Apparatus for manufacturing a pleated curtain

A device for manufacturing a pleated curtain includes elongate pleating means for forming a first fold in the curtain by folding the curtain around a long side of the pleating means along a fold line, clamping means for clamping a pleat portion of the curtain on either side of the first fold along a clamping line parallel to the fold line such that the pleat portion forms a loop, and control means for controlling the pleating means and the clamping means. The control means move the pleating means and/or clamping means such that the pleating means are arranged from a position inside the loop to a position adjacent the loop, while the clamping means clamp the pleat portion, such that a remaining portion of the curtain is folded round an outer end of the clamping means and a second fold is formed adjacently of and parallel to the first fold.

This application is a national stage filing under 35 U.S.C. 371 of pending International Application No. PCT/NL2022/0050097, filed Feb. 22, 2022, which claims priority to Netherlands patent application 2027651, filed Feb. 25, 2021, the entirety of which applications are incorporated by reference herein.

The present invention relates to a device for manufacturing a pleated curtain.

A known device for manufacturing curtains with multiple pleats typically comprises an automated folding station for arranging multiple pleats which co-acts with a sewing station which is provided with a sewing machine for stitching the multiple pleats. The folding station is disposed separately of the sewing station and typically has two sets of mutually adjacently arranged, vertically oriented plate-like elements, wherein the elements of the one set are disposed offset opposite those of the other set. The sets form in cross-sectional view as it were two combs, the teeth of which are arranged with their outer ends offset opposite each other such that the teeth of the one comb can be arranged between the teeth of the other comb by vertical movement. By arranging curtain fabric between the sets and sliding the pleating blades of the two sets vertically into each other folds/pleats are arranged in the curtain fabric. A multiple pleat is then obtained by (i) moving the blades in each set toward each other so that a compact package of pleats and pleating blades is obtained and the folds in this package are held together, (ii) then transporting the package of folds and pleating blades to the sewing machine, wherein the package must be rotated through 90 degrees in order to be arranged horizontally on the table of the sewing machine, (iii) removing the pleating blades from the package and (iv) stitching the folds/pleats with the sewing machine.

In order to arrange a triple pleat in the curtain fabric seven pleating blades are needed, which are slid into each other. This causes the folding station to comprise many moving parts.

Subsequently transporting the triple pleat to the sewing station means that the package of all seven blades with the curtain fabric therebetween must be displaced to the sewing machine and rotated in order to arrange the package on the table of the sewing machine. This requires a relatively complex mechanism.

The complex mechanism consisting of a relatively large amount of components is moreover expensive to manufacture and maintain.

Such a device further has a relatively large size due to the presence of two stations.

Finally, it is important when forming the folds/pleats in the curtain fabric with the pleating blades of the known device that the fabric co-displaces with the pleating blades but at the same time also lies tightly therearound. This requires a great deal of experience and skill on the part of the person operating the device.

All aspects stated above form drawbacks of the known device.

It is therefore an object of the present invention to provide a device for arranging multiple pleats in a curtain which is easier to operate, more compact and cheaper.

The present invention provides for this purpose a device for manufacturing a pleated curtain, comprising elongate pleating means configured to form a first fold with a predetermined pleat height in the curtain by folding the curtain round a long side of the pleating means along a fold line, clamping means configured to clamp a pleat portion of the curtain on either side of the first fold over the predetermined pleat height at least along a clamping line parallel to the fold line and at a predetermined pleat depth distance from the fold line, such that the pleat portion, as seen in a cross-sectional plane perpendicular to the fold line, forms a U-shaped loop, and control means for controlling the pleating means and the clamping means, wherein the control means are configured to move the pleating means and/or the clamping means relative to each other such that, as seen in said cross-sectional plane, the pleating means are arranged from a position inside the loop to a position adjacently of the loop, while the clamping means clamp the pleat portion, such that a remaining portion of the curtain differing from the pleat portion is folded round an outer end of the clamping means and at least a second fold round the pleating means arranged adjacently of the loop is formed adjacently of and parallel to the first fold. The second fold here forms a second pleat portion, i.e. a second loop in the curtain adjacently of the loop clamped by the clamping means.

Since the device is configured to move the pleating means out of the loop and arrange them adjacently of the pleat portion, i.e. the first pleat, while the clamping means hold the pleat portion, both the first fold and the second fold can be formed using the same pleating means. The device according to the present invention can thereby form pleats with fewer components than known devices for arranging a multiple pleat in a curtain. This makes the device according to the present invention more compact and cheaper than said known devices. Because the control means are configured to move the pleating means and/or the clamping means relative to each other such that pleated portions can thereby be arranged adjacently of each other, the device enables both single and double, triple or multiple pleats to be arranged in a curtain using the same pleating means.

The pleating means and the clamping means are preferably configured to arrange the first and the second fold and the pleat portions corresponding therewith in the curtain by means of substantially horizontal relative movement of the pleating means and the clamping means, such that the pleat depth dimension extends substantially in horizontal direction. The pleats are hereby already horizontally oriented and no mechanism is needed to rotate the pleats in order to arrange them on the table of the sewing machine. This makes the device mechanically simpler, more compact and cheaper than known devices for arranging a multiple pleat in a curtain. It is noted in this respect that the pleat depth is the dimension of the pleat as it protrudes forward relative to the adjacent curtain material. The pleat height is the height dimension of the pleat when the curtain is hung.

The pleating means and the clamping means are preferably arranged in the vicinity of a table of a sewing machine. The sewing machine is more preferably integrated with the device. The pleating means and the clamping means are most preferably arranged behind a stitching needle of the sewing machine.

It is further noted that the terms ‘fold’ and ‘pleat’ have the same meaning as each other, i.e. the line along which the curtain/the curtain fabric is folded over. In the present application the term pleat is however also used to indicate the portion of the curtain fabric which has been folded over once or multiple times for the purpose of forming respectively a single or multiple pleat in the curtain, and which extends.

In a preferred embodiment the control means are further configured to successively (i) arrange the clamping means round the pleat portion such that the clamping means at least make contact with the pleat portion, wherein the pleating means are arranged in the loop, (ii) move the pleating means away from the fold line in a pleat depth direction perpendicularly of the fold line over a distance greater than the predetermined pleat depth distance, such that the pleating means move out of the loop, (iii) clamp the loop at the predetermined pleat depth distance with the clamping means, and (iv) move the pleating means along an outer side of the clamping means and arrange them adjacently of the loop.

In a preferred embodiment the pleating means comprise two elongate pleating fingers which extend parallel to each other in their longitudinal direction and are movable between a closed state, in which the pleating fingers lie against each other along their length, and an open state in which the pleating fingers are removed a distance from each other such that they can each be arranged on one of either side of the loop by the movement of the pleating means and/or the clamping means perpendicularly of the extending direction of the fold line, while the clamping means clamp the loop.

Both the first fold/pleat and a second and a third fold/pleat can thus be formed using the two elongate pleating fingers, wherein the clamping means clamp the first pleat portion while the second and the third fold/pleat are formed. A triple pleat can be arranged in the curtain using the same pleating means by relative movement thereof relative to the clamping means. The device according to the present invention can thereby form a triple pleat with far fewer components than the known device for arranging a triple pleat, wherein use is made of seven pleating blades. The device according to the present invention is thereby more compact and cheaper than said known devices.

The pleating fingers and the clamping means are preferably configured to arrange the pleating fingers on either side of the loop while the clamping means clamp the loop, i.e. to form the first, the second and the third fold and the pleat portions corresponding therewith, by means of substantially horizontal relative movement of the pleating fingers and the clamping means, such that the pleat depth dimension extends substantially horizontally. The pleats are hereby already horizontally oriented and no mechanism is needed to rotate the pleats in order to arrange them on the table of the sewing machine. This makes the device mechanically simpler, more compact and cheaper than known devices for arranging a triple pleat in a curtain.

In a preferred embodiment the control means are configured to hold the pleating fingers in the closed state until the pleating fingers are situated outside the loop and to bring them into the open state before the pleating fingers are arranged adjacently of the loop along the outer side of the clamping means. In this way the pleating fingers “pull” on the curtain fabric as little as possible when the pleating fingers are moved out of the loop. The outer surface of the pleating fingers directed toward the fabric is preferably convex and/or smooth, so that the friction force between the pleating fingers and the curtain fabric when the surface of the pleating fingers and the surface of the curtain fabric slide along each other—both when moving the pleating fingers out of the loop and when arranging them adjacently of the clamping means—is reduced.

In a preferred embodiment an intermediate space is formed between the pleating fingers in the open state, this having a height such that the clamping means with the loop therebetween can be arranged in the intermediate space and wherein the control means are further configured to enable the pleating fingers to be arranged on either side of the loop by moving the clamping means with the loop therebetween into the intermediate space. The intermediate space between the pleating fingers is preferably at least twice as large as the greatest distance between the two outer surfaces of the clamping means at the position of the portion situated between the pleating fingers, wherein each of the two outer surfaces is directed toward one of the pleating fingers when the clamping means are situated between the pleating fingers.

In a preferred embodiment the control means are configured to arrange the pleating means at the position of the fold line of the first fold on the outer side of the loop. In this way a triple pleat is obtained with three pleated portions, each having the same pleat depth.

In a preferred embodiment the device further comprises a table for arranging thereon the curtain pleated round the pleating means and a presser foot arranged opposite the table and configured to press the pleated curtain against the table on a side of the clamping line remote from the fold line. The presser foot ensures that the curtain fabric arranged round the pleating means remains in place when the pleating means and/or the clamping means are moved, so that the position of the fold(s) does not change when the pleating means and/or the clamping means move. This ensures that an optionally multiple pleat yet to be arranged is arranged at the correct distance from a directly adjacent, optionally multiple pleat already arranged previously.

In a preferred embodiment the control means are configured to move the presser foot toward the table in order to press the curtain against the table with the presser foot until the pleating means are outside the loop and the clamping means clamp the loop.

In a preferred embodiment the control means are configured to move the presser foot away from the table after the pleating means have been arranged outside the loop and the clamping means clamp the loop, and before the pleating means are arranged adjacently of the loop. Because the presser foot is moved away from the table at this moment, the fabric is given space so that the pleating means, preferably the two elongate pleating fingers, can spread the fabric and can fold it round the clamping means.

In a preferred embodiment the device further comprises a presser plate configured to press the loop and pleated portions of the curtain lying adjacently of the loop against the table, wherein the control means are configured to move the presser plate toward the table in order to press the curtain against the table with the presser plate after the pleating means have been arranged adjacently of the loop. The presser plate ensures that the package of a plurality of pleated portions stays together such that the folds of the pleated portions are each held at their desired position, i.e. along the desired fold line.

In a preferred embodiment the presser plate is provided on the presser foot, such that a movement of the presser foot from and to the table results in a movement of the presser plate respectively from and to the table.

In a preferred embodiment the device further comprises fixing needles configured to fix the loop and the pleated portions of the curtain lying adjacently of the loop relative to each other by arranging the fixing needles through the loop and the pleated portions of the curtain lying adjacently of the loop. The fixing needles enable the pleating means, clamping means and the presser plate to be moved away from the package of a plurality of pleated portions, while the pleats remain in place. Removing the pleating means, clamping means and the presser plate is necessary in order to then be able to stitch the optionally multiple pleat using a sewing device.

In a preferred embodiment the clamping means comprise recesses for arranging the fixing needles therethrough. This enables the fixing needles to be arranged through the loop and the pleated portions of the curtain lying adjacently of the loop, while the loop and the pleated portions of the curtain lying adjacently of the loop are held in their desired place by the clamping means.

In a preferred embodiment the control means are further configured to arrange the fixing needles through the loop and the pleated portions of the curtain lying adjacently of the loop after the presser plate presses the curtain against the table after the pleating means have been arranged adjacently of the loop. In this way the presser plate ensures that the pleated portions do not shift relative to each other due to movement of the fixing needles through the pleated portions.

In a preferred embodiment the control means are further configured to move the clamping means and the pleating means away from the loop and the pleated portions of the curtain lying adjacently of the loop after the fixing needles have been arranged through the loop and the pleated portions of the curtain lying adjacently of the loop, such that the loop and the pleated portions lying adjacently of the loop lie clear of the clamping means and the pleating means.

In a preferred embodiment the control means are further configured to move the presser plate away from the table before the clamping means and the pleating means are moved away from the loop and the pleated portions of the curtain lying adjacently of the loop, and to move the presser plate toward the table after the loop and the pleated portions lying adjacently of the loop have come to lie clear of the clamping means and the pleating means. Moving the presser plate away from the table before the clamping means and the pleating means are moved away from the loop and the pleated portions of the curtain lying adjacently of the loop prevents excessive friction forces between the clamping means and the pleating means on one side and the curtain fabric on the other, which cause the pleated portions to shift relative to each other when the clamping means and the pleating means are removed.

In a preferred embodiment the device further comprises a sewing device for fixing the loop and portions of the curtain pleated adjacently of the loop by means of stitching, such that the portions pleated adjacently of the loop form loops adjacently of the loop.

FIG.1shows a machine100for manufacturing a pleated curtain200. Machine100is particularly suitable for arranging a triple pleat250in a curtain. Whereas in known devices such a triple pleat is arranged using a folding station disposed separately of the sewing machine and having seven mutually engaging pleating blades, the functionality of both the folding and the sewing is integrated compactly in the machine100ofFIG.1.

For this purpose the machine100specifically has a device101for arranging a triple pleat250in the vicinity of means for fixedly stitching the pleat in the curtain. This makes the machine100very compact.

Forming the triple pleat250is done with the device101as circled inFIG.1. An exploded view of components of this device101is shown inFIG.2.

The components comprise among other things a set of two pleating fingers102,103extending parallel to each other. The pleating fingers102,103are movable between a closed state, in which mutually facing, longitudinally extending surfaces104,105of pleating fingers102,103lie one on the other, and an open state in which pleating fingers102,103lie at a mutual distance with an intermediate space G1between said surfaces104,105.

The device further has a set of two pleating blades106,107which are movable for pivoting round pivot shaft108between an open state, in which outer ends108,109of pleating blades106,107which are directed toward a curtain200arranged in machine100lie at a mutual distance with an intermediate space G2therebetween, and a closed state in which the outer ends108,109are arranged one on the other. Moving the pleating blades106,107away from and toward each other is done by means of moving a spacer110arranged between pleating blades106,107respectively away from said outer ends108,109and toward said outer ends108,109.

Device101additionally has a lance or knock-out pin111for arranging a hook also to be stitched into pleat250for the purpose of attaching the curtain200to a curtain rail at the position of the pleat.

Device101further has a presser foot112for keeping curtain200in place on a table113of machine100while the triple pleat250is being formed in curtain200. Arranged on a side of presser foot112facing toward the curtain200is a biased presser plate114for keeping the pleats of the triple pleat250together before they are fixed relative to each other using fixing needles115.

The fixing needles115are situated under the table113and are movable between a position in which the outer ends of needles115are situated under table113and a position in which the outer ends of needles115extend to a position above the upper pleat of the triple pleat250. For this purpose fixing needles115are arranged in a special moving unit116to enable fixing needles115to be moved upward and downward.

At the position where the pleat is stitched the table113has an opening which is covered with a table plate118provided with recesses117. The recesses117have a position, shape and size such that they ensure that a stitching needle of the sewing machine is able to secure the triple pleat250by means of stitching through pleat250and table113. The presser foot112and the presser plate114also have recesses119, corresponding with the table plate recesses117, for moving the stitching needle therethrough.

In order to be able to arrange the fixing needles115through the triple pleat250held together by the pleating blades106,107, presser foot112, presser plate114and table plate118the pleating blades106,107and the table plate118are each provided with recesses for moving the fixing needles115therethrough.

Forming a triple pleat250with the shown device101is done as follows, wherein reference is made toFIGS.3-7, each showing a random view during the process of manufacturing the triple pleat250in curtain200.

A portion of the fabric of curtain200to be pleated is firstly arranged round the pleating fingers102,103, wherein pleating fingers102,103are in the closed state. This creates a fold120in curtain200at the position of pleating fingers102,103. At the same time as the fabric being arranged round pleating fingers102,103, the fabric is arranged around the knock-out pin111, on which is arranged a hook to be stitched into the pleat. The knock-out pin111is here situated on a side of presser foot112remote from fold120.

Presser foot112is then moved toward table plate118such that the curtain fabric200is clamped between outer ends121of presser foot112and upright edges122of table plate118placed opposite the outer ends121of presser foot112. After this, the pleating blades106,107are arranged round the curtain fabric200arranged round pleating fingers102,103and moved to the closed state in order to engage curtain fabric200on either side of the fold120with pleating fingers102,103therein with such force that the position of the fold120is preserved when pleating fingers102,103move away from fold120. This is shown inFIG.4.

The pleating fingers102,103in the closed state then move away from fold120, while pleating blades106,107hold the curtain fabric200at the position of the fold120. The presser foot112is then moved upward, such that fabric200is given space to move. These two steps are shown inFIG.5.

After presser foot112has been moved upward the pleating fingers102,103are moved to the open state. Movement to the open state is facilitated in that the presser foot112is moved upward, whereby curtain fabric200is given space. In the open state the intermediate space G1has resulted between pleating fingers102,103, between which can be arranged end portions108,109of pleating blades106,107with the folded curtain fabric200clamped therebetween. In this respect reference is made to the situation as shown inFIG.6.

Finally, pleating blades106,107with the folded portion of curtain200clamped therebetween are arranged between the elongate pleating fingers102,103, so that a second loop/pleat126and a third loop/pleat27is formed on each of either side of the loop/pleat125situated between pleating blades106,107. The movement of the pleating blades106,107between the elongate pleating fingers102,103is such that the folds128,129of respectively the second and the third pleat126,127are arranged at the position of the fold120of the first pleat125.

Presser foot112then moves downward so that the outer ends121thereof are once again arranged on the upright edges122of table plate118. The presser plate114situated on the underside of presser foot112simultaneously presses the package250of the three pleats125,126,127together before the fixing needles115situated under table113are arranged through each of the pleats125,126,127of triple pleat250. The needles115here move successively through the recesses in table plate118and pleating blades106,107. Reference is made toFIG.7.

Presser foot112with presser plate114is then moved upward so that pleating blades106,107can be moved out from between pleats125and126and pleats125and127with little friction. Pleating blades106,107here move rearward, i.e. to the right in the views ofFIGS.3-7. When pleating blades106,107have been removed from triple pleat250, presser foot112with presser plate114is moved back downward in order to press together the package of three mutually adjacent pleats125,126,127.

Pleating fingers102,103are then removed from the outer pleats126,127of triple pleat250. Pleating fingers102,103here move out of pleats126and127in their longitudinal direction, i.e. in a direction out of the paper in the views ofFIGS.3-7. Simultaneously to removal of the pleating fingers102,103, the knock-out pin111is also removed in the same direction as pleating fingers102,103from the folded-over portion of the curtain fabric200which is situated on a side of outer ends121of presser foot112remote from triple pleat250. The hook also to be stitched in remains here in said folded-over the portion of the curtain fabric.

Finally, the triple pleat250is formed permanently by fixing the triple pleat250by means of stitching using a sewing machine (not shown).

The pleating blades106,107, pleating fingers102,103, knock-out pin111, presser foot112with presser plate114, fixing needles115and the sewing machine, among other things, are controlled by control means (not shown) of the machine100. Parameters of the pleats to be arranged can be set using a touchscreen130.

The present invention is not limited to the shown embodiments but also extends to other embodiments falling within the scope of protection of the appended claims.