in FIG. 7 with the retaining member arranged in the channel member and rotated to a orientation that is perpendicular to the channel member.

FIG. 9 is a is a perspective view of the sheet attachment assembly shown in FIG. 8 with the retaining member arranged in the channel member and a grasping portion of the retaining member rotated into contact with a top surface of the channel member.

FIG. 10 is a schematic perspective view of a prior art sheet attachment assembly.

FIG. 11 is a schematic perspective view of another prior art sheet attachment assembly.

Throughout the drawings, identical reference characters and descriptions indicate similar, but not necessarily identical, elements. While the exemplary embodiments described herein are susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and will be described in detail herein. However, the exemplary embodiments described herein are not intended to be limited to the particular forms disclosed. Rather, the instant disclosure covers all modifications, equivalents, and alternatives falling within the scope of the appended claims.

DETAILED DESCRIPTION

The present disclosure relates to devices and methods for securing a material sheet to a quilting system. One aspect of the present disclosure is a sheet attachment device that releaseably secures a fabric sheet to a fabric leader. The fabric leader, in turn, is fastened to a rail on a quilting rack assembly. The rail is used to roll up the fabric sheet. The rail can be a take up rail or any one of the feeder rails of the quilting rack assembly. In some embodiments, the sheet attachment device is directly mounted to the rail of a quilting rack assembly. The fabric sheet can include a single sheet of material or can include multiple sheets of material that are, for example, stitched together as a quilt. The sheet attachment device can provide a reduction in the time involved with loading and unloading a sheet of material (i.e., a quilt or a sheet of fabric from a quilt machine frame). The sheet attachment device can include features that are user friendly and minimize incidence of injury involved with other methods of securing a sheet of material to a rail member or fabric leader.

An example quilting system 10 is shown and described with reference to FIGS. 1-2. The quilting system 10 includes a quilting machine 12, a quilting rack assembly 14, and a sheet attachment device 16. The quilting machine 12 and quilting rack assembly 14 are primarily illustrated in FIG. 1. Aspects of the sheet attachment device 16 are included along with the quilting machine 12 and a portion of the quilting rack assembly 14 in FIG. 2.

The quilting machine 12 includes a base 24, an arm 26, a throat 28 defined between the base 24 and arm 26, and a needle bar 30 that supports a needle. The quilting machine 12 can be configured as a longarm quilting machine wherein the arm 26 has a length and the throat 28 has a size sufficient for a rolled up portion of a sheet of fabric to be retained within the throat 28 while a stretched out portion of the sheet of fabric is stitched by the quilting machine 12. Other types of sewing and/or quilting machines can be used in conjunction with the attachment device examples disclosed herein.

The quilting rack assembly 14 includes a frame 32 and a carriage assembly 34. The frame 32 includes a plurality of support legs 36, longitudinally arranged track members 38, at least one takeup rail 40 (also referred to as a quilt rail 40), a backing rail 42 (also referred to as a first sheet rail), and a top rail 44 (also referred to as a second sheet rail 44). The frame 32 can include other structures, such as a table top, upon which portions of the frame are supported such as, for example, the longitudinal tracks 38.

The frame 32 can be configured to adjustably position one or more of the rails 40, 42, 44 at various locations relative to each other, relative to other portions of the frame 32, and relative to the quilting machine 12. The frame 32 shown in FIGS. 1 and 2 is exemplary only as many other various frame configurations are available.

The carriage assembly 34 includes a first platform 46, a first set of rollers 48 engaged with the longitudinal tracks 3 8, a plurality of carriage tracks 50, a second platform 52, and a second set of rollers 54 that are engaged with the carriage tracks 50. The first platform 46 and associated rollers 48 provide longitudinal movement of the quilting machine 12 relative to the frame 22 in the direction 56. The second platform 52 and associated rollers 54 provide lateral movement of the quilting machine 12 relative to the first platform 46 and the frame 32 in the direction 58.

Typically, the quilting machine 12 is supported directly on the second platform 52. The carriage assembly 34 can be configured to provide relatively precise movement of the quilting machine 12 relative to the sheets of fabric supported by the frame 32 to produce desired stitch patterns on the sheets of fabric as part of creating a quilt.

The frame 32 illustrated in FIG. 1 and FIG. 2 includes three rails 40, 42, 44. In other arrangements, more than three rails can be used to support additional layers of material that are combined to make a quilt that is stored on the quilt rail 40. In still other arrangements, the frame 32 can include less than three rails such as only the quilt rail 40 to support a stitched sheet of material and the first sheet rail 42 to support one or more sheets of unstitched or partially stitched material.

The rails 40, 42, 44 shown in FIGS. 1 and 2 have a generally circular cross-section and elongate shape. Other rail embodiments comprise different cross-sectional shapes and include other features such as, for example, features for use in attaching material sheets to the rail.

The sheet attachment device 16 includes at least one channel member 60, at least one retaining member 62, and optionally at least one insert member 64 (see FIGS. 2-5). The channel member 60 includes a channel cavity 66, an inner surface 68 within the channel cavity 66, an outer surface 70, a top side 72, a bottom side 74, and a channel opening 77 defined between opening edges 76A, 76B. The channel member 60 can also have a length L1 (see FIG. 3). Typically, the length L1 is substantially the same as width W1 of the fabric sheet 18, and in some instances longer than the width W1.

The channel member 60 has a generally C-shaped cross-section as shown in FIG. 4. The channel member 60 can be constructed as a single length of channel that extends across the leader 86 and has a length at least as great as W2. Alternatively, the channel member 60 can include a plurality of leg segments that are arranged end-to-end in a straight line. Typically, the plurality of leg segments can have a combined length L1 that is at least width W1. The size of the channel opening 77 can be varied to accommodate different sized insert members 64 and portions of the retaining member 62. The size and shape of the channel opening 77 is typically configured to provide limited access into the channel cavity 66 regardless of the cross-sectional shape and size of the channel member 60. For example, referring to FIG. 5, an alternative channel member 160 includes a generally C-shaped cross-section but does not include any pointed corners along the inner or outer surfaces 168, 170.

The inner surface 68 of channel member 60 is defined along that portion of the channel cavity 66 that is inside of the channel opening 77 or positioned radially inward relative to the channel opening 77. The outer surface 70 is defined as that surface of the channel member 60 that is outside of the channel opening 77 or radially outward relative to the channel opening 77.

The channel opening 77 is defined along a top side 72 of the channel member 60. The bottom side 74 is defined along a portion of the channel member 60 that is opposite the top side 72. The channel member 60 can also include first and second sides 73, 75 that extend between the top and bottom sides 72, 74 (see FIG. 4).

The channel member 60, 160 shown in FIGS. 2-5 typically is a unitary, single piece member. In other arrangements, the channel member can comprise a plurality of members positioned along the width W2 of the leader 86. The channel member segments can be positioned end-to-end in engagement with each other or longitudinally spaced apart from each other.

The retaining member 62 includes first or insert portions 78A, 78B (also referred to as an insert portion 78), and a grasping portion 80. Typically, the insert portions 78A, 78B extend through the channel opening 77 into the channel cavity 66 and the grasping portion 80 remains outside of the channel cavity 66. In the arrangement shown in FIG. 4, the retaining member 62 comprises a spring-type construction wherein application of a compression force in the direction 82 moves the insert portions 78A, 78B towards each other to permit the retaining member 62 to be inserted into and removed from the channel cavity 66 in the direction I. Release of the compression force in the direction 82 permits the insert portion 78A, 78B to move away from each other. After the insert portions 78A, 78B are moved into the channel cavity 66 in the direction 84, release of the compression force 82 moves the insert portion 78A, 78B toward the inner surface 68 to help retain the retaining member 62 within the channel cavity 66.

The insert portion 78A, 78B can apply forces within the channel cavity 66 in various directions. For example, in one arrangement, the retaining member 62 applies a force in a generally downward direction along a bottom inside surface of the channel cavity 66. If the optional insert member 64 is used, the downward force compresses the insert member 64 against the sheet 18 along a bottom inside surface of the channel cavity 66. Alternatively, the retaining member 62 can be configured to apply a force laterally to the side such that the insert portion 78A, 78B directly engage the sheet 18 to capture the sheet 18 against the inner surface 68. In still further arrangements, portions of the insert portion 78A, 78B apply a force in a generally vertical upward direction within the channel cavity 66 toward the top side 72 to again directly engage the sheet 18. In similar arrangements, the retaining member is configured to engage the sheet 18 against the opening edges 76A, 76B of the channel opening 77 to apply a force to sheet 18 that retains the sheet 18 within the channel cavity 66.

The retaining member 62 can have many different configurations in various embodiments. For example, the retaining member has a generally upside down U-shaped construction in the embodiment shown in FIG. 4. An alternative retaining member construction 162 is shown in FIG. 5 having an upright U-shaped construction. Retaining member 162 includes an insert portion 178 configured to fit within a channel cavity 166. The insert portion 178 is inserted through an opening 177, wherein the insert opening 177 is defined between opening edges 176A, 176B. Application of a compression force 82 to the grasping portions 180A, 180B of the retaining member 162 reduces a size of the insert portion 178 sufficiently to remove the insert portion 178 from within the channel cavity 166. Release of the compressing force 82 after the insert portion 178 is positioned within the channel cavity 166 permits the grasping portions 180A, 182 to move away from each other and towards the inner surface 168 to hold the retaining member 162 within the channel cavity 166.

Various other shapes, sizes and operation constructions are possible for the retaining members 62, 162. Typically, the retaining members 62, 162 are configured to provide easy grasping and compressing the retaining member and inserting and removing the retaining member relative to the channel cavity. While a spring-like construction is shown for the retaining member 62, 162, other configurations are possible that provide inserting and removing portions of the retaining member relative to the channel cavity 66, 166.

In some examples, the retaining member is configured to reduce the size of the insert portion 78, 178 (i.e., a total width W3 measured between outer ends of the insert portions 78A, 78B shown in FIG. 4) at least temporarily while inserting the retaining member into the channel cavity. In some configurations it is possible to insert the insert portion 78, 178 into the channel cavity 66 in the direction I with a width axis A2 of the retaining member 62, 162 aligned with a longitudinal axis Al of the channel member 60, 160 as shown in FIG. 7. The retaining member 62, 162 is then rotated in the rotation direction R while the insert portion 78, 178 is positioned within the channel cavity 66, 166 to move the insert portion 78, 178 into a locked or otherwise retained state wherein the axis A2 is arranged generally perpendicular to the axis Al as shown in FIG. 8. In other configurations, it is possible to insert the portions 78, 178 into the channel cavity 66 in the direction I with the width axis A2 of the retaining member 62, 162 aligned perpendicular to the longitudinal axis A1. In this configuration, no rotating of the retaining member 62, 162 in the rotation direction R is needed to position the retaining member 62, 162 in a locked or retained state.

The grasping portion 80 of the retaining member 62, 162 can then be rotated in the direction R2 towards the channel member 60 as shown in FIG. 9. The grasping portion 80 can be rotated in direction R2 until the grasping portion 80 lays down relatively flat against a top surface 72 of the channel member. In some arrangements, the grasping portion 80 can have a size that permits movement through the channel opening 77 into the channel cavity 66 when rotating in direction R2 from the position shown in FIG. 8. Moving the grasping portion 80 in the direction R2 towards the channel 60 can reduce an overall profile of the sheet attachment device 16 for improved ease in rolling up the fabric sheet 18 onto one of the quilt rails.

The insert member 64 can include a single length of insert member or can include a plurality of insert member segments 64A-C as shown in FIG. 3. Typically, the insert member 64 is sized to fit entirely within the channel cavity 66. In some arrangements, the insert member 64 is configured for insertion into the channel cavity 66 via only the channel opening 77. Alternatively, the insert member 64 can be configured for insertion into the channel cavity 66 through an open end of the channel cavity at one of the opposing ends of the channel member 60.

The insert member 64 can be a relatively rigid member. Alternatively, the insert member 64 can have some flexibility that permits temporary deformation. Such flexibility may provide additional ease in inserting the insert member 64 into the channel cavity through the channel opening 77. The insert member 64 can be relatively thin (i.e., having a greater width than thickness). In some arrangements, the insert member has a generally rectangular cross-section. In other arrangements, the insert member has a circular or oval cross-section.

Typically, the channel cavity 66 is sized sufficiently large to permit an edge portion 19 of a fabric sheet 18 (alternatively, a quilted sheet, batting, or other material sheet) to fit therein, in addition to receiving the insert member 64 and the insert portions 78A, 78B of the retaining member 62. In some configurations, the retaining member 62 is configured to retain the insert member 64 within the channel cavity, and the insert member 64 primarily provides the tension or friction forces necessary to retain the sheet 18 within the channel cavity 66 at locations between the retaining members 62. In other arrangements, the retaining member alone (i.e., without an additional insert member) can be used to retain the sheet 18 within the channel cavity 66. For example, referring to FIG. 5, the insert portion 178 of the retaining member 162 directly engages the sheet 18 within the channel cavity 66 while applying a force directed toward the inner surface 168 of the channel member 160 to frictionally hold the sheet 18 within the channel cavity 166. In still further arrangements, the insert member 64 is formed integral or at least coupled together as an assembly with at least one retaining member 62.

While in some arrangements a single retaining member can be used to provide the necessary retaining force needed to hold the insert member 64 within the channel cavity 66, a plurality of retaining members 62 is typically utilized. In arrangements such as that shown in FIG. 5, a plurality of retaining members 162 positioned at longitudinally spaced apart locations along a length of the channel member 160 is particularly helpful in retaining the sheet 18 within the channel cavity 166.

While the retaining member 62, 162 shown in FIGS. 2-5 includes a grasping portion 80, 180A, 180B that is always positioned outside of the channel cavity 66, 166, other configurations of the retaining member are possible wherein the entire retaining member can be positioned within the channel cavity. Further, other mechanical devices such as latches, brackets, linkages, and other quick release mechanisms can be used in place of the spring-like retaining member 62, 162 shown in FIGS. 2-5 to accomplish the same or similar purpose described above related to retaining members 62, 162.

The insert members 64A-C shown in FIG. 3 each have a corresponding length L2-L4, respectively. The combined lengths of the insert members 64A-C can be substantially equal to the length L1 of the channel member 60. When a single insert member 64 is used, the single insert member may also have a total length that is substantially the same as the length L1. Alternatively, the total length of the insert members, whether a single insert member or a plurality of insert members, can be less than the length L1.

The channel members 60, 160 are typically mounted to a leader 86 as shown in FIGS. 2-5. The leader 86 includes a first side edge 88 that is mounted or otherwise secured to a rail of the frame 32 (i.e., the quilt rail 40 or first and second sheet rails 42, 44). A second side edge portion 90 of the leader 86 is typically secured or otherwise mounted to the channel member 60, 160. FIG. 4 illustrates the leader 86 being secured to the bottom side 74 of the channel member 60 with both a fastener 96 and an adhesive 94 or other connecting member. In some arrangements, only one of the adhesive 94 and fastener 96 is used. Alternatively, any other device or method may be used to secure the channel member 60, 160 to the leader 86. The adhesive 94 can be, for example, a double-sided adhesive tape, an epoxy or glue. The fastener 96 can include, for example, a rivet, bolt, screw, clamp, or other connecting structure such as Velcro®.

Typically, the channel member 60, 160 is secured to the leader 86 in advance of securing the sheet 18 to the channel member 60, 160. Alternatively, the sheet 18 (or other sheet of material) can be secured to the channel member 60, 160 in advance of securing the channel member 60, 160 to the leader 86. For example, the sheet 18 can be secured to the channel member 60, 160 at a sheet mounting station, and then the assembly of the sheet 18 with the channel member 60, 160 can be carried to the rack assembly 14 and wherein the channel member 60, 160 is mounted to the fabric leader 86 which, in turn, is secured to one of the rails 40, 42, 44.

The leader 86 is shown in FIGS. 4 and 5 being secured only to the bottom side 74, 174 of the channel member. In other arrangements, the leader 86 can be secured to multiple sides or portions of the outer surface 70, 170, or to any single one side or portion of the outer surface (i.e., one of the side surfaces 73, 173, 75, 175 or a portion of the top surface 72, 172). In still other arrangements, at least a portion of the leader 86 can be secured to a portion of the inner surface 68, 168. Typically, the insert member 64 and retaining member 62, 162 are not used to secure the leader 86 to the channel member 60, 160.

FIGS. 4 and 5 illustrate the sheet 18 extending completely through the channel cavity 66, 166 from one side 73, 173 to the other side 75, 175. In other arrangements, the sheet 18 extends only partially through the channel cavity so as to engage, for example, only the insert member 64 and the insert portion 78B of the retaining member 62.

FIG. 6 illustrates another example arrangement in which a channel member 260 is mounted directly to a rail of a rack assembly (e.g., rail 44). The channel member 260 is mounted to the rail 44 along a bottom side 274 using, for example, a connecting member such as an adhesive 94. Other connecting structures and methods are possible including, for example, fasteners, Velcro®, or brackets. The channel member 260 can also include an opening 277 into an internal cavity 266. The opening 277 is defined between opening edges 276A, 276B. The cavity 266 defines an inner surface 268 of the channel member 260. The cavity 266 can be sized to receive a portion of sheet of material 18, an insert member 64, and portions of a retaining member 62. In some arrangements, the channel member 260 is configured for use with only at least one of the retaining members 62 and not with the insert member 64.

At least a portion of the channel member 260 can include a shape that matches a portion of the outer contoured surface of the rail 44, as shown in FIG. 6. Providing a portion of the channel member 260 with a contoured shape can promote easier wrapping of the sheet of material 18 about the rail 44. In other arrangements, the channel member 260, insert member 64 and retaining members 62 can have other shapes and sizes, such as those configurations shown in FIGS. 1-5.

The preceding description has been provided to enable others skilled in the art to best utilize various aspects of the exemplary embodiments described herein. This exemplary description is not intended to be exhaustive or to be limited to any precise form disclosed. Many modifications and variations are possible without departing from the spirit and scope of the instant disclosure. It is desired that the embodiments described herein be considered in all respects illustrative and not restrictive and that reference be made to the appended claims and their equivalents for determining the scope of the instant disclosure.

Unless otherwise noted, the terms “a” or “an,” as used in the specification and claims, are to be construed as meaning “at least one of.” In addition, for ease of use, the words “including” and “having,” as used in the specification and claims, are interchangeable with and have the same meaning as the word “comprising.”

Claims

1. A material sheet attachment device, comprising:

a channel member defining an outer channel surface and a channel cavity having an inner channel surface, the channel member being mounted to a fabric leader along at least a portion of the outer channel surface, the channel cavity being sized to receive a portion of a material sheet;

a plurality of retaining members configured to releaseably mount to the channel member, wherein when each retaining member is mounted to the channel member, a first portion of the retaining member is positioned in the channel cavity in engagement with the material sheet to retain the material sheet between the inner channel surface and the first portion of the retaining member, and a second portion of the retaining member is positioned outside the channel cavity and configured for grasping by a user to insert and remove the retaining member relative to the channel cavity member.

2. The device of claim 1, further comprising at least one insert member sized to fit within the channel cavity between the first portion of the retaining member and the material sheet.

3. The device of claim 1, wherein the channel member has a C-shaped cross-section.

4. The device of claim 1, wherein the retaining member comprises a spring construction.

5. The device of claim 2, wherein the at least one insert member includes a plurality of insert member each having an elongate construction.

6. The device of claim 1, wherein the retaining member has a generally U-shape construction.

7. The device of claim 1, further comprising a fastener or an adhesive configured to secure the leader to the outer surface of the channel member.

8. The device of claim 1, wherein the leader is a fabric sheet and the material sheet comprises fabric.

9. A quilting system, comprising:

a quilting machine;

a quilting rack assembly configured to support the quilting machine and including at least one fabric rail;

a sheet attachment device, including: a channel member defining a channel cavity and an outer surface, the channel cavity sized to receive a portion of a fabric sheet; a fabric leader secured along one edge to the at least one fabric rail and secured along an opposite edge to the outer surface of the channel member; a retaining member configured to releaseably mount to the channel cavity, wherein when the retaining member is mounted to the channel, a first portion of the retaining member is positioned in the channel cavity to secure the fabric sheet to the channel member, and a second portion of the retaining member is positioned outside of the channel cavity for engagement by a user to insert and remove the retaining member from the channel member.

10. The quilting system of claim 9, wherein the channel member has a C-shaped cross-section.

11. The quilting system of claim 9, wherein the retaining member comprises a spring construction.

12. The quilting system of claim 9, wherein the fabric leader is secured to the outer surface of the channel member with an adhesive.

13. The quilting system of claim 9, wherein the fabric leader is secured to the outer surface of the channel member with a fastener.

14. The quilting system of claim 9, further comprising at least one elongate insert member sized to fit within the channel cavity between the first portion of the retaining member and the fabric sheet.

15. A method of securing a fabric sheet to a quilting machine rail with a material sheet attachment system, the material sheet attachment system including a channel member and a retaining member, the method comprising.

coupling an outer surface of the channel member to the quilting machine rail;

positioning a portion of the fabric sheet within a channel cavity defined by the channel member;

positioning a portion of the retaining member within the channel cavity to secure the fabric sheet to the channel member.

16. The method of claim 15, wherein positioning a portion of the retaining member within the channel cavity includes removeably positioning a first portion of the retaining member within the channel cavity while maintaining a second portion of the retaining member outside the channel cavity for grasping by a user.

17. The method of claim 15, further comprising operatively positioning an insert member within the channel cavity between the fabric sheet and the portion of the retaining member.

18. The method of claim 15, wherein positioning a portion of the retaining member within the channel cavity to secure the fabric sheet to the channel member includes orienting the retaining member in a first orientation while inserting the portion of the retaining member within the channel cavity, and then rotating the retaining member into a second orientation.

19. The method of claim 15, wherein an opening into the channel cavity is positioned along a top side of the channel member and the fabric leader is secured to a bottom side of the channel member.

20. The method of claim 15, wherein coupling the channel member to the quilting machine rail further includes securing a fabric leader to the quilting machine rail along a first edge of the fabric leader and securing a second edge of the fabric leader that is opposite the first edge to the outer surface of the channel member.

21. The method of claim 15, wherein securing the opposite edge of the fabric leader to the outer surface of the channel member includes applying an adhesive or securing a fastener between the outer surface of the channel member and the opposite edge of the fabric leader.