Abstract:
A quilting frame for the purpose of both free hand and machine quilting consisting of a pair of frame ends ( 21  and  22 ) supporting three rods ( 25, 26,  and  27 ). The rods ( 25, 26,  and  27 ) hold material to be quilted. As the quilting process progresses, the material is wound onto the take-up rod ( 25 ). The proper tension for both hand and hand-machine guided quilting is applied to each piece of material mounted on the rods through clutch assemblies ( 55 ). The quilt frame is adjustable for both tilt and height using assemblies  60  and  65  respectively. The adjustment technique is simple and easy to perform, facilitating both hand and home machine quilting.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims benefit of PPA Serial No. 60/376,892, filed May 2, 2002 by the present inventor. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field 
     This invention relates to a quilting frame system that can be used for hand quilting or machine quilting. 
     2. Background of the Invention 
     Quilting frames are used for the purpose of both free hand and machine quilting. They typically consist of a pair of frame ends supporting three rods. The rods hold the material to be quilted. As the quilting process progresses, the material is wound onto one of the rods—the take-up rod. A steady tension is applied to each piece of material mounted on the rods. The tension is important for consistently creating patterns in the material being quilted. 
     As the material continues to collect on the take-up rod, its diameter increases. When used for machine quilting, the increase in diameter causes a downward pressure to increase drag on the sewing machine. To reduce drag, quilting frames should be adjustable for both tilt and height. The adjustment techniques should be simple and easy to perform, allowing for fine tension adjustment. 
     Current quilting frame systems are typically set up on a semi-permanent or permanent basis, due to their designs. In order to accommodate the growing home quilting market, a modern quilting frame system should be simple to erect and take down, provide a high degree of portability and be easy to adjust and operate. 
     Prior patents for quilting frames have presented techniques for tensioning the fabric. U.S. Pat. No. 843,269 discloses a hanging frame using a pin, through a hole in the frame, passing though holes in a disc attached to the end of the pole for tensioning. This tensioning system, while providing positive tension, does not allow for fine tension adjustment. It also requires the use of both hands in the tensioning process. 
     U.S. Pat. No. 940,070 discloses a floor frame for hand quilting, using a ratchet and pawl tension system. U.S. Pat. No. 988,913 discloses a hanging frame for hand quilting, using a ratchet and pawl arrangement for tensioning. U.S. Pat. No. 1,326,776 discloses a hand quilting device using a ratchet and pawl tension system. The ratchet and pawl tension system provides positive tension and allows for one-hand adjustment, but does not allow for fine tension adjustment. 
     U.S. Pat. No. 1,843,834 discloses a 2-pole hand quilting system using a radial spline arrangement for pivoting the frame and a friction system for tension adjustment. Friction tension adjustment allows for fine tension adjustment, but does not provide for positive tension adjustment. Over time the friction surfaces can wear down and reduce the effectiveness of such a system. This system requires both hands for tension adjustment. 
     U.S. Pat. No. 5,913,275 discloses a radial spline coupling approach for both ends of the rods, using a bolt and wing nut to pull the radial splines into engagement. While this approach provides for a finer tension adjustment than the previously stated ratchet and pawl systems, it requires the use of both hands in the tensioning process. One hand holds the rod in the rotated, tensioned position and the other hand tightens the wing nut. 
     In conclusion, insofar as I am aware, no home quilting frame system formerly developed provides for positive, fine tension adjustment; separate height and tilt adjustment; integral attachment system for clamping to the end of a table or rails. The present invention provides a high degree of portability, versatility and simplicity of operation for the growing number of home quilters. 
     SUMMARY 
     The invention, an improved quilting frame system, can be used for hand quilting or machine quilting. The frame is comprised of three spaced, parallel rods supported by a pair of parallel frame ends. The rods are located perpendicular to the frame ends. The frame ends allow for each of the three parallel rods to be individually rotated and individually locked in position for tensioning. The individual rotation and tensioning of the parallel rods is accomplished by attaching one end of each rod to a roller clutch assembly on one of the frame ends and a passive spindle on the other frame end. The top and bottom layers of the material to be quilted are attached to the rods, with the batting sandwiched between these two layers of material. The quilting area between the rods is kept taut to allow for proper quilting of the material. 
     A pair of vertical rods supports each of the end frames. The support rods attach to the side of the end frames in a manner that allows the end frames to slide vertically along the support rods when the support rod attachments are loose. These two support rods provide the independent height and tilt adjustment for the end frames. 
     The base of the support rods is a length of channeling. The channeling is oriented such that the open end can be slid over the end of a table, with the support rods resting on top of the channel. The channel also allows for attachment of a rail system for increased portability or extending the length of the quilt frame system for larger quilts. When used with the rail system for extending the quilting frame system, extending both the quilting rods and rails is accomplished by separate extension pieces with attachment devices. 
    
    
     DRAWINGS 
     FIG. 1 is a plan view of the quilting frame system according to the present invention. 
     FIG. 2 is a longitudinal sectional view taken along section line  2  of FIG. 1 illustrating arrangement of quilting rods, support rods and roller clutch assembly on active frame end, showing the direction of rotation for tensioning. 
     FIG. 3 is a side view taken along section line  3  of FIG. 1 of the frame ends illustrating quilting rods connecting between roller clutch assembly and passive spindle and frame ends clamped to a table. 
     FIG. 4 is an enlarged elevation view of a portion of the active frame end illustrating the roller clutch assembly and locking knob. 
     FIG. 5 is a side sectional view taken along section line  5  of FIG. 4 illustrating details of the roller clutch assembly and locking knob. 
     FIG. 6A is side sectional view of the roller clutch assembly illustrating the locking knob tightened against the roller clutch body. 
     FIG. 6B is side sectional view of the roller clutch assembly illustrating the locking knob loosened, allowing rotation of the roller clutch body. 
     FIG. 6C is side sectional view of the roller clutch assembly illustrating the locking knob recessed into the frame end, and the roller clutch assembly removed from frame. 
     FIG. 7 is an enlarged elevation view of a portion of the active frame end illustrating the main frame end support system. 
     FIG. 8 is a side sectional view taken along section line  8  of FIG. 7 illustrating the frame support system. 
    
    
     DESCRIPTION 
     FIG. 1 is a plan view of the quilt frame  50  of this invention. Three quilting rods  25 ,  26  and  27  are each supported on the active frame end  21  by shaft  4 , which is part of the roller clutch assembly  55 . On the passive frame end  22 , the three quilting rods are each supported by a passive spindle  6 . Each of the frame ends is supported by two clamping systems  60  and  65 . These clamping systems are attached to vertical rods  13  and  20  respectively. Height is adjusted on each frame end by loosening knobs  16  and  9 , setting the proper height and then re-tightening. Adjusting tilt is performed using only knob  9 . The base of each of the support rods is a channel  14 . The channel is used for attachment of each frame end to a table end or rail system. 
     FIG. 2 is a longitudinal sectional view of the active frame end  21  illustrating the support rods  20  and  13  attached to the base  14  and supporting the active frame end. Knobs  23  provide the clamping force for attachment to the end of a table. The square end of the roller clutch shaft  4  engages the square quilting rods  25 ,  26  and  27  allowing for control of rotation and tension. The roller clutch  3  is contained in the roller clutch body  2 . The lines  28  and  29  are provided to illustrate the direction of rotation for tensioning of fabric placed on the quilting rods  25 ,  26  and  27 . Quilting rod  25  is the take up rod. Both the top layer fabric  28  and the bottom layer fabric  29  are wound onto rod  25 . The batting that is sandwiched between these layers is not shown in this illustration. The direction of rotation allowed by the roller clutches when the locking knob  5  is in locked position, as illustrated in FIG. 6A, is indicated by the arrows at the ends of  28  and  29 . Rotation of rods  25 ,  26  and  27  when all three locking knobs  5  are in this position provides for fine tension adjustment. In order to advance the quilting material, locking knobs  5  for roller clutch assemblies associated with rods  26  and  27  must be in the unlocked position as illustrated by FIG.  6 B. The locking knob  5  for the roller clutch associated with rod  25  would be in locked position as illustrated in FIG. 6A, allowing it to roll the quilting material on to rod  25 . 
     FIG. 3 is a side view of the quilting frame system. Each frame end channel  14  is shown clamped to a table using knobs  23 . Only one of the quilting rods is shown for clarity. The square end of shaft  4  is engaged with the square quilting rod, allowing for rotation using knob  1 . The passive spindle  6  on the passive frame end  22  only provides support for the quilting rod. 
     FIGS. 4 and 5 illustrate the roller clutch assembly  55  and associated locking knob  5  in the frame end  21 . Since the frame ends can be fabricated from a relatively soft material such as wood or plastic, the use of a threaded insert  24  provides for a strong threaded receptacle for locking knob  5 . The roller clutch  3  is fixed to the roller clutch body  2 . When the roller clutch knob  5  is in the position illustrated (also shown in FIG.  6 B), the roller clutch body  2  is allowed to rotate freely in both directions within the frame end  21 . When the roller clutch knob  5  is tightened against the roller clutch body  2 , as illustrated in FIG. 6A, the roller clutch body  2  is pressed against frame  21 , disallowing its movement. In this position, the roller clutch  3  will only allow the shaft  4  to rotate in one direction. 
     FIGS. 7 and 8 illustrate the main frame end support system  65 . Both frame support systems  60  and  65  employ the same securing technique, so only the main support system  65  will be described. When securing the frame ends  21  and  22  in proper position, knob  16  (FIG. 8) is rotated, pulling the support body  19  against spacer  18 . The support rod  20  is held in place by the tension maintained by knob  16  on support body  19 . Due to the contact surface area between  19  and  20 , only a small amount of tensioning pressure is required to hold the frame end in place. 
     REFERENCE NUMERALS IN DRAWING 
       1 . Shaft Rotating Knob 
       2 . Roller Clutch Body 
       3 . Roller Clutch (one-way clutch) 
       4 . Quilt Rod Engaging Shaft 
       5 . Roller Clutch Locking Knob 
       6 . Passive Spindle 
       7 . Spacer 
       8 . Spindle Bolt 
       9 . Angle Knob 
       10 . Washer 
       11 . Washer 
       12 . Angle Support Body 
       13 . Vertical Support 
       14 . Channel 
       15 . None 
       16 . Height Knob 
       17 . Washer 
       18 . Height Support Body 
       19 . Height Support Body 
       20 . Vertical Support 
       21 . Active Frame End 
       22 . Passive Frame end 
       23 . Table Attachment Knob 
       24 . Threaded Insert 
       25 . Quilt Take-up Rod 
       26 . Quilt Top Rod 
       27 . Quilt Backing Rod 
       28 . Top Quilt Layer Illustrative Line 
       29 . Backing Illustrative Line 
       50 . Quilting Frame System 
       55 . Roller Clutch Assembly 
       60 . Tilt Clamping Assembly 
       65 . Height Clamping Assembly 
     OPERATION 
     Attach frame end bases  14  to opposite ends of the table and tighten knobs  23 . The length of rods  25 ,  26  and  27  must be approximately equal to the length of the table. 
     Remove roller clutch assemblies  55  from frame end  21  by loosening the locking knob  5  to the position illustrated in FIG.  6 C. 
     Attach each of the rods  25 ,  26  and  27  on passive frame  22  in turn by placing one end of each rod onto spindle  6  on frame  22 . Next attach the rod to the active frame end  21 , by inserting roller clutch assembly  55  into frame  21  while engaging shaft  4  with the rod end. Place the roller clutch assembly  55  back into the frame end  21 , and adjust locking knob  5  to the position illustrated in FIG.  6 B. This process is repeated until all three rods  25 ,  26  and  27  are attached to both frame ends. 
     Attach cloth leaders to rods  25 ,  26 , and  27 . This can be done with tape or other means. 
     Attach backing of quilt to leader attached to rod  27  using straight pins or other fabric attachment device. Tighten locking knob  5  for roller clutch assembly  55  associated with rod  27  to the position illustrated in FIG.  6 A and then roll backing onto rod  27  using knob  1  of roller clutch assembly  55  associated with rod  27 . 
     With quilt top facing up, attach top to rod  26  and in a similar manner roll fabric onto rod  26 . 
     Tighten knob  5  for the roller clutch assembly associated with rod  25  to the position illustrated by FIG.  6 A. 
     Place quilt batting in between rods  26  and  27 , sandwiching the batting between the quilt top and quilt bottom Loosen locking knobs  5  for roller clutch assemblies  55  associated with rods  26  and  27  to the position illustrated in FIG. 6B to allow for bi-directional rotation. 
     Attach all three front edges (backing, batting and top) to cloth leader on take up rod  25 . Tighten locking knobs  5  for roller clutch assembly  55  associated with rods  26  and  27  to the position illustrated in FIG. 6A to allow for only one direction of rotation only. If using frame for hand quilting, turn knobs  1  of roller clutch assembly  55  associated with rods  25 ,  26  and  27  until proper tension is attained. 
     If frame is to be used with sewing machine on a moveable platform, loosen locking knob  5  for roller clutch assembly  55  associated with take up rod  25  to the position illustrated in FIG.  6 C. Remove roller clutch assembly  55  from frame end  21 , lift take up rod  25  slightly while pivoting on the associated passive spindle  6  on frame end  22  in order to pass rod  25  through the sewing machine throat. Reattach rod  25  to roller clutch assembly  55  and tighten associated locking knob  5 . After assuring all three locking knobs  5  are tightened, turn knobs  1  attached to rods  25 ,  26 , and  27  in the direction allowed by the roller clutch until proper tension is achieved. 
     Adjust height of end frames  21  and  22  by loosening knob  9  of tilt adjustment assembly  60  and knob  16  of height adjustment assembly  65  on frame end  21 . Set height and tighten knob  16 . Repeat the process on the passive frame end  22 , matching the height of frame end  21 . With height adjustment set, adjust frame tilt by moving frame end  21  vertically at a point near rod  25 . When the desired position is found, tighten knob  9  and repeat process on frame end  22 . 
     Roll completed quilted areas onto take up rod  25  by loosening locking knobs  5  on roller clutch assemblies associated with rods  26  and  27  and rotate knob  1  of roller clutch assembly associated with roll take up rod  25 . Tighten locking knobs  5  on roller clutch assemblies associated with rods  26  and  27  and then selectively rotate all three rods  25 ,  26 , and  27  until proper tension is achieved once more. 
     As the quilting process progresses, the amount of quilted material on rod  25  will increase. As this occurs, a further adjustment of the height and angle may be required for smooth operation. 
     To remove completed quilt from frame, loosen all three locking knobs  5  to the position illustrated in FIG.  6 B. Unpin back edges on quilt top and bottom from leader on rods  26  and  27  and unroll take up rod  25  until completed quilt is totally unrolled. Then unpin the front edge from the leader attached to take up rod  25 . 
     The foregoing should be considered as illustrative only of the principles of the invention. It is not desired to limit the invention to the exact construction and operation shown and described. Since modifications and changes will readily occur to those with skill in the field, all suitable modifications may be resorted to while falling within the scope of this invention.