Apparatus and method for producing draperies

Abstract

An apparatus and method are provided for simultaneously feeding one or more rolls of material into a sewing and cutting system. In one embodiment, the material is cut into predetermined lengths of cloth and during processing, each side of the cloth is hemmed automatically. The system of the present invention is particularly well suited to producing draperies and other similar fabric products.

What is claimed is:  
     
         1 . An apparatus for automatically processing a roll of material into predetermined lengths of fabric having vertically folded and sewn edges and at least one horizontally folded and sewn edge, said apparatus comprising: 
 a roll let off for supporting and feeding a roll of material;    first and second edge folding and positioning units positioned to receive opposite vertical edges of a material as said material is unwound from said let off, wherein said edge folding and positioning units form a vertical fold along said edges of said material;    a pair of corresponding hem sewing heads located to receive said folded edges formed by said respective edge folding and positioning units, said hem sewing heads for sewing hems along said edges;    a cloth puller for engaging and pulling an end of said material a predetermined length;    a fabric length cutter for cutting said predetermined lengths of material after said material has been pulled by said cloth puller;    a third edge folding and positioning unit positioned to receive a horizontal edge of said material after said material has been cut, said third edge folding and positioning unit forming a horizontal fold along said edge of said material; and    a sewing head located to receive said folded edge formed by said third edge folding and positioning unit, said sewing head for sewing said fold along said edge.    
     
     
         2 . The apparatus as defined in    claim 1   , wherein said first and second edge folding and positioning units maintain said folds formed along said vertical edges of said material a predetermined width as said material is fed therethrough.  
     
     
         3 . The apparatus as defined in    claim 2   , wherein said first and second edge folding and positioning units include an edge sensor for sensing the edge of said material along said vertical folds, said edge sensor sending signals to a fold adjustment device for maintaining said vertical folds a uniform width.  
     
     
         4 . The apparatus as defined in    claim 3   , wherein said fold adjustment device includes a controller for receiving signals from said edge sensor and a wheel positioned on top of a guide plate, said edge of said material folding over said guide plate and passing between said wheel and said plate, wherein when an adjustment in the width of said fold is necessary, said controller rotates said wheel for a predetermined interval of time for adjusting the width of said fold.  
     
     
         5 . The apparatus as defined in    claim 1   , further comprising a pair of hem edge curlers positioned before said respective hem sewing heads, wherein said hem edge curlers receive said folded vertical edges of said material and further curl said edges within said fold for forming a doubled back border along said material.  
     
     
         6 . The apparatus as defined in    claim 1   , further comprising a second roll let off for simultaneously feeding a liner with said material.  
     
     
         7 . The apparatus as defined in    claim 1   , wherein said pair of corresponding sewing heads include a sewing head in communication with a roller arrangement for sewing and advancing said material, wherein at least one roller in said roller arrangement is eccentrically connected to a drive shaft located on said sewing head by a ratchet arm such that said at least one roller is driven intermittently, only advancing said material when a needle connected to said sewing head is raised out of the material.  
     
     
         8 . The apparatus as defined in    claim 1   , further comprising a cloth shifter for laterally shifting said cut material to said third edge folding and positioning unit.  
     
     
         9 . The apparatus as defined in    claim 8   , wherein said cloth shifter comprises a plurality of conveyor belts positioned beneath said cut material.  
     
     
         10 . The apparatus as defined in    claim 1   , wherein said third edge folding and positioning unit comprises at least one folding die that is capable of being suspended above and released onto said cut material, and a trailing end folder, wherein, after said folding die has been released onto said material, said trailing end folder folds said horizontal edge of said material over said folding die.  
     
     
         11 . The apparatus as defined in    claim 1   , wherein said cloth puller engages and pulls said end of said material a predetermined length over a table.  
     
     
         12 . An apparatus for automatically forming a hemmed edge on predetermined lengths of fabric, said apparatus comprising: 
 a table for receiving predetermined lengths of fabric;    a cloth shifter for moving said fabric across said table;    an edge folding unit positioned to receive an edge of said fabric as said fabric is supported on said table, said edge folding unit including an edge folder in operative association with a folding die, wherein when said edge of said fabric is placed on top of said edge folder, said edge folder is configured to fold said edge of said fabric over said respective folding die; and    a sewing head located to receive said folded edge of said fabric, said sewing head for sewing a hem along said edge.    
     
     
         13 . An apparatus as defined in    claim 12   , wherein said edge folding unit is configured to fold the edge of said fabric over said respective folding die all at one time.  
     
     
         14 . An apparatus as defined in    claim 12   , further comprising a hem edge curler positioned after said edge folding unit, wherein said hem edge curler receives said folded edge of said fabric and further curls said edge within said fold for forming a doubled back border along said fabric.  
     
     
         15 . An apparatus is defined in    claim 12   , wherein said cloth shifter includes at least one moveable conveyor belt.  
     
     
         16 . An apparatus is defined in    claim 12   , wherein said edge folder includes a L-shaped member that moves over an end of said table to fold the edge of said fabric over said folding die.  
     
     
         17 . An apparatus is defined in    claim 12   , wherein said edge folder has a length that is substantially the same length as said edge of said fabric.  
     
     
         18 . An apparatus for folding an edge of a cut piece of material comprising: 
 a table for receiving a cut piece of material; and    an edge folding unit positioned to receive an edge of said cut material placed on said table, said edge folding unit being configured to form a fold along said edge of material, said edge folding unit comprising an edge folder in operative association with a folding die, wherein when said cut material is placed on top of said edge folder, said edge folder is configured to fold said edge of said material over said folding die.    
     
     
         19 . An apparatus as defined in    claim 18   , wherein said edge folder is configured to move over said table for folding said edge of said material.  
     
     
         20 . An apparatus as defined in    claim 18   , wherein said edge folder has a size sufficient to fold said edge of material all at once.  
     
     
         21 . An apparatus as defined in    claim 18   , wherein said folding die is suspended above said table such that said cut piece of material can be positioned between said table and said folding die.  
     
     
         22 . An apparatus as defined in    claim 18   , further comprising a cloth shifter for moving the cut material over said table.  
     
     
         23 . The apparatus as defined in    claim 22   , wherein said cloth shifter comprises a plurality of movable belts.  
     
     
         24 . An apparatus is defined in    claim 18   , wherein said edge folder includes an L-shaped member that moves over an end of said table to fold said edge of said fabric over said folding die.  
     
     
         25 . An apparatus is defined in    claim 18   , further comprising a sewing head located to receive said folded edge of said material, said sewing head for sewing a hem along said edge.  
     
     
         26 . An apparatus is defined in    claim 25   , further comprising a hem edge curler positioned after said edge folder and prior to said sewing head, wherein said hem edge curler receives said folded edge of said fabric and further curls said edge within said fold for forming a doubled back border along said material.