Patent Publication Number: US-7594311-B2

Title: Mattress bordering apparatus

Description:
The present invention relates to a mattress bordering apparatus. 
   BACKGROUND OF THE INVENTION 
   Bordering machines are known which comprise a worktable on which the mattress is turned with respect to a stationary sewing machine, which borders peripherally the longitudinal and transverse sides. The mattress is turned not only manually but also by way of mechanical devices. Devices of this type are known for example from EP-264,618 and EP-682,135 in the name of this same Applicant. 
   In particular, EP-682,135 also discloses an overturning device, which, after the bordering of one face of the mattress has ended, turns over the mattress in order to allow to border the other face of the mattress. 
   Current bordering machines have operational limitations, owing to which they are capable of bordering one mattress at a time. The use of several bordering machines in order to increase productivity, however, clashes with the fact that these machines are very bulky and cannot be accommodated in industrial buildings. Moreover, the search for a vertical solution in which bordering machines are stacked on multiple levels, in addition to being often unfeasible due to technical problems, would force operators to work at considerable heights, producing unacceptable safety conditions. 
   SUMMARY OF THE INVENTION 
   The aim of the present invention is to provide an apparatus which allows to border a plurality of mattresses simultaneously but has a limited space occupation. 
   Within this aim, an object of the present invention is to provide an apparatus which is capable of not compromising the working conditions of its operators. 
   This aim and this and other objects which will become better apparent hereinafter are achieved with an apparatus for bordering mattresses, the characteristics of which are defined in the claims. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Further characteristics and advantages of the present invention will become better apparent from the following detailed description of a preferred embodiment thereof, illustrated only by way of example in the accompanying drawings, wherein: 
       FIG. 1  is a perspective view of the apparatus according to the invention; 
       FIG. 2  is a side elevation view of the apparatus; 
       FIG. 3  is a plan view of the apparatus; 
       FIG. 4  is a front elevation view of the apparatus; 
       FIG. 5  is an exploded view, illustrating the various assemblies of the apparatus; 
       FIG. 6  is a perspective view of the lower bordering assembly, viewed from the mattress exit side, in an operating position; 
       FIG. 7  is a perspective view of the assembly of  FIG. 6 , viewed from the mattress entry side; 
       FIG. 8  is a perspective view of the assembly of  FIG. 6 , in a second operating position; 
       FIG. 9  is a perspective view of the upper bordering assembly, viewed from the mattress exit side; 
       FIG. 10  is a perspective view of the assembly of  FIG. 9 , viewed from the mattress entry side; 
       FIG. 11  is a perspective view of the assembly for overturning the mattress bordered by the lower assembly; 
       FIG. 12  is an exploded view of the overturning assembly of  FIG. 11 ; 
       FIG. 13  is a perspective view of the assembly for distributing the mattresses to the lower and upper bordering assemblies; 
       FIG. 14  is a perspective view of the assembly of  FIG. 13  in a second operating position; 
       FIG. 15  is a perspective view of the assembly for positioning the mattresses at the output of the apparatus; 
       FIGS. 16-19  illustrate an operating sequence of the upper bordering assembly; and 
       FIGS. 20-23  illustrate an operating sequence of the lower bordering assembly. 
   

   DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   Before delving into the details, a brief general description of the structure of the apparatus and of its operating method is given. 
   The apparatus comprises an assembly  1  for distributing mattresses M (see  FIGS. 16-19 ) which have not yet been bordered and are fed by devices which are not illustrated. The assembly  1  comprises an articulated feed table  2 , which can be tilted and distributes the mattresses between two mutually superimposed bordering assemblies  3 ,  4 . When the table  2  is horizontal, the mattresses M are conveyed in the direction A to the lower assembly  3 , while when the table  2  is inclined, the mattresses M are conveyed to the upper assembly  4 . 
   The assemblies  3  and  4  are provided with horizontal worktables and mattress overturning means, on which the mattresses are moved (turned) in order to be bordered peripherally by way of bordering machines, which in each instance border the upper face of the mattresses. 
   The upper assembly  4  is equipped with the overturning means comprising an overturning device  5 , which is integrated in the worktable and which, when the bordering of the upper face has been completed, turns over the mattress in order to allow the bordering machine to border the other face. 
   The mattress M bordered by the upper assembly  4  is then transferred, by means of a chute  6 , onto a receiving table  7  and is positioned thereon by means of appropriate pusher elements  8 . 
   A device  9  for overturning the mattresses M that is part of the overturning means, is also associated with the lower assembly  3 . However, the overturning device  9  is not integrated in the worktable of the assembly  3  but is located at the output thereof. In order to prevent the apparatus from becoming excessively high, the distance between the worktables of the assemblies  3  and  4  is in fact selected constructively as small as possible, to the extent allowed by the operating requirements of the operators, such as accessibility of the components, maintenance and so forth. As is evident, with this reduced distance the space available between the worktables of the assemblies  3  and  4  in order to turn over the mattress that must be bordered in the lower assembly  3  would not be sufficient, also in view of the dimensions of some types of mattress, such as double mattresses. 
   The overturning device  9  is arranged below the chute  6 , which in any case would hinder the overturning of the mattress. However, when a mattress that arrives from the lower assembly  3  after bordering one face arrives at the overturning device  9 , the chute  6  opens momentarily in order to form a space which is sufficient to overturn the mattress. Once the mattress has been overturned, it is returned to the worktable of the lower assembly  3  in order to complete the bordering and is then transferred onto the conveyor  8 . 
   In detail, the distribution assembly  1  is constituted (see  FIGS. 13 ,  14 ) by a base framework  10 , which comprises two rails  11 , which are perpendicular to the mattress advancement direction A and on which a carriage  12  which supports the feed table  2  can move. 
   The feed table  2  comprises a motorized belt  13 , which is closed in a loop around two parallel rollers  14 ,  15 , of which the roller  15  is actuated by a motor  16 . 
   The table  2  is articulated to table actuation means comprising the carriage  12  about the axis of the driving roller  15  and can be lifted and lowered on the side of the guiding roller  14  by means of a jack  16   a , which acts between the carriage  12  and the table  2 . In the lowered position, the table  2  is aligned horizontally with the worktable of the lower assembly  3 . In the raised position, the table  2  is inclined and connected to a series of rollers  17  (see  FIGS. 1-3 ,  5 ), which act as a bridge with the worktable of the upper bordering assembly  4 . 
   The reference numeral  18  designates a jack for moving the carriage  12  along the rails  11  and for positioning the worktable  2  with respect to the bordering assemblies  3 ,  4 . 
   The upper bordering assembly  4  is supported above the lower one  3  by a frame  19 , which is substantially shaped like a portal and can be reached by the operators of a lateral platform  20 , which is accessed by means of a set of steps  21  (see  FIG. 5 ). The upper assembly  4  has a structure which is similar to the one disclosed in the above-mentioned EP-682,135 in the name of this same Applicant, which is referenced here for the sake of better comprehension as an integral part of the invention. It comprises two posts  22 , which rise from the frame.  19  above a conveyance worktable  23  constituted by rows of mutually parallel freely rotating rollers  24  that are perpendicular to the advancement direction of the mattress. The rollers  24  are very close to each other but not in mutual contact, so that they can rotate freely and allow the movement of the mattress M deposited thereon. 
   Two respective carriages  25  can be positioned on the posts  22 , and a bracket  26  cantilevers out from them and supports a stationary bordering machine  27 , which comprises a traditional sewing machine equipped with means for guiding a tape, which is intended to be sewn so as to cover the seams that join the upper and lower faces of the mattress to the perimetric band thereof. The bracket  26  is conveniently provided with an adjustable inclination in order to be able to orient the bordering machine  27  at an angle which allows the diagonal sewing adapted to form the ridge that surrounds the faces of the mattress. 
   An arm  28  protrudes from the top of the posts  22  and supports, at its ends, a sleeve  29 , the axis C of which is vertical and passes at the region where the stitch of the bordering machine is produced. 
   A substantially triangular side-hinged structure  30  hinged about one side is supported rotatably within the sleeve  29  and is composed of an upright  31 , which by means of two arms  32 ,  33  is rigidly coupled to a pivot which can rotate within the sleeve  29 , and of a beam  34 , which cantilevers out from the lower end of the upright  31  and is supported by a stringer  35 , which joins the beam to the top of the upright. 
   The side-hinged structure  30  can be oriented through an angle of substantially 90° by way of a motorization assembly  36  installed on the arm  28  which acts on the articulation pivot of the side-hinged structure  30 . 
   A rectangular frame  37  is fixed to the beam  34  of the structure  30 , proximate to the upright  31 , and two jacks  38  are fitted frontally thereon, their stems protruding downward and supporting respective disks  39 . The beam is further provided with two guiding bushes for two vertical and parallel rods  40 , which rise from a bar  41 , which is arranged below the beam  34  and acts as a pusher means in order to make the mattress turn about the axis C, as will become better apparent hereinafter. 
   The bar  41  can be lifted and lowered on the conveyance worktable  23  by means of a pair of jacks  42 , in which the cylinders are mounted on the beam  34  and the stems are rigidly coupled to the bar  41 . 
   A plurality of vertical rollers  43  is part of the described assembly  4 ; said rollers are mounted so that they can rotate freely on the longitudinal member of the frame  19 , which delimits the worktable of the side of the bordering machine  27 . The rollers  43  form a vertical wall for guiding the mattress during the bordering of the longitudinal and transverse sides. 
   For better comprehension of the overall operation of the apparatus, the operation of the upper assembly  4  is described hereafter (see also  FIGS. 16-19 ) in order to better appreciate the functional connection to the operation of the lower assembly  3 , which will be described hereinafter. 
   The mattress M to be bordered, once transferred onto the roller conveyance worktable  23  by the distribution assembly  1  (the feed table  3  of which is appropriately inclined), is arranged so that the side to be bordered abuts against the rollers  43  and is then made to advance in the direction A through the bordering machine  27  in order to produce the border along the corner formed by the perimetric band with respect to the upper face. 
   When the corner upstream of the mattress is located at the axis C, the jacks  38  are activated and, by descending, lock the mattress M on the roller worktable  23 . At the same time, the jacks  42  are actuated so as to move the bar  41  from a raised position to a position which is adjacent to the perimetric band of the freshly bordered side. 
   It should be noted that the height of the bar  41  and of the rollers  43  is such as to exclude mutual contacts when the bar  41  is in the lowered position. 
   At this point, the motorization assembly  36  is activated and acts on the structure  30 , making it rotate through 90° about the axis C. At the end of this operation, the mattress M is oriented so that its longitudinal side is adjacent to the vertical rollers  43 . 
   After reactivating the jacks  38  and  42 , thus lifting the disks  39  and the bar  41 , the longitudinal side is bordered in the manner described above and then the other sides are bordered until the entire perimeter of the mattress is completed. 
   Advantageously, the rotation axis C of the structure  14  passes within the peripheral edge of the mattress proximate to the border. 
   In this manner, the bordering at the corners of the mattress can follow a circular arc-like path, which allows to form rounded corners. 
   The substantial advantage of the device is provided by the rollers  24 , which, by being able to rotate freely in both directions, greatly reduce the resistance of the mattress to rotation. Moreover, it is possible to interpose between the rollers  24  overturning means such as the overturning device  5  which, after the bordering of one face of the mattress, overturn the mattress in order to complete the bordering of the opposite face. 
   For this purpose, the rollers  24  of the worktable  23  are arranged so that it is possible to arrange between them two articulated frames  44 ,  45 , which compose the overturning device  5 . The articulated frames  44 ,  45  (see  FIGS. 9 ,  10 ) can be lifted by way of jack means, forming frame actuation means, from an arrangement in which they are coplanar with respect to the worktable  23  to an arrangement in which they lie opposite and substantially in a V-shaped configuration with respect to the worktable  23 . 
   The frames  44 ,  45 , for the structure and operation of which reference is also made to the cited EP-682,135, are constituted by respective arms  46 , which are articulated in the roller worktable  23  and protrude in the mutually opposite directions A and B, respectively, between the rollers  24  of the various rows and are conveniently spaced so as to form a channel for accommodating the arms  46 . 
   Rods  47  extend at right angles from each arm  46  in opposite directions and are accommodated between the various rows of rollers  24 . 
   The overturning of the mattress occurs by placing the mattress on a frame, for example on the frame  44 , and then turning it about its fulcrum so that the mattress M, after moving beyond the vertical position by inertia, rests against the other frame  45 , which has been lifted beforehand in front of the frame  44  in order to assume an inclined position. The frame  45 , once the mattress rests thereon, is lowered in order to deposit the mattress in an overturned position on the roller worktable  23 . 
   The lower bordering assembly  3  is shown in  FIGS. 6 ,  7  and  8  and has a structure which is substantially similar to the structure of the upper assembly  4 , except for some differences which are specified below. Therefore, for the sake of brevity in description, parts which are identical or similar to the parts of the assembly  3  are designated in the figures by the same reference numerals with the addition of the letter “a”. 
   As can be observed from  FIGS. 6 and 7 , one of the differences of the assembly  3  with respect to the assembly  4  consists in that the pusher means constituted by the bar  41   a , instead of moving vertically as in the case of the bar  41  of the assembly  4 , is articulated to the beam  34   a  and is actuated by a pair of jacks  42   a  between a vertical position for pushing against the mattress and a horizontal position (see  FIG. 8 ) for being able to pass above the mattress. 
   However, the most important difference is that, since the overturning of the mattress is performed downstream of the assembly  3  by the overturning device  9 , the conveyance worktable of the assembly  3  is constituted by a belt  48 , which is closed in a loop around a guiding roller  49 , and a driving roller  50 , which is actuated by a motor  51  so as to be able to transfer the mattress onto the overturning device  9 , once the bordering of the upper face of the mattress has been completed, and to return the mattress onto the belt  48  in order to border the opposite face after the mattress has been turned over. 
   The overturning device  9  (see  FIGS. 11 ,  12 ) is constituted by a footing  52 , on which feet  53  are fixed which support a rectangular frame  54  which is coplanar with respect to the belt  48  of the bordering assembly  3 . Freely rotating rollers  55  are supported in the frame  54 , on the side which is adjacent to the belt  48 , and act as a bridge for the passage of the mattress M on the belt  48  on a plurality of freely rotating rollers  56  arranged in two parallel rows which lie laterally with respect to the longitudinal centerline plane of the frame  54 . 
   Four columns  57  are arranged on the footing  52  and support, at the top, advancement means comprising four respective advancement assemblies  58 ,  59 ,  60 ,  61 , each of which is constituted by a pair of belts  62 ,  63 , which are closed in a loop around respective pulleys (see  FIG. 11 ) so that the upper portions of the belts are mutually parallel and coplanar with respect to the belt  48 . The two advancement assemblies  58 ,  59  are arranged proximate to the rollers  55  and are actuated by means of a gearmotor  64  and a shaft  65 , which connects the driving pulleys of the belts  62 ,  63 . 
   The other two advancement assemblies  60 ,  61  are arranged proximate to the side of the frame  54  which lies opposite the rollers  55  and are also actuated in a similar manner by means of a gearmotor  66  and a shaft (not shown in the figure) which transmits the motion to the driving pulleys of the belts. 
   The mattress overturning element  67  designed to turn over the mattress is arranged on the footing  52  below the two rows of rollers  56 . The overturning element  67  (see  FIG. 12 ) is constituted by a sort of fork, which is composed of two arms  68  connected by a cross-member  69  and is hung articulately to a portal  70 , which is fixed to the footing  52 . The fork  67  is actuated by overturn actuating means comprising a jack actuator  71 , which acts on the cross-member  69  so as to perform an oscillating motion around the pivots  72  by means of which it is articulated to the portal  70 . 
   The arms  68  have a mutual distance and length which allows them to pass, during the oscillating motion imparted by the jack  71 , between the rows of rollers  56  and the advancement assemblies  60 ,  61 . Moreover, the arms  68  are shaped so that in the lowered condition of the fork  67  their upper edges are coplanar with respect to the upper portions of the belts  62 ,  63  of the advancement assemblies  60 ,  61 . 
   As mentioned initially, the overturning device  9  is arranged below the chute  6  which allows to unload the mattresses that have been bordered in the upper assembly  4 . The chute  6  comprises a movable element constituted by a first beam  73 , which is articulated by means of pivots  74  to the top of two posts  75 , which rise from the footing  52 . A rectangular frame  76  is rigidly coupled to the beam  73 , is provided with rows of freely rotating rollers  77 , and is wide enough to act as an extension of the roller worktable  23  and provide complete support for the mattresses that arrive from the upper bordering assembly  4 . Given the normal dimensions of a mattress, the frame  76  covers the advancement assemblies  58 ,  61  of the overturning device  9 . 
   The frame  76  is actuated between an inclined position and a raised position by means of actuating means constituted by two jacks  78 , which act between the beam  73  and the respective posts  75 . In the inclined position, the frame  76  rests on a portal  79  which rises from the footing  52 . 
   The chute  6  is completed by a movable element constituted by a second frame  80 , which is rigidly coupled to a beam  81  articulated by means of pivots  82  to the top of a pair of posts  83  which rise from the footing  52 . The frame  80  is provided with rows of rollers  80 , which are aligned with the rollers  77  of the frame  70 , and can be lifted and lowered by means of actuating means constituted by two jacks  85  which act between the posts  83  and the beam  81 . In the lowered position, the frame  80  rests on the portal  79  so that it is coplanar with respect to the frame  76 . 
   The described chute is completed by an oscillating barrier  86 , which is arranged at the lower end of the frame  80 . The barrier  86  has, at its opposite ends, two arms  87  by means of which it is articulated on the beam  81 , at the sides of the frame  80 , and on which barrier actuation means constituted by actuators  88  act which can be actuated so as to move the barrier  86  from a locking position which lies above the plane of the chute  6 , in order to stop the mattresses, to a position which lies below the plane of the chute, in order to allow the mattresses to fall onto the receiving table  7 . 
   As shown by  FIGS. 1-3  and  5 , the receiving table  7  is constituted by a plurality of rollers  89 , which are parallel and mutually spaced so as to allow the passage of rods  90  by means of which a pusher  91  is fixed to a carriage  92  which lies below the roller table  89 . The carriage  92  can slide on a pair of rails  93  and is actuated by means of a jack  94  so that the pusher  91  can move above the roller table  89  and move the received mattress to the selected position in order to be conveyed toward subsequent packaging stations. 
   The operation of the described apparatus is evident from the description given. In particular, the distribution assembly  1  directs the mattresses toward the lower or upper bordering assembly  3  or  4 , depending on the request made by the individual operators, for example because it is required by different bordering speeds. 
   In any case, the mattresses fed into the upper assembly  4  (see  FIGS. 16-19 ), after completion of the bordering of both faces, are conveyed by the chute  6  onto the receiving table  7 . If the receiving table  7  is still occupied by a previously bordered mattress, the mattress that arrives on the chute is stopped temporarily by the barrier  86  and released when the table  7  has been cleared. 
   The mattresses that reach the lower assembly  3  (see  FIGS. 20-23 ), after the bordering of the upper face, are transferred by the belt  48  onto the advancement assemblies  58 - 61 . The frames  76  and  80  of the chute are then opened, actuating the jacks  78 ,  85 . When enough space has been cleared above the mattress arranged on the advancement assemblies, the jack  71  is actuated and, by acting on the face or overturning element  67 , lifts the mattress and turns it over. Then the advancement assemblies  58 - 61  are actuated and return the mattress onto the belt  48  in order to form the border of the opposite face of the mattress. Once bordering is completed, the mattress is again transferred onto the advancement assemblies  58 - 61  and from there onto the receiving table  7 . 
   It should be noted that if a mattress that arrives from the upper bordering assembly  4  is arranged on the frame  80  during the lifting of the frames  76 ,  80 , it is stopped by the barrier  86  and is prevented from turning over onto the receiving table  7  by an arc  95  which lies above the frame  80 . 
   The described apparatus is susceptible of numerous modifications and variations, all of which are within the scope of the appended claims. 
   All the details may further be replaced with other fully equivalent ones. 
   The disclosures in Italian Patent Application No. BO2005A000006 from which this application claims priority are incorporated herein by reference. 
   Where technical features mentioned in any claim are followed by reference signs, those reference signs have been included for the sole purpose of increasing the intelligibility of the claims and accordingly, such reference signs do not have any limiting effect on the interpretation of each element identified by way of example by such reference signs.