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.

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.

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.