Abstract:
A process for covering at least a portion of an article with covering material, applying a wet material composition between the cover material and a core material of the article, and de-watering the wet material to form a reinforcing layer.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a divisional of U.S. patent application Ser. No. 10/835,246, filed Apr. 29, 2004, issued as U.S. Pat. No. 6,931,822, which is a continuation-in-part of U.S. patent application Ser. No. 10/234,630, filed Sep. 4, 2002, issued as U.S. Pat. No. 6,927,183, both of which are relied on and incorporated herein by reference. 
    
    
     BACKGROUND 
     The present invention relates generally to systems and methods for manufacturing covered articles. 
     Examples of reinforced materials are well-known in the art, including U.S. Pat. No. 5,728,458 to Sweeney entitled “Light-Weight High-Strength Composite Pad” and U.S. Pat. No. 5,209,968 to Sweeney entitled “Composite Structure With Waste Plastic Core And Method of Making Same,” both of which are incorporated herein by reference. These examples disclose the use of core materials coated with reinforcing layers for multi-use pads, equipment pads, building panels, and other applications. 
     Typically, these prior art reinforced layered structures are formed by manual covering processes such as wrapping a core, trimming excess wrapping material, and attaching the material to or into the article with adhesive, physical bindings, or direct insertion into the article core. These manual steps can require a number of individuals, limit the quantity of articles that can be manufactured in a given time frame, and result in inconsistent products. Accordingly there is a need to automate the covering of articles. 
     The present invention answers this need by providing a covering apparatus and method that automates the covering process for manufacturing articles. 
     SUMMARY OF THE INVENTION 
     The present invention provides an apparatus and method for covering articles. In embodiments of the invention, covering, trimming, and/or tucking of material into a core material is automated. 
     In an embodiment of the invention a conveyor system is provided for transporting an article to covering, trimming and/or tucking stations to cover the article. 
     In an embodiment of the invention a fibrous fabric is tucked into a core material comprising expanded polystyrene (EPS) foam, moldable into any desired shape. In further embodiments, additional material layers may be applied or injected on and/or beneath the covering material to achieve desired reinforcing characteristics. 
     The present invention further provides a system and method for manufacturing reinforced articles with a core material covered with a covering material by injecting a desired compound or mixture between the core material and covering material to create an inner reinforcing layer. 
     In another embodiment of the invention, an automated covering station is provided wherein covering material is dispensed for surrounding an article core. In one embodiment, the core material is covered by the dispensed material as the core drops through a slot in a covering table across which the covering material is dispensed. 
     In a further embodiment of the present invention, an automated tucking station is provided on a conveyor system for tucking one or more portions of the covering material into the core material. In some embodiments, the tucking apparatus includes parallel pairs of horizontal and vertical tucking apparatuses for plunging covering material into the core. 
     In another embodiment of the present invention, a corner trimming station with an automated pincher and welder is provided for trimming excess fabric at the corners of the covered core material by pulling and welding the excess corner fabric. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a cross-sectional view of a reinforced article in an embodiment of the present invention. 
         FIG. 2  is a perspective view of a bottom surface of a core material in a stack of core materials with receiving channels being burned at a receiving channel burning station in an embodiment of the present invention. 
         FIG. 3  is a top perspective view of a core material and covering material being positioned thereon at a covering material template table in an embodiment of the present invention. 
         FIG. 4  is a top perspective view of a covering material tucking station in an embodiment of the present invention. 
         FIG. 5  is a perspective view of a tucking apparatus including an automated tucking needle and plunger in an embodiment of the present invention. 
         FIG. 6  is a perspective view of an excess fabric weld trimming station including pinchers, weld holders, and weld blade in an embodiment of the present invention. 
         FIG. 7  is a top perspective view of a four corner automated weld trimming apparatus in an embodiment of the present invention. 
         FIG. 8  is a top perspective view of a reinforcing layer injection station in an embodiment of the present invention. 
         FIG. 9  is a perspective partial cut-away view of a covered core material being injected with an inner reinforcing layer mixture in an embodiment of the present invention. 
         FIG. 10  is a texturizing station in an embodiment of the present invention. 
         FIG. 11  is a top perspective view of a core material covering, trimming and tucking conveyor apparatus in an embodiment of the present invention. 
         FIG. 12  is a top perspective view of an automated covering station in an embodiment of the present invention. 
         FIG. 13  is a top perspective view of a magazine cylinders apparatus of an automated covering station in an embodiment of the present invention. 
         FIG. 14  is a partial perspective view of a core material and fabric lowered beneath a fabric table of an automated covering station in an embodiment of the present of the invention. 
         FIG. 15  of the is a partial perspective view of the trimming apparatus of an automated covering station prior to trimming the corner of a covered core material in an embodiment of the present invention. 
         FIG. 16  is a partial perspective view of the trimming apparatus of an automated covering station during trimming of the corner of a covered core material in an embodiment of the present invention. 
         FIG. 17  is a top perspective view of a horizontal tucking apparatus station in a conveyor apparatus with retracted tucking cylinders in an embodiment of the present invention. 
         FIG. 18  a the top perspective view of a horizontal tucking apparatus station in a conveyor apparatus with tucking cylinders in lowered operation in an embodiment of the present invention. 
         FIG. 19  is a top perspective view of a vertical tucking apparatus station in a conveyor apparatus with retracted tucking cylinders in an embodiment of the present invention. 
         FIG. 20  is a top perspective view of a vertical tucking apparatus station in a conveyor apparatus with tucking cylinders in lowered operation in an embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention provides a reinforced article and system and method for making the same. Those of ordinary skill in the art will appreciate that an embodiment described herein including an expanded polystyrene (EPS) foam core material with a fabric covering material and cement mixture reinforcing layer is by way of example only, and a variety of alternative materials could be used. In this regard, exemplary covering materials may include fabric, fibrous wrap, webs, mesh, glass mats, paper, and any other types of synthetic or natural fibrous material that is pregnable by a desired reinforcing layer. Core materials include foamable materials such as polyurethane, polyisocyanurate, EPS, other rigid foams, plastics, corks, wood, synthetic polymers, and similar rigid core materials. Those of ordinary skill in the art will further appreciate that such core materials may be molded into virtually any shape or size as may be desired for the reinforced article. The reinforced mixture layer may include mixtures of concrete, plaster, epoxy, synthetic resins, polymers, paint, waterproofing compounds, glues, foams, and similar mixtures or materials capable of injection between a core material and covering material. In this regard, “injection” may include the deposit of the reinforcing material by injection entirely through a core material at any desired angle, or, alternatively, with an appropriate injection head, through the covering material, so as to deposit the reinforcing layer between the covering material and core material. 
     Referring to  FIG. 1 , a cross section of reinforced article  5  is shown. A core material  10  is surrounded by covering material  15 . In an embodiment of the invention, covering material  15  includes fabric woven or non-woven. An inner reinforcing mixture layer  20 , including a cement mixture in one embodiment, is provided between the core material  10  and the covering material  15 . 
     Covering material edges  19  are tucked into tucking grooves  30  in the core material  10 . The tucked edges  19  keep the covering material  15  tightly surrounding the core material. Further, the tucked edges  19  and tucking groove  30  maximize retention of inner reinforcing mixture layer  20  between core material  10  and covering material  15 . 
     In alternative embodiments, tucking of edges  19  may be replaced or augmented by gluing or other adhesives, taping, stapling, sewing, heat binding, and like methods for adhering edges  19  to the core material  10 . 
     In an embodiment of the invention, the inner reinforcing mixture layer  20  is injected between the core material  10  and covering material  15  after the covering material  15  is secure with tucked edges  19  in tucking groove  30 . As described subsequently, a needle head with a dispersion hole may be used for depositing the inner reinforcing mixture layer  20 . 
     In an embodiment of the invention, the inner reinforcing mixture layer  20  is injected as a slurry mixture, such as a cement mixture, concrete mixture, plaster mixture, epoxy mixture, synthetic resin mixture, polymer mixture, paint mixture, or waterproofing mixture and the like, depending on the desired end use of the reinforced article. Such mixtures are preferably metered to deposit such amounts as are necessary to create a desired thickness and characteristics of the reinforcing layer  20  and reinforced article  5 . Accordingly, depending on the properties of the mixture deposited for the inner reinforcing mixture layer  20 , such mixture is cured to provide the desired reinforcing characteristics of the mixture used. 
     In alternative embodiments of the invention, one or more outer reinforcing mixture layers  25  may be provided in reinforced article  5 . Outer layer  25  may be the same or a different substance from inner layer  20 . In an embodiment of the present invention where the reinforced article  5  is an equipment pad, both the inner layer  20  and outer layer  25  are cured cement mixtures. However, optional outer layer  25  may comprise one or multiple layers that include any materials with desired characteristics for reinforced article  5 . In embodiments of the present invention, the outer reinforcing mixture layer  25  includes concrete, plaster, epoxy, synthetic resins, polymers, paint, waterproofing compounds, cement, glues, and the like. It will be understood that this is only an exemplary list, and further appreciated that the curing of any applied mixtures, such as slurry mixtures, may be desirable to achieve desired characteristics of the outer reinforcing mixture layer  25 . 
     In another embodiment of the present invention, an outer reinforcing layer  25  includes a texture layer  50  ( FIG. 10 ). In one embodiment of the present invention, the texture layer  50  includes a solid substance, such as sand  710  ( FIG. 10 ), but may include virtually any solid with desired texture and binding characteristics with outer layer  25 . 
     In embodiments of the present invention where covering material  15  is a fabric or other fibrous material, inner layer  20  and optional outer layers  25  and texture layer  50 , at least in part, impregnate the covering material  15  to bind and create the desirable reinforced surface layers surrounding core material  10  of reinforced article  5 . 
     Referring to  FIG. 2 , in an embodiment of the present invention, core material  10  includes inner reinforcing layer receiving channels  40 . Where core material  10  is EPS foam, the receiving channels  40  are burned at a receiving channel burning station  100 . 
     The receiving channel burning station includes hot wire burners  105  on which the core material  10  is placed to burn the receiving channel  40 . 
     The receiving channels  40  are burned on any surface of the core material which will contact the inner reinforcing mixture layer  20  and be surrounded by covering material  15 . For instance, the receiving channels may be burned along all surfaces of the core material  10 , or along side surfaces  15 , or top surfaces and side surfaces, or any combinations thereof. 
     The receiving channels  40  permit greater deposition of the inner reinforcing mixture layer  20  than a mere flat surface. Accordingly, the depths of the receiving channels  40  may be increased or decreased for the desired purpose of the reinforced article  5  and reinforcing characteristics of the inner layer  20 . 
     As shown in  FIG. 2 , the core material may be stacked as a plurality of core materials to burn receiving channels on multiple core materials&#39;  10  surfaces at once. The stack is rotated to each desired receiving channel burning surface for burning on hot wires  105 . In this embodiment, it will be appreciated that front and back surfaces may be burned with receiving channels  40  by separating each individual core material  10  from the stack to burn the desired surface. 
     Further, depending on the properties and material of the core material  10 , receiving channels  40  may be formed by alternative methods such as cutting, drilling and boring. 
     In an embodiment of the present invention for manufacturing a reinforced pad, the receiving channels  40  are preferably burned into a top surface (not shown) and side surfaces of a core material  10  made of EPS foam. 
     Referring again to  FIG. 1 , with continuing reference to  FIG. 2 , the inner reinforcing mixture layer  20  of cement mixture forms a layer on the top and side surfaces of the core material and between the covering material  15 . In this embodiment, the covering material is preferably pregnable fibrous fabric and the tucked ends  19  sustain the inner reinforcing layer  20  around the top and side surface of the core material  10  to also promote deposition of the inner reinforcing mixture layer  20  into the receiving channels  40  of the top and side surfaces. In this embodiment, the receiving channels  40  are preferably ⅛″ wide by ¼″ deep. 
     Referring to  FIG. 3 , a covering material application station  200  is shown. In embodiments where optional receiving channels  40  are utilized, the core material  10  is covered with covering material  15  after forming the receiving channels  40 . Alternatively, where receiving channels  40  are not desired, the covering material is applied prior to injection of inner reinforcing mixture layer  20 . 
     In an embodiment of the present invention, the covering material application station provides proper alignment of fabric covering material  15 . A fabric template  205  is sized to the shape of the core material  10  so that the core material is centered on the fabric covering material  15 . The fabric application station  200  is preferably a light table wherein the fabric template includes a template periphery for aligning the fabric covering material  15 . 
     Once the core material is centered on the fabric covering material  15 , the flaps  17  of the fabric are folded over the core material  10 . 
     Referring to  FIG. 4 , the core material  10  including the folded flaps  17  of covering material  15  is placed in covering material tucking station  300 . 
     The tucking station  300  includes a conveyor belt  305  for directing a plurality of covered core materials to a tucking apparatus  320 . As shown in  FIG. 4 , two pairs of tucking apparatuses  320  are used in one embodiment of the invention to tuck flaps  17  into tucking grooves  30  ( FIG. 1 ) as folded edges  19  ( FIG. 1 ). 
     On opposite sides of the conveyor belt  305 , flap rail guides  310  are provided for maintaining the folded flaps  17  in a desired position against core material  10 . The rail guides  310  terminate at flap folder  315  as the covered core material  10  is directed at each opposite flap  17  to tucking apparatus  320 . 
     Referring to  FIG. 5 , and continuing reference to  FIG. 4 , tucking apparatus  320  includes a groove perforation needle  325  and tucking plunger  330 . Each of the needle  325  and plunger  330  are automated so as to actuate a rapid up and down plunging movement. 
     After the flaps  17  are directed through the flap folder  315 , the needle  325  perforates the flap  17  and core material  10  to create a tucking groove  30  ( FIG. 1 ) perforation line. A blunt plunger head  330  follows the perforation needle  325  to tuck covering material edge  19  ( FIG. 1 ) into tucking groove  30  ( FIG. 1 ). In an embodiment of the invention, a plurality of tucking apparatuses  320  may be used to reinforce tucking of the covering material edge  19  into tucking groove  30 . In other embodiments of the present invention, multiple tucking apparatuses are implemented to form multiple tucked grooves for additional tucking of portions of the covering material  15  into the core material  10 . 
     In further embodiments of the invention, where the core material  10  is square or rectangular shaped, the covered core material  10  is rotated 90 degrees following initial tucking on opposite flaps  17 . Unfolded opposite flaps  14  are folded and the covered core material similarly placed on conveyer  305  of the tucking station  300  to tuck flaps  14  with tucking apparatus  320 . In such embodiment, the top and four side surfaces of the core material  10  are completely covered by covering material  15  and all four edges of the fabric covering material  15  are tucked into the bottom surface  11  of the core material  10 . 
     Referring to  FIG. 6 , in an embodiment of the invention with fabric covering material  15  covering a corner  12  of the core material  10 , and adjacent sides of the covering material tucked into a surface of the core material  10 , excess fabric corner  16  will result at corner  12 . 
     In embodiments of the invention, it is desirable to trim the excess fabric corner  16  at a corner weld and trimming station  500 . The corner trimming station  500  includes actuated pinchers  505  that pinch excess fabric corner  16  and subsequently pull the excess fabric corner  16  outward from the core material corner  12 . Corner weld holders  510  actuate to pinch and hold the excess fabric corner  16  at a point near the core material corner  12 . An automatic trim weld blade  515  is actuated toward the pinched excess fabric corner  16  and the weld blade  515  welds the excess fabric corner  16 , such as a fibrous woven or non-woven fabric, to create a welded tight, trimmed edge while the excess fabric corner  16  is burned off and discarded. In some instances, additional trimming, such as by hand, of the fabric welded corner may be necessary to achieve a smooth welded corner edge. 
     Referring to  FIG. 7 , in an embodiment of the invention wherein the reinforced article  5  is square or rectangular shaped, the corner trimming station  500  includes four sets of pinchers  505 , weld holders  510 , and weld blades  515 . In this embodiment, the covered core material  10  is placed so that each corner is positioned between each set of pinchers  505 , weld holders  510 , and weld blades  515 , to allow automatic welding and trimming of all four corners at once. 
     In a further embodiment, a plurality of covered core materials may be stacked to permit trimming of a plurality of stacked corners  12  simultaneously. 
     Referring to  FIG. 8 , a reinforcing layer injection station  600  is depicted with an injector  620  connected to a mixture supply line  630 . 
     In an embodiment of the present invention, the injection station  600  includes a conveyor  602  to provide automated injection of a plurality of covered core materials  10 . 
     In a further embodiment of the present invention, square or rectangular covered core materials  10  are stacked at a stacking partition  605  that aligns the stacked covered core material  10  for positioning on the conveyor  602  to the injector  620 . 
     An indexer  610  is actuated in the line of conveyor movement toward the bottom covered core material  10  in the stack. The indexer  610  strikes the bottom covered core material  10  from the stack to propel it out of the stack and along the conveyor toward the injector  620 . Gravity causes the remaining covered material  10  in the stack to move downward along the partition  605  when the indexer  610  retracts in a reverse direction from the movement of the conveyor  602 . 
     It will be appreciated that in an embodiment of the present invention the covered core material propelled from the stack is covered facedown and the reverse face, facing upward, includes the bottom surface  11  tucked portions. Accordingly, the tucked face is exposed toward the injector  620 . 
     The indexer  610  and injector  620  are in timed synchronization so that the indexer pushes the next covered core material  610  forward as the injector  620  lifts up and down to receive and pin the covered core material in the injector. Metal injector guide  622  preferably holds the covered core material in position for injection. Following injection of the inner reinforcing layer  20 , the injection guides  622  retract upward to permit the next indexed covered material into the injector  620 . 
     Referring to  FIG. 9 , with continuing reference to  FIG. 8 , the injector includes an injection needle  625  and retracting needle arm  621 . As the covered core material  10  is received by injector  620 , needle arm  621  and needle  625  are lowered through the core material  10  until injection needle  625  is positioned so that injection hole  628  is positioned between the surface of the core material  10  and the covering material  15 . The reinforcing mixture  21 , such as cement slurry, is provided by a mixture feed line  630  connected to injection needle  625 . The mixture  21  is injected in a desired metered amount, depending on the desired characteristics and thickness of the inner reinforcing layer  20 . 
     Referring again to  FIG. 8 , in an embodiment of the invention, the injector  620  includes a vacuum base that removes excess water from the mixture  21  ( FIG. 9 ) to form inner reinforcing layer  20  between the covering material  15  and the core material  10 . In an additional embodiment, the injected mixture  21  includes a 1:1 cement/water ratio to promote dispersion. The increased water ratio, compared to typical cement mixtures, provides a better dispersion consistency for venting the reinforcing layer  20 . The vacuum action acts to dewater the mixture  21  to solidify the injected cement mixture  21 . 
     Once the desired inner reinforcing layer  20  is provided by the injection of mixture  21 , the injector, including the injector guide  622 , retractable needle arm  621  and needle  625 , are lifted upward to permit the injected article  5  to be removed. As disclosed, the next covered core material  10  is indexed forward and the injector, including injector guide  622 , needle arm  621  and injector needle  625 , lowered to pin the covered core material  10  and repeat the process. 
     The reinforced article with inner injection layer  20  may be cured as desired. 
     In one embodiment, the covered core material  10  including the injected inner reinforcing layer  20  is further coated with an outer reinforcing mixture layer  25  ( FIG. 1 ). The application of an outer reinforcing mixture layer  25  is well known in the art, and may include automated or by-hand application of a desirable outer reinforcing layer  25  to the outside of the covering material  15 . 
     Referring to  FIG. 10 , in another embodiment of present invention, a solid textured layer  50  ( FIG. 1 ) is further applied to the outer reinforcing mixture layer  25 . At texturizer station  700  the covered core material  10 , including inner and outer mixture layers, is moved along conveyor  701  beneath pad texturizer  705 . Sand, or other desired solid texture substance, is disbursed by the rotating pad texturizer  705  to create a desired textured surface on reinforced article  5  ( FIG. 1 ). 
     Referring to  FIG. 11 , in an alternative embodiment, core material covering, fabric trimming and fabric tucking operations are automated with computer settings and a conveyor system. 
     In the exemplary embodiment, a fabric dispenser provides fabric  15  from a fabric roll  815  to an automated covering station  900  and automated trimming station  1000 . Fabric  15  is provided to the core material  10  at the covering table  905  and the fabric corners are trimmed beneath the table  905 . 
     After the fabric  15  is applied to the core material  10 , the covered core material  10  is conducted on a conveyor belt  1200  to the tucking station  1100 . The tucking station  1100  includes a pair of horizontal plunging apparatus  1105  and a pair of vertical plunging apparatus  1110  for automatically tucking the fabric  15  into and along each side of the core material  10 . 
     With reference to  FIG. 12 , the fabric dispenser  810  includes a fabric roll  815  that dispenses fabric  15  across the automated covering table  905 . The fabric dispenser  810  rolls out the desired length of fabric  15  based on computer programmable settings. Such programs settings are well known in the art. 
     The fabric  15  is dispensed between a raised stack  910  of core material  10  and a trimming station elevator  915 . A “hot wire” powered by a moveable cylinder is lowered to burn the fabric  15  so it is cut to the desired length. It will be appreciated that a variety of alternative cutting apparatuses may be used to cut the fabric. 
     In a fabric  15  receiving position, the elevator  915  is generally level with the covering table  905 . The elevator  915  includes a vacuum that secures the fabric  15  across the elevator. As a safety mechanism, a photo eye is provided approximately two inches past the elevator  915  to detect if the fabric  15  does not come within view. In the event that fabric  15  is not detected, the system is stopped for troubleshooting. 
     With reference to  FIG. 13 , the elevator  915  and fabric  15  are raised beneath the bottom core material  10  of the raised magazine assembly  911 . The magazine dispenser control apparatus  920 , such as a moveable cylinder with retractable stabbers  925 , releases a core material article  10 . It will be appreciated that moveable cylinders include hydraulic cylinders, pneumatic cylinders, electric actuators and the like. 
     The elevator  915  is lowered with the core material  10  and fabric  15 , and the stack  910  adjusts so that the next article  10  in the magazine assembly  911  is engaged by the stabbers  925  until the next cycle. In one embodiment, a photo eye is positioned on the magazine assembly  911  to detect if there are not at least two core materials  10  in the magazine. Because of the ease of loading before the magazine is completely empty, the system will not initiate if there are less than two articles detected. The switch may be bypassed to use all of the articles by covering the photo eye. 
     As shown in  FIG. 14 , the elevator  915  is lowered beneath the fabric receiving table  905 . As the fabric  15  and core material  10  pass through the elevator slot  907 , the edges of the fabric  15  that extend beyond the edges of the core material  10  fold vertically against the sides of the core material  10  and the slot  907 . 
     Referring to  FIG. 15 , the elevator  915  supporting a rectangular covered core material  10  stops centered between four sets of corner trimming pinchers  1005 . Each pincher set  1005  is generally “L” shaped with a horizontal portion  1009  extending over the top of the covered article  10  and a vertical portion  1007  extending along a side of the covered article  10 . Each pincher set closes at a respective corner  12  of the covered article  10  so that the vertical portion  1007  of a pincher set  1005  folds the fabric  15  around the sides of the core material  10  and the horizontal portion  1009  folds fabric  15  over a portion of the top of the article  10 . The pinchers also hold excess fabric  15  at each corner  12  for trimming. 
     Referring to  FIG. 16 , a long cylinder with a small gripper  1120  indexes to each of the four corners  12  and the gripper  1120  grabs and holds the excess fabric  15  at the corner  12 . A “hot wire” between the jaws of the pinchers sets  1005  is energized while the fabric  15  is being held by the grippers  1120 . The “hot wire” cuts the excess fabric  15  from the corner  12  while simultaneously welding the fabric around the corner  12  of the article  10 . The long cylinders for the grippers  1120  retract to pull the cut off fabric away from each of the corners  12 . 
     In an embodiment of the invention, a cooling nozzle  1125  is provided at each corner  12  where the pinchers  1005  conduct trimming operations. Pressurized air is provided to the corner  12  following the weld cut and removal of the excess fabric  15  from the corner  12  to cool and strengthen the weld. 
     In a further embodiment, a debris removal air nozzle is also provided at each corner  12  of the trimming station to blow away the excess fabric  15  from the grippers  1120 . After the grippers  1120  retract with the cut excess corner fabric  15 , each gripper  1120  is opened and the debris removal nozzle provides a burst of air to blow away fabric  15  debris from the machine. 
     The folding pinchers  1005  are subsequently opened to release the article  10  with fabric folded over the bottom face and side surfaces. The elevator  915  is raised up to the height of the covering table  905  until the covered article  10  is beneath the stack  910  of core material  10  in the magazine assembly  911 . 
     A pressurized air nozzle subsequently blows air to propel the article  10  out from underneath the magazine  911  and on to a conveyor  1200  for carrying the article  10  to the tucking station  1100 . As a safety precaution, a photo eye is also used to detect if the article  10  does not enter and/or leave the elevator  915  and covering table  905 . 
     The cycle restarts for covering and fabric trimming the next article  10  at the bottom of the stack  910  in the magazine assembly  911 . 
     Referring to  FIG. 17 , as it is being blown from the covering table, the article  10  is carried on a first conveyor belt  1205  ( FIG. 18 ) to the automated tucking station  1100 . With reference to  FIGS. 18 and 19 , the tucking station  1100  includes a first set of horizontal automated tucking apparatuses  1105  and a second set of vertical automated tucking apparatuses  1110 . 
     Referring to  FIG. 20 , in an embodiment of the invention, a tucking apparatus  1105  and  1110  includes four plungers  1150  and a rolling mechanism  1158 . Along an edge of the top surface of the covered article  10 , the plurality of plungers  1150  are actuated up and down by a tucking cylinder as the tucking apparatus  1105  and  1110  rolls along the edge in which fabric is being tucked. 
     With further reference to  FIGS. 17-19 , along parallel opposite sides of the top fabric covered article  10 , each of the horizontal tucking apparatuses  1105  is actuated forward and/or backward to tuck the loose fabric along the top into and along a horizontal edge of the article  10 . Similarly, along parallel opposite vertical sides of the covered article  10 , the vertical apparatuses  1110  are actuated forward and/or backward to tuck the loose fabric into the article  10 . 
     In the described embodiment, the fabric  15  is first tucked horizontally into opposite edges of the top surface of the article  10 . Following the horizontal tucking operation, the article  10  is conveyed to vertical tucking station for the vertical tucking operation. Those of ordinary skill will appreciate that the sequence of horizontal and vertical tucking may be reversed, and that in other embodiments, the tucking operations may be combined, as with programmable timing logic. 
     Referring to  FIG. 18 , in one embodiment, the article  10  is blown away from the folding station  900  ( FIG. 11 ) on to the conveyor  1205  to the horizontal tucking station. A first automated stop  1170  or set of stops is pivoted up from the plane of the first conveyor belt  1205  to block and hold the article for horizontal tucking operations. In alternative embodiments, the stop(s)  1170  could be actuated from other positions such that the stop  1170  blocks the path of the article  10  to hold it in place. 
     After reaching the first stops  1170 , a moveable guide rail  1180  is extended to a side of the article  10  to secure it in place. The guide rail  1180  is attached to a cylinder and presses the article  10  against a raised edge  1160  along the conveyor belt  1205  on the opposite side of the article  10  to create a tight fit for consistent tucking of all articles  10 . The conveyor  1205  is stopped on actuation of the moveable guide rail  1180 . 
     The horizontal tucking apparatuses  1105  are positioned opposite of one another on the horizontal tucking station frame  1104 . The frame  1104  lowers to position the plungers  1150  ( FIG. 20 ) near the article  10  for plunging. The frame  1104  raises to move the tucking apparatuses  1105  away from the article  10 , such as accepting and releasing the article  10  for tucking. 
     After the guide rail  1180  secures the article, the horizontal tucking station frame  1104  is lowered to position the tucking apparatuses  1105  along horizontal tuck lines of the loose fabric  15  on the top surface of the article  10 . 
     With continuing reference to  FIG. 20 , the rolling mechanisms  1158  of the tucking apparatus contact the article  10  when the frame  1104  is lowered. The tucking apparatus  1105  moves laterally by pneumatic actuation along the frame  1104  as the frame  1104  acts as a track to maintain the tucking apparatus  1105  and plungers  1150  on the tuck line. The plungers  1150  are actuated by cylinders to move rapidly up and down to tuck the fabric  15  into the top surface of the article  10 . 
     Following horizontal tucking, the horizontal stop  1170  is retracted upward and the conveyor  1205  is turned on. In one embodiment a second conveyor belt  1207  is provided to the vertical tucking station. From the first conveyor  1205 , and following retraction of the horizontal stops  1170 , the covered article with horizontal tucks moves to the vertical tucking station. 
     Referring to  FIG. 19 , a vertical station stop  1185  is actuated to stop the article at the desired position on the second conveyor  1207  at the vertical station. Like the horizontal tucking apparatuses  1105 , the vertical tucking apparatuses  1110  are positioned on a vertical tucking station frame  1106 . However, the set of vertical apparatuses  1110  are positioned perpendicular with respect to the horizontal apparatuses  1005 . Accordingly, the remaining loose fabric  15  on the top surface edges of the article  10  is vertically tucked. 
     Mechanically, the vertical tucking operation is identical to the horizontal tucking apparatus operation. 
     Following the vertical tucking operation, the vertical station frame  1106  and vertical guide rail  1181  is retracted. The second conveyor belt  1207  is then turned on and the vertical station stops  1185  moved from the path of the covered article  10 . The second conveyor  1207  transports the covered article  10  from the vertical tucking station for removal from the system, or, alternatively, carries the article  10  on further conveyor(s) for additional processing, such as the application of reinforcing material. 
     As a safety precaution and to increase consistency, in one embodiment of the present invention photo eyes are positioned next to each of the horizontal and vertical station stops. The tucking apparatuses will not start unless the pad is detected in the proper position at each station. 
     In another embodiment, a program switch is also provided that restricts operation of the first conveyor belts from the folding and trimming station to the horizontal tucking station until at least one cycle of the automated tucking and trimming station occurs. In this and alternative embodiments, another program switch is also provided to prevent propulsion of the article following trimming from the elevator area to the horizontal tucking station if the tucking operations are in process. Similarly, the second belts will not be turned on the article transported from horizontal tucking station to the vertical tucking station if an another program switch senses vertical tucking operations are not complete. In such embodiments, any detected problem must be corrected and the system reset for operations to resume. 
     Accordingly, while the invention has been described with reference to the structures and processes disclosed, it is not confined to the details set forth, but is intended to cover such modifications or changes as may fall within the scope of the following claims.