METHOD AND SYSTEM FOR FORMING A PLEATED TEXTILE PRODUCT

Abstract: The invention relates to a method for forming a pleated textile product, comprising the steps of feeding a length of flat material, arranging in the length of material in longitudinal direction thereof a number of pleats which become gradually sharper in the feed direction, and fixing the pleats by heating and/or pressing. The length of material can herein be finished after applying and fixing of the pleats, for instance be cut into pieces in transverse direction. A longitudinal edge of the length of material can also be cut off. The invention further relates to a system for performing this method, with a feeding device, a pleating device and a fixing device. The pleating device can herein comprise a mould with a profiled opening corresponding with the desired contour of the pleated product, while the fixing device can comprise a heated roller with a relatively large diameter. The system can further display a device for finishing the length of material with the fixed pleat(s) which is provided with cutting means.

Description: METHOD AND SYSTEM FOR FORMING A PLEATED TEXTILE PRODUCT The invention relates to a method and a system for forming a pleated textile product . Pleated textile products are used for instance as basic material for making clothing, usually women's clothing, and for the production of furnishing textiles, particularly window-covering products such as curtains, so-called 'panel tracks' and the like, and wall covering products . In a conventional method for manufacturing a pleated textile product, a strip of textile material is fed to a pleating station in which one or more folds are arranged in the material . The known pleating stations comprise, depending on the direction of the folds which must be arranged in the material, one or more upward and downward movable pleating knives received in a guillotine-like guide frame. In this manner pleats are arranged in transverse direction in the material, wherein the length of the pleats is thus limited by the maximum possible length of the knife on the one hand and the maximum width of the textile length on the other. The formed pleats are otherwise immediately fixed in this method as a result of the temperature of the pleating knives . The invention now has for its object to provide a method for manufacturing pleated textile products with which a textile material can be pleated and optionally finished on industrial scale and at great speed, and with which products of very diverse dimensions can be manufactured. For this purpose the method according to the invention comprises the steps of feeding a length of flat material, arranging in the length of material in longitudinal direction thereof at least one pleat which becomes gradually sharper in the feed direction, and fixing the pleat by heating and/or pressing. Because the pleat or pleats are arranged gradually, the use of movable pleating members such as pleating knives can be dispensed with. Furthermore, because the pleats are arranged in lengthwise direction of the length of material, pleated products can in principle be formed in any desired length. Immediate fixing of the formed pleats prevents the material attempting to return to its original state. After applying and fixing of the pleat or pleats the length of material is preferably finished, for instance in that it is cut into pieces in transverse direction. At least one longitudinal edge of the length of material can also be cut off. It is recommended herein that the cut edge is immediately heat-sealed during cutting, whereby the form of the pleated material is preserved. For forming of the final textile product a number of pieces can be mutually connected in longitudinal direction, for instance be stitched together. Depending on the desired end product, the pieces for mutually connection can herein be placed adjacently of each other in the same position, but it is also possible for at least one of the pieces to be turned over before connection. The invention also relates to a system for performing the above described method. Such a system is provided according to the invention with a device for feeding a length of flat material, a device for arranging in the length of material in longitudinal direction thereof at least one pleat which becomes gradually sharper in the feed direction, and a device for fixing the pleat by heating and/or pressing. The pleating device can herein comprise at least one mould with a profiled opening corresponding with the desired contour of the pleated products. A continuous length of material can hereby be pleated with little effort. The fixing device preferably comprises at least one heated roller, which can have a relatively large diameter. Deformation in transverse direction of the just pleated material is hereby minimized. In preference the roller further has an infeed part lying practically in line with the outfeed opening of the mould, so that it is no longer necessary to change the direction of the pleated material between the mould and the roller. Further provided is at least one pressure belt extending round the roller along a part of the periphery and co- acting therewith, whereby over a large part of the periphery of the roller the material is held in contact therewith. This enables a prolonged and effective fixation process. The system is preferably also provided with a device for finishing the length of material with the fixed pleat or pleats . This finishing device can comprise cutting means for cutting the length of material into pieces in transverse direction, in addition to cutting means for severing one or more longitudinal edges of the length of material. The cutting means, which are preferably adapted to heat-seal the formed cut edge so as to preserve the form of the product, can preferably comprise ultrasonic cutters . The cutting means can be further adjustable in order to form textile products with different dimensions. For this purpose further means controllably connected to the cutting means can be present for detecting the position of the length of material, which may for instance comprise optical sensors. A buffer can also be provided for temporarily storing the material for cutting, for instance during adjustment of the cutting means . Finally, the system can further comprise a device for mutually connecting a number of pieces in longitudinal direction. This connecting device can for instance comprise a sewing machine, in particular a longitudinal seam sewing machine . In order to enable concealment of the connecting seam from view, a further device can be arranged between the finishing device and the connecting device for turning over one of the severed pieces, which can then be stitched to the other pieces in the reversed position. The invention also relates to a pleating device, a fixing device, a finishing device and a connecting device for use in a system as described above. The invention will now be elucidated on the basis of two embodiments, wherein reference is made to the annexed drawing, in which: figure 1 shows a schematic view of a system for forming a pleated textile product which is stored on a roll, figure 2 shows a view corresponding with figure 1 of a system for forming pleated pieces of fabric, figure 3 is a schematic perspective view of the feeding device and the pleating device of the system according to the invention, figures 4A and 4B show respectively a view from the infeed side and from the outfeed side of the pleating device of figure 3, figure 5 shows the fixing device according to the invention in partly cross-sectional side view, figures 6A and 6B show respectively a top view and schematic side view of the finishing device according to the invention, figures 7A and 7B show the manner of cutting the length of textile material for use as curtain fabric respectively as panel track, and figure 8 is a schematic view of the manner in which the pieces of fabric are sewn together. A system 1 for forming a pleated textile product comprises a device 2 for feeding a length of flat material 3, a device 4 for ■ arranging one or more longitudinal pleats 5 in the length of material 3 and a device 6 for fixing the pleat or pleats 5. The system 1 is further provided with a finishing device 7, which is placed in series with fixing device 6 and which is adapted to cut longitudinal edges 8 from the length of pleated material 3. Behind finishing device 7 can be arranged a conveyor table or belt 9, behind which a winding unit 10 is arranged (fig. 1) . This arrangement is used particularly when, after pleating, the material will be further processed into a textile product at a different location. However, when the processing takes place for the greater part immediately after pleating, finishing device 7 can also be adapted to cut the length of pleated material in transverse direction, whereby pieces or panels 48 are formed. A conveyor belt or table 9 can then also be present to feed pieces or panels 48 through to a take-off device 11 on which pieces 48 are received to then be mutually connected to form a complete product (fig. 2) . Feeding device 2 comprises a holder 12 for a supply roll 13 and a number of tension rollers 14, 15 and 16 (fig. 3) . At least the last tension roller 16 is herein provided with a profile 17 running outward on both sides from the centre, whereby length 3 is pulled tight in transverse direction. Feeding device 2 further comprises two co-acting contour rollers 18, 19 whereby the length of material is already brought to some extent into the desired pleat form. Pleating device 4 comprises a mould 20 with an opening, the contour of which corresponds with the ultimately desired pleat pattern in the material . The contour, which is formed by co-acting standing and hanging T-shaped guides 21 and 22, herein tapers gradually in the feed direction. T-shaped guides 21, 22 are relatively high and narrow on the infeed side (fig. 4A) , while on the out-feed side they are relatively low and wide whereby the material is gradually carried into the desired (box) pleat form (fig. 4B) . Forms of mould other than shown here are otherwise also possible. A sawtooth mould could thus possibly be used if so-called flat pleats have to be arranged in the material instead of the shown box pleats . Fixing device 6 follows on immediately from pleating device 4, which can be virtually integrated therein (fig. 5) . Fixing device 6 is provided with a roller 23 of relatively large diameter and a pressure belt 25 co-acting therewith which is guided over a number of rollers 24. Roller 23 is heated, whereby pleats 5 are fixed in the length of material 3 by a combination of heat and pressure. In order to limit the heat loss in fixing device 6 as far as possible, an insulation cover 55 is placed around the part of roller 23 which does not co-act with pressure belt 25. Since the material in fact consists of a plurality of layers after pleating, deformations thereof transversely of the plane must be avoided as far as possible, since any deflection will result in the outer layer having to cover a greater distance than the inner layer, whereby creases could eventually be formed in the inner layer. The choice of radius for roller 23 is therefore as large as possible, whereby the curving of the length of material 3 remains limited during fixing. The infeed of the roller moreover lies substantially in one line with the outfeed of mould 20 of pleating device 4, so that the length of material 3 is in principle only bent in one direction. Since in the shown embodiment of finishing device 6 use is made of a per se conventional roller, this latter is here placed at an angle . in a frame 26, whereby the infeed is indeed situated at the same height as pleating device 4. After being released from roller 23 the length of material 3 is guided along a cooling device 27, whereafter the material is deflected downward over a number of rollers 28 in the direction of finishing device 7. Finishing device 7 comprises means 29 for cutting the or each longitudinal edge 8 off the length of material 3, in addition to means 30 for cutting length of material 3 in transverse direction into pieces or panels 48. Both longitudinal cutting means 29 and transverse cutting means 30 can be formed by ultrasonic cutting units with a lower knife or horn 31 and an upper knife or cutting wheel 32. The choice of an ultrasonic cutting unit results in the material being heat -sealed immediately on forming of the cut, whereby the form, particularly the pleat form, is preserved and, in addition, fraying of the material is prevented. With the embodiment having upper knives and lower knifes moving away from and towards each other the cutting means 29, 30 can moreover be displaced without damaging the material, whereby possible cutting losses are minimized. In the shown embodiment the longitudinal cutting means 29 are adjustable in transverse direction along a beam 53, wherein the one knife 29 has only a fine adjustment with a displacement range of about 175 mm, this being particularly intended to enable following of variations in the progression of material 3, while the other knife has a relatively large adjustment range in the order of 1.40 m, whereby material lengths of different width can be formed. This knife also has a fine adjustment in order to follow the progression of pleats 5 in length of -material 3. Longitudinal cutting means 29 are controlled in each case by an optical sensor 33, here a photocell, which detects the progression of pleats 5. The position of optical sensors 33 is also adjustable. Adjustment of the knifes and sensors can herein take place both manually and pneumatically. In order not to have to stop the entire system when longitudinal cutting means 29 are adjusted, the finishing device 7 is provided with a first buffer 34. This buffer comprises a compensation roller 35 displaceable transversely of the transport direction of the material and a guide plate 36. During normal use of finishing device 7 the material is guided over plate 36 to cutting means 29. However, when the cutting means have to be adjusted and no transport of material can therefore take place at the location of cutting means 29, compensation roller 35 drops slowly downward in the direction of the position 35' shown in dotted lines, while feeding device 2 and fixing device 6 run on slowly. The speed at which roller 35 drops is of course adapted herein to the speed at which the material leaves fixing device 6. Once cutting means 29 have been properly adjusted, the first buffer 34 can be emptied by accelerated driving of rollers 37 and 38, whereby the material is pulled into finishing device 7, wherein compensation roller 35 moves upward again to its starting position. Drive rollers 37 and 38 are otherwise rollers which are only rotatable in one direction and which co- act with a pressure roller 39 respectively 40 arranged thereabove. Strips 41 severed by longitudinal cutting means 29 along the edges 8 of length of material 3 are eventually discharged downward via a guide roller 42. In the shown embodiment, finishing device 7 is also adapted to perform a transverse cutting operation. For this purpose a transverse cutting unit 30 is present which takes a dual form in the shown embodiment in order to increase the effectiveness and reduce the time length of material 3 has to be stopped. Transverse cutting unit 30 is herein displaceable in transverse direction of length of material 3 along a beam 54, wherein, as stated, the length of material 3 is brought to a standstill . So as not to have to stop the entire installation, finishing device 7 has a second buffer 43 which is likewise formed by a compensation roller 44 and a guide plate 45 placed thereunder. In the case of a transverse cutting operation a driven roller 46 which co-acts with a roller 47 to tighten the length of material 3 is temporarily stopped. Compensation roller 44 then moves downward at a speed such that all the material supplied by longitudinal cutting means 29 is stored in buffer 43. After the transverse cutting operation has been performed and the driven roller 46 has been started again, the material is pulled out of buffer 43 by temporarily causing this roller to rotate more rapidly. The material of the length 3 can otherwise be supported during both the cutting operation in longitudinal direction and the transverse cutting operation. For the transverse cutting operation use can be made of a static support, for instance by means of a pneumatic system with which the material is sucked against a surface. For the longitudinal cutting means use can be made of a dynamic support system, for instance in the form of guide plates or guide rollers, whereby the material is stabilized and the pleats can optionally be opened up in order to enable a cutting operation to be carried out in the pleat without damaging the surrounding material . Although a cutting device with a fixed transverse cutting unit in combination with a buffer is shown above, it is of course also conceivable for transverse unit 30 to take a "flying" form and to thus co-displace with the length of material 3 for cutting (fig. 2) . As -stated, after the finishing device 7 the material reaches a conveyor belt or table 9, whereby it is discharged. When finishing device 7 is provided with transverse cutting means and it is not therefore the intention to roll up the material in a winding device 10, this conveyor belt or table 9 will be provided with means for controlling transverse cutting means 30. These control means then comprise a sensor (not shown here) which ascertains that a determined quantity of material has passed through transverse cutting means 30, whereafter these latter can be activated. The pieces or panels 48 formed by transverse cutting means 30 can finally be taken off conveyor 9 and stacked by a transfer device 11. Panels 48 can also be passed directly to a connecting device in which they are mutually connected in longitudinal direction. This will apply particularly to pieces and panels 48 which are used in the form of curtains, the width of which generally amounts to a multiple of the width of a piece of fabric. When on the other hand the pieces or panels are used as panel tracks, it will generally not be necessary to mutually connect them, but it will only be necessary to arrange all manner of suspension members, weightings and the like therein. When pieces or panels 48 must indeed be mutually connected in longitudinal direction, a slightly different cutting pattern is also chosen for this purpose. In this case the length of material is cut on either side on a fold line 5 (fig. 7A) , whereafter one of the panels is turned over prior to the connecting. The short leg 51 of the last pleat of this panel 48' is unfolded slightly and connected to the long leg 52 of the last pleat of the other panel 48 (fig. 8) , whereby after this second panel 48' has been folded back to its original position a relatively wide pleated panel results, the seam 50 of which is invisible from the visual side 49 of the panel. When however the panel will be used as panel track, it can in principle be cut at any desired location, since there is anyway no connecting seam. In practice a cutting line is herein chosen in a pleat lying on the rear side, which falls behind the pleat on the visual side 49 during use (fig. 7B) . In the above described manner the method and the system according to the invention enable pleating, cutting to size and processing into end products of lengths of textile material at relatively great speed and on industrial scale. Although the invention is elucidated above on the basis of a number of embodiments, it will be apparent that it is not limited thereto. The cutting means can thus be embodied in many ways other than in the form of ultrasonic cutting units, while for the detecting means options other than photocells can also be envisaged. The specific embodiment of the fixing device and the pleating device as shown here also represent no more than examples, and the scope of the invention is therefore defined solely by the appended claims .

Claims: CLAIMS 1. Method for forming a pleated textile product, comprising the steps of feeding a length of flat material, arranging in the length of material in longitudinal direction thereof at least one pleat which becomes gradually sharper in the feed direction, and fixing the or each pleat by heating and/or pressing. 2. Method as claimed in claim 1, characterized in that the length of material is finished after applying and fixing of the pleat or pleats . 3. Method as claimed in claim 2, characterized in that the length of material is cut into pieces in transverse direction. 4. Method as claimed in claim 2 or 3 , characterized in that at least one longitudinal edge of the length of material is cut off . 5. Method as claimed in claim 3 or 4 , characterized in that the cut edge is heat-sealed during cutting. 6. Method as claimed in any of the claims 3-5, characterized in that a number of pieces are mutually connected in- longitudinal direction. 7. Method as claimed in claim 6, characterized in that the pieces are stitched together. 8. Method as claimed in claim 6 or 7, characterized in that at least one of the pieces is turned over before connection. 9. System for forming a pleated textile product, comprising a device for feeding a length of flat material, a device for arranging in the length of material in longitudinal direction thereof at least one pleat which becomes gradually sharper in the feed direction, and a device for fixing the or each pleat by heating and/or pressing. 10. System as claimed in claim 9, characterized in that the pleating device comprises at least one mould with a profiled opening corresponding with the desired contour of the pleated product . 11. System as claimed in claim 9 or 10, characterized in that the fixing device comprises at least one heated roller. 12. System as claimed in claim 11, characterized in that the roller has a relatively large diameter. 13. System as claimed in claim 11 or 12, characterized in that the roller comprises an infeed part lying practically in line with the outfeed opening of the mould. 14. System as claimed in any of the claims 11-13, characterized by at least one pressure belt extending round the roller along a part of the periphery and co-acting therewith. 15. System as claimed in any of the claims 9-14, characterized by a device for finishing the length of material with the fixed pleat (s) . 16. System as claimed in claim 15, characterized in that the finishing device comprises means for cutting the length of material into pieces in transverse direction. 17. System as claimed in claim 15 or 16, characterized in that the finishing device comprises means for cutting at least one longitudinal edge of the length of material . 18. System as claimed in claim 16 or 17, characterized in that the cutting means are adapted to heat -seal the cut edge formed thereby. 19. System as claimed in any of the claims 16- 18, characterized in that the cutting means comprise at least one ultrasonic cutter. 20. System as claimed in any of the claims 16- 19, characterized by means controllably connected to the cutting means for detecting the position of the length of material . 21. System as claimed in claim 20, characterized in that the detecting means comprise at least one optical sensor. 22. System as claimed in any of the claims 16-21, characterized in that the cutting means are adjustable. 23. System as claimed in any of the claims 16-22, characterized by at least one buffer for temporarily storing the length of material for cutting. 24. System as claimed in any of the claims 16-23, characterized by a device for mutually connecting a number of pieces in longitudinal direction. 25. System as claimed in claim 24, characterized in that the connecting means comprise a longitudinal seam sewing machine . 26. System as claimed in claim 24 or 25, characterized by a device placed between the finishing means and the connecting means for turning over at least one of the severed pieces . 27. Pleating device evidently intended for use in the system as claimed in any of the claims 9-26. 28; Fixing device evidently intended for use in the system as claimed in any of the claims 9-26. 29. Finishing device evidently intended for use in the system as claimed in any of the claims 15-26. 30. Connecting device evidently intended for use in the system as claimed in any of the claims 24-26.

Inventors: ZINKEN JOHANNES MATHIAS GERARD, ZINKEN, JOHANNES, MATHIAS, GERARDUS
Applicants: TEXTILES PARTNERS & TRADERS N, ZINKEN JOHANNES MATHIAS GERARD, TEXTILES PARTNERS & TRADERS N.V., ZINKEN, JOHANNES, MATHIAS, GERARDUS
Application year: 1998
Main classification: D06J1
IPC codes: D06J1