U.S. patent application number 11/845478 was filed with the patent office on 2008-10-30 for modular gauging element assembly.
Invention is credited to Marshal Allen Neely.
Application Number | 20080264315 11/845478 |
Document ID | / |
Family ID | 39885478 |
Filed Date | 2008-10-30 |
United States Patent
Application |
20080264315 |
Kind Code |
A1 |
Neely; Marshal Allen |
October 30, 2008 |
Modular Gauging Element Assembly
Abstract
A modular gauging element assembly for a tufting machine is
provided that allows for broken and damaged gauging elements of the
tufting machine to be replaced. The modular gauging element
assembly includes a series of gauge modules each having a module
body including a series of spaced slots in which gauge elements are
received. Locating devices help position the gauge modules along
their gauge bars, after which the gauge modules can be mounted in
place by fasteners received through the gauge modules.
Inventors: |
Neely; Marshal Allen; (Soddy
Daisy, TN) |
Correspondence
Address: |
WOMBLE CARLYLE SANDRIDGE & RICE, PLLC
ATTN: PATENT DOCKETING 32ND FLOOR, P.O. BOX 7037
ATLANTA
GA
30357-0037
US
|
Family ID: |
39885478 |
Appl. No.: |
11/845478 |
Filed: |
August 27, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60913948 |
Apr 25, 2007 |
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Current U.S.
Class: |
112/80.43 ;
112/80.6 |
Current CPC
Class: |
D05C 15/22 20130101;
D05C 15/20 20130101 |
Class at
Publication: |
112/80.43 ;
112/80.6 |
International
Class: |
D05C 15/20 20060101
D05C015/20 |
Claims
1. A modular gauging element assembly for a tufting machine,
comprising: a series of gauge modules each including a module body
having a front face, a rear face, an upper portion, a lower
portion, and a plurality of spaced openings formed in said upper
portion and said front face of said module body; a gauge bar
mounted within the tufting machine, adapted to receive said gauge
modules in desired positions along the gauge bar and including a
shoulder formed along a lower portion of said gauge bar; at least
one guide member located along said rear surface of each module
body and adapted to engage said gauge bar to horizontally align
each gauge module along said gauge bar; a locating element
extending transversely along said lower portion of each module body
and adapted to engage said shoulder of said gauge bar to vertically
align and support said gauge modules along said gauge bar; a
fastener received through each of said gauge modules and engaging a
corresponding fastener opening within said gauge bar when said
guide member of said gauge module is received in its desired
position along said gauge bar; and a plurality of gauge elements
each received within one of said spaced openings of said module
bodies of said gauge modules.
2. The modular gauging element assembly of claim 1 and wherein said
gauge elements comprise loop pile loopers.
3. The modular gauging element assembly of claim 1 and wherein said
gauge elements comprise cut pile hooks.
4. The modular gauging element assembly of claim 1 and wherein said
gauge elements comprise needles.
5. The modular gauging element assembly of claim 1 and wherein each
module body of said gauge modules is cast with said gauge elements
mounted therein.
6. The module gauging element assembly of claim 1 and wherein said
gauge elements comprise level cut loop loopers.
7. The module gauging element assembly of claim 1 and further
comprising at least one fastener received within said module body
of each gauge module for affixing said gauge elements within said
spaced openings of each said module body.
8. In a tufting machine for forming a series of tufts of yarns in a
backing material, the improvement comprising: at least one gauge
bar having a longitudinally extending ledge and a plurality of
receiving sites located in spaced series along said gauge bar; and
a plurality of gauge modules each comprising a front side, rear
side, top and bottom portions, at least one first locating element
along said rear side thereof and adapted to engage one of said
receiving sides of said gauge bar for horizontally locating said
gauge module along said gauge bar, and at least one second locating
element adjacent said bottom portion of said gauge module and
adapted to engage said ledge of said guide bar for vertically
locating said gauge module along said gauge bar; and gauge parts
received within said top portions of said gauge modules, projecting
from said front sides thereof.
9. The tufting machine of claim 8 and wherein said gauge parts
comprise loop pile loopers.
10. The tufting machine of claim 8 and wherein said gauge parts
comprise cut pile hooks.
11. The tufting machine of claim 8 and wherein said gauge parts
comprise needles.
12. The tufting machine of claim 8 and wherein said gauge parts
comprise level cut loop loopers.
13. The tufting machine of claim 8 and wherein each module body of
said gauge modules is cast with said gauge parts mounted
therein.
14. The tufting machine of claim 8 and wherein said gauge modules
further comprise a series of spaced slots each adapted to receive
one of said gauge parts therein, and fasteners received along said
front sides of said gauge modules for releasably mounting said
gauge parts within said gauge modules.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present patent application is a formalization of
previously filed, co-pending U.S. provisional patent application
Ser. No. 60/913,948, filed Apr. 25, 2007. This patent application
claims the benefit of the filing date of the cited provisional
patent application according to the statutes and rules governing
provisional patent applications, particularly USC .sctn. 119(e)(1)
and 37 CFR .sctn. 1.78(a)(4) and (a)(5). The specification and
drawings of the provisional patent application are specifically
incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention generally relates to the design and
assembly of gauge parts for tufting machines, and in particular to
gauge modules for tufting machines to enable easy and efficient
replacement of the gauging elements in a tufting machine.
BACKGROUND OF THE INVENTION
[0003] During the operation of tufting machines, a series of
needles mounted along a reciprocating needle bar and carrying a
series of yarns penetrate a backing material and are engaged by a
series of hooks or loopers for forming cut and loop pile tufts of
yarn in the backing material. Such engagement requires close
precision in the positioning and operation of the needles and the
hooks or loopers to ensure efficient and accurate operation of the
tufting machine. During assembly of the tufting machines,
therefore, it is important that the needles, loopers, hooks, and/or
other gauge parts be accurately mounted along their respective
gauge bars to ensure that such gauge parts are accurately and
consistently spaced and positioned along their gauge bars. If the
gauge parts are misaligned, the individual gauge parts can become
broken or damaged, and tufts of yarns can be mis-sewn, resulting in
inaccurate or irregular patterns being formed, which carpets have
to be discarded.
[0004] Accordingly, it has been common practice to assemble gauge
parts, such as loopers or hooks in modules, including cast modules
in which the loopers or hooks are cast or mounted in a solid block
or module, typically including five to ten, or more, individual
gauge parts, precisely spaced in a series. These modules then are
mounted on a gauge bar to help ensure substantially consistent and
accurate spacing of the gauge parts. One problem that arises,
however, is that typically with such cast modules, especially where
such modules are used in smaller gauge (i.e., 10 gauge or less)
tufting machines, if a single gauging element or part fails, (such
as becoming broken or dull), the whole gauge module generally must
be replaced. Such replacement of the modules is often time
consuming and expensive and can require removal and replacement of
several undamaged or fully functional gauging elements or parts
within each of the modules, which leads to potential waste of other
gauging elements or parts in the module that are still
operable.
[0005] Accordingly, it can be seen that a need exists for an easily
replaceable gauge module that addresses the foregoing and other
related and unrelated problems in the art.
SUMMARY OF THE INVENTION
[0006] Briefly described, in one embodiment, the present invention
generally relates to a modular gauging element assembly for use in
a tufting machine that facilitates and enables easy and accurate
installation and replacement of gauge elements or parts of the
tufting machine, including needles, loopers, or hooks. The modular
gauging element assembly generally includes an elongated gauge bar,
such as a hook bar, needle bar, etc., typically having a series of
spaced openings or recesses in which a series of gauge modules are
received. A shoulder or ledge further is formed along a lower or
bottom edge of each gauge bar, extending beneath the recesses or
openings for receiving the gauge modules.
[0007] Each of the gauge modules generally includes a module body
having front and rear faces, parallel sides, and upper and lower
portions terminating at upper and lower edges, respectively. A
series of spaced openings or slots generally can be formed in the
module body of each gauge module, spaced in series across the top
and front faces of each module body. A series of gauging elements
or gauge parts generally will be received within such slots or
openings formed in the module bodies. Such gauging elements
generally can include loop pile loopers, cut pile hooks, level cut
loop loopers or hooks, needles, reeds, or other gauge parts. Such
gauging elements can be removably secured within the body of the
gauge module, such as by one or more fasteners inserted within and
engaging or holding the gauging elements in place, or can be cast
in place in the modules, with the gauge modules being cast from a
metal material such as aluminum or other similar material.
[0008] The gauge modules further will include one or more guide
members or locating elements/devices such as a tab, one or more
pins or projections, a detent, or other similar locating device
mounted or formed along the rear side surface of each gauge module.
Such locating devices are adapted to engage or fit within the
corresponding openings or slots formed along the gauge bar for
receiving the gauge modules, to assist in mounting the gauge
modules to the gauge bar in a desired horizontal alignment or
position.
[0009] In addition, a locating element or member generally can be
formed along the lower portion of each gauge module along the rear
sides surface thereof, and can include a ledge or other similar
projection, pin, or other elements adapted to engage the shoulder
or ledge formed along the lower edge of the gauge bar to help
provide a vertical fixation point for the gauge modules. As a
result, the gauge modules each can be located in a desired position
both horizontally and vertically along the gauge bar, and can be
provided with further support for resisting any upward pulling
movement of the yarns acting thereon during a tufting operation.
Thereafter, a fastener, such as a set screw or other similar
fastener can be received through each gauge module and through a
corresponding opening formed in the gauge bar for securing the
gauge modules to the gauge bar.
[0010] Various features, objects and advantages of the present
invention will become apparent to those skilled in the art upon a
review of the following detailed description, when taken in
conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF DRAWING
[0011] FIG. 1 is a side elevational view of a tufting machine
including the module gauging element assembly according to one
embodiment of the invention.
[0012] FIG. 2 is an exploded prospective view of a modular gauging
element assembly according to one embodiment of the present
invention.
[0013] FIG. 3 is a perspective view of an example gauge module
according to one embodiment of the present invention as illustrated
in FIG. 1.
[0014] FIG. 4 is a perspective illustration of the modular gauging
element assembly of FIG. 1 in an installed configuration.
DETAILED DESCRIPTION
[0015] Referring now in greater detail to the drawings in which
like numerals indicate like parts throughout the several views,
FIGS. 1-3 illustrate a modular gauging element system 10 according
to one example embodiment of the present invention. The modular
gauging element assembly 10 generally is adapted for use in a
tufting machine for use in mounting a series of gauging elements or
parts 11 at desired spacings for the tufting machine. For example,
the tufting machine can include a series of needles and loopers or
hooks, shown at 12 and 13, respectively, mounted in modules or
directly along one or more needle bars or hook bars, respectively,
within a tufting zone 14 of the tufting machine T for forming a
series of loops or tufts 16 of yarns 17 within a backing material
18 moving through the tufting zone. As further indicated in FIG. 1,
as the needles 12 are reciprocated vertically into and out of the
backing material, they carry a series of yarns 17 fed from a yarn
feed system or mechanism 19, into the backing material. As the
needles approach their full, downward stroke, the yarns 17 are
engaged by loopers or hooks 13 below the backing material so as to
be picked and pulled from the needles in order to form the tufts 16
within the backing material 18.
[0016] As indicated in FIGS. 1, 2, and 4, the modular gauging
element assembly 10 of the present invention typically includes an
elongated gauge bar 21 that is mounted to a reciprocating drive
mechanism 22 so as to move the gauge bar 21, and thus the gauging
elements 11 mounted thereto in a reciprocating motion toward and
away from the needles 12 as the needles penetrate the backing
material 18, as indicated by arrows 23 and 23' (FIG. 1). As further
indicated in FIGS. 2 and 4, the gauge bars 21 can comprise a hook
bar, needle bar, or similarly elongated gauge bar typically
including an upper surface 26, lower surface 27, rear side 28 and a
front facing side 29.
[0017] A series of spaced openings 31 further are formed in the
front facing surface 29 of each gauge bar 21. While the openings 31
are shown in one example embodiment as substantially rectangularly
shaped channels or recesses that extend vertically through the
front facing surface of the gauge bar, between the upper and lower
surfaces 26 and 27 thereof, other types or configurations of such
openings, including substantially horizontally oriented slots,
recesses, channels, one or more substantially circular holes, or
other similar elements/openings also can be formed in the gauge
bars. Additionally, an elongated shoulder or ledge 32 further
typically will be formed along the lower edge or corner portion
between the lower or bottom surface 27 and forwardly facing surface
29 of the gauge bar, extending longitudinally along the length of
the gauge bar and forming a recessed area below the slots or
openings 31 thereof. As indicated in FIGS. 2 and 4, the openings 31
formed in the gauge bar 21 thus act as receiving sites or areas for
receiving a series of modules 35 holding the gauging elements or
parts 11, in the example illustrated in the drawings being shown as
a series of loopers or hooks 13, therein for mounting the gauging
elements 11 to the gauge bar 21.
[0018] As indicated in FIGS. 2 and 3, each of the gauge modules 35
generally includes a module body 36 typically formed from a metal,
such as aluminum or steel, or other similar rigid, durable
material. The body of each gauge module further generally includes
an upper surface 37, a lower or bottom portion 38, spaced parallel
sides 39, a rear face or side 41, and a front face or side 42. As
indicated in FIG. 3, the rear face 41 further includes an upper
section 43 that extends or projects rearwardly from the body 36 of
the gauge module 35, and a recessed lower section 44 below the
upper section 43. One or more first guide members or locating
elements/devices 46 (FIG. 3) also generally will be formed along
the rearwardly facing surface 47 of the lower section 44 of the
rear side 41. While such a guide member or locating element is
illustrated in the drawings as possibly including a tab or similar
projection, it will also be understood that other types of locating
elements, such as one or more pins, projections, tabs, blocks,
ribs, a detent, or other similar locating elements or devices can
be mounted or formed along the rearwardly facing surface 47 of the
side 41 of the gauge module body 36. These locating devices or
guide elements 46 generally are adapted to engage and/or fit within
the corresponding receiving openings 31 (FIG. 2) formed along the
gauge bar 21, so as to assist in horizontally locating and mounting
the gauge modules 35 to the gauge bar 21 in a desired horizontal
alignment or position.
[0019] The rearwardly extending upper section 43 of the rear face
or side 41 further typically engages or rests on the upper surface
of the gauge bar, as indicated in FIG. 4, so as to provide an upper
stop or limit to further help vertically position the gauge modules
along the gauge bar. In addition, a second or lower locating
element or member 48 generally can be formed along the lower
portion 38 of the module body 36, projecting rearwardly from the
rear face or side 41 as indicated in FIGS. 2, 3 and 4. The lower
locating element 48 can be formed as a shoulder, ledge, or similar
projection and can be formed as an integral part of the vertically
extending locating or guide element 46, or as a separate component.
In addition, other types of locating elements including pins, tabs,
a tongue, or other similar device(s) also can be formed along the
lower portion 38 of the gauge module body 36. This lower locating
element 48 is adapted to engage the shoulder or ledge 32 formed in
the front facing surface 29 of the gauge bar 21, along the lower
surface or edge 27 thereof. As a result, the gauge modules are
provided with a second vertical fixation point, generally indicated
by 49 in FIG. 4, which helps to further vertically locate and
substantially fix the gauge modules in a desired vertical position
along their gauge bars. Such a construction further enables the
gauge modules 35 to be more resistant to the upward pulling
movements or motion acting thereon as a result of the yarns caught
or engaged by the gauging elements 11 pulling upwardly on the
gauging elements as the needles are reciprocated out of engagement
with the banking material.
[0020] As additionally indicated in FIGS. 2 and 4, a fastener 51
generally is received through a fastener opening 52 formed through
the body 36 of each gauge module 35. Each fastener 51 generally can
include a screw, rivet, bolt or similar fastener, and generally
will be extended through each fastener opening 52 and into
engagement with a corresponding fastener opening 53 (FIG. 2) of the
gauge bar 21. The fasteners help secure the gauge modules 35 in
place along the gauge bar 21.
[0021] As further indicated in FIGS. 2-4, the front face or side 42
of each gauge module body 36 generally includes an upper portion
60, and an inwardly sloping or tapered lower section 61 extending
downwardly therefrom. A series of spaced openings or slots 62
generally are formed in the front surface 63 of the upper portion
60 of each gauge module, which slots generally extend rearwardly
through the body 36 of each gauge module 35. As further indicated
in FIG. 3, the slots can extend to the rear face or side 41 of the
module body, such as for use in level cut loop looper or hook
assemblies, so as to provide a passage for movement of extensible
clips through the module body, and further generally will extend at
least partially along the upper surface 37 of the module body. The
slots define a series of openings in which the gauging elements 11
are received within the body 36 of each gauge module 35 as
illustrated in FIGS. 2-4.
[0022] The gauging elements or gauge parts 11 are shown in the
drawings, for purposes of illustration, as including cut pile hooks
or loopers 13, or alternatively, as level cut loop loopers or hooks
13' as indicated in FIG. 3. It will be understood, however, that
various types of gauging elements can also be utilized with the
modular gauging assembly of the present invention, including loop
pile loopers, cut pile hooks, needles, reeds, level cut loop
loopers or hooks, or other gauge parts. As indicated in FIG. 2,
such gauging elements can be removably secured with the body of
each gauge module, such as by use of one or more fasteners 64
inserted into the front face of each gauge module in desired
positions for securing the gauging elements in place within their
gauge module. Alternatively, such gauging elements also can be cast
in place within their gauge modules as a single, unitary structure,
with the gauge modules typically being cast from the metal material
such as aluminum, or other, similar material.
[0023] For installation of the gauge modules 35 of the modular
gauging assembly 10 of the present invention, after the gauge bar
has been installed within the tufting machine, each gauge module
can be aligned with the desired receiving opening of the gauge bar
and slid or pivoted upwardly from below the gauge bar and will be
substantially automatically guided and located in their desired
location or placement both vertically and horizontally along the
gauge bar. Thereafter, the gauging modules can be fixedly mounted
in place by the insertion of the fasteners 51 (FIGS. 2 and 4)
therein, to complete the installation of the gauge modules along
their gauge bar.
[0024] As a result of the construction of the present invention,
the gauge modules can be quickly and easily located both
horizontally and vertically so as to enable substantially greater
uniformity of alignment of the gauging elements or gauge parts
within the tufting machine. In addition, removal and installation
of the gauge modules on a finished or operational tufting machine
is further facilitated by the simple removal of the fastener 51 and
thereafter the removal and replacement of the gauge modules since
the gauge modules are substantially automatically located within
their desired or proper alignment along the gauge bars, which
alignment can be easily monitored or checked and corrected, without
having to break down and remove the gauge bar or other elements of
the tufting machine in order to replace or reinstall the gauge
modules. In addition, the lower locating element helps provide a
further vertical fixation point for the gauge modules to help
align/locate the modules on the gauge bar as well as helping resist
any upward pulling movement or motion acting thereon due to the
loops of yarns that are caught on the gauging elements and are
being pulled upwardly with the retraction or reciprocation of the
needles out of the backing material so as to further help reduce
pull-back or back robbing of the yarns and enhance uniformity of
the tufts of yarns being formed in the backing material.
[0025] It will be further understood by those skilled in the art
that while the present invention has been described above with
reference to preferred embodiments, numerous variations,
modifications, and additions can be made thereto without departing
from the spirit and scope of the present invention as set forth in
the following claims.
* * * * *