Apparatus and method for joining a plurality of textile webs together in side-by-side relation

That which is claimed:

1. A method for forming a convolute roll of a relatively wide textile fabric by joining together a plurality of textile webs in side-by-side relation, each of the textile webs comprising heat fusible nonwoven textile material, said method comprising the steps of:

positioning a first textile web overlying a second textile web while advancing the first and second textile webs along a predetermined path of travel;

forming a relatively narrow flexible joint between the first and second textile webs by heat fusing together adjacent portions thereof as the textile webs are moved along the predetermined path of travel;

unfolding the thus joined first and second textile webs about the joint so that the first and second textile webs lie in a common plane to define the relatively wide textile fabric and so that the relatively narrow flexible joint extends outwardly from adjacent portions of the relatively wide textile fabric; and

winding the relatively wide textile fabric into successive convolute wound layers with the relatively narrow flexible joint folded to lie flat between successive layers so that the successive convolute wound layers define a cylindrical convolute roll being devoid of a substantial bulge at the joint.

2. A method according to claim 1 wherein the step of winding the relatively wide textile fabric comprises winding the successive convolute wound layers of the textile fabric with variations in axial alignment among the layers so that the relatively narrow joint is offset throughout the successive convolute wound layers.

3. A method according to claim 1 wherein the first and second textile webs have a predetermined thickness, and wherein the step of forming the joint further comprises pressing together the adjacent portions of the first and second textile webs so that the joint has a thickness less than the predetermined thickness of the textile webs.

4. A method according to claim 3 further comprising the step of trimming predetermined portions of heat fused textile material at the joint so that the joint has a relatively narrow width of less than about five times the predetermined thickness of the textile webs.

5. A method according to claim 1 wherein the step of forming the joint comprises ultrasonically welding the adjacent portions of the first and second textile webs.

6. A method according to claim 1 wherein the step of positioning the first and second textile webs further comprises relatively positioning the first and second textile webs so that respective first longitudinal edges of the first and second textile webs are generally aligned with each other.

7. A method according to claim 6 further comprising the steps of:

positioning a third textile web on the second textile web so that a longitudinal edge of the third textile web is generally aligned with a second longitudinal edge of the second textile web;

forming a second relatively narrow flexible joint between the second and third textile webs by heat fusing together adjacent portions of the second and third textile webs; and

wherein said unfolding step further includes unfolding the second and third webs about the second joint so that all of the webs lie in a common plane to further define the relatively wide textile fabric.

8. An apparatus for forming a convolute roll of a relatively wide textile fabric by joining together a plurality of textile webs in side-by-side relation, each of the textile webs comprising heat fusible nonwoven textile material, said apparatus comprising:

feeder means for positioning a first textile web overlying a second textile web and advancing the textile webs along a predetermined path of travel;

welding means positioned along the predetermined path of travel for forming a relatively narrow flexible joint between the first and second textile webs by heat fusing together adjacent portions thereof;

an unfolding frame positioned downstream from said welding means for unfolding the first and second textile webs about the joint so that the textile webs lie in a common plane to define the relatively wide textile fabric and so that the relatively narrow flexible joint extends outwardly from adjacent portions of the relatively textile wide fabric; and

take-up means positioned downstream from said unfolding frame to wind the relatively wide textile fabric into successive convolute wound layers with the relatively narrow flexible joint folded to lie flat between successive layers so that the successive convolute wound layers define a cylindrical convolute roll being devoid of a substantial bulge at the joint.

9. An apparatus according to claim 8 wherein said take-up means comprises means for winding successive convolute wound layers of the textile fabric with variations in axial alignment among the layers so that the relatively narrow joint is offset throughout the successive convolute wound layers.

10. An apparatus according to claim 8 wherein all of the textile webs have a same predetermined thickness, and wherein said welding means comprises means for pressing together the adjacent portions of the first and second textile webs so that the joint has a thickness less than the predetermined thickness of the textile webs.

11. An apparatus according to claim 10 wherein said welding means further comprises trimming means for trimming portions of heat fused material from the joint so that the joint has a relatively narrow width outward from the textile fabric less than about five times the predetermined thickness of the textile webs.

12. An apparatus according to claim 8 wherein said feeder means comprises means for relatively positioning the first and second textile webs so that respective first longitudinal edges of the first and second textile webs are generally aligned with each other.

13. An apparatus according to claim 12 wherein said welding means comprises an ultrasonic horn and an anvil cooperating therewith to form the joint from respective first longitudinal edge portions of the first and second textile webs.

14. An apparatus according to claim 12 wherein said feeder means further comprises means for positioning a third textile web on the second textile web so that a longitudinal edge of the third textile web is generally aligned with a second longitudinal edge of the second textile web; wherein said welding means further comprises means for forming a second relatively narrow flexible joint between the second and third textile webs by heat fusing together adjacent respective edge portions thereof; and wherein said unfolding frame comprises means for unfolding the second and third textile webs about the second joint so that the third textile web lies in the common plane with the first and second textile webs to further define the relatively wide textile fabric.

15. An apparatus for forming a convolute roll of a relatively wide textile fabric by joining together a plurality of textile webs in side-by-side relation, each of the textile webs comprising heat fusible nonwoven textile material, said apparatus comprising:

feeder means for positioning a first textile web overlying a second textile web and advancing the textile webs along a predetermined path of travel;

ultrasonic welding means positioned along the predetermined path of travel for forming a relatively narrow flexible joint between the first and second textile webs by heat fusing together adjacent portions thereof, said ultrasonic welding means comprising an ultrasonic horn and an anvil cooperating therewith to form the joint from the respective adjacent portions of the first and second textile webs;

an unfolding frame positioned downstream from said ultrasonic welding means for unfolding the first and second textile webs about the joint so that the textile webs lie in a common plane to define the relatively wide textile fabric and so that the relatively narrow flexible joint extends outwardly from adjacent portions of the relatively wide textile fabric; and

take-up means positioned downstream from said unfolding frame to wind the relatively wide textile fabric into successive convolute wound layers with the relatively narrow flexible joint folded to lie flat between successive layers so that the successive convolute wound layers define a cylindrical convolute roll being devoid of a substantial bulge at the joint.

16. An apparatus according to claim 15 wherein said take-up means comprises means for winding successive convolute wound layers of the textile fabric with variations in axial alignment among the layers so that the relatively narrow joint is offset throughout the successive convolute wound layers.

17. An apparatus according to claim 15 wherein all of the textile webs have a same predetermined thickness, and wherein said ultrasonic welding means further comprises means for pressing together the adjacent portions of the first and second textile webs so that the joint has a thickness less than a thickness of the first and second textile webs.

18. An apparatus according to claim 17 wherein said ultrasonic welding means further comprises trimming means for trimming portions of heat fused material at the joint so that the joint has a relatively narrow width outward from the textile fabric less than about five times the predetermined thickness of the textile webs.

19. An apparatus according to claim 15 wherein said feeder means comprises means for relatively positioning the first and second textile webs so that respective first longitudinal edges of the first and second textile webs are generally aligned with each other.

20. An apparatus according to claim 19 wherein said feeder means further comprises means for positioning a third textile web on the second textile web so that a longitudinal edge of the third textile web is generally aligned with a second longitudinal edge of the second textile web; wherein said ultrasonic welding means further comprises means for forming a second relatively narrow flexible joint between the second and third textile webs by heat fusing together adjacent respective edge portions thereof; and wherein said unfolding frame comprises means for unfolding the second and third textile webs about the second joint so that the third textile web lies in the common plane with the first and second textile webs to further define the relatively wide textile fabric.

21. An apparatus for forming a convolute roll of a relatively wide textile fabric by joining together first, second and third textile webs in side-by-side relation, each of the textile webs comprising heat fusible nonwoven textile material, said apparatus comprising:

feeder means for positioning the first textile web in contact with the second textile web adjacent a first longitudinal edge thereof, for positioning the third textile web in contact with the second textile web adjacent a second longitudinal edge thereof, and for advancing the textile webs along a predetermined path of travel;

welding means positioned along the predetermined path of travel for forming first and second relatively narrow flexible joints between the first and second textile webs and the third and second textile webs, respectively, by heat fusing together respective adjacent portions of the textile webs;

an unfolding frame positioned downstream from said welding means for unfolding the first and third webs about the respective first and second joints so that all of the textile webs lie in a common plane to define the relatively wide textile fabric and so that the first and second relatively narrow flexible joints extend outwardly from respective adjacent portions of the relatively wide textile fabric; and

take-up means positioned downstream from said unfolding frame to wind the relatively wide textile fabric into successive convolute wound layers with the first and second relatively narrow flexible joints folded to lie flat between successive layers so that the successive convolute wound layers define a cylindrical convolute roll being devoid of substantial bulges at the joints.

22. An apparatus according to claim 21 wherein said take-up means comprises means for winding successive convolute wound layers of the textile fabric with variations in axial alignment among the layers so that each of the relatively narrow joints is offset throughout the successive convolute wound layers.

23. An apparatus according to claim 21 wherein all of the textile webs have a same predetermined thickness, and wherein said welding means further comprises means for compressing the adjacent portions of the first and second textile webs and adjacent portions of the second and third textile webs so that the respective first and second joints each have a thickness less than the predetermined thickness of the textile webs.

24. An apparatus according to claim 23 wherein said welding means comprises trimming means for trimming predetermined portions of heat fused material at the first and second joints so that each of the joints has a relatively narrow width of less than about five times the predetermined thickness of the textile webs.

25. An apparatus according to claim 21 wherein said feeder means further comprises means for generally aligning a longitudinal edge of the first textile web with a first longitudinal edge of the second textile web and for generally aligning a first longitudinal edge of the third textile web with a second longitudinal edge of the second textile web.

26. An apparatus according to claim 25 wherein said welding means comprises a respective ultrasonic horn and an anvil cooperating therewith to form each of the first second joints from respective edge portions of the respective textile webs.

Description Submit all comments and votes

FIELD OF THE INVENTION

The present invention relates to the field of equipment and methods for making textile fabrics, and more particularly, to an apparatus and method for making a relatively wide textile fabric from a plurality of textile webs joined together in side-by-side relation.

BACKGROUND OF THE INVENTION

Many textile manufacturing operations produce side trims of textile webs, such as nonwoven textile webs used for bedding products. These side trims are often of first quality nonwoven textile material, such as polyester or polypropylene. However, these side trims are typically not sufficiently wide to be readily used for other textile products. For example, a side trim less than about 60 inches has a relatively low commercial value, while side trims in the 30 to 40 inch range are quite commonly produced and available, yet which also have relatively little commercial value. Typical bedding product related applications use textile fabrics having widths in the range of 86 to 104 inches, with 96 inches being a common commercially desired width. Accordingly, the relatively narrow side trims are often disposed of as waste at an additional expense to the manufacturer.

Various efforts have been attempted to join or otherwise connect two or more such side trims into a textile fabric having a sufficiently large width to be useful in forming bedding products, such as a backing for a mattress cover. A mattress cover typically includes a nonwoven textile fabric as the backing, an overlying layer of fiberfill, and an outer fabric layer or ticking. The backing layer simply serves to permit quilting of the ticking and fiberfill together to form an integral unit.

Referring to FIGS. 1-3, a prior attempt by the inventor of the present invention is explained, wherein the inventor joined together three side trims, or textile webs 21, 22 and 23, to form a wider textile fabric using a heat calendaring apparatus 20 (FIG. 1). More particularly, side edges of adjacent textile webs were overlapped several inches and heated under pressure by suitable heating means, such as a pair of heated calender rolls 27, to form overlapping seams or joints 26, thereby joining the adjacent webs together.

Unfortunately, the overlapped joints 26 represented essentially a double thickness of material which, when arranged in the plurality of convolute wound layers, tended to form bulges in the convolute roll of the textile fabric 25. Moreover, these bulges introduced biases into the textile fabric which could not be readily removed upon unwinding of the fabric from the roll and thereby rendered the biased textile fabric unsuitable for many potential applications, including the backing layer for a mattress cover. In addition, polypropylene, a common nonwoven textile material, could not be used in the heat calendaring process.

SUMMARY OF THE INVENTION

In view of the foregoing background it is therefore an object of the present invention to provide an apparatus and method for forming a relatively wide textile fabric by joining a plurality of textile webs, such as textile side trims, together in side-by-side relation.

It is another object of the present invention to provide an apparatus and method for forming a relative wide textile fabric formed from a plurality of textile webs that may be wound into convolute roll form without imparting undesirable biases into the textile fabric and without undesirable bulges at the joints.

These and other objects, features and advantages of the present invention are provided by an apparatus for forming a relatively wide textile fabric from a plurality of textile webs wherein the apparatus includes feeder means for positioning a first, or upper, textile web overlying a second, or base, textile web and advancing the textile webs along a predetermined path of travel; welding means for forming a relatively narrow flexible joint between the textile webs by heat fusing together adjacent portions thereof; and an unfolding frame for unfolding the textile webs about the joint so that the textile webs lie in a common plane to define the relatively wide textile fabric. More particularly, in order to form the convolute roll of the relatively wide textile fabric, the apparatus also preferably includes take-up means positioned downstream from the unfolding frame to wind the relatively wide textile fabric into successive convolute wound layers. Accordingly, the relatively narrow flexible joint is thus folded to lie flat between successive layers so that the successive convolute wound layers define a cylindrical convolute roll being devoid of a substantial bulge at the joint.

As used herein, the terms "textile fabric" or "relatively wide textile fabric" are used to define the resultant textile product of joining together a plurality of "textile webs". As would be readily understood by those skilled in the art, the textile webs and the textile fabric are formed of the same nonwoven heat fusible textile material, such as polyester or polypropylene. Commercially undesirable side trims may thus be joined to provide a commercially valuable relatively wide textile fabric.

All of the textile webs may have a same predetermined thickness. The welding means preferably includes means for pressing together the adjacent portions of the textile webs so that the joint has a thickness less than the predetermined thickness of the textile webs. In addition, the welding means also preferably includes trimming means for trimming portions of heat fused material from the joint so that the joint has a relatively narrow width outward from the textile fabric less than about five times the predetermined thickness of the textile webs.

Another feature of the invention is that the relatively narrow joint may be axial offset slightly in successive convolute wound layers by the take-up means. Accordingly, the likelihood of forming a bulge and imparting undesirable biases in the textile fabric is further avoided. A random offset may be obtained by the take-up means in view of the relative narrow width of the joint and the speed of operation of take-up.

The welding means is preferably provided by an ultrasonic horn cooperating with an opposing ultrasonic anvil. The feeder means preferably includes means for relatively positioning the first and second textile webs so that respective first longitudinal edges of the first and second textile webs are generally aligned with each other. Accordingly, the ultrasonic horn and anvil cooperate to form the joint from respective first longitudinal edge portions of the textile webs.

The plurality of textile webs joined together may also be three in a preferred embodiment of the invention. Thus, the feeder means preferably further includes means for positioning a third textile web on the second textile web so that a longitudinal edge of the third textile web is generally aligned with a second longitudinal edge of the second textile web. In addition, the welding means also preferably includes means for forming a second relatively narrow flexible joint between the second and third textile webs by heat fusing together adjacent respective edge portions thereof. In this embodiment, the unfolding frame also further includes means for unfolding the second and third textile webs about the second joint so that the third textile web lies in the common plane with the other textile webs to further define the relatively wide textile fabric.

A method aspect according to the present invention includes the steps of positioning a first textile web overlying a second textile web while advancing the first and second textile webs along a predetermined path of travel; forming a relatively narrow flexible joint between the textile webs by heat fusing together adjacent portions thereof as the textile webs are moved along the predetermined path of travel; and unfolding the thus joined textile webs about the joint so that the textile webs lie in a common plane to define the relatively wide textile fabric. The method also preferably includes the step of winding the relatively wide textile fabric into successive convolute wound layers with the relatively narrow flexible joint folded to lie flat between successive layers so that the successive convolute wound layers define a cylindrical convolute roll being devoid of a substantial bulge at the joint. As discussed above, a third textile web may be joined to the second textile web to form an even wider overall textile fabric.

BRIEF DESCRIPTION O THE DRAWINGS

FIG. 1 is a schematic perspective view of a heat calendaring apparatus for joining textile webs as in the prior art.

FIG. 2 is an enlarged cross-sectional view of a textile fabric as in the prior art taken along lines 2--2 of FIG. 1 and as produced using the prior art apparatus as shown in FIG. 1.

FIG. 3 is a greatly enlarged cross-sectional view of a bulging portion of textile fabric as in the prior art taken along lines 3--3 of FIG. 1.

FIG. 4 is a perspective view of a convolute roll of the textile fabric produced using the apparatus and method according to the present invention.

FIG. 5 is an enlarged cross-sectional view of the textile fabric taken along lines 5--5 of FIG. 4.

FIG. 6 is a greatly enlarged cross-sectional view of a portion of the textile fabric taken along lines 6--6 of FIG. 4.

FIG. 7 is a perspective schematic view of first embodiment of the apparatus according to the invention.

FIG. 8 is an enlarged cross-sectional view taken along lines 8--8 of FIG. 7.

FIG. 9 is a greatly enlarged view of the unfolding frame of the apparatus according to the invention viewed from the upstream side.

FIG. 10 is a greatly enlarged view of the unfolding frame of the apparatus according to the invention viewed from the downstream side.

FIG. 11 is a perspective view of the unfolding frame of the apparatus according to the invention with the textile fabric removed for greater clarity.

FIG. 12 is an exploded view of the unfolding frame as illustrated in FIG. 11.

FIG. 13 is a cross-sectional view of the unfolding frame as taken along lines 13--13 of FIG. 11.

FIG. 14 is a perspective view of a first embodiment of a convolute roll of textile fabric produced using the first embodiment of the apparatus according to the invention as shown in FIG. 7.

FIG. 15 is a perspective view of a second embodiment of a convolute roll of textile fabric produced using the second embodiment of the apparatus according to the invention as shown in FIG. 18.

FIG. 16 is an enlarged schematic perspective view of a portion a joint and adjacent portion of textile fabric produced by the apparatus according to the present invention.

FIG. 17 is a greatly enlarged schematic perspective view of a portion the joint and adjacent portion of textile fabric as shown in FIG. 16.

FIG. 18 is a perspective schematic view of a second embodiment of the apparatus according to the invention.

FIG. 19 is an enlarged cross-sectional view taken along lines 19--19 of FIG. 18.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, applicant provides these embodiments so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout and prime notation is used to indicate similar elements of alternate embodiments.

Referring now first to FIGS. 4-8, a first illustrated embodiment of the apparatus 20 for producing a first embodiment of textile fabric 30 according to the invention is described. The textile fabric 30 includes a plurality of textile webs, such as the medial 31 and two side webs 32 and 33 in the illustrated embodiment, joined together in side-by-side relation. A respective joint 35 (FIG. 6) having a generally strip-like shape joins each pair of adjacent textile webs. Each joint 35 is formed from edge portions of respective adjacent webs being heat fused together so that each joint extends outwardly from a predetermined face of the textile fabric 30. Each joint 35 preferably extends continuously along an entire length of the textile webs.

Each of the textile webs 31, 32 and 33 may be provided by commercially available first quality side trims including a nonwoven heat fusible textile material. For example, side trims produced as a result of making a backing layer for a mattress cover, may typically be available in convolute roll form having widths less than about 60 inches and more commonly ranging between about 30 to 40 inches. Thus, the overall width of the textile fabric 30 is desirably in the range of about 86 to 104 inches, with 96 inches being a commercially preferred width, for example.

All of the textile webs 31, 32 and 33 preferably also include the same nonwoven heat fusible textile material, such as including spunbonded or meltblown polyester or polypropylene. Those having skill in the art will recognize other suitable nonwoven textile materials. The nonwoven textile material of the webs 31, 32 and 33 also preferably has a relatively soft hand. In addition, the textile material of the textile webs is preferably relatively lightweight having a weight in a range between about 1/2 to 2 ounces, and more preferably, in the range of about 1/2 to 1 ounces.

The textile fabric 30 is preferably manufactured and provided to end users as a convolute roll 40 including a plurality of convolute wound layers as shown in FIG. 3. The convolute roll 40 may be wound upon a tubular core 37 and supported on a spindle 38 as would be readily understood by those skilled in the art. The convolute roll 40 facilitates take-up during the manufacturing process of the textile fabric 30, permits convenient storage and transportation of the textile fabric, and facilitates delivery of the textile fabric into an apparatus of the end user.

As shown in the illustrated embodiment, each of the textile webs 31, 32 and 33 preferably has a respective substantially uniform width throughout an entire length thereof. As shown perhaps best in the greatly enlarged view of FIG. 6, each joint 35 lies substantially flat (FIG. 6) on a respective textile web 31 or 32 in successive convolute wound layers because of the flexibility of the joint, and each joint is relatively thin. Accordingly, although the joint 35 in successive layers is somewhat aligned because of the uniform width of the textile webs 31, 32 and 33, the convolute wound layers still define a cylindrical shape for the outer surface of the convolute roll 40. In other words, the convolute roll 40 is devoid of a substantial bulge at each joint 35, in sharp contrast to the heat calendared textile fabric forming a convolute roll 25 as in the prior art (FIGS. 1-3).

The joints 35 according to the invention provide a sufficiently strong connection between adjacent textile webs, and, moreover, impart substantially no bias to the convolute roll 40 of the textile fabric 30. For example, for a backing for a mattress cover, the strength of the joint 35 need be about only 50% of the strength of the textile web