U.S. patent number 3,650,228 [Application Number 04/699,987] was granted by the patent office on 1972-03-21 for tufting machines.
This patent grant is currently assigned to D. C. One Limited. Invention is credited to Robert Douglas Lynch.
United States Patent |
3,650,228 |
Lynch |
March 21, 1972 |
TUFTING MACHINES
Abstract
A tufting machine of the cut pile type in which a pair or more
of eccentrically operated needle bars are spaced apart, two or more
series of eccentrically operated looping hooks and knife cutters
co-operate respectively with the sets of needles, the spacing of
the needle bars and amplitude of sideways traverse of the fabric is
a number of times greater than the pitch of the needles for forming
symmetrical cross-over patterns of stitching, and the patterns are
changeable by for example removing equally spaced needles and/or
adjusting the feed of the fabric and/or adjusting the amplitude of
sideways traverse of the fabric, by the use for example of
differently shaped cams and differently sized pulleys, with common
or separate operating mechanisms for the needles and associated
parts.
Inventors: |
Lynch; Robert Douglas
(Cleveleys, EN) |
Assignee: |
D. C. One Limited
(N/A)
|
Family
ID: |
25755237 |
Appl.
No.: |
04/699,987 |
Filed: |
January 8, 1968 |
Foreign Application Priority Data
|
|
|
|
|
Jan 12, 1967 [GB] |
|
|
1,653/67 |
|
Current U.S.
Class: |
112/80.31;
112/439 |
Current CPC
Class: |
D05C
15/12 (20130101) |
Current International
Class: |
D05C
15/00 (20060101); D05C 15/12 (20060101); D05c
015/28 () |
Field of
Search: |
;112/79,226,117,439,221,118,79.5 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Hunter; H. Hampton
Claims
We claim:
1. A cut pile tufting machine for forming a plurality of series of
wavy lines of cut pile loops in fabric, the wave amplitude being
substantially the same in each series, comprising adjustable feed
means for varying the feeding of the fabric through the machine,
and means at each of a plurality of stations spaced apart
longitudinally of the direction of fabric feed, for producing a
lateral row of cut pile loops which are spaced apart along that
row, said means at each station comprising a lateral row of
laterally spaced needles for passing yarn loops through the fabric,
looping hooks for engaging said loops, and cutters for cutting the
loops, a carriage in combination with fabric-engaging and laterally
reciprocating roller means for engaging the fabric in advance of
each row of needles and for imparting to the fabric lateral
reciprocating movement with substantially the same amplitude at
each station.
2. A cut pile tufting machine comprising in combination, adjustable
feed means for feeding fabric in a path from front to rear, a
plurality of transversely extending series of needle, looper and
knife elements whereof the elements in each series have a
predetermined pitch spacing and the different series are spaced
apart for a distance greater than said pitch spacing, means for
operating said plurality of series of elements for forming a series
of longitudinally extending laterally spaced rows of cut pile loops
in the fabric, a carriage having a plurality of fabric-gripping
rollers, one of said rollers being positioned in front of and in
parallel relation to each of said series of elements respectively,
and patterning means operably connected to said carriage for
effecting by lateral shifting of said plurality of fabric-gripping
rollers positive transverse reciprocations of the fabric at a
plurality of locations of its approaches in said path to said
plurality of series of elements respectively all with like
amplitudes greater than said pitch spacing.
3. A machine as claimed in claim 2, having drive shaft means, first
eccentric drive means on said drive shaft means, first connecting
means connecting said first eccentric drive means to said plurality
of series of needle elements, second eccentric drive means on said
drive shaft means, lay shaft means, second connecting means
connecting said lay shaft means to said second eccentric drive
means and to said plurality of series of looper and knife
elements.
4. A cut pile tufting machine comprising in combination, adjustable
feed means for feeding fabric in a path from front to rear, a
plurality of spaced transversely extending rows of needle, looper
and knife elements, drive shaft means, first eccentric drive means
on said drive shaft means, first connecting means connecting said
first eccentric drive means to said plurality of series of needle
elements, second eccentric drive means on said drive shaft means,
lay shaft means, second connecting means connecting said lay shaft
means to said second eccentric drive means and to said plurality of
series of looper and knife elements, a carriage having a plurality
of fabric-gripping rollers, one of said rollers being positioned in
front of and in parallel relation to each of said series of
elements respectively, and patterning means operably connected to
said carriage for effecting by lateral shifting of said plurality
of fabric-gripping rollers positive transverse reciprocations of
the fabric at a plurality of locations of its approaches in said
path to said plurality of series of elements respectively all with
like amplitudes greater than said pitch spacing.
5. A machine as claimed in claim 2 having a plurality of needle
bars mounting said plurality of series of needle elements
respectively, a drive shaft, a first eccentric drive member on said
drive shaft, a first connecting rod connecting said eccentric drive
member to one of said needle bars, first elongate connecting means
interconnecting said needle bars, a second eccentric drive member
on said drive shaft, first and second lay shafts, a second
connecting rod with arm and link means, connecting said first and
second lay shafts jointly to said second eccentric drive member and
respectively to one of said plurality of series of looper elements
and one of said plurality of series of knife elements, and second
and third elongate connecting means interconnecting said plurality
of series of looper elements and said plurality of series of knife
elements respectively.
6. A machine as claimed in claim 2 having a plurality of needle
bars mounting said plurality of series of needle elements
respectively, a like plurality of drive shafts, a first like
plurality of eccentric drive members on said drive shafts
respectively, a first like plurality of connecting rods connecting
said eccentric drive members to said needle bars respectively, a
second like plurality of eccentric drive members on said plurality
or drive shafts respectively, a like plurality of first and second
lay shafts, a second like plurality of connecting rods and arm and
link means connecting each said first and second lay shafts jointly
to one of said second eccentric drive members and respectively to
one of said series of looper elements and one of said series of
knife elements.
7. A machine as claimed in claim 2 having a wide needle bar
mounting said plurality of series of needle elements at opposite
side edges thereof, a drive shaft, an eccentric drive member on
said drive shaft, and a connecting rod connecting said eccentric
drive member to a middle portion of said wide needle bar.
8. A machine as claimed in claim 4 having only two of said rows of
needle, looper and knife elements, a first elongate member
interconnecting said two rows of needle elements, said lay shaft
means comprising first and second lay shafts, said second
connecting means comprising a connecting rod extending from said
second eccentric drive means together with a long arm connecting
said connecting rod to said second lay shaft, and a first short arm
and link connection between said long arm and said first lay shaft,
a short arm and bar connection between said first shaft and said
two rows of looper elements, and a second short arm and link
connection between said second lay shaft and said two rows of knife
elements.
9. A machine as claimed in claim 4 having only two of said rows of
needle, looper and knife elements, a first elongate member
interconnecting said two rows of needle elements, said lay shaft
means comprising first and second lay shafts, said second
connecting means comprising a connecting rod extending from said
second eccentric drive means together with a long arm connecting
said connecting rod to said second lay shaft, a short arm and bar
connection between said first shaft and said two rows of looper
elements, a second short arm and link connection between said
second lay shaft and said two rows of knife elements, and link and
lever means connecting said long arm to said short arm and link
connection.
Description
This invention is for improvements in or relating to tufting
machines of the cut pile type having a bar of needles each formed
with an eyelet through which its own yarn is threaded and which
carry their yarns through the fabric to be tufted, a series of
looping hooks cooperating under the fabric with the needles to form
the pile loops from the needle's yarns, and a series of knife
cutters cooperating with the looping hooks for cutting the pile
loops.
Although it has been previously proposed to effect a form of
patterning of the pile loops by providing operating means to
traverse the fabric with a sideways motion, this patterning has
been of small and simple form effected by a staggered formation of
needles of one needle bar and by employing an eccentric to impart a
small sideways motion to the fabric. This pattern is of zigzag form
but because of the needles being staggered and the traverse and
feed of the fabric being suitably arranged, the alternate zigzag
lines are in such opposite phase relationship to the other
alternate zigzag lines that the peaks of adjacent lines abut each
other so that a simple diamond pattern is formed. In any instances
heretofore where more elaborate patterning has been required, this
has been effected by a machine in which the fabric has been guided
by hand.
An object of the invention is to provide a cut pile tufting machine
of such improved construction that a variety of attractive patterns
can be formed automatically.
The invention provides a cut pile tufting machine having at least a
pair of eccentrically operated needle bars which are spaced apart,
two series of eccentrically operated looping hooks and knife
cutters cooperating respectively with the two sets of needles, and
variably adjustable means for variably controlling feed and
sideways motion of the fabric. Conveniently the spacing of the
needle bars and amplitude of sideways traverse of the fabric is so
much greater than the pitch of the needles that wavy lines of
tufting formed by the needles, hooks, and cutters, have a
symmetrical crossover relationship. In one arrangement the spacing
of the needle bars and the amplitude of sideways motion of the
fabric is five times the pitch distance of the needles to produce a
pattern of opposed wavy lines which at intervals crossover in a
diamond pattern.
Other pattern arrangements are obtained by for example removal of
alternate or other equally spaced needles, and/or adjusting the
feed of the fabric and/or adjusting the amplitude of sideways
traverse of the fabric. The latter adjustment may be such that the
amplitude of sideways traverse of the fabric periodically varies so
as to periodically vary the pattern.
The machine may be an existing machine having a second needle bar
secured to the existing needle bar, for operation by the same
eccentric drive mechanism, a second series of looping hooks
connected to the existing mechanism for operating the existing
series of looping hooks, a second series of knife cutters connected
to the existing mechanism for operating the existing knife cutters,
and having patterning cam means adapted for effecting the sideway
traverse of the fabric. There may be a range of differently shaped
cams which are inter-changeable for obtaining different patterns.
There may also be a range of different sized pulleys for changing
the feed of the fabric to suit the pattern required. Associated
with the second needle bar there is conveniently a fabric presser
foot similar to the existing presser foot associated with the
existing needle bar, and there may be a temple roller for the
fabric in its approach to the second needle bar, similar to the
existing temple roller for the fabric in its approach to the
existing needle bar.
In an alternative arrangement the second needle bar, the second
series of looping hooks, and the second series of knife cutters may
each be operated by its own operating mechanism independently of
the operating mechanisms for the existing needle bar, looping hooks
and knife cutters respectively.
In a further modification the machine may be pre-designed with a
single operating mechanism for two series of needles secured to a
common needle bar.
The invention also provides tufted fabric or articles e.g.,
candlewick bedspreads, patterned in the manner and by the machine
above referred to.
The above and other features of the invention set out in the
appended claims are incorporated in the construction which will now
be described, as a specific embodiment with reference to the
accompanying drawings in which:
FIG. 1 is a cross sectional view of a cut pile tufting machine
according to the invention.
FIG. 2 is an enlarged cross sectional view of yarn looping and
cutting means in the machine.
FIG. 3 is an enlarged rear perspective view of needle bar mechanism
in the machine.
FIG. 4 is a cross sectional view of a modified form of the machine
according to the invention.
FIG. 5 is a similar view to FIG. 4 showing looping hook and knife
cutter operating mechanism in the modified machine.
FIG. 6 is a detail sectional view showing a modified form of needle
mechanism in the machine, according to the invention.
FIG. 7 is a rear face view of fabric produced on the machine with a
patterned cut pile.
FIG. 8 is a front face view of the fabric of FIG. 7.
FIG. 9 is a rear face view of fabric produced on the machine with a
modified pattern of cut pile.
FIG. 10 is a front face view of the fabric of FIG. 9.
FIG. 11 is a cross sectional view of modified looper and cutter
control means.
Referring to FIG. 1, the cut pile tufting machine is basically of
any suitable general type such for example as disclosed in U.S.
Pat. No. 3,440,983 comprising a frame 1, a bar 2 of eyeletted
needles 3 operated by eccentric mechanism 4 through connecting rod
means 5, a foot means 6, a stationary work plate 7, fabric feed
roller means 8, a fabric-engaging temple roller 9 gripping the
fabric in its approach to the needles 3, looping hooks 10 connected
rigidly to rocking shaft 11, knife cutters 12 connected rigidly to
rocking shaft 13, and means for rocking the shafts 11, 13
comprising arm means 14, 15 inter-connected by link means 16, and
the arm means 14 being connected by connecting rod means 17 to
eccentric mechanism 18.
In usual operation of this type of machine, rotation of the
eccentric mechanism 4, 18 causes the bar of needles 3 to
reciprocate, each to carry a loop of thread through the fabric, the
loops being held by the looping hooks 10, and cut by the knife
cutters 12. Consequently as the fabric is fed longitudinally to the
needles, there is produced in the fabric longitudinally extending
straight parallel lines of cut pile loops.
In a modification of this arrangement the fabric is mounted for
limited lateral reciprocation, and eccentric mechanism E, such as
cam 30 disclosed in FIG. 1 of said U.S. Pat. has been provided for
producing this lateral reciprocation in repetitive manner, the
result being that instead of the cut pile loops being in straight
parallel lines, the cut pile loops appear in zigzag lines in the
fabric.
In a further modified arrangement the needles have been in
staggered formation such that the zigzag lines of cut pile loops
formed by alternate needles are so out of phase with the zigzag
lines of the cut pile loops formed by the other alternate needles
that the peaks of each pair of adjacent zigzag lines abut each
other forming a diamond pattern such as shown in FIG. 9 of said
U.S. Pat.
According to the invention, the needles 3 are in a straight line,
and a second similar straight line of needles 19, see also FIG. 2,
is provided spaced rearwardly from the needles 3, the machine being
thus provided with a lateral row of laterally spaced needles at
each of a plurality of stations spaced apart longitudinally of the
direction of fabric feed.
The needles 19 are carried by a second needle bar 20 which, in this
example, is secured to the needle bar 2 by a number of cross bars
such as 21, so that the needles 19 are operated together with the
needle bar 2 by the same eccentric mechanism 4.
There is also provided associated with the needles 19 a foot means
22 similar to the foot means 6, a stationary work plate 23 similar
to the work plate 7, and a fabric-engaging temple roller 24 similar
to the fabric-engaging temple roller 9.
Also for cooperation with the needles 19 there is a series of
looping hooks 25, FIG. 2, similar to the series of hooks 10, and a
series of knife cutters 26 similar to the series of knife cutters
12.
It will be seen from FIG. 2 that the looping hooks 10 are connected
to the rocking shaft 11 by mounting means 27 and connecting bar
means 28. The mounting means 27 is connected rigidly by bar means
29 to mounting means 30 for the looping hooks 25, so that these
latter hooks are operated in association with the needles 19, in
the same manner as the hooks 10 are operated in association with
the needles 3, by the same rocking shaft 11.
Similarly the knife cutters 12 are connected by means 31 to the
rocking shaft 13, and the means 31 are connected by arm means 32,
and link means 33, to an arm means 34 secured to a shaft 35 to
which mounting means 26 for the knife cutters 26 is rigidly
secured. Consequently the knife cutters 26 are operated in
association with the hooks 25 and needles 19 in the same manner as
the knife cutters 12 operate in association with the hooks 10 and
needles 3, by the same rocking shaft 13.
In this particular example the needles, in each series thereof,
have about a one inch pitch spacing throughout, and the two series
of needles are about five inches apart. The two series of needles
are also in staggered relationship. The fabric is carried by
mounting means which in this instance includes the temple roller 24
in such known manner as to be capable of lateral reciprocation, and
patterning cam means, e.g., said eccentric means E, are provided
for effecting the lateral reciprocation with a predetermined
amplitude at a predetermined frequency.
In this example the amplitude of movement is about five inches.
The rate of feed of the fabric is also predetermined to suit
requirements.
There is also provided a number of different inter-changeable cams,
e.g., said eccentric means E, for suitably changing the amplitude
of lateral reciprocation of the fabric either for producing
different patterns in different fabrics or for producing a variable
pattern in a fabric.
Similarly there is provided change speed means for the fabric feed
such as by the use of a plurality of interchangeable different
sized pulleys one of which is shown at P in FIG. 1, e.g., in the
belt drive 22 disclosed in FIG. 1 of said U.S. Pat.
By the employment of the machine, any one of a number of different
patterns of tufting can be automatically produced in a fabric in a
manner which will be hereinafter fully described.
It is to be understood that the machine may be of various modified
forms without departing from the invention.
For example, whereas the arrangement hereinbefore described
consists of an existing machine suitably modified according to the
invention, a machine may be pre-designed in somewhat different
manner but producing the same result.
FIGS. 4 and 5 illustrate one form of pre-designed machine and it
will be seen from FIG. 4 that it is characterized by the needle bar
2 being connected by one connecting rod means 37 to eccentric means
38 at the front of the machine, and the other needle bar 20 is
connected by a connecting rod means 39 to a eccentric means 40 at
the rear of the machine, so that each needle bar is operated by its
own mechanism independently of the other.
Similarly the looping hooks 25 are connected to their own rocking
shaft 41 and the knife cutters 26 are connected to their own
rocking shaft 42.
FIG. 5 shows that the two rocking shafts 41, 42 are operable
independently of the rocking shafts 11, 13, by arm means 43, 44
being connected by link means 45, and the arm means 43 being
connected by connecting rod means 46 to further eccentric mechanism
such as 47.
In another example, FIG. 6, the needles 3, 19 are mounted in a
common bar 48 which is secured at a middle location to the
connecting rod 5.
In use of a machine according to the invention fabric is fed
longitudinally of the direction of feed and is repeatedly displaced
to and fro laterally by the mounting means including the temple
rollers 9, 24. In the fabric is repeatedly formed, by the needles,
loopers and knives, laterally extending rows, in this example two,
of cut pile loops which are spaced apart longitudinally of the
direction of feed. In each of these rows the cut pile loops are
spaced apart laterally by a distance less than the distance between
the rows. The amplitude of lateral reciprocation of the fabric is
greater than the distance by which the cut pile loops are spaced
apart laterally. The result is that the cut pile loops are disposed
in the fabric in long wavy lines which cross over one another to
form cut pile loops such as indicated in FIGS. 3 and 7, these
Figures showing the rear face of the fabric and FIG. 8 showing the
tufting effect on the front face of the fabric.
This form of patterning is possible because of the relationship
between the two bars of needles, the sideways traverse of the
fabric, and the feed of the fabric.
Specifically it will be seen that due to the lateral reciprocation
of the fabric by the mounting means including the two temple
rollers 9, 24, which are reciprocated in the same direction at the
same time, both sets of needles produce substantially the same wave
form of tufting as shown in FIGS. 3 and 7. It is important to note
that not only are the respective wave forms substantially the same
in shape but they are also substantially the same in amplitude.
This is occasioned by the fact of having associated with the second
bar of needles 19 the second temple roller 24 which by its grip on
the fabric adjacent the needles 19, and the fact that it has the
same amplitude of lateral reciprocation as that of the first temple
roller 9, ensures that in actual practice the fabric in its
approach to the second bar of needles 19 has the same amplitude of
lateral reciprocation as that of the fabric in its approach to the
first bar of needles 3. The two sets of like wave forms are
produced with a fixed pitch spacing since the pitch spacing of the
needles is fixed. Because of the fixed distance between the needle
rows, the two sets of wave forms are produced by the different sets
of needles one in fixed advance of the other, see FIG. 3 wave forms
`A` by the front needles 3 and wave forms `B` by the rear needles
19, and it will be seen that the two wave forms are not in parallel
relationship. The actual relationship between the two sets of wave
forms laterally of the fabric is to some extent controlled by the
amplitude of lateral reciprocation of the fabric, and this is
conveniently arranged by the cam control of the carriage mounting
the two temple rollers in the same direction at the same time, to
be a variably predetermined amount greater than the distance by
which the cut pile loops or needles are spaced apart laterally of
the fabric. The frequency of the lateral reciprocation, which also
affects the relationship, is initially predetermined by trial and
error. The feed of the fabric is arranged initially by trial and
error so that by the time a part that is curved in one direction,
for example, of each wave form produced by the front needles 3
reaches the rear needles 19, each of these rear needles 19 is
complementarily forming a part of its wave form which is curved in
the opposite direction, whereby the two sets of wave forms are in
direct opposed relationship to form the regular symmetrical pattern
illustrated.
The combined control is such that the two sets of wave forms cross
each other several times, as indicated at "C," at longitudinally
spaced positions.
The complete pattern is clearly shown in FIG. 7 from which it will
be seen that the crests such as `D` and `E` of the wave forms are
in symmetrically opposed relationship at longitudinally spaced
positions, and between these positions the crossings `C` of the
wave forms result in the formation of a diamond pattern.
For obtaining this pattern, the needles have about a 1 inch pitch
spacing, the two needle rows are about 5 inches apart, the temple
rollers 9, 24 have a reciprocation of about 3 inches to provide
about 21/2 inches lateral reciprocation of the fabric at the needle
rows, the frequency of the lateral reciprocation is from either
side to the other side for approximately 5 in. of fabric feed, and
the fabric feed is at a rate of nine stitches per inch. In practice
the machine is run initially with an elected fabric feed and
elected lateral reciprocation of the temple rollers, the patterning
of the series of cut pile loops is observed and adjustments and
changes are made by trial and error until the required pattern
relationship is acquired. These adjustments and changes are noted
and are effected whenever the same particular pattern is
required.
FIG. 8 shows that although the tufting is patterned, the outline of
the pattern in this example is not clearly seen from the cut
pile.
In a modification of FIGS. 9 and 10 every third needle has been
removed, so that in each laterally extending row of cut pile loops
the loops are disposed at different pitch spacings. In this manner
a more open pattern is formed, and this pattern is generally
discernible in the cut pile as shown in FIG. 10.
It will be understood that other patterns of cut pile can be formed
by use of the aforesaid inter-changeable cams such as E and pulleys
such as P, and different needle spacings.
It will be also understood that the fabric is of particular
advantage for manufacture into articles such for example as
candlewick bedspreads.
FIG. 11 shows a modified form of control for the looping hooks 10,
25 and knife cutters 12, 26, in which the eccentric operated
mechanism 17 is connected by arm means 50 directly to the rocking
shaft 11 for operation of the looper hooks and for operation of the
knife cutters, the arm means 50 is connected by a link means 51 to
an arm means 52 and the latter is, pivoted to a bracket means 53
and has fork means embracing peg or roller means 54 carried by the
link means 33.
It is to be further understood that there may be more than a pair
of the bars of needles and associated mechanism, e.g., four
bars.
* * * * *