Patent Description:
Quilting is a sewing process by which layers of textile material and/or other fabrics are joined to produce compressible panels that may be both decorative and functional. The manufacture of certain products, such as mattress covers, involves the application of large-scale quilting processes. These large-scale quilting processes typically use high-speed multi-needle quilting machines to form a series of cover panels along webs of the multiple-layered materials. Large-scale quilting processes typically use chain-stitch sewing heads that produce resilient stitch chains which are supplied by large spools of thread.

In a typical quilting process, the chain stitches bring together the multiple layers to be joined. <CIT>, <CIT> and <CIT> disclose examples of the prior art. Prior to the present invention, lofted materials could not be sewn together without compressing the materials. Therefore, lofted materials such as foam, heretofore were joined together with adhesive.

When multiple layers of lofted material such as foam and fiber are joined together for use in a bedding or seating product, the layers are typically joined with adhesive. Such adhesive is expensive relative to the cost of sewing them together using the present invention. In addition, water-based adhesive must cure or dry which takes time and energy, thereby increasing manufacturing time.

Thus, improved methods, apparatuses, and computer program products are needed for producing quilted products comprising lofted layers of material, such as foam, without compressing the lofted layers of material. There is further a need for methods, apparatuses, and computer program products which enable multiple lofted layers of material to be sewn together, thereby eliminating the need for adhesive.

A quilting machine is provided which sews together an input web comprising multiple pieces of lofted material without compressing the pieces of lofted material. Additionally, a quilting machine is provided which sews together an input web comprising multiple webs of materials, at least one of which is usually lofted, such as a web of foam, without compressing the webs of material.

The quilting machine includes a frame, a sewing assembly powered by a first servo motor and a feed assembly powered by a second servo motor. Each of the servo motors is supported by the frame. The machine further comprises a third servo motor which moves a pre-contact roller to a desired position for a particular input web. A programmable controller determines when each servo motor is actuated, and other tasks described herein such as activating air cylinders to move a post-contact roller or activate thread tensioners. The first and second servo motors are typically programmed to operate one at a time. However, they may be programmed to overlap slightly or operate together for a short time.

The sewing assembly further comprises a first drive pulley rotated by the first servo motor. The first drive pulley rotates a first endless drive belt. The first endless drive belt surrounds the first drive pulley, an indexer pulley of an indexer assembly and a first transfer pulley of a transfer assembly. In operation, rotation of the first drive pulley causes rotation of the first endless drive belt which rotates the indexer pulley and first transfer pulley.

The transfer assembly of the sewing assembly further comprises a second transfer pulley in addition to the first transfer pulley. The transfer pulleys are located at opposite ends of a transfer shaft which extends transversely across the machine and extends through rear bearing assemblies supported by the frame.

The crank assembly of the sewing assembly further comprises a crank pulley secured to a crank drive shaft. The crank drive shaft extends through front bearing assemblies supported by the frame. An endless transfer belt surrounds the crank pulley and the second transfer pulley to transfer rotation of the second transfer pulley to rotation of the crank pulley and crank shaft. The crank assembly further comprises first and second rotatable cranks secured to the crank drive shaft which rotate together. The crank assembly further comprises drive rods. An upper end of each drive rod is secured to one of the rotatable cranks. A needle bar is secured to a lower end of each drive rod. Spaced needles are secured to the needle bar.

The needles extend through aligned holes in a movable platen and a stationary needle plate below the platen. The platen is moved by linear actuators connected by a torque tube. Activation of the linear actuators is controlled by the programmable controller. During operation of the machine, the feed assembly moves the input web downstream between the platen and needle plate without compressing the input web.

In addition to the indexer pulley, the indexer assembly of the sewing assembly further comprises a mechanical indexer which functions to laterally move a retainer bar and oscillate a looper shaft at desired times and desired distances underneath the stationary needle plate. The indexer pulley is connected to an indexer input shaft. A first bevel gear attached to the indexer input shaft rotates a second bevel gear which rotates an output shaft of the mechanical indexer. Rotation of the input shaft of the indexer assembly causes linear movement of a retainer bar to which multiple spreaders are attached. Rotation of the output shaft of the indexer assembly causes oscillation of the looper shaft to which multiple spaced loopers are attached. A looper and spreader correspond to each needle which cooperate to form the stitches created by the machine.

The feed assembly comprises a second drive pulley rotated by a second endless drive belt. The programmable controller activates the second servo motor which activates the second drive pulley when the first servo motor is turned off in most instances. However, the first and second servo motors may operate simultaneously for a programmed amount of time. The second endless drive belt surrounds the second drive pulley and a feed pulley. The feed pulley is connected to a feed shaft which extends transversely across the machine. A plurality of spaced endless feed belts surround the feed shaft and a front shaft supported by the frame in front of the feed shaft. The feed and front shafts are generally parallel with each other. The stationary needle plate is located inside the feed belts and supported by riser plates. The riser plates are located between the spaced endless feed belts to not interfere with rotation of the endless feed belts.

One rotation of the first drive pulley and a specified amount of rotation of the second drive pulley completes a first chain stitch without compressing the pieces of the input web. Thereafter, one rotation of the first drive pulley and a specified amount of rotation of the second drive pulley complete each of the remaining chain stiches of stitch lines without compressing the pieces of the input web. A top of each chain stitch comprises a section of needle thread extending above the quilted panel. A bottom of each chain stitch comprises two different portions. One portion comprises two sections of needle thread and one section of looper thread. The other portion of the bottom of the chain stitch comprises three sections of looper thread. The side of each chain stitch comprises a section of needle thread.

Stated another way, the quilting machine is capable of sewing multiple pieces of lofted material of an input web into a quilted panel without compressing the lofted pieces. The quilting machine includes a frame, a sewing assembly powered by a first servo motor supported by the frame and a feed assembly powered by a second servo motor supported by the frame.

The sewing assembly further comprises a needle bar, needles secured to the needle bar, needle thread passing through each needle, a needle plate having holes through which the needles extend, loopers below the needle plate from which looper thread is provided to form chain stitches extending through the quilted panel without reducing the height of the quilted panel, a retainer bar below the needle plate movable from side-to-side and spreaders secured to the retainer bar. The feed assembly further comprises endless feed belts for moving the input web under the needles, the needle plate being inside the endless feed belts.

The machine further comprises a controller programmed to operate the first and second servo motors at different or overlapping times. One rotation of the first drive pulley driven by the first servo motor completes one stroke of the needles and one cycle of the retainer bar and loopers. One rotation or portion thereof of the second drive pulley rotates the endless feed belts a programmed distance to move the input web a predetermined distance. The predetermined distance may be any distance but in most instances is from <NUM> to <NUM> inches, for example.

The invention refers to a method of quilting an input web as defined by claim <NUM>. The method includes providing a quilting machine including a sewing assembly powered by a first servo motor and a feed assembly powered by a second servo motor. The method further comprises moving the layered input web through the quilting machine using the feed assembly to form chain stitches in the input web without compressing the quilted panel using the sewing assembly. In most instances, only one of the feed assembly and sewing assembly operates at a time. However, as described herein, both the feed assembly and sewing assembly may operate at the same time for a pre-programmed amount of time.

The method of quilting a layered input web comprises providing a quilting machine with a feed assembly and a sewing assembly. The method further comprises powering the sewing assembly with a first servo motor to form a chain stitch in the layered input web without compressing the layered input web. The method further comprises powering the feed assembly with a second servo motor to move a stack of lofted materials through the quilting machine a fixed distance, wherein the fixed distance may be changed by a programmable controller.

Further, a computer program product is provided for quilting webs that includes a non-transitory computer-readable storage medium. The storage medium includes program code that is configured, when executed by one or more processors, to cause the quilting machine to active the appropriate servo motor at the desired time to move the input web a desired distance and then complete a portion of a chain stitch. The program code further causes the quilting machine to move the pre-contact roller to the appropriate position via the third servo motor.

Resulting from the disclosed method is a quilted panel comprising a first lofted layer having a first height, a second lofted layer having a second height and spaced stitch lines joining the layers and extending through the layers. Each of the stitch lines comprises multiple chain stitches. Each chain stitch comprises two sides, a top and a bottom. Each of the sides extends through the first and second lofted layers and comprises two sections of needle thread. The top of the chain stitch comprises one section of needle thread and the bottom of the chain stitch comprises two sections of needle thread and three sections of looper thread. The linear distance between the top and bottom of the stitch is the sum of the first and second heights.

Stated another way, the quilted panel may comprise a top lofted layer, a bottom lofted layer and a middle layer between the top and bottom lofted layers. Spaced stitch lines extend through the layers. Each of the stitch lines comprises multiple chain stitches. Each of the chain stitches comprises two sides, a top and a bottom. Each of the sides extends through the layers and comprises one section of needle thread. The top of the chain stitch comprises one section of needle thread extending above the top lofted layer. A portion of the bottom of the chain stitch comprises two sections of needle thread and one section of looper thread below the bottom lofted layer. None of the layers is compressed. At least one of the lofted layers may be foam or may be made of pocketed springs or may be fiber or any combination thereof.

Stated another way, the quilted panel may comprise a top layer, a bottom layer and a middle layer between the top and bottom layers. Spaced stitch lines extend through the layers. Each of the stitch lines comprises multiple chain stitches. Each of the chain stitches comprises two sides, a top and a bottom. Each of the sides extends through the layers and comprises one section of needle thread. The top of the chain stitch comprises one section of needle thread extending above the top layer. A portion of the bottom of the chain stitch comprises two sections of needle thread and one section of looper thread below the bottom layer. None of the layers is compressed. At least one of the layers may be made at least partially of foam or of fiber. At least one layer may be made of at least some pocketed springs.

The above summary may present a simplified overview of some embodiments of the invention to provide a basic understanding of certain aspects of the invention discussed herein. The summary is not intended to provide an extensive overview of the invention, nor is it intended to identify any key or critical elements or delineate the scope of the invention. The sole purpose of the summary is merely to present some concepts in a simplified form as an introduction to the detailed description presented below.

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate various embodiments of the invention and, together with the general description of the invention given above, and the detailed description of the embodiments given below, explain the embodiments of the invention.

<FIG>, <FIG> and <FIG> provide perspective views of a multi-needle quilting machine <NUM>. The machine <NUM> may be used, for example, to quilt webs of multi-layered material without compressing the webs. The layers may include foam, fiber or pocketed spring blankets or any combination thereof used in the manufacture of mattresses. As best shown in <FIG> and <FIG>, the machine <NUM> has an upstream or input end <NUM> and a downstream or output end <NUM>. For purposes of this document, the words "left" and "right" will refer to the machine as oriented as seen from the front, as shown in <FIG>.

The machine <NUM> includes a base <NUM> and a frame <NUM> supported by the base <NUM>. The base <NUM> has a generally planar top <NUM>. Although one configuration of base <NUM> is shown, the base may be any other configuration. Although one configuration of frame <NUM> is shown, the frame may be any other configuration.

As best shown in <FIG> and <FIG>, the frame <NUM> comprises left and right vertically oriented frame legs 19a, 19b, respectively, a middle frame member <NUM>, two diagonal frame members <NUM> and a top frame member <NUM>. The middle frame member <NUM> comprises two hollow spanners <NUM> and two mounting plates <NUM>, each mounting plate <NUM> being secured to one of the frame legs <NUM> and each of the hollow spanners <NUM> extending between mounting plates <NUM> of middle frame member <NUM>.

<FIG> shows a supply table <NUM> supporting an input web <NUM> comprising multiple pieces of lofted material (e.g., a facing piece <NUM>, a middle piece <NUM>, and a backing piece <NUM>) enters the machine <NUM> at the input end <NUM> of the machine <NUM>. The supply table <NUM> is illustrated being a non-motorized table comprising multiple rollers <NUM>. However, the supply table may be motorized or any known table used in the industry.

<FIG> also shows an output table <NUM> supporting a quilted panel <NUM> exiting the machine <NUM> at the output end <NUM>. The output table <NUM> comprises a conveyor <NUM> powered by a servo-motor <NUM>. The output table <NUM> is illustrated being a motorized table. However, the output table may be non-motorized or any known table used in the industry.

The quilted panel <NUM> comprises the three pieces of lofted material <NUM>, <NUM> and <NUM> sewn together with multiple parallel, spaced stitch lines <NUM> as shown in detail in <FIG> and <FIG>. Although the input web <NUM> is shown made from three pieces of lofted material <NUM>, <NUM> and <NUM>, each being a separate layer in the quilted panel <NUM>, any number of pieces of material pre-cut to size may be quilted together using the quilting machine <NUM> to form a quilted panel having any number of layers without compressing the layers. <FIG> also shows guard panels <NUM> used to protect an operator from injury during operation of the machine <NUM>.

Although <FIG> shows pieces of lofted material <NUM>, <NUM> and <NUM> cut to a predetermined size to be sewn together, <FIG> illustrates another embodiment of quilting machine 10a which is identical to quilting machine <NUM> but includes a cutter <NUM>. Rather than individual pieces of lofted material pre-cut to size prior to entering the quilting machine 10a, <FIG> shows a roll <NUM> containing a web of first lofted material <NUM>, a roll <NUM> containing a web of second lofted material <NUM> and a roll <NUM> containing a web of a third lofted material <NUM>. After the first, second and third webs of lofted materials <NUM>, <NUM>, <NUM> are sewn together using the machine 10a, the cutter <NUM> cuts the quilted web <NUM> to a desired size to create a quilted panel before the quilted panel travels along the output table <NUM>. Although each of the webs <NUM>, <NUM>, <NUM> is shown in <FIG> being a lofted material, any input web may be a pocketed spring web or non-lofted material.

As best shown in <FIG> and <FIG>, the input web <NUM> moves through the machine <NUM> in an incremental fashion, as opposed to a continuous fashion, via operation of a feed assembly <NUM>. The feed assembly <NUM> comprises a feed servo-motor <NUM> supported by one of two frame legs 19a, 19b. The operation of the feed servo-motor <NUM> is controlled by the controller <NUM>. As best shown in <FIG> and <FIG>, the frame <NUM> further comprises left and right L-shaped braces 42a, 42b, respectively, one on each side of the machine <NUM>. Each L-shaped brace 42a, 42b comprises a horizontal member 44a, 44b secured to one of the frame legs 19a, 19b, respectively, and a vertical member 46a, 46b secured to the generally planar top <NUM> of base <NUM>. As best shown in <FIG>, each of the left and right L-shaped braces 42a, 42b extends forwardly from the left and right frame legs 19a, 19b, respectively.

As best shown in <FIG> and <FIG>, operation of the feed servo-motor <NUM> rotates a drive pulley <NUM> located outside a mounting plate <NUM>. The feed servo-motor <NUM> is located inside the mounting plate <NUM>. The mounting plate <NUM> is secured to the left frame leg 19a.

The feed assembly <NUM> further comprises a feed drive shaft <NUM> supported by four rear brackets <NUM>, each rear bracket <NUM> being secured to one of the frame legs 19a, 19b. As best shown in <FIG>, a bearing assembly <NUM> is secured to each of the rear brackets <NUM> to facilitate rotation of the feed drive shaft <NUM>. A feed pulley <NUM> is located outside the left most rear bracket <NUM> and is operatively coupled to the feed drive shaft <NUM> such that rotation of the feed pulley <NUM> rotates the feed drive shaft <NUM>. As best shown in <FIG>, an endless drive belt <NUM> surrounds the drive pulley <NUM>, the feed pulley <NUM> and an adjustable tensioner <NUM> for adjusting the tension of the endless drive belt <NUM>. The controller <NUM> controls the operation of the feed servo-motor <NUM>.

As best shown in <FIG>, the feed assembly <NUM> further comprises a front shaft <NUM> supported by four front brackets <NUM>, each front bracket <NUM> being secured to one of the left and right L-shaped braces 42a, 42b, respectively. As best shown in <FIG>, a bearing assembly <NUM> is secured to each of the front brackets <NUM> to facilitate rotation of the front shaft <NUM>. A plurality of pulleys <NUM> are secured to the front shaft <NUM> in desired locations.

As best shown in <FIG> and <FIG>, endless feed belts <NUM> surround the pulleys <NUM> secured to the front shaft <NUM> and pulleys <NUM> secured to the feed drive shaft <NUM>. The endless feed belts <NUM> are rotated by rotation of the feed drive shaft <NUM> caused by rotation of the drive pulley <NUM> rotated by the feed servo-motor <NUM>. As the input web <NUM> exits the supply table <NUM> the input web <NUM> rests upon the endless feed belts <NUM> and is moved downstream in the machine <NUM> by the rotation of the endless feed belts <NUM>.

As best shown in <FIG>, <FIG> and <FIG>, the feed assembly <NUM> further comprises two transition rollers <NUM> located at the rear of the machine <NUM> mounted to brackets <NUM> supported by transition posts <NUM>. The transition posts <NUM> are bolted or otherwise secured to the top <NUM> of base <NUM>. Each of the transition rollers <NUM> extends between the brackets <NUM> and is located behind the endless feed belts <NUM>. The transition rollers <NUM> are not driven, but rather rotate as the quilted panel <NUM> passes over them from the machine <NUM> to the output table <NUM>. Although the drawings show two transition rollers <NUM>, any number of transition rollers may be used to provide a smooth path for the quilted panel <NUM> to move from the machine <NUM> onto the output table <NUM>.

As best shown in <FIG> and <FIG>, the feed assembly <NUM> further comprises a pre-contact roller <NUM> located at the front of the machine <NUM>. The height of the pre-contact roller <NUM> is controlled by linear actuators <NUM> powered by a platen servo-motor <NUM>. When power is provided to the linear actuators <NUM>, the linear actuators <NUM> lift the pre-contact roller <NUM> upwardly. A torque tube <NUM> extends between the linear actuators <NUM>. As best shown in <FIG>, each linear actuator <NUM> is bolted to a large lift plate <NUM> which is bolted to a small plate <NUM> of an L-shaped lifter <NUM> which is bolted to a platen <NUM>. The platen <NUM> extends between the L-shaped lifters <NUM>. An arm <NUM> extends forwardly from each of the L-shaped lifters <NUM>. The pre-contact roller <NUM> extends between holes <NUM> at the front of each of the arms <NUM> (only one being shown in <FIG>).

As best shown in <FIG>, the feed assembly <NUM> further comprises a post-contact roller <NUM>, the position of which is controlled by air cylinders <NUM>. The air cylinders <NUM> are operated by controller <NUM>. When power is provided to the air cylinders <NUM>, the air cylinders <NUM> lift the post-contact roller <NUM> upwardly. When power is not supplied to the air cylinders <NUM>, gravity drops the post-contact roller <NUM>.

As best shown in <FIG> and <FIG>, the machine <NUM> further comprises a plurality of riser plates <NUM> secured to the top <NUM> of base <NUM>. As best shown in <FIG>, a needle plate <NUM> is welded or otherwise secured to the upper surfaces <NUM> at four locations <NUM> of each of the riser plates <NUM>. The riser plates <NUM> are located between the endless feed belts <NUM> to not interfere with the movement of the endless feed belts <NUM>. As best shown in <FIG>, the needle plate <NUM> is located inside the endless feed belts <NUM>. As best shown in <FIG>, the needle plate <NUM> has a plurality of holes <NUM>, one per needle <NUM> (nine shown).

As best shown in <FIG> and <FIG>, the machine <NUM> further comprising a sewing assembly <NUM> including a transfer assembly <NUM>, a crank assembly <NUM> and an indexer assembly <NUM>, described below. As best shown in <FIG>, the sewing assembly <NUM> is driven by a servomotor <NUM> secured to the frame <NUM> and, more particularly, to the middle frame member <NUM>. Operation of the sewing servo-motor <NUM> rotates a drive pulley <NUM>.

The transfer assembly <NUM> is located above the sewing servo-motor <NUM> and supported by the frame <NUM> and, more particularly, by the top frame member <NUM>. As best shown in <FIG>, the transfer assembly <NUM> comprises inner and outer mounting brackets <NUM>, <NUM> secured to the top frame member <NUM>, respectively. Rear bearing assemblies <NUM> are attached to the inner and outer mounting brackets <NUM>, <NUM>, respectively. A rotatable transfer shaft <NUM> extends through the rear bearing assemblies <NUM> and rotates about an axis A, as shown in <FIG>. An outside transfer pulley <NUM> is secured to an outside end of the rotatable transfer shaft <NUM> and an inside transfer pulley <NUM> is secured to an inside end of the rotatable transfer shaft <NUM>.

The crank assembly <NUM> is in front of the transfer assembly <NUM> and in front of the top frame member <NUM>. As best shown in <FIG> and <FIG>, the crank assembly <NUM> comprises a first front bearing assembly <NUM> secured to the inner mounting bracket <NUM> and a second front bearing assembly <NUM> secured to a mounting bracket <NUM>. The mounting bracket <NUM> is supported by the frame <NUM> and, more particularly, by the top frame member <NUM>. A crank drive shaft <NUM> extends between the first and second front bearing assemblies <NUM>, <NUM>, respectively, and rotates about an axis AA, as shown in <FIG>. A crank pulley <NUM> is secured to one end of the crank drive shaft <NUM> and upon rotation functions to rotate the crank drive shaft <NUM>. An endless transfer belt <NUM> surrounds the crank pulley <NUM> and the inside transfer pulley <NUM>. As best shown in <FIG> and <FIG>, a belt tensioner <NUM> connected to an L-shaped mounting bracket <NUM> is manually set to provide the proper tension to the endless transfer belt <NUM>. As best shown in <FIG> and <FIG>, the L-shaped mounting bracket <NUM> is secured to the top frame member <NUM>.

As best shown in <FIG> and <FIG>, the crank assembly <NUM> further comprises two rotatable cranks <NUM>, each crank <NUM> being secured to an end of the crank drive shaft <NUM>. One rotation of the crank drive shaft <NUM> causes one rotation of the cranks <NUM>. As best shown in <FIG> and <FIG>, an upper end <NUM> of a drive rod <NUM> is secured to a narrow portion <NUM> of a crank <NUM> with a bolt <NUM> such that one rotation of the crank <NUM> equals one stroke of the drive rod <NUM>. As best shown in <FIG>, <FIG> and <FIG>, a bracket <NUM> is pivotally secured to the lower end <NUM> of each drive rod <NUM> with a bolt <NUM>. The two brackets <NUM> (only one being shown in <FIG> and <FIG>) are secured to a needle bar <NUM> having a hollow interior <NUM>.

As best shown in <FIG>, <FIG>, <FIG>, two spaced hollow members <NUM> are secured to the horizontally oriented spanners <NUM> of frame <NUM>. As best shown in <FIG>, a spacer <NUM> is secured to each of the hollow members <NUM> in front thereof and a rail <NUM> is secured to each of the spacers <NUM> in front thereof. As best shown in <FIG>, a carriage <NUM> is secured to another spacer <NUM> which is secured to the needle bar <NUM>. The machine has two carriages <NUM>. Each carriage <NUM> is configured to engage one of the two rails <NUM> such that the needle bar <NUM> moves in a generally vertical direction and does not separate from the rails <NUM>. The rails <NUM> are thereby configured to reciprocate the needle bar <NUM> in a generally linear path perpendicular to the quilting plane Q (see <FIG>) in response to rotation of the crank pulley <NUM>.

Nine needles <NUM> are bolted to the needle bar <NUM> and move with the needle bar <NUM>. However, any number of needles may be secured in any known manner to the needle bar <NUM>. In one embodiment, each of the needles <NUM> is six inches in length. However, the needles may be any desired length.

An endless drive belt <NUM> surrounds the drive pulley <NUM> rotated by the servo-motor <NUM>, the outside transfer pulley <NUM>, an indexer pulley <NUM> described below and a belt tensioner <NUM>. The position of the belt tensioner <NUM> is changed manually. The operation of the sewing servo-motor <NUM> which rotates the drive pulley <NUM> is controlled by the controller <NUM>.

The indexer assembly <NUM> of the machine <NUM> is driven by rotation of the indexer pulley <NUM> rotated by the endless drive belt <NUM> and functions to oscillate a looper shaft <NUM> and move a retainer bar <NUM>. As shown in <FIG> and <FIG>, the looper shaft <NUM> extends through openings <NUM> in the riser plates <NUM> and the retainer bar <NUM> extends through cutouts <NUM> in the riser plates <NUM> above looper shaft <NUM>. As shown in <FIG>, <FIG>, <FIG> and <FIG>, a plurality of spreaders <NUM> are secured to the retainer bar <NUM>.

As shown in detail in <FIG>, the indexer assembly <NUM> of the machine <NUM> comprises an indexer input shaft <NUM> connected to the indexer pulley <NUM> such that rotation of the indexer pulley <NUM> by the endless drive belt <NUM> rotates the indexer input shaft <NUM>. As shown in detail in <FIG>, the indexer input shaft <NUM> extends through an outer wall <NUM> of an indexer housing <NUM> and ends in an inner bearing assembly <NUM> having a bearing mount <NUM> attached to an inner wall <NUM> of the indexer housing <NUM>. As shown in detail in <FIG>, the indexer housing <NUM> also has an inner wall <NUM>, a front wall <NUM>, a rear wall <NUM>, a top <NUM> and a bottom <NUM>. As shown in detail in <FIG>, the indexer input shaft <NUM> extends (from left to right as seen in <FIG>) through an outer bearing assembly <NUM> having a bearing mount <NUM> secured to the outer wall <NUM> of the indexer housing <NUM>, a drive bevel gear <NUM>, a spacer <NUM> surrounding the indexer input shaft <NUM>, a barrel cam <NUM> and inner bearing assembly <NUM> including a bearing mount <NUM> secured to the inner wall <NUM> of the indexer housing <NUM>. The barrel cam <NUM> is attached to the indexer input shaft <NUM> such that upon rotation of the indexer input shaft <NUM>, the barrel cam <NUM> rotates.

As best shown in <FIG>, <FIG>, <FIG> and <FIG>, the barrel cam <NUM> has a groove <NUM> machined therein to move a thruster <NUM> linearly in the direction of the y-axis <NUM>. The thruster <NUM> has an extension <NUM> which rides inside groove <NUM> of the barrel cam <NUM> as the barrel cam <NUM> rotates to move the thruster <NUM> linearly in the direction of the y-axis <NUM>.

As best shown in <FIG>, a bearing assembly <NUM> including a bearing mount <NUM> is secured to the outer wall <NUM> of the indexer housing <NUM>. As best shown in <FIG>, <FIG> and <FIG>, a stationary rod <NUM> is secured to the bearing assembly <NUM> at one end and to another bearing assembly <NUM> at the other end. The bearing assembly <NUM> includes a bearing mount <NUM> secured to the inner wall <NUM> of the indexer housing <NUM>. A linearly moveable thruster shaft <NUM> is attached to the thruster <NUM> and moves linearly with the thruster <NUM> as determined by the groove <NUM> of the barrel cam <NUM>. As best shown in <FIG>, the linearly moveable thruster shaft <NUM> extends through the bearing assembly <NUM> and extends outside the indexer housing <NUM>. A thruster paw <NUM> is attached to an inner end of the thruster shaft <NUM> and moves linearly with the thruster shaft <NUM> and thruster <NUM> in response to rotation of the indexer input shaft <NUM> and barrel cam <NUM>. As best shown in <FIG>, the thruster paw <NUM> has a straight groove <NUM> outside the thruster shaft <NUM>. As shown in detail in <FIG>, a retainer bar mounting block <NUM> is secured to the mounting block with fasteners <NUM>. The retainer bar mounting block <NUM> has an extension <NUM> which fits inside the straight groove <NUM> of the thruster paw <NUM>. Linear movement in the direction of the y-axis <NUM> by the thruster <NUM> caused by rotation of the barrel cam <NUM> causes linear movement in the direction of the y-axis <NUM> of the thruster shaft <NUM> and thruster paw <NUM>. See arrows <NUM>, <NUM> in <FIG> and <FIG>, respectively. Linear movement in the direction of the y-axis <NUM> of the thruster paw <NUM> causes linear movement in the direction of the y-axis <NUM> of the retainer bar mounting block <NUM>, which causes linear movement in the direction of the y-axis <NUM> of the retainer bar <NUM> and attached spreaders <NUM>.

As shown in detail in <FIG>, drive bevel gear <NUM> mates with driven bevel gear <NUM> to rotate driven bevel gear <NUM>. Rotation of the input shaft <NUM> and drive bevel gear <NUM>, as shown by the arrow <NUM> in <FIG> and <FIG>, rotates the driven bevel gear <NUM> and output shaft <NUM>, as shown by the arrow <NUM> in <FIG> and <FIG>. A globoidal cam <NUM> having a uniquely shaped groove <NUM> is attached to the output shaft <NUM>. As shown in <FIG> and <FIG>, bearings <NUM>, <NUM> are located on opposite sides of the globoidal cam <NUM> and surround the output shaft <NUM>.

Indexer output shaft <NUM> is located below the globoidal cam <NUM>. A collar <NUM> surrounds the indexer output shaft <NUM> and is secured thereto. The collar <NUM> has a neck <NUM> having an extension <NUM> which rides inside the uniquely shaped groove <NUM> of the globoidal cam <NUM> to oscillate the neck <NUM> of indexer output shaft <NUM>, as shown by the arrow <NUM> and therefore, oscillate the indexer output shaft <NUM>, as shown by the arrow <NUM>. As shown in <FIG>, the indexer output shaft <NUM> extends through a bearing assembly <NUM> and extends outside the inner wall <NUM> of the indexer housing <NUM>. A drive pulley <NUM> is attached to the end of the indexer output shaft <NUM>. A looper shaft pulley <NUM> is in front of the drive pulley <NUM> and oscillates with the drive pulley <NUM> due to an endless belt <NUM> surrounding the drive pulley <NUM>, the looper shaft pulley <NUM> and a belt tensioner <NUM>.

In operation, the indexer assembly <NUM> functions to turn rotation of the indexer pulley <NUM> into an oscillation movement of the output shaft <NUM> and looper shaft <NUM>. As the cranks <NUM> of the sewing assembly <NUM> rotate their first one hundred (<NUM>) degrees, as shown by the arrow <NUM> in <FIG>, the looper shaft <NUM> does not move as shown in <FIG> and <FIG>. As the cranks <NUM> of the sewing assembly <NUM> rotate their next eighty (<NUM>) degrees, as shown by the arrow <NUM> in <FIG>, the looper shaft <NUM> rotates twenty (<NUM>) degrees, as shown by the arrow <NUM> shown in <FIG>, causing the loopers <NUM> attached to the looper shaft <NUM> to move from their forward or home position shown in <FIG> to their rear position shown in <FIG>. As the cranks <NUM> of the sewing assembly <NUM> rotate their next ten (<NUM>) degrees as shown by the arrow <NUM> in <FIG>, the looper shaft <NUM> remains stationary. As the cranks <NUM> rotate their next eighty (<NUM>) degrees, as shown by the arrow <NUM> in <FIG>, the looper shaft <NUM> rotates in the opposite direction twenty (<NUM>) degrees back to its original position, as shown by the arrow <NUM> in <FIG>, the loopers <NUM> attached to the looper shaft <NUM> returning from their rear position shown in <FIG> to their forward position shown in <FIG>. As the cranks <NUM> rotate the remaining two hundred thirty (<NUM>) degrees to complete a three hundred sixty (<NUM>) degree cycle, as shown by the arrow <NUM> in <FIG>, the looper shaft <NUM> remains stationary. The process then repeats itself due to the unique configuration of the indexer assembly <NUM>.

Rotation of the indexer pulley <NUM> also creates a linear movement of the retainer bar <NUM> and spreaders <NUM> attached to the retainer bar <NUM>. As the cranks <NUM> of the sewing assembly <NUM> rotate their first fifty two (<NUM>) degrees, as shown by the arrow <NUM> in <FIG>, the retainer bar <NUM> and spreaders <NUM> move <NUM> inch away from the indexer housing <NUM>, as shown by the arrow <NUM> of <FIG>, causing the spreaders <NUM> attached to the retainer bar <NUM> to move from their home position shown in <FIG> to their side position shown in <FIG>. As the cranks <NUM> of the sewing assembly <NUM> rotate their next forty (<NUM>) degrees as shown by the arrow <NUM> in <FIG>, the retainer bar <NUM> and spreaders <NUM> remain stationary. As the cranks <NUM> rotate their next sixty (<NUM>) degrees, as shown by the arrow <NUM> in <FIG>, the retainer bar <NUM> and spreaders <NUM> move in the opposite direction <NUM> inch towards the indexer housing <NUM> as shown by arrow <NUM> of <FIG> causing the spreaders <NUM> attached to the retainer bar <NUM> to move from their extended position shown in <FIG> to their home position shown in <FIG>, <FIG> and <FIG>. As the cranks <NUM> rotate the remaining two hundred thirty (<NUM>) degrees to complete a three hundred sixty (<NUM>) degree cycle, as shown by the arrow <NUM> in <FIG>, the retainer bar <NUM> and spreaders <NUM> remain stationary in their home position. The process then repeats itself due to the unique configuration of the indexer assembly <NUM>.

Alternatively, the indexer input shaft <NUM> of indexer assembly <NUM> of the machine <NUM> could be driven by another servo motor (not shown) instead of being driven by rotation of the indexer pulley <NUM>. In such an embodiment, the indexer pulley <NUM> could be omitted and the drive pulley <NUM> rotated by sewing servo motor <NUM> would drive only the outside transfer pulley <NUM> of the transfer assembly <NUM> via an endless drive belt. The indexer assembly <NUM> of the machine <NUM> would still oscillate the looper shaft <NUM> and move the retainer bar <NUM> with spreaders <NUM> attached to the retainer bar <NUM>.

As shown in detail in <FIG>, in operation the input web <NUM> passes between the platen <NUM> and the needle plate <NUM>. The controller <NUM> controls the operation of the feed servomotor <NUM>, platen servo-motor <NUM>, sewing servo-motor <NUM> and the air cylinders <NUM>. The needle plate <NUM> supports the input web <NUM> as stitch lines <NUM> are stitched through the input web <NUM> to form a quilted panel <NUM>. The platen <NUM> has a plurality of platen holes <NUM> and the needle plate <NUM> has a plurality of needle holes <NUM> that are aligned vertically to allow the needle <NUM> to pass through the input web <NUM> and extend below the needle plate <NUM>. At the start of a stitching cycle, the platen <NUM> may be moved toward the needle plate <NUM>, thereby moving the input web <NUM> against the needle plate <NUM> to hold the input web <NUM> as the needle <NUM> is extended through the input web <NUM>. At the end of the cycle, the platen <NUM> may be moved up to facilitate insertion of another input web <NUM>.

The location and movement of the components of machine <NUM> may be described using a coordinate system <NUM> that includes an x-axis <NUM>, a y-axis <NUM>, and a z-axis <NUM>. The x-axis <NUM> of coordinate system <NUM> is in a quilting plane Q defined by the needle plate <NUM> in the downstream direction of the movement of the input web <NUM> between the platen <NUM> and needle plate <NUM>. The y-axis <NUM> of coordinate system <NUM> is in a direction perpendicular to the x-axis <NUM> and parallel to the transverse movement of the retainer bar <NUM>. The z-axis <NUM> of coordinate system <NUM> is perpendicular to both the x-axis <NUM> and the y-axis <NUM>, and in the direction of movement of the needles <NUM>.

One or more needle assemblies <NUM> may be mounted to a support structure <NUM> that couples the needle assemblies <NUM> to the frame <NUM>. See <FIG> and <FIG>. One or more looper assemblies <NUM> may be mounted to a support structure <NUM>. See <FIG> and <FIG>. The support structures <NUM>, <NUM> locate each needle assembly <NUM> on a needle facing side of platen <NUM> and locates each looper assembly <NUM> on a looper facing side of needle plate <NUM>. Each of the needle assemblies <NUM> is provided with thread from a respective needle thread spool <NUM>, and each of the looper assemblies <NUM> is provided with thread from respective looper thread spool <NUM>. Each needle assembly <NUM> is located opposite a corresponding looper assembly <NUM> to form a sewing station <NUM>. The needle and looper assemblies <NUM>, <NUM> of each sewing station <NUM> may be configured to work cooperatively to form a series of chain stitches in the input web <NUM> using the thread provided by the needle and looper thread spools <NUM>, <NUM>, respectively.

As best shown in <FIG>, the machine <NUM> comprises a plurality of sewing stations <NUM> arranged in a row (e.g., nine shown) spaced laterally along the row. The lateral spacing in the row may be selected so that each sewing station <NUM> is offset from its neighboring sewing station along the y-axis <NUM> by a fixed distance d<NUM> (e.g., <NUM> inches) corresponding to the distance between needles <NUM> and corresponding stitch lines <NUM> produced by the machine <NUM>. This spacing may enable the machine <NUM> to simultaneously produce stitch lines <NUM> having a desired spacing by synchronous operation of the sewing stations <NUM>.

<FIG> and <FIG> present respective side and front views of one needle assembly <NUM>. The needle assembly <NUM> of each sewing station <NUM> is configured to reciprocate a needle <NUM> in a generally linear path along an axis NA thereof that is perpendicular to the quilting plane Q. <FIG> and <FIG> present respective side and perspective views of one looper assembly <NUM>. The corresponding looper assembly <NUM> is configured to oscillate a looper <NUM> in a plane that is generally perpendicular to the quilting plane Q and which intersects the path of the needle <NUM>. The platen <NUM> is coupled to linear actuators <NUM> by arms <NUM> that moves the platen <NUM> linearly along the z-axis <NUM> to selectively release the input web <NUM> in response to activation of the platen servo motor <NUM>.

As shown in <FIG> and <FIG>, each of the needle assemblies <NUM> receives needle thread <NUM> from its corresponding needle thread spool <NUM> through a needle thread handler <NUM>. The needle thread handler <NUM> includes a thread tensioner <NUM> and a thread tension monitor <NUM>, as disclosed in <CIT>.

As shown in <FIG> and <FIG>, the needle thread <NUM> extends from the needle thread spool <NUM> upwardly through an upper eyelet <NUM> and lower eyelet <NUM> in an L-shaped bracket <NUM> mounted to diagonal member <NUM> of support structure <NUM>. After exiting the lower eyelet <NUM>, the needle thread <NUM> passes through the thread tensioner <NUM>, the thread tension monitor <NUM> and then through an eyelet <NUM> secured to a stationary eyelet bar <NUM>. The stationary eyelet bar <NUM> is secured to a stationary L-shaped bracket <NUM> which is bolted to another stationary L-shaped bracket <NUM> which is secured to one of the spanners <NUM> of frame <NUM>. After exiting the eyelet <NUM>, the needle thread <NUM> passes through an eyelet <NUM> secured to the top of an L-shaped bracket <NUM>. The L-shaped bracket <NUM> is secured to and moves with the needle bar <NUM>. After exiting the eyelet <NUM>, the needle thread <NUM> passes through an opening <NUM> in the needle <NUM>, as best shown in <FIG>.

As shown in <FIG> and <FIG>, the looper assembly <NUM> of each sewing station <NUM> is positioned beneath the corresponding needle assembly <NUM>. Each looper assembly <NUM> includes a looper <NUM>, a looper holder <NUM> and a spreader <NUM> secured to the retainer bar <NUM>. Each looper assembly <NUM> receives looper thread <NUM> from the looper thread spool <NUM> through a looper thread handler <NUM>. The looper assemblies <NUM> are transversely spaced on looper shaft <NUM>, so that each looper <NUM> is in a generally vertical alignment with the needle <NUM> of the corresponding needle assembly <NUM> at a sewing station <NUM>. The looper shaft <NUM> is configured to oscillate about an axis LSA (<FIG> and <FIG>) of the looper shaft <NUM> synchronously with the reciprocal movement of the needle <NUM>. This synchronous oscillation causes the loopers <NUM> to reciprocate in a vertical plane generally perpendicular to the quilting plane Q and parallel to the movement of the needle <NUM>.

<FIG> depict a portion of the looper assembly <NUM> including the looper <NUM>, a looper holder <NUM>, the retainer bar <NUM> and the spreader <NUM>. The looper holder <NUM> couples the looper <NUM> to the looper shaft <NUM>. The looper <NUM> further includes a hook <NUM> having a tip <NUM> at a forward end thereof, and a base <NUM> at a rearward end thereof from which the hook <NUM> extends. The hook <NUM> includes a longitudinal bore or channel that connects an opening <NUM> at the back or rearward side of the looper <NUM> with an opening or eye <NUM> (<FIG>) at the tip <NUM>. Looper thread <NUM> from the looper thread spool <NUM> enters the opening <NUM> in the back of the looper <NUM> and emerges from the eye <NUM> of looper <NUM>. The base <NUM> of looper <NUM> may be secured to the looper holder <NUM> by a set screw <NUM>. As best shown in <FIG>, a rearward end of spreader <NUM> may form a bracket that couples the spreader <NUM> to a retainer bar <NUM>.

<FIG> and <FIG> depict a looper thread tensioner <NUM> similar to needle thread tensioner <NUM> of the corresponding needle assembly <NUM> and a thread tension monitor <NUM> identical to the thread tension monitor of the corresponding needle assembly <NUM>. The looper thread tensioner <NUM> is identical to the one disclosed in <CIT>.

The looper thread <NUM> may be received from the looper thread spool <NUM> and directed to the thread tensioner <NUM> by a guide bracket <NUM> secured to base <NUM>. The guide bracket <NUM> has a lower thread guide <NUM> and an upper thread guide <NUM>. After leaving the upper thread guide <NUM> of the guide bracket <NUM>, the looper thread <NUM> enters the thread tensioner <NUM>. After exiting the thread tensioner <NUM>, the looper thread <NUM> may pass through the thread tension monitor <NUM> before being provided to the respective looper <NUM>.

With reference to <FIG> and <FIG>, the position of the needle <NUM> may be described in terms of the angular position of the cranks <NUM>. As shown in <FIG>, the positions of the cranks <NUM> are considered to be at a <NUM>-degree position when the needle <NUM> is at its most retracted position above the quilting plane Q along its axis NA, or its Top Dead Center (TDC) position. As shown in <FIG>, when the needle <NUM> is at its most extended position through the quilting plane Q along its axis NA, or its Bottom Dead Center (BDC) position, the cranks <NUM> are at <NUM> degrees. Because the movement of the looper <NUM> and spreader <NUM> are synchronized with the movement of the needle <NUM>, the angular position of the cranks <NUM> also define the positions of these elements. Thus, the orientation of the needle <NUM>, looper <NUM>, and spreader <NUM>, or the "stitch forming elements" <NUM>, <NUM>, <NUM>, may be fully defined as a function of the angular position of the cranks <NUM>, with each stitch cycle beginning at the <NUM>-degree reference position and repeating for each <NUM> degrees of rotation.

<FIG> provides a perspective view that illustrates the positions of the stitch forming elements <NUM>, <NUM>, <NUM> at a point in the stitch cycle associated with the <NUM>-degree position of the cranks <NUM>. In this position, the needle <NUM> is fully retracted in its TDC or home position, the looper <NUM> is in its most forward or home position, the spreader <NUM> is in its home position, the needle thread <NUM> is wrapped around the hook <NUM> of looper <NUM> and around the looper thread <NUM>.

As shown in <FIG>, while the stitch forming elements <NUM>, <NUM>, <NUM> are in their home positions as illustrated in <FIG> and the cranks <NUM> are in their <NUM>-degree positions as illustrated in <FIG>, the feed assembly <NUM> indexes the input web <NUM> rearwardly or downstream as shown by the arrow <NUM> in a position direction along the x-axis <NUM> (to the left in <FIG>). As the input web <NUM> is indexed downstream a pre-programmed distance, the needle thread <NUM> is drawn through an eye <NUM> of needle <NUM> downwardly until it contacts the top surface <NUM> of input web <NUM> (see arrow <NUM>), across the top surface <NUM> of the input web <NUM> below the platen <NUM> (to the left in <FIG>), downwardly through the input web <NUM>, across the bottom surface <NUM> of the input web <NUM> above the needle plate <NUM> (to the right in <FIG>), around the hook <NUM> of looper <NUM> forming a loop <NUM> around the hook <NUM> of looper <NUM>, back across the bottom surface <NUM> of the input web <NUM> above the needle plate <NUM> (to the left in <FIG>), back up through the input web <NUM> and across the top surface <NUM> of the input web <NUM> below the platen <NUM> (to the left in <FIG>) which is the top of the previous chain stitch.

As shown in <FIG>, during movement of the input web <NUM> downstream, the looper thread <NUM> is pulled through the hook <NUM> of looper <NUM> (see arrow <NUM>), passes through the loop <NUM> of needle thread <NUM> around the hook <NUM> of looper <NUM> and through another loop <NUM> of needle thread <NUM>, moves upstream across the bottom surface <NUM> of the input web <NUM> and around the two sections of needle thread <NUM> which become the sides of the chain stitches, and back through the loop <NUM> of needle thread <NUM>. This process repeats itself each time the input web is moved downstream.

As shown in <FIG>, as the stitch cycle begins, the cranks <NUM> rotating from their <NUM>-degree positions, the needle <NUM> lowers from its TDC or home position and begins to move toward the input web <NUM>. When the cranks <NUM> reach the <NUM> degree positions, the spreader <NUM> begins to move from its home position shown in <FIG> towards an extended position direction along the y-axis <NUM> shown by arrow <NUM>. The looper <NUM> remains stationary in its home position.

As shown in <FIG>, when the cranks <NUM> have rotated to the <NUM> degree point in the stitch cycle and the needle <NUM> has entered the input web <NUM>, the looper <NUM> begins to move rearwardly from its home position (to the left in <FIG>) as shown by the arrow <NUM> in <FIG>. The needle <NUM> is illustrated passing through the input web <NUM>. The spreader <NUM> is still moving towards its fully extended position furthest along the Y-axis from its home position. The looper thread <NUM> gets grabbed by a notch <NUM> in the spreader <NUM> during the movement of the spreader <NUM> to open a triangle <NUM> having sides defined by the needle thread <NUM>, the hook <NUM> of looper <NUM>, and the looper thread <NUM>.

To further explain the movement of the spreader <NUM>, when the cranks <NUM> have rotated to the <NUM> degree point in the stitch cycle, the spreader <NUM> is in its fully extended position. As the cranks <NUM> move between <NUM> degrees and <NUM> degrees, the spreader <NUM> dwells or remains in its fully extended position. When the cranks <NUM> reach <NUM> degrees, the spreader <NUM> begins to move towards its home position. as shown by the arrow <NUM> in <FIG>. When the cranks <NUM> have rotated to the <NUM> degree point in the stitch cycle, the spreader <NUM> is finally back to its home position.

<FIG> depicts stitch forming elements <NUM>, <NUM>, <NUM> at a point in the stitch cycle when the cranks <NUM> are approaching their <NUM>-degree positions as illustrated in <FIG>. The needle <NUM> is illustrated having passed through the input web <NUM>. The looper <NUM> is illustrated moving further downstream or in a positive direction in the x-axis <NUM> from its position shown in <FIG>. The needle <NUM> has begun passing through the triangle <NUM>. The spreader <NUM> is moving towards its home position, as indicated by arrow <NUM> and the looper <NUM> is still moving away its home position, as indicated by arrow <NUM>.

<FIG> depicts stitch forming elements <NUM>, <NUM>, <NUM> at a point in the stitch cycle when the cranks <NUM> are in their <NUM>-degree positions as illustrated in <FIG>. In this position, the needle <NUM> is in its BDC position fully extended through the platen hole <NUM> in platen <NUM>, the input web <NUM> and needle hole <NUM> of needle plate <NUM>. The looper <NUM> is stationary in its rearward position (i.e., its most extended position in the positive direction of the x-axis <NUM>), and the spreader <NUM> is moving upstream towards its home position as shown by arrow <NUM>. The needle thread <NUM> passes through an eye <NUM> of needle <NUM> proximate the tip thereof and extends from the opposite side of the needle <NUM> to the last formed stitch <NUM>. The looper thread <NUM> extends from the tip <NUM> of hook <NUM> to the last formed stitch <NUM>, which is now completely formed but may remain to be tightened.

As illustrated by <FIG>, the needle <NUM> begins to move upwardly as the cranks <NUM> rotate past the <NUM>-degree position in the stitch cycle. At this point, the looper <NUM> is moving upstream towards its home position (e.g., in a negative direction with respect to x-axis <NUM>), and the spreader <NUM> is still moving towards its home position, as indicated by arrow <NUM>.

Further rotation of the cranks <NUM> brings the stitch forming elements <NUM>, <NUM>, <NUM> to the positions depicted in <FIG>. At this point, the tip <NUM> of hook <NUM> of looper <NUM> passes against the looper facing side of the needle <NUM> and slips between the needle thread <NUM> and the needle <NUM> as it enters from the stitch side of the needle <NUM>. As illustrated by <FIG>, as the looper <NUM> continues moving upstream (e.g., in a negative direction with respect to x-axis <NUM>), the needle thread <NUM> wraps around the hook <NUM> of looper <NUM>, and the needle <NUM> raises upwardly, pulling more needle thread <NUM> through the opening <NUM> in needle <NUM> until the stitch forming elements <NUM>, <NUM>, <NUM> return to their home positions depicted in <FIG>.

After the chain stitch is completed, the feed servo-motor <NUM> is activated by the controller <NUM>, causing rotation of the endless feed belts <NUM>, thereby moving the input web <NUM> a pre-programmed distance in the downstream direction which is depicted as the positive direction along the x-axis <NUM>.

Referring now to <FIG>, a needle thread cutting assembly <NUM> whose operation is controlled by controller <NUM> is illustrated. As shown in <FIG>, the needle thread cutting assembly <NUM> extends across the machine generally in the direction of the y-axis <NUM> and functions to cut all the needle threads <NUM> simultaneously upon the completion of a job. <FIG> illustrates a portion of the needle thread cutting assembly <NUM> in an assembled condition. <FIG> shows the same portion of the needle thread cutting assembly <NUM> in a disassembled condition. As shown in <FIG>, the needle thread cutting assembly <NUM> comprises a rail <NUM> secured to the platen <NUM>. As shown in <FIG>, the rail <NUM> has a bottom <NUM> having a plurality of keyhole slots <NUM> (only one being shown), sides <NUM> and lips <NUM> extending towards each other from sides <NUM> which define an inner groove <NUM> in rail <NUM> inside which moves a slider <NUM>. As shown in <FIG>, each keyhole slot <NUM> has a circular end opening <NUM> which is aligned with an opening <NUM> (only one being shown) in the slider <NUM> when the needle thread cutting assembly <NUM> is at rest. As shown in <FIG>, a slider mounting block <NUM> is secured to the slider <NUM> and a clevis <NUM> is bolted to the slider mounting block <NUM> with bolt <NUM> and nut <NUM>. A large nut <NUM> secures the clevis <NUM> to a moving rod <NUM> which is moved by a pneumatic cylinder <NUM> controlled by controller <NUM>.

As best shown in <FIG>, the needle thread cutting assembly <NUM> further comprises a blade <NUM> having a cutting edge <NUM> and an opening <NUM>. A pin <NUM> has a removable snap ring <NUM> which fits inside a groove <NUM> (<FIG>) in the pin <NUM> such that to the snap ring <NUM> may be quickly and easily removed to remove the blade <NUM>. The pin <NUM> fits inside the opening <NUM> of blade <NUM> and is welded to the blade <NUM>. The pin <NUM> extends through an opening <NUM> in the slider <NUM> and moves inside the keyhole slot <NUM>. The blade <NUM> moves along a slot (not shown) underneath the rail <NUM> as the pin <NUM> moves in the keyhole slot <NUM>. A spring <NUM> is sandwiched between the removable snap ring <NUM> and the slider <NUM> to urge the pin <NUM> upwardly, thus keeping the blade <NUM> against the slider <NUM>.

<FIG> illustrate operation of the needle thread cutting assembly <NUM>. <FIG> illustrates the needle thread cutting assembly <NUM> at rest, opening <NUM> of the movable slider <NUM> being aligned with the stationary circular end opening <NUM> of the keyhole slot <NUM> of the rail <NUM>. The needle thread <NUM> extends through the aligned openings <NUM>, <NUM>.

<FIG> illustrates the needle thread cutting assembly <NUM> being activated by the controller <NUM>, the pneumatic cylinder <NUM> extending the moving rod <NUM> to move the slider <NUM>, blade <NUM> and pin <NUM> away from the pneumatic cylinder <NUM>. The openings <NUM> of the movable slider <NUM> pull the needle threads <NUM> (only one being shown) through the openings <NUM> in needles <NUM> (only one being shown), the needle threads <NUM> still extending through the stationary circular end openings <NUM> of the keyhole slots <NUM> (only one being shown) of the rail <NUM>.

<FIG> illustrates the needle thread cutting assembly <NUM> being further activated by the controller <NUM>, the pneumatic cylinder <NUM> further extending the moving rod <NUM> to move the slider <NUM>, blade <NUM> and pin <NUM> further away from the pneumatic cylinder <NUM>. The openings <NUM> (only one being shown) of the movable slider <NUM> continue to pull the needle threads <NUM> (only one being shown) through the openings <NUM> in needles <NUM> (only one being shown), the needle threads <NUM> still extending through the stationary circular end openings <NUM> of the keyhole slots <NUM> (only one being shown) of the rail <NUM> until the cutting edges <NUM> of blades <NUM> (only one being shown) cut the needle threads <NUM> (only one being shown). After the needle threads <NUM> are cut, the moving rod <NUM> is pulled back inside the pneumatic cylinder <NUM> to the position shown in <FIG>.

Referring now to <FIG>, three (of nine) looper thread cutting assemblies <NUM> are illustrated, each one of which is controlled by controller <NUM>. As shown in <FIG>, each looper thread cutting assembly <NUM> is secured to the needle plate <NUM> with fasteners <NUM> and functions to cut one the looper threads <NUM> upon the completion of a job. <FIG> illustrates a portion of a looper thread cutting assembly <NUM> in a partially assembled condition before the looper thread <NUM> is cut. <FIG> illustrates a blade <NUM> in a home position and a cover <NUM> pulled away from the needle plate <NUM>. <FIG> shows the same portion of the looper thread cutting assembly <NUM> in a partially assembled condition after the looper thread <NUM> is cut. <FIG> illustrates the blade <NUM> in a finished position.

<FIG> show a flow chart illustrating the operation of the quilting machine. <FIG> shows a block <NUM> illustrating an operator turning on the machine by pushing a start button on a control panel (shown as block <NUM> in <FIG>). Block <NUM> indicates that upon the start button being pushed the stack lights (not shown) turn from red to green indicating the quilting machine is turned on. These stack lights <NUM> are a safety feature which preferably are incorporated into the machine but may be omitted. Upon the machine <NUM> being turned on, the controller <NUM> activates the feed servo-motor <NUM> which rotates the drive pulley <NUM> which rotates the endless drive belt <NUM> which rotates the feed belts <NUM> of the feed assembly <NUM> at a staging speed. Block <NUM> indicates the feed belts <NUM> moving at a staging speed and the start of a timeout counter. Block <NUM> indicates that the controller <NUM> detects whether a leading edge of the input web <NUM> is detected within the time set by the timeout counter. If the leading edge of the input web <NUM> is not detected, the controller <NUM> turns the machine off, as indicated by block <NUM>.

As indicated by block <NUM>, if the leading edge of the input web <NUM> is detected, the controller <NUM> activates the feed servo-motor <NUM> which rotates the drive pulley <NUM> which rotates the endless drive belt <NUM> which rotates the feed belts <NUM> of the feed assembly <NUM> at a pre-programmed staging speed to move the input web <NUM> downstream at a staging speed until the input web is underneath the needles <NUM>. As indicated by block <NUM>, when the feed belts <NUM> of the feed assembly <NUM> are moving at the staging speed, a series of short stitches <NUM> are created. Typically, each of these short stiches <NUM> is less than <NUM> inch in length.

As indicated by block <NUM>, when the input web <NUM> is stationary between incremental movements, the controller <NUM> activates the sewing servo-motor <NUM> of sewing assembly <NUM> which causes rotation of the endless drive belt <NUM> via the drive pulley <NUM>. The endless drive belt <NUM> rotates the indexer pulley <NUM> which causes movement of the retainer bar <NUM> and attached spreaders <NUM> and oscillation of the looper shaft <NUM>. Each rotation of the drive pulley <NUM> causes one rotation of cranks <NUM> which causes one rotation or cycle of the needle bar <NUM>, attached needles <NUM> and hence needle axis NA of each needle <NUM>. Each chain stitch created by the sewing assembly <NUM> is created by one rotation of the drive pulley <NUM> and cranks <NUM>. After each chain stitch the controller <NUM> temporarily stops rotation of the drive pulley <NUM> of sewing assembly122 by stopping the sewing servo-motor <NUM>. When the sewing assembly is inactive, the controller <NUM> activates rotation of the drive pulley <NUM> of feed assembly <NUM> by activating the feed servo-motor <NUM> for a programmed time depending upon the desired travel distance of the input web <NUM> before the next stitch is started.

As indicated by blocks <NUM> and <NUM>, if the desired stitch length is less than <NUM> inch, in other words, a short stitch <NUM> is desired, the looper thread tensioner <NUM> of a looper assembly <NUM> and the needle thread tensioner <NUM> of the corresponding needle assembly <NUM> are turned off during activation of the feed assembly <NUM> and downstream movement of the input web <NUM>.

As indicated by blocks <NUM> and <NUM>, if the desired stitch length is greater than <NUM> inch, in other words, a long stitch <NUM> is desired, the looper thread tensioner <NUM> of a looper assembly <NUM> and the needle thread tensioner <NUM> of the corresponding needle assembly <NUM> are turned on during activation of the feed assembly <NUM> and downstream movement of the input web <NUM>.

As indicated by block <NUM>, regardless of whether the looper thread tensioner <NUM> of a looper assembly <NUM> and the needle thread tensioner <NUM> of the corresponding needle assembly <NUM> are turned on, during the initial sewing period of a job, the feed assembly <NUM> moves the input web <NUM> and the sewing assembly <NUM> cooperate to create a condensed or short stitch length or short stitches <NUM>.

As indicated by decision block <NUM>, the controller <NUM> is programmed to stitch a certain number of short stitches <NUM> along a beginning period of a job and again at an ending period of a job. If less than the desired number of short stitches <NUM> have been completed, the controller <NUM> instructs the machine to sew another short stitch <NUM>, as indicated by block <NUM>. If the desired number of short stitches <NUM> have been completed, the controller <NUM> instructs the machine to sew a long stitch <NUM> by changing the distance the input web travels between stitches, as indicated by block <NUM>.

As indicated by block <NUM>, the controller <NUM> is programmed to stitch a certain number of long stitches <NUM> along a middle period of a job. Every rotation of the drive pulley <NUM> causes one rotation of cranks <NUM> which causes one rotation or cycle of the needle bar <NUM>, attached needles <NUM> and needle axis NA of each needle <NUM>. As indicated by decision block <NUM> and block <NUM>, if the stitch length is greater than <NUM> inch, the looper thread tensioner <NUM> of a looper assembly <NUM> and the needle thread tensioner <NUM> of the corresponding needle assembly <NUM> are turned on during activation of the feed assembly <NUM> and downstream movement of the input web <NUM>. As indicated by decision block <NUM> and block <NUM>, if the stitch length is less than <NUM> inch, the looper thread tensioner <NUM> of a looper assembly <NUM> and the needle thread tensioner <NUM> of the corresponding needle assembly <NUM> are turned off during activation of the feed assembly <NUM> and downstream movement of the input web <NUM>. The downstream movement of the input web <NUM> the programmed distance defining the stitch length is indicated by block <NUM>.

As indicated by decision block <NUM> and block <NUM>, if the leading edge sensor is blocked, the controller <NUM> operates the sewing assembly <NUM> to perform another stitch. As indicated by decision block <NUM> and block <NUM>, if the leading edge sensor is not blocked the controller <NUM> changes the time between stitches, i.e. the downstream travel time of the input web <NUM> which fixes the stitch length.

As indicated by block <NUM>, after the controller <NUM> changes the stitch length to a short stitch length, the drive pulley <NUM> is rotated one rotation, causing one full rotation of cranks <NUM> which causes one rotation or cycle of the needle bar <NUM>, attached needles <NUM> and needle axis NA of each needle <NUM>. This creates a short stitch at the tail end of the job.

As indicated by decision block <NUM> and block <NUM>, if the stitch length is greater than <NUM> inch, the looper thread tensioner <NUM> of a looper assembly <NUM> and the needle thread tensioner <NUM> of the corresponding needle assembly <NUM> are turned on during activation of the feed assembly <NUM> and downstream movement of the input web <NUM>. As indicated by decision block <NUM> and block <NUM>, if the stitch length is less than <NUM> inch, the looper thread tensioner <NUM> of a looper assembly <NUM> and the needle thread tensioner <NUM> of the corresponding needle assembly <NUM> are turned off during activation of the feed assembly <NUM> and downstream movement of the input web <NUM>. The downstream movement of the input web <NUM> the programmed distance defining the stitch length is indicated by block <NUM>.

As indicated by decision block <NUM>, the controller <NUM> is programmed to stitch a certain number of short stitches <NUM> along a beginning period of a job and again at an ending period of a job. If less than the desired number of short stitches <NUM> have been completed, the controller <NUM> instructs the machine to sew another short stitch <NUM>, as indicated by block <NUM>. If the desired number of short stitches <NUM> have been completed, the controller <NUM> instructs the machine to sew another short stitch <NUM>, as indicated by block <NUM>.

As indicated by the block <NUM>, the needle thread cutting assembly <NUM> is activated, cutting all needle threads. As indicated at block <NUM>, after the last short stitch <NUM> has been completed, the controller <NUM> turns off the needle thread tensioner <NUM> of each needle assembly <NUM> and the looper thread tensioner <NUM> of each looper assembly <NUM>.

As indicated by the block <NUM>, the feed assembly <NUM> is activated by the controller <NUM> to move the quilted panel <NUM> downstream. As indicated at block <NUM>, after the controller <NUM> turns off the needle thread tensioner <NUM> of each needle assembly <NUM> and the looper thread tensioner <NUM> of each looper assembly <NUM>. As indicated at block <NUM>, the looper thread cutting assemblies <NUM> are activated by controller <NUM> to cut the looper threads <NUM>. As indicated at block <NUM>, the feed assembly <NUM> is activated for the last time, thereby ejected the completed quilted panel <NUM>.

Referring now to <FIG>, the controller <NUM> may include a processor <NUM>, a memory <NUM>, an input/output (I/O) interface <NUM>, and a Human Machine Interface (HMI) <NUM>. The processor <NUM> may include one or more devices configured to manipulate signals (analog or digital) based on operational instructions that are stored in memory <NUM>. Memory <NUM> may include a single memory device or a plurality of memory devices including, but not limited to, read-only memory (ROM), random access memory (RAM), volatile memory, non-volatile memory, hard drives, optical storage, mass storage devices, or any other device capable of storing data.

The processor <NUM> may operate under the control of an operating system <NUM> that resides in memory <NUM>. The operating system <NUM> may manage controller resources so that computer program code embodied as one or more computer software applications, such as a controller application <NUM> residing in memory <NUM>, can have instructions executed by the processor <NUM>. One or more data structures <NUM> may also reside in memory <NUM>, and may be used by the processor <NUM>, operating system <NUM>, and/or controller application <NUM> to store data.

The I/O interface <NUM> operatively couples the processor <NUM> to the other components of the machine <NUM> and may also couple the processor <NUM> to an external computing system or network (not shown). The external computing system or network may be used, for example, to exchange data files, such as quilting patterns, updated applications, and/or other operational data, with controller <NUM> to update the controller <NUM> and/or collect data related to the operation of the quilting machine <NUM>.

The I/O interface <NUM> may include signal processing circuits that condition or encode/decode incoming and outgoing signals so that the signals are compatible with both the processor <NUM> and the components to which the processor <NUM> is coupled. To this end, the I/O interface <NUM> may include analog to digital (A/D) and/or digital to analog (D/A) converters, voltage level and/or frequency shifting circuits, optical isolation and/or driver circuits, protocol stacks, solenoids, relays, pneumatic valves, and/or any other devices suitable for coupling the processor <NUM> to the other components of the machine <NUM> and/or an external computing system.

The HMI <NUM> may be operatively coupled to the processor <NUM> of controller <NUM> to enable a user to interact directly with the controller <NUM>. The HMI <NUM> may include video or alphanumeric displays, a touch screen, a speaker, and any other suitable audio and visual indicators capable of providing data to the user. The HMI <NUM> may also include input devices and controls such as an alphanumeric keyboard, a pointing device, keypads, pushbuttons, control knobs, microphones, etc., capable of accepting commands or input from the user and transmitting the entered input to the processor <NUM>.

In general, the routines executed to implement the embodiments of the invention, whether implemented as part of an operating system or a specific application, component, program, object, module or sequence of instructions, or a subset thereof, may be referred to herein as "computer program code," or simply "program code. " Program code typically comprises computer-readable instructions that are resident at various times in various memory and storage devices in a computer and that, when read and executed by one or more processors in a computer, cause that computer to perform the operations necessary to execute operations and/or elements embodying the various aspects of the embodiments of the invention. Computer-readable program instructions for carrying out operations of the embodiments of the invention may be, for example, assembly language or either source code or object code written in any combination of one or more programming languages.

Various program code described herein may be identified based upon the application within which it is implemented in specific embodiments of the invention. However, it should be appreciated that any particular program nomenclature which follows is used merely for convenience, and thus the invention should not be limited to use solely in any specific application identified and/or implied by such nomenclature. Furthermore, given the generally endless number of manners in which computer programs may be organized into routines, procedures, methods, modules, objects, and the like, as well as the various manners in which program functionality may be allocated among various software layers that are resident within a typical computer (e.g., operating systems, libraries, API's, applications, applets, etc.), it should be appreciated that the embodiments of the invention are not limited to the specific organization and allocation of program functionality described herein.

The program code embodied in any of the applications/modules described herein is capable of being individually or collectively distributed as a program product in a variety of different forms. In particular, the program code may be distributed using a computer-readable storage medium having computer-readable program instructions thereon for causing a processor to carry out aspects of the embodiments of the invention.

Computer-readable storage media, which is inherently non-transitory, may include volatile and non-volatile, and removable and non-removable tangible media implemented in any method or technology for storage of data, such as computer-readable instructions, data structures, program modules, or other data. Computer-readable storage media may further include RAM, ROM, erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), flash memory or other solid state memory technology, portable compact disc read-only memory (CD-ROM), or other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium that can be used to store the desired data and which can be read by a computer. A computer-readable storage medium should not be construed as transitory signals per se (e.g., radio waves or other propagating electromagnetic waves, electromagnetic waves propagating through a transmission media such as a waveguide, or electrical signals transmitted through a wire). Computer-readable program instructions may be downloaded to a computer, another type of programmable data processing apparatus, or another device from a computer-readable storage medium or to an external computer or external storage device via a network.

Computer-readable program instructions stored in a computer-readable medium may be used to direct a computer, other types of programmable data processing apparatuses, or other devices to function in a particular manner, such that the instructions stored in the computer-readable medium produce an article of manufacture including instructions that implement the functions, acts, and/or operations specified in the flow-charts, sequence diagrams, and/or block diagrams. The computer program instructions may be provided to one or more processors of a general purpose computer, a special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the one or more processors, cause a series of computations to be performed to implement the functions, acts, and/or operations specified in the flow-charts, sequence diagrams, and/or block diagrams.

In certain alternative embodiments, the functions, acts, and/or operations specified in the flow-charts, sequence diagrams, and/or block diagrams may be re-ordered, processed serially, and/or processed concurrently consistent with embodiments of the invention. Moreover, any of the flow-charts, sequence diagrams, and/or block diagrams may include more or fewer blocks than those illustrated consistent with embodiments of the invention.

<FIG> illustrates the quilted panel <NUM> exiting the machine <NUM>. The quilted panel <NUM> has two end surfaces <NUM>, the linear distance between which defines the longitudinal dimension or length "L" of the quilted panel <NUM>. The quilted panel <NUM> has two side surfaces <NUM>, the linear distance between which defines the transverse dimension or width "W" of the quilted panel <NUM>. As shown in <FIG> and <FIG>, the quilted panel <NUM> has an upper layer <NUM> having a uniform height H1 comprising the piece <NUM> of the input web <NUM>, a middle layer <NUM> having a uniform height H2 comprising the piece <NUM> of input web <NUM> and a lower layer <NUM> having a uniform height H3 comprising the piece <NUM> of the input web <NUM>. Each of the layers <NUM>, <NUM>, <NUM> may be made of any known material including any known foam or fiber material or combination thereof. Alternatively, any of the layers <NUM>, <NUM>, <NUM> may be made of the same material in different densities. <FIG>, <FIG> and <FIG> illustrate multiple spaced stitch lines <NUM> extending parallel the side surfaces <NUM> of the quilted panel <NUM> and extending in the longitudinal direction.

Each of the stitch lines <NUM> is identical and made up of chain stitches <NUM>, <NUM>. It is within the scope of the present invention that any of the stitch lines of any of the examples shown or described herein may have any number of different chain stitches of any desired length or may comprise chain stitches of the same length as described below. For example, short chain stitches may be on opposite sides of long chain stitches in the stitch lines or versa visa.

<FIG> best illustrates short and long chain stitches <NUM>, <NUM>, respectively, of stitch lines <NUM> holding the layers <NUM>, <NUM>, <NUM> of the quilted panel <NUM> together. Each of the stitch lines <NUM> comprises multiple short chain stitches <NUM> comprising an end section <NUM> at each end of the quilted panel <NUM>. Each of the stitch lines <NUM> further comprises multiple long chain stitches <NUM> comprising a middle section <NUM> between the end sections <NUM> of each stitch line <NUM> of the quilted panel <NUM>.

As best shown in <FIG>, each chain stitch, shown as short chain stitches <NUM> comprises two sides <NUM>, a top <NUM> and a bottom <NUM>. Each side <NUM> comprises one section <NUM> of a needle thread <NUM>. The side <NUM> of one chain stitch <NUM> abuts the side of an adjacent chain stitch <NUM>, except for the outermost side of each outermost short chain stitch <NUM>. As best seen in <FIG> and <FIG>, the top <NUM> of each chain stitch <NUM>, comprises a single section <NUM> of needle thread <NUM> which extends across an upper surface <NUM> of the quilted panel <NUM>. The bottom <NUM> of each chain stitch <NUM> comprises two portions, a short portion <NUM> comprising three sections <NUM> of looper thread <NUM> and a long portion <NUM> comprising one section <NUM> of looper thread <NUM> and two sections <NUM> of needle thread <NUM>. Each of the short and long portions <NUM>, <NUM> of the bottom <NUM> of each chain stitch <NUM> extends below a lower surface <NUM> of the quilted panel <NUM>. Although <FIG> illustrates short chain stitches <NUM>, the composition of the chain stitch is the same regardless of the size/ length of the chain stitch.

The linear distance between the opposed sides <NUM> of a long chain stitch <NUM> is greater than the linear distance between the opposed sides <NUM> of a short chain stitch <NUM>. Similarly, the length of the top <NUM> and bottom <NUM> of a long chain stitch <NUM> is greater than the length of the top <NUM> and bottom <NUM> of a short chain stitch <NUM>.

<FIG> and <FIG> illustrate an alternative quilted panel 32a comprising a pocketed spring layer <NUM> sandwiched between upper layer <NUM> (same as in quilted panel <NUM>) and lower layer <NUM> (same as in quilted panel <NUM>). The stitch lines <NUM> extend longitudinally between rows of pocketed springs as seen in <FIG>. The chain stitches <NUM>, <NUM> of stitch lines <NUM> holding the layers <NUM>, <NUM>, <NUM> of the quilted panel 32a together are the same as in the quilted panel <NUM>, so for simplicity like numbers are used. The quilted panel <NUM> has an upper surface 552a and a lower surface 560a. Layers <NUM>, <NUM> may be made of any known material including any known foam or fiber material or combination thereof. Alternatively, the layers <NUM>, <NUM> may be made of the same material in different densities.

<FIG> and <FIG> illustrate an alternative quilted panel 32b comprising only two lofted layers: upper layer <NUM> (same as in quilted panel <NUM>) and lower layer <NUM> (same as in quilted panel <NUM>). The chain stitches <NUM>, <NUM> of stitch lines <NUM> holding the layers <NUM>, <NUM> of the quilted panel 32b together are the same as in the quilted panel <NUM>, so for simplicity like numbers are used. The quilted panel 32b has an upper surface 552b and a lower surface 560b. Each of the layers <NUM>, <NUM> may be made of any known material including any known foam or fiber material or combination thereof. Alternatively, any of the layers <NUM>, <NUM> may be made of the same material in different densities.

<FIG> and <FIG> illustrate an alternative quilted panel 32c comprising the same three lofted layers as in the quilted panel <NUM>: an upper layer <NUM>, a middle layer <NUM> and a lower layer <NUM>. In this example each of the spaced stitch lines 34c comprises chain stitches <NUM> of the same length holding the layers <NUM>, <NUM>, <NUM> of the quilted panel 32c together. For simplicity like numbers are used. The quilted panel 32c has an upper surface 552c and a lower surface 560c. Although <FIG> and <FIG> illustrate chain stitches <NUM> of a particular length, the drawings are not intended to be limiting. The length of the chain stitches may be any desired length throughout the stitch lines of the quilted panel.

<FIG> and <FIG> illustrate an alternative quilted panel 32d comprising four lofted fiber layers: an upper layer <NUM>, an upper middle layer <NUM> and a lower middle layer <NUM> and a lower layer <NUM>. In this example each of the spaced stitch lines 34d comprises short and long chain stitches <NUM>, <NUM> of different lengths holding the layers <NUM>, <NUM>, <NUM> and <NUM> of the quilted panel 32d together. For simplicity like numbers are used. The quilted panel 32d has an upper surface 552d and a lower surface 560d. Although <FIG> and <FIG> illustrate chain stitches <NUM>, <NUM> of a particular length, the drawings are not intended to be limiting. The length of the chain stitches may be any desired length throughout the stitch lines of the quilted panel.

Although the example of <FIG> and <FIG> is the only example illustrated having spaced stitch lines comprising chain stitches of the same length, any of the quilted panels shown as described herein, regardless of the composition of all or any of the layers, may have spaced stitch lines each comprising chain stitches of the same length.

It will be further understood that the terms "comprises" and/or "comprising," when used in this specification, specify the presence of stated features, integers, actions, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, actions, steps, operations, elements, components, and/or groups thereof. Furthermore, to the extent that the terms "includes", "having", "has", "with", "comprised of", or variants thereof are used in either the detailed description or the claims, such terms are intended to be inclusive in a manner similar to the term "comprising".

Claim 1:
A method of quilting a layered input web (<NUM>), the method comprising:
providing a quilting machine (<NUM>; 10a) including a sewing assembly (<NUM>) powered by a first servo motor (<NUM>) and a feed assembly (<NUM>) powered by a second servo motor (<NUM>);
moving the layered input web (<NUM>) through the quilting machine (<NUM>; 10a) using the feed assembly (<NUM>); and
forming chain stitches in the layered input web (<NUM>) using the sewing assembly (<NUM>), wherein the feed assembly (<NUM>) operates without operation of the sewing assembly (<NUM>) for a programmed time,
characterized in that
the chain stitches are formed in the layered input web (<NUM>) using the sewing assembly (<NUM>) without compressing the layered input web (<NUM>), wherein the feed assembly (<NUM>) moves the layered input web (<NUM>) without compressing the layered input web (<NUM>).