Improvements in Machines for Making Tufted Upholstered Work.
Year: 1899

page_text: Date of Application, 4th Apr., 1899—Accepted, 27th May, 1899
COMPLETE SPECIFICATION.
Improvements in Machines for Making Tufted Upholstered Work.
We, WILLIAM CARRICK, residing at 176, Simcoe Street, in the City of Toronto,
in the County of York, and Province of Ontario, Upholsterer, and JOHN A.
MCLAUGHLIN, residing at 159, Simcoe Street, in the said City of Toronto, Uphol-
sterer, do hereby declare the nature of this invention and in what manner the
same is to be performed, to be particularly described and ascertained in and by
the following statement:.
In the manufacture of tufted upholstered work by means of mechanical appli-
ances, the fabric or material forming the outer surface of the tufting is spread
with its finished ornamental face downward upon the mold and is arranged within
the cells or chambers of the mold as follows: Fabric material enough to form
one tuft is pressed into a cell or chamber either by hand or by a block known
as a former, and this formed tuft is secured by filling it with stuffing material.
It is necessary to completely arrange each tuft before a succeeding tuft is com-
menced, as by this means the fabric material required for one tuft is kept from
being used in forming an adjoining tuft. When all of the tufts have been formed
and stuffed in the same manner as the first one a small space equal to the thickness
of the partition of the mold remains between the tufts on all sides. The stuffing
material is pressed into the mold so that it lies completely below the top edges
of the partition walls, in order that the backing when it is applied can come in
contact with the back of the face fabric at the top of the partition walls. When
the tufts are stuffed the backing is applied and fastened to the face fabric either
by means of glue or by sewing. When glue is used as the securing medium a
coating of glue is spread over one face of the backing, which is then laid on top
of the filled tufts and caused to adhere to the face fabric at the top of the partitions
by laying on the backing a follower-board, and placing the mold and its contents
in a press where it is allowed to remain until the glue is thoroughly dry. When
sewing is used as the fastening medium for fastening the backing to the face
fabric, slots are left in the partition walls and follower-board and the face fabric
and backing are then sewn together through the slots. In some instances, anıl
especially where hair is used as the stuffing material, it is necessary to employ a
separate piece of cardboard for each cell to hold the stuffing material in place, the
cardboard being held in position by the frictional contact of its edges with the face
fabric of the material within the cell. Owing to the time occupied in making
the tufted upholstered work according to these methods the cost of manufacture
of the finished article is necessarily greater than if the same or better work were
performed in a cheaper or more economical manner.
When buttons are used as the fastening medium as in the case of hand-made
work they are sewn to the face fabric and backing by thread or string, and in this
case it is necessary to exercise the greatest skill in forming the plaits for the tufts
with uniformity and care, as unless the tufts are carefully plaited and arranged
they will detract from the appearance of the finished article instead of adding to
its beauty. Then, again, the thread or string shanks of the fastening buttons

page_text: owing to their natural weakness are constantly broken by the spring of the
stufting material, and allow the face fabric to fall away from the backing and
destroy the shape of the tuft and the symmetry of the work.
To obviate the objections to the above-named processes, and to make an article
of manufacture in which the tufts will be properly plaited and uniform, and to
fasten the face fabric to the backing in such a manner that it will resist the
tendency to separate under ordinary wear and tear, is the object of our present
invention; and it consists of a mold embracing in its construction a plurality of
depressed cells or chambers the corners of which are raised to form projections
having flat or concaved tops to receive the heads of the fastening buttons, and a
rim or upturned flange surrounding the cells exqual in height to the height of
the projections. On the top of the cells and projections is adapted to be placed
a follower-board fitted with holes or openings, corresponding in number and
location with the projections; and a press to force the follower-board down upon
the projections.
The method which we employ in connection with this apparatus is hereinafter
described.
In the drawings:
Fig. 1 is a plan view of a section of tufted upholstered work.
Fig. 2 is a transverse section on the lines aa Fig. 1.
Fig. 3 is a perspective view of a section of the mold showing a portion of the
face fabric spread over the cells.
Fig. 4 is a plan view of the mold.
Fig. 5 is a transverse section through the mold and press.
Fig. 6 is an enlarged sectional view through two adjacent cells.
Fig. 7 is a view of a section of the follower-board.
Fig. 8 is a perspective view of the button-guard.
Like letters of reference refer to like parts throughout the specification and
drawings.
A represents the mold which is of any suitable size and shape, and consists of
any number of cells a of uniform shape and size. At the corners of the cells are
projections b, the top of each of which is flattened or slightly concaved to receive
the head of the fastening button. In each of the projections 6 is a vertical hole c.
The shape and size of the cells and projections may vary according to the design
of the tufted upholstered work.
A¹ represents a rim projecting upwardly from the sides and ends of the mold,
the top of which is practically in the same plane as the top of the projections b.
D represents the button-guard, consisting of a sleeve d to receive the shank
of the button, and a peg d¹ to enter the hole c.
E represents the follower-board, which is provided with a series of holes F,
corresponding in number and location, with the projections b, and two ribs F1, F¹.
fastened to the top or upper surface of the follower-board.
Grepresents the table of the press, H. H, the standards, I the cross beam,
and J, J, the hand-screws working vertically through the cross beam I the lower
ends of which are opposed to the ribs F¹, F¹.
The use of the invention is as follows: The face fabric is marked out in the
usual manner as for hand-made work, the size of the squares corresponding to
the cells of the mold. A button K having a divided or clincher-shank K' is passed
through the corners of each square from the face side of the fabric. When a
button has been passed through the corners of each square the fabric is spread
over the top of the mold, face downwards, the heads of the buttons resting on
the top of the projections b; the guards D are then placed in position so that the
shank K of each button extends upwardly into the sleeve d of its respective guard
and the peg d¹ of each guard enters its respective hole in the projection. The
entry of the peg d' into the hole c prevents the displacement of the guard and
the consequent displacement of the button and the fabric. The stuffing material
is then spread over the back of the fabric and pressed into the cells to form the

page_text: tufts. As soon as the tufts are formed and sufficient stuffing material is applied
to the back of the formed tufts to hold them firmly in position and shape the
guards are removed and a backing of buckram or other fabric material is applied,
being pressed down so that the shanks K' of the buttons project through it;
the follower-board is then applied to the back of the buckram and pressed tightly
down by means of hand screws J, J, to pack the filling material firmly into the
formed tufts and form a firm backing for the same. When the stuffing material
has been firmly packed the shanks ₁ of the buttons are bent and clinched down
over the back of the buckram or backing material, the hand-screws J, J, are then
released, and the follower-board and tufted upholstered work removed from the
mold. When the tufted upholstered work is removed from the mold the tufts
will correspond in size, shape and number with the cells of the mold, and the sides
and ends of the mold will have formed-sharp and well defined edges for the work.
It is customary when placing the face fabric on the mold to leave sufficient material
to overhang the edges to cover the frame of the article of furniture to which it
is to be applied. When the work is completed plaits will be formed between the
buttons, and the tufted upholstered work will have the appearance of the best
hand-made work with a greater degree of uniformity on the part of the tufts.
By using buttons in the manufacture of the goods with divided shanks and
clinching these shanks over the back of the backing material it is impossible, under
ordinary circumstances, for the buttons to give way and allow of the separation
of the face goods from the backing, and the defacement of the work.
The whole operation in making the cushion for a couch can be performed in
about seven minutes by this method and appliance.
Having now particularly described and ascertained the nature of our said
invention and in what manner the same is to be performed, we declare that what
we claim is: -
1. The improved method of making tufted upholstered work, which consists of
taking a piece of pliable material, marking out on it the lines of the tufts, passing
through the lines at the intersecting points buttons having divided shanks, then
spreading the material over a form having a plurality of depressed cells with
projections at the corners of the cells on which are supported the heads of the
buttons, holding the buttons and material in position on the cells by hollow guards
fitted to receive the shanks of the buttons and with pegs to enter holes in the
projections, spreading the stuffing material over the back of the pliable material
which is pressed into the cells to form the tufts, applying a backing of fabric
material over the stuffing material, through which projects the divided shanks
of the buttons, and then clinching the divided shanks over the backing material,
substantially as specified.
2. The improved method of making tufted upholstered work, which consists of
spreading a piece of fabric material over a mold having a plurality of depressed
cells, passing buttons with divided shanks through the fabric from the face at the
corners of the tufts, spreading stuffing material over the fabric and packing it
down into the cells to form the tufts, spreading a backing over the filling material
through which passes the divided shanks and clinching the divided shanks over
the backing material, substantially as specified.
3. The improved method of making tufted upholstered work, which consists
of spreading a piece of fabric material over a mold having a plurality of depressed
cells, passing buttons with divided shanks through the fabric from the face at
the corners of the tufts, spreading stuffing material over the fabric and packing
it down into the cells to form the tufts, spreading a backing over the filling
material through which passes the divided shanks, apply a follower-board to the
backing material with pressure to pack the filling material and clinching the
divided shanks over the backing material, substantially as specified.
4. A machine for making tufted upholstered work consisting of a mold having
a plurality of depressed cells, projections at the corners of the cells the tops of

page_text: which are arranged to receive the heads of the fastening buttons, a hole in each
projection, hollow guards to receive the shanks of the fastening buttons, each
provided with a peg to enter the hole in its respective projection, a follower-board
provided with holes, corresponding in number and location with the projections
of the mold, substantially as specified.
5. A machine for making fufted upholstered work consisting of a mold having
a plurality of depressed cells, projections at the corners of the cells, the tops of
which are arranged to receive the heads of the fastening buttons, a hole in each
projection, hollow guards to receive the shanks of the fastening buttons, each
provided with a peg to enter the hole in its respective projection, a follower-board
provided with holes, corresponding in number and location with the projections
of the mold, and a press to force the follower-board down on top of the projections,
substantially as specified.
6. A machine for making tufted upholstered work consisting of a mold having
a plurality of depressed cells, projections at the corners of the cells, the tops of
which are arranged to receive the heads of the fastening buttons, a hole in each
projection, hollow guards to receive the shanks of the fastening buttons, each
provided with a peg to enter the hole in its respective projection, a follower-board
provided with holes, corresponding in number and location with the projections
of the mold, and an upturned rim for the mold, substantially as specified.
7. A machine for making tufted upholstered work, embracing in its construction
a mold having a plurality of depressed cells and an upturned rim surrounding
the cells, and seats at the corners of the cells to support the head of the fastening
button, substantially as specified.
WILLIAM CARRICK.
JOHN A. MCLAUGHLIN.
By Lewis Wm. Goold,
Agent for Applicants.