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Патент USA US2072602

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March 2, 1937.
A. s. MITCHELL
2,072,602
METHOD AND APPARATUS FOR MANUFACTURING UPHOLSTERED PANELS
Filed July 10', 1935
3 Sheets-Sheet l
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March 2, 1937.
I
A. SQMITCHELL
‘ 2,072,602
METHOD AND APPARATUS _.FOR MANUFACTURING UPHOLSTERED PANELS
Filed July 10, 1955
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2,072,602
A. s. MITCHELL
METHOD AND APPARATUS FOR MANUFACTURING UPHOLSTERED PANELS
Filed July 10, 1935
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2,072,602
Patented Mar; 2, 1937
UNITED STATES
PATENT OFFICE
2,072,602
METHOD AND APPARATUS FOR MANUFAC
TURING UPHOLSTERED PANELS
Allister S. Mitchell, Detroit, Mich., assignor to
National Automotive Fibres, Inc., Detroit,
Mich., a corporation of Delaware
Application July 10, 1935, Serial No. 30,757
18 Claims. (01. 154-2)
This invention relates particularly to upholstery downwardly through the openings in the plates
and through the spaces between or surrounding
panels adapted to be used as trim-panels in auto
the plates and trimmers with which the apparatus
mobile bodies, to an improved method of manu
facturing such panels, and to improved apparatus is equipped serve to trim off the cotton which is
thus drawn downwardly about the edges of the 5
5. adapted to the practice of said method.
10
The primary object is to provide an improved
upholstery panel, an economical method of manu
plates.
facturing the same, and simple apparatus well
prising a panel-plate, and a layer of cotton bat
ting, or other soft unwoven ?bre adhesively joined
to one surface of the panel-plate. It has been 10
found that the padding-layer thus applied is of
even thickness and presents a smooth, unru?led
outer surface. Moreover, some of the cotton
?bres are drawn downwardly over some of the
edges of the panel-plate, thus tending to round 15
adapted to the practice of said method.
It is known to provide, for the purpose of up
holstering automobiles, trim-panels equipped with
snap-fasteners which can be inserted through
holes or sockets in the framework of the body of
the automobile.
15
, '
It is desirable that such upholstery panels shall
be provided, between the foundation-plate of the
padding in smooth, even condition upon the
cover, with a padding-sheet, giving softness to the
panel-plate.
Upholstery panels of the character mentioned
are of suitable size and contour for the space
example, upholstery panels for doors may have
25 portions cut away to conform to the contour of
the lower portion of the door, and may have open
ings,_as for example for the handle-shaft, the
shaft of the window-operating mechanism, or
the like. Heretofore, it has been the practice to
30 provide a relatively stiff sheet of material to serve
as a foundation-plate, this sheet being cut to suit
able contour and provided with necessary open
ings; and, where a layer of ?lling material has
been interposed between the foundation-plate
35 and the ?nish-fabric, it has been common prac
tice to employ a sheet of what is known in the
trade as “blue wedding”, the padding being cut
or stamped by dies to give it a contour corre
sponding with the base-plate and to provide
openings corresponding with those in the base
plate. In this method of manufacture, consider
able di?iculty is encountered in applying the
padding to the base-plate and getting it to regis
ter properly.
.
The panel-plate, after the padding has been
which they are to occupy; and, where necessary,
openings or cut-away portions are provided. For
to
the edges of the product and aid in, securing the
panel and the ?nish-fabric which serves as a
upholstery.
'20
This method provides an upholstery panel com
Such method 'of manufacture in
45 volves undue expense, and, moreover, fails to
give a desirably even surface next to the cover
fabric.
In accordance with the preferred process herein
described, foundation-plates having a surface
50 sprayed or coated with adhesive, are fed in suc
cession through suitable apparatus, together with
a continuous strip of cotton batting which be
comes adhesively joined to the successive founda
tion-plates; and suction-means with which the
55 apparatus is provided serves to draw the cotton
thus applied, has a cover-fabric applied over the
padding, the margins of the fabric being com
monly lapped over the peripheral edge-portions of
the panel-plate and cemented to the under or
back surface thereof. The cover-fabric may be
applied in any desired manner.
It may, for ex
ample, be applied in the manner illustrated in my
application Ser. No. 11,527, ?led March 16;,1935.
The invention, in a preferred‘ embodiment, is
illustrated in the accompanying drawings, in
Which—-
.
'
30
Fig. 1 is a broken side elevational view of- novel
mechanism embodying the invention which is
adapted to the practice of the improved process;
Fig. 2, a plan view of the same; Fig. 3, a vertical
sectional view' taken ‘as indicated at line 3 of 35
Fig. 2; Fig. 4, a broken vertical longitudinal sec
tional view of the machine, the feed rolls and
stripper-rolls being shown in elevation, however;
Fig. 5, a fragmentary-view illustrating the man
ner in which the trimmer-roll, which is second
in order of operation, performs the function of
trimming the cotton against the forwardly pre
sented edges (the initial end-edge of the panel
and the ?nal edges of the perforations); Fig. 6,
a broken transverse sectional view taken as indi-'
cated at line 6 of Fig. 1; and Fig. 7, a broken sec
tional view illustrating my improved trim-panel
applied to a frameLmember of an automobile
body.
,1'
In the drawings illustrating the improved ma
chine, A designates a frame which may be of any
suitable construction, presenting a‘ bed' A’ over
which the work passes; B, B’ and 13”, sets of feed.
rolls, the bights of which are located at or just
above the bed of the machine; 0, a counter-clock~
45
2
9,072,602
wise-turning trimmer-roll, with which is associ
ated a feed-roll C’; D, a clockwise-turning, trim
mer-roll with which is associated a feed-roll D’;
E, a suction-box connected with an exhaust con
5 duit E’, the top of the suction-box constituting
a portion of the bed of the machine; F, a con
veyor which preferably is employed for feeding
the materials to the feed-rolls; G, a conveyor
serving to convey the cotton-covered panel-boards
10 from the machine; H, an electric motor which
drives the trimmer-rolls C and D at a high rate of
speed through the medium of a belt or chain H’;
I, a speed-reducing gear-set driven from the
motor H, as by means of a belt or chain‘ I’, and
15 from which a belt or chain. 1’, operating at re
duced speed, serves to drive a wheel or pulley J
which is fixedly mounted upon the shaft of the
front roller J ' of the conveyor F.
The exhaust pipe E’ of ‘the suction-box may
20. have suction applied thereto in any suitable man
ner, as by means of a suction fan (not shown)
driven by the motor.
It will be understood that the trimmer-rolls C
and D are driven directly from the motor at a high
25 rate of speed. The shaft of the trimmer-roll C is
designated I, and that of the trimmer-roll D is
designated 2. As shown in Fig. 1, the rolls are
geared together by gears 3, which cause the rolls
to rotate in opposite directions.
30
As shown in Fig. 3, the shaft of the roller J’
serves, through the medium of a belt or chain 4,
to actuate the feed-rolls. The feed-rolls are
connected by a system of belts or chains 5 at one
side of the machine and spur-gears 6 at the other
side of 'the machine in such manner that mem
bers of each set of feed-rolls are rotated in op
posite directions and in such a way as to feed
the materials through the machine. It will be
understood that the feed-rolls C’ and D’ which
.40 coact with the trimmer-rolls C and D, rotate at
the same speed as the sets of feed-rollers B, B’
and B2. The final conveyor G is actuated from
one of the rear feed-rolls B’ by means of a belt
or chain ‘I.
45
The surfaces of the sets of feed-rolls B, B’ and
B2 may be 01' any suitable material. They may,
for example, be of rubber adapted to yield
slightly.
,
The trimmer-rollers C and D preferably are
50 covered with wire-bristle cloth, as indicated at 8,
the bristles being set so as to incline rearwardly
with respect to the direction of rotation. The
surfaces of the coacting feed rolls C’ and D’ may
be of any suitable material. Preferably they
55 are covered with wire-bristle cloth, the bristles
having a rearward inclination at the bight. The
use of wire bristles on the feed-rolls proper tends
to give a more positive forward feed of the mate
rials while they are being operated upon by the
60 trimmer-rolls.
The suction-box E is shown provided with’
cross-members 9 and "I which support rigidly se
cured metal plates 9BL and I0“ interposed between
the rolls, as shown in Fig. 4. An additional trans
65 verse plate I l forming a part of the bed is shown
at the left of the trimmer-roll D in Fig. 4. Be
tween the plates and also between the plate 9“
and the front wall l2 of the suction-box are open
ings through which air may be drawn downwardly
70 through the suction-box.
'
The machine enables panels of various forms
to be fedv through and have a layer of cotton
batting, for example, applied thereto. In Fig. 2,
two series of door-panels l3 are shown as being
15 fed through the machine; and, in addition, small
panels I4 and I5 (located in the cut-away por
tions of the door-panels) are being fed through
the machine. The panel-board I3 is shown pro
vvided~ with openings I3“. It is noted, also, that
the panel-boards are spaced with relation to each C1
other. This, in effect, is the same as perfora
tions through the panel-board, since the cotton
can be drawn downwardly through the spaces and
brought within the range of action of the trim
10
mer-rolls C and D.
The cotton preferably isv supplied to the ma
chine from a roll K supported on a core K’ which
is vertically movable in standards K2 which ?ank
the conveyor F. As shown, the strip I6 of cot
ton batting is drawn from the roll K by the feed 15
rolls. In turn, the roll of batting operates, in
conjunction with the conveyor F, to convey the
panel-boards [3, I4 and I5 to the feed-rolls.
In the preferred practice of the process, the
panel-boards, having their upper surfaces sprayed 20
with adhesive, are placed on the conveyor F, and
thereby carried between the roll of batting and
the conveyor and thence forwardly to the feed
rolls. In passing between the sets of feed-rolls
B and B’, the cotton padding is evenly ironed 25
upon the panel-boards as they pass in succes
sion through the machine. As the work passes
over the suction-box E, the suction is su?icient to
rupture the cotton at all points not supported by
the panel-boards, and the projecting portions of 30
the cotton are drawn downwardly about the edges
of the panel boards into the suction-box. As the
downwardly depending portions of the cotton pass
the trimmer-roll C, that roll operates to trim
away portions of the cotton, these portions then 35
passing through the suction-duct E’ to a suit
able collec‘torlnot shown). The trimmer-roll C
operates to effectively trim, against any rear
wardly presented edges of the panel-boards, the
depending portions of cotton. Thus, the trim 40
mer-roll 0 acts particularly with respect to the
rearwardly presented front walls of the perfora
tions and the rearwardly presented rear edges
of the panel-boards to trim‘ the cotton with re
spect to said edges.
As the work progresses through the machine,
the trimmer-roll D operates particularly to trim
the depending cotton against the forwardly pre
sented edges of the panel-boards, that is, the
front edges of the panel boards and the forwardly
presented rear Walls of the openings in the panel
boards.
'
The first trimmer-r011 C operates to remove
most of the cotton which depends over the lat
eral edges of the panel-boards; and this action 55
is supplemented by the action of the second trim
mer-roll B as the work progresses through the
machine.
‘
In Fig. 5, the action of the second trimmer-r011
(the trimmer-roll D) is illustrated, trimming the 60
cotton against the forwardly presented edge 'of
the opening 13“ in the panel-board. It will bev
understood that before the work reached this
point, the cotton had already been trimmed with
respect to the front. half of the opening l3“ by 65
the roller C’ acting against the rearwardly pre
sented edge of the opening. It'will be noted that
the cotton fibres are drawn downwardly about
the wall of the opening, as indicated at I6“.
Thus, in effect, the cotton ?bres form a lining 70
for the wall of the opening. A similar result is
secured wherever the trimmer-rolls act in oppo
sition to the forwardly presented edges or the
rearwardly presented edges, as'the case may be,
of the panel-boards. In Fig. 2, the cut-away por 75
3
2,072,602
tion of the panel I3 is indicated at I3"). When
the panel is passed through the machine in the
direction indicated, the wall of the cut-away por
tion is, in e?ect, presented rearwardly, acting like
the rearwardly presented front wall of a per
foration. Both trimmers act upon the downward
ly drawn cotton at the lateral edges of the panel
board, the trimmer-roll D serving to remove any
bits of cotton which have not been removed by
10 the trimmer-roll C. At the lateral edges, some
of the ?bres are left drawn downwardly and in
e?ect wrapped about the lateral edges. tending
to hold the margins of the cotton in position and.
produce a certain amount of binding of the ?bres
about the lateral edges of the panel-board. If
desired, the mechanism may be varied to pro
vide trimmers which will operate with respect
to the lateral edges of the panel-boards very
much as the trimmer-rolls C and D operate with
respect to the forwardly and rearwardly pre
sented edge-walls of the panel-boards and the
portions downwardly about the edges of the panel
board. Accordingly, the use of pneumatic pres
sure, however applied, for accomplishing this re
sult is to be regarded as an equivalent and With
in the scope of appended claims.
The foregoing detailed description has been
given for clearness of understanding only, and
no unnecessary limitations should be understood
therefrom, but the appended claims should be
construed as broadly 'as permissible in view of 10
the prior art.
What I regard as new and desire to secure by
Letters Patent is:
1. A method of producing an upholstery panel
which comprises applying pneumatic action to a
panel-plate and an associated layer of ?brous pad
ding material to force projecting portions of the
padding material about the edges of the panel
plate, and removing marginal portions of the pad
ding material.
2. A method of producing upholstery panels
Preferably, as stated, the trimmer-rolls C and
D are equipped with wire bristles which scratch
or tear the padding material bit by bit from the
which comprises passing a series of panel-plates
and an overlying continuous strip of padding ma
terial within the range of a pneumatic device and
drawing portions of the padding material down~ 25
unwoven sheet. Thus, said rolls actto brush
trim the projecting margins of the padding ma
wardly about the edges of the panel-plates, and
trimming'away the projecting portions of the
terial at the edges of the panel~board.
padding material.
openings therein.
.
‘
Fig. 7 illustrates one of the improved trim
3. A method of producing upholstery panels
panels applied to a frame-member ll! of an au
which comprises adhesively joining a series of 30
tomobile body. Between the layer of cotton l6 panel plates and a layer of padding material, sub
and the panel-board I3 is a coating of adhesive . jecting them to suction to rupture the padding
designated l8. Applied over the padding it is material and draw portions of the padding ma
a cover 19 of suitable ?nish-fabric. The fabric terial about the edges of the panel-plates, and
ill has ‘its margins turned about the margins of
the padded panel-board and cemented to the rear
surface'of the panel-board by adhesive id“. The
panel-board is shown provided near its edges
with snap-fasteners 20 “which may be of any suit
40 able form and which may be secured to the trim
panel in any desired manner.
In the illustra
tion given, the spring-prongs 20a in the fastener
extend through‘ a perforation illa of the frame
member llL, It will be noted that the ?bres of
45 the cotton it are drawn downwardly about the
edge of the panel-board l3,,as indicated at it",
corresponding, in thisrespect, with the e?ect
shown at the perforation m in Fig. 5.
The improved method enables production to be
50 speeded up enormously, and provides an improved
product, in which the layer of padding material
is very smoothly applied to the panel-board and
very effectively secured thereto. In a measure,
the edges of the panel-board are moderately pad
55 ded and rounded.
That very great economy is
effected will be evident to those skilled in the
art when it is remarked that it becomes unneces
sary, because of the improved process, to manu
facture blue wadding and dye-cut the same into
pre~formed pads for application to the panel
boards; As mentioned above, di?culty is ex
perienced in the old method, in obtaining per
fect registration of the pre~cut padding sheet
and the panel-board. Not only is the expense of
65 the old method far greater, but the same uni
formity in thickness and. unruilied smoothness of
surface adjacent the inner surface of the cover
ing cannot be attained.
The panel-plates which are to be upholstered
70 may be of any suitable material, such as ?bre
board, ply-board, or the like. Sheet metal
may be employed, but is less desirable.
In a broad sense, the use of suction in the im
proved process utilizes pneumatic pressure for
75 rupturing the cotton and forcing the marginal
removing the projecting portions of the padding 35
material.
4. In the manufacture of upholstery panels, a
method which comprises: passing over a suction
device a series of panel-plates and an overlying
continuous sheet of unwoven padding material, 40
and by means of suction rupturing the padding
material and drawing portions of the padding ma
terial about the edges of the panel-plates, and
trimming away projecting portions of the pad
45
ding material.
5. A method of producing upholstered panels
which comprises feeding a series of adhesive
coated panel-plates and an overlying continu
ous sheet of padding material through compress
ing means ‘and then over a suction-device; apply
ing suction to rupture the padding material and
draw portions thereof downwardly about the
edges of the panel-plates; and trimming away
projecting portions of the padding material.
6. A method as speci?ed in claim 4, character
60
55
ized by performing the trimming action'by rotary
trimmers acting against opposed edges of the
panel-rplates.
-
7. A method of producing panels which com;
prises feeding a series of adhesive-coated panel liil
plates and a continuous strip of batting between
compression-rolls, the batting being taken from
a roll and acting inconjunction with a conveyor
to feed the panel-plates to the compression-rolls; 65
passing the work over a suction bed and applying
suction to rupture the batting and draw portions
thereof downwardly about the edges of the panel
plates; and trimming the depending portions of
the batting and conveying the trimmed portions 70
away by suction.
8. Apparatus for the purpose set forth, com
prising a suction device; trimmers associated
therewith; and means for feeding a series of
panel-plates and an associated layer of batting
2,072,602
4
across the suction-device and within the range of
said trimmers.
9. Apparatus for the purpose set forth, com
prising a suction-bed; trimmers therein; and
5 means for feeding a continuous sheet of batting
and an underlying series of panel-plates to and
across said bed, said means comprising a con
veyor for advancing the panel-plates and a su
perposed source of supply for the continuous sheet
10 of batting.
l
10. Apparatus'for the purpose set'forth, com
prising a suction-bed; means for applying suc
tion thereto; trimmers associated with said suc
tion-bed; compression feed-rolls between which
15 the materials pass on their way to the trimmers;
a conveyor for feeding adhesive-coated panel
plates; and a source of supply from which the
layer of batting is placed upon the panel-plates
as they are forwarded in succession by said con
20 veyor to said compression-rolls.
11. Apparatus for the purpose set forth, com
prising a bed equipped with a suction-device;
bristle-equipped trimmers mounted in said suc
tion-device below said bed; and means for feeding
25 over the suction-device and trimmers a series of
panel-plates and an overlying continuous sheet
of padding material,
12. Apparatus for the manufacture of uphol~
stery-panels comprising: a suction-device; trim
mer-rolls associated with the mouth of said suc
tion-device and equipped with means for actuat
ing them at relatively high speed; feed-rolls, in
cluding rolls opposed to said trimmer~rolls, said
feed-rolls operating at slower speed; and means
35 for supplying a continuous sheet of batting to
the feed-rolls.
13. Apparatus for the manufacture of uphol
stery-panels comprising: a bed equipped with
feed-rolls and with trimming-rolls; means for
40 supplying a continuous sheet of batting and a
series of panel-boards to said feed-rolls with said
panel-boards at the side of said sheet which is to
wards the trimming-rolls; and means for forcing
cotton from said sheet downwardly about the
edges of the panel-boards to bring said cotton
within the action of said trimming-rolls.
14. In apparatus for use in producing uphol
stered panels comprising a panel-plate and bat
ting applied to a surface thereof: a power-driven
permanent conveyor serving to support a plu
rality of pre-formed panel-plates in series and
advance said plates; and means for supplying a
continuous sheet of batting, such as cotton bat
ting, over and compressing the same upon the ad
10
vancing panel-plates.
15. Apparatus as specified in claim 14, in which
said conveyor is an endless conveyor having a
panel-loading end-portion disposed back of the 15
zone of application of the batting to the advanc
ing panel-plates.
'
'
16. Apparatus as speci?ed in claim 14, in which
said conveyor is an endless conveyor having a
panel-loading end-portion disposed back of the 20
zone of application of the batting to the advanc
ing panel-plates, and in which the compressing
means includes compression-rolls receiving the
batting and underlying panels from said endless
25
conveyor.
17. In the manufacture of upholstery panels,
the steps which comprise: feeding a continuous
sheet of unwoven ?brous padding material; ad
hesively applying a series of pre-formed panel
plates thereto; and, afterwards rupturing said 30
sheet of padding material between adjacent edges
of said panel-plates and brush-trimming the pad
ding material at the edges of said panel-plates.
18. In the manufacture of upholstered panels,
the steps which comprise: feeding a continuous 35
sheet of unwoven fibrous padding material; ap
plying a series of pre-formed panel-plates there
to; and then rupturing said sheet of padding
material between the panel-plates and brush
trimming projecting portions of said padding
material at the edges of said panel-plates.
ALLIS'IER S. MITCHELL.
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