U.S. patent number 3,908,570 [Application Number 05/257,152] was granted by the patent office on 1975-09-30 for patterned tufted fabrics and method of making same.
This patent grant is currently assigned to Fieldcrest Mills, Inc.. Invention is credited to Sandres Alfred Puckett.
United States Patent |
3,908,570 |
Puckett |
September 30, 1975 |
**Please see images for:
( Certificate of Correction ) ** |
Patterned tufted fabrics and method of making same
Abstract
Tufted pile farbics and a method of making the same wherein
first and second sets of pile yarns are shogged laterally to form
respective rows of pile tufts on one surface of the base material,
with the pile yarns of the respective sets crossing the rows of
pile tufts formed of the pile yarns of the other sets on the
reverse side of the base material from the pile tufts.
Inventors: |
Puckett; Sandres Alfred
(Laurinburg, NC) |
Assignee: |
Fieldcrest Mills, Inc. (Eden,
NC)
|
Family
ID: |
22975101 |
Appl.
No.: |
05/257,152 |
Filed: |
May 26, 1972 |
Current U.S.
Class: |
112/410;
112/80.41 |
Current CPC
Class: |
D05C
17/026 (20130101) |
Current International
Class: |
D05C
17/00 (20060101); D05C 17/02 (20060101); D05C
017/02 () |
Field of
Search: |
;112/410,79R,79A,79FF,266 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Schroeder; Werner H.
Attorney, Agent or Firm: Parrott, Bell, Seltzer, Park &
Gibson
Claims
That which is claimed is:
1. A tufted pile fabric comprising a base and pile yarns
penetrating the base and forming on one surface of the base
longitudinal rows of pile tufts, each of said longitudinal rows of
pile tufts comprising successive groups of pile tufts with each
group having a series of pile tufts therein, the pile tufts in any
given group being formed of the same pile yarn with adjacent groups
of pile tufts in each longitudinal row being formed of different
pile yarns, alternate rows of said pile tufts being formed of one
set of pile yarns and intervening rows of tufts being formed of a
different set of pile yarns, and said pile yarns forming said
alternate rows crossing said pile yarns forming said intervening
rows on the reverse side of said base from said pile tufts.
2. A tufted pile fabric comprising a base and pile yarns
penetrating said base, said pile yarns being arranged in two sets
of pile yarns with one set of pile yarns penetrating said base and
forming alternate longitudinal rows of pile tufts on one face of
said base and with said other set of pile yarns penetrating said
base and forming intervening rows of pile tufts on said one face of
said base, each of said rows of pile tufts comprising successive
groups of pile tufts with each group comprising a series of pile
tufts, adjacent groups of pile tufts in each row being formed of
different pile yarns, and said one set of pile yarns crossing said
other set of pile yarns on the reverse face of said base from said
pile tufts.
3. A tufted pile fabric comprising a base and pile yarns
penetrating the base and forming on one surface of the base
longitudinal rows of pile tufts, said pile yarns being arranged in
two sets of pile yarns with the pile yarns of one set forming
alternate longitudinal rows of tufts on said surface and the pile
yarns of the other set forming intervening longitudinal rows of
tufts on said surface, but wherein said alternate rows have
successive tufts thereof formed of respective different yarns of
said one set and said intervening rows have successive tufts
thereof formed of respective different yarns of said other set with
the pile yarns forming said alternate rows crossing said pile yarns
forming said intervening rows and vice versa on the reverse side of
said base from said tufts.
4. A tufted fabric comprising a base and pile yarns extending
through the base and forming pile tufts arranged in longitudinal
rows on the face thereof, pile tufts in alternate rows being formed
from a first set of pile yarns and pile tufts in intervening rows
being formed from a second set of pile yarns, offset pile tufts in
adjacent alternate rows being interconnected by the respective pile
yarn extending across the back of the intervening rows along the
back of the base, and offset pile tufts in adjacent intervening
rows being interconnected by the respective pile yarn extending
across the back of the alternate rows along the back of the
base.
5. A tufted fabric comprising a base and pile yarns penetrating the
base and forming pile tufts arranged in longitudinal rows on the
face thereof, pile tufts in alternate rows being formed from a
first set of pile yarns and pile tufts in intervening rows being
formed from a second set of pile yarns, and offset groups of
successive pile tufts in adjacent alternate rows being
interconnected by the respective pile yarn extending across the
back of the intervening rows of tufts along the back of the
base.
6. A tufted fabric comprising a base and pile yarns extending
through the base and forming pile tufts arranged in longitudinal
rows on the face thereof, pile tufts in alternate rows being formed
from a first set of pile yarns and pile tufts in intervening rows
being formed from a second set of pile yarns, offset groups of
successive pile tufts in adjacent alternate rows being
interconnected by the respective pile yarn extending across the
back of the intervening rows along the back of the base, and offset
groups of successive pile tufts in adjacent intervening rows being
interconnected by the respective pile yarn extending across the
back of the alternate rows along the back of the base.
7. A tufted fabric comprising a base and pile yarns extending
through the base and forming pile tufts arranged in longitudinal
rows on the face thereof,
each of said longitudinal rows of pile tufts comprising successive
groups of pile tufts with each group having a series of pile tufts
therein,
the pile tufts in any given group being formed of the same pile
yarn with adjacent groups of pile tufts in each longitudinal row
being formed of different pile yarns, and
alternate rows of said pile tufts having offset groups of pile
tufts formed of the same pile yarn and being interconnected by the
respective pile yarn extending across the back of intervening rows
along the back of the base.
8. A tufted fabric comprising a base and pile yarns extending
through the base and forming pile tufts arranged in longitudinal
rows on the face thereof, pile tufts in certain spaced rows being
formed from one set of pile yarns and pile tufts in other spaced
rows being formed from another set of pile yarns, said other spaced
rows being positioned between said certain spaced rows, offset pile
tufts in said certain spaced rows being interconnected by the
respective pile yarn forming the offset pile tufts extending across
the back of said other spaced rows along the back of the base, and
offset pile tufts in said other spaced rows being interconnected by
the respective pile yarn forming the offset pile tufts extending
across the back of said certain spaced rows along the back of the
base.
9. A tufted fabric comprising a base and pile yarns extending
through the base and forming pile tufts arranged in longitudinal
rows on the face thereof, each row of pile tufts comprising a
plurality of successive tufts formed from a plurality of respective
pile yarns successively arranged in a predetermined sequence, and
spaced rows of pile tufts having certain pile tufts therein formed
of the same pile yarn and being connected by said same pile yarn
extending across the back of an intervening row of tufts along the
back of the base.
Description
Tufted fabrics of the type having variegated tuft patterns on one
face thereof formed of pile yarns extending through a base material
and also extending laterally on the reverse side of the base
material between adjacent longitudinal rows of tufts, are well
known in the art, as disclosed, for example, in U.S. Pat. Nos.
3,026,830; 3,109,395; 3,249,078 and 3,396,687. In some such fabrics
two sets of pile yarns are used and, between the formation of
successive tufts, the needle bars for either or both sets of pile
yarns are shogged laterally a distance equal to the distance from
one row of tufts to the next adjacent row so that tufts of both
sets of pile yarns always appear at certain intervals in the same
rows of tufts.
It is also known to utilize two lateral rows of tufting needles
with the needles aligned with respect to the path of travel of a
base material, and wherein the base material is shifted to and fro
laterally of its path of travel at the point of action of one only
of the rows of needles so that the pile yarns carried thereby
extend in a zigzag manner across straight rows of tufts formed of
the pile yarns carried by the other row of needles, as disclosed in
U.S. Pat. No. 3,585,948, for example.
It has now been determined that enhanced pattern effects are
obtainable by utilizing at least two lateral rows of tufting
needles with the needles in one row staggered relative to the
needles in the other row, but which rows of needles are shogged or
shifted laterally a distance equal to twice the distance between
the center of two adjacent rows of tufts to form respective
separate rows of tufts from respective sets of pile yarns carried
by the two rows of needles, with tufts of different yarns of the
same set appearing at certain successive intervals in given rows of
tufts, and wherein the pile yarns forming alternate rows of tufts
cross the pile yarns forming intervening rows of tufts, and vice
versa, on the reverse side of the base material from the pile
tufts.
It is therefore an object of this invention to provide a patterned
tufted fabric and method of making the same wherein a plurality of
sets of pile yarns are shogged or shifted laterally of a base
material to form respective longitudinal rows of pile tufts on one
face of the base material, and wherein, between the formation of
successive tufts, each pile yarn of at least one set extends
laterally across one or more adjacent rows of tufts formed from
pile yarns of a different set.
It is another object of this invention to provide a tufted pile
fabric and method of making the same, wherein pile yarns penetrate
a base material and form on one surface thereof longitudinal rows
of pile tufts, with each of the longitudinal rows of tufts
comprising successive groups of pile tufts and with each group
having a series of pile tufts therein. The pile tufts in any given
group are formed of the same pile yarn with adjacent groups of pile
tufts in each longitudinal row being formed of different pile
yarns, alternate rows of the pile tufts being formed of one set of
pile yarns and intervening rows of pile tufts being formed of a
different set of pile yarns, and wherein the pile yarns forming the
alternate rows of pile tufts cross the pile yarns forming the
intervening rows of pile tufts on the reverse side of the base
material from the pile tufts.
According to the method, first and second parallel rows of spaced
apart tufting needles are employed with respective first and second
sets of pile yarns carried thereby, and wherein the first needles
are staggered relative to the second needles. A base material is
advanced longitudinally while the pile yarns carried by the needles
are inserted through the base material to form respective rows of
pile tufts of the first and second pile yarns while, at times,
between the formation of successive tufts, both rows of needles are
shifted laterally of the base material to lay the first pile yarns
across the back of adjacent rows of tufts formed of the second pile
yarns and to lay the second pile yarns across the back of adjacent
rows of tufts formed of the first pile yarns whereby tufts of each
first yarn are formed adjacent opposite sides of tufts of each
second yarn, and vice versa, in at least a portion of the tufted
pile fabric.
Some of the objects of the invention having been stated, other
objects will appear as the description proceeds when taken in
connection with the accompanying drawings in which
FIGS. 1, 2 and 3 are fragmentary views of three partially tufted
fabric sections formed in accordance with this invention and
embodying respectively different variegated patterns, all of which
may evolve from the same patterned manipulations of the pile yarns,
but which are formed by utilizing respective differently arranged
colors of pile yarns;
FIGS. 1A, 2A and 3A are fragmentary views looking at the reverse
side or back side surfaces of the respective tufted fabric sections
shown in FIGS. 1, 2 and 3, and also showing an arrangement of two
needle bars which are out-of-phase with respect to the cyclical
pattern of the respective sets of pile yarns;
FIG. 4 is a fragmentary perspective view of a portion of a tufting
machine showing how the needle bars and the respective rows of
tufing needles may be manipulated in accordance with the method of
this invention;
FIG. 5 is an enlarged elevation of one of the pattern control cams
shown in FIG. 4 for effecting lateral shifting of the respective
row of tufting needles;
FIG. 6 is a schematic view of the pile face of another fabric
section illustrating a single repeat in the patterning of each of
the two sets of pile yarns, which repeat differs from the repeats
of FIGS. 1-3 and 1A-3A; and
FIG. 7 is a view of the reverse side surface of the fabric section
shown in FIG. 6.
Referring more specifically to the drawings, portions of a tufting
machine suitable for forming the novel fabrics according to the
method of this invention are shown in FIGS. 4 and 5. The tufting
machine may be in the form of a suitably modified conventional
tufting machine of the general type disclosed in U.S. Pat. No.
3,396,687, and having at least two rows of tufting needles, but
wherein the pile yarns and the tufting needles are arranged and
controlled in a manner peculiar to the present invention.
Accordingly, only so much of the tufting machine will be described
as is deemed necessary to a clear understanding of the method of
this invention, and reference is made to said U.S. Pat. No.
3,396,687 for a more detailed description of a tufting machine.
As shown in FIG. 4, the tufting machine may include at least two
parallel rows of spaced apart tufting needles, namely, a first row
10 and a second row 11. The rows of tufting needles 10, 11 may be
carried by a common needle bar, but are shown carried by respective
needles bars 12, 13 extending laterally over a forwardly and
longitudinally advancing base material B through which first and
second sets of pile yarns, carried by the respective needles 10,
11, are inserted. The tufting needles 10, 11 cooperate with
respective loopers, not shown, to form pile tufts of the pile yarns
inserted through the base material B as is conventional.
Accordingly, details of the supporting means for the base material
B and the loopers are not shown and will not be described in
detail.
The needle bars 12, 13 are carried by vertically reciprocating rods
14 driven to reciprocate in timed relation to a rotating cam shaft
15. Cam shaft 15 has a pair of control cams 16, 17 mounted thereon
which serve as pattern means for shogging or shifting the
respective needle bars 12, 13 and needles 10, 11 laterally of the
path of travel of base material B at predetermined intervals and
for predetermined distances, according to a predetermined pattern.
It is apparent that needles 10, 11 occupy a raised or withdrawn
position with respect to base material B whenever the needles are
shifted laterally of base material B.
In this instance, control cams 16, 17 are shown as being configured
for forming the fabric sections of FIGS. 1-3 such as to cause each
needle bar 12, 13 to occupy three different positions at different
times laterally of the path of travel of base material B. Thus,
each cam 16, 17 is in form of a grooved disc or face cam having
low, high and intermediate cam surfaces 21-23 spaced at different
radii from the axis of cam shaft 15. The grooves in the respective
control cams 16, 17 are engaged by followers 25, 26 carried by
respective guide bars 27, 28. Guide bars 27, 28 are suitably guided
for lateral movement in the frame of the machine and have
respective posts 30, 31 mounted on their inner ends on which the
adjacent ends of needle bars 12, 13 are guided for vertical
movement.
Referring to FIGS. 1A-3A, it will be observed that needles bars 12,
13 are shown in phantom lines superimposed over the back side of
fabric sections broadly designated at 40, 41, 42, all of which may
be combined in a single tufted fabric if desired. According to the
invention, in the fabric embodiments of FIGS. 1-3 and the
respective FIGS. 1A-3A, the longitudinal rows of pile tufts are
formed from at least two sets of pile yarns, with alternate
longitudinal rows of tufts being formed of one set of pile yarns
and with intervening longitudinal rows of pile tufts being formed
of another set of pile yarns. Thus, as shown in FIGS. 1A-3A, the
first needles 10 are staggered relative to the second needles 11,
and respective first and second sets of pile yarns P-1, P-2 are
threaded through or carried by the respective first and second rows
of tufting needles 10, 11.
Since the alternate rows of pile tufts are formed of the first set
of pile yarns P-1 and intervening rows of pile tufts are formed of
the second set of pile yarns P-2, it follows that the lateral
distance between the centers of adjacent tufting needles in each
row is twice the gauge of the fabric. The term "gauge" as used
herein means the distance between the centers of two immediately
adjacent rows of tufts. Thus, the staggered relationship between
the first and second needles 10, 11 is such that there is a
distance of one gauge between the center of each first needle 10
and the next adjacent second needle 11 measured laterally of the
path of travel of the base material B. However, there is a distance
of two gauges between the adjacent needles in each row 10, 11.
Also, the difference between the radii of adjacent cam surfaces
21-23 (FIG. 5) preferably is such as to effect movement to the
needle bars 12, 13 of two gauges, although such movement may be a
multiple of two gauges, if desired.
For illustrative purposes, control cams 16, 17 are shown in FIG. 4
as being positioned in in-phase relationship so that, during each
lateral shifting movement of the needle bars 12, 13 and tufting
needles 10, 11 all of the needles 10, 11 move the same distance
(two gauges) and in the same direction. Accordingly, the first row
of tufting needles 10 is spaced rearwardly of the second row of
tufting needles 11 in out-of-phase relation thereto with respect to
the particular pattern cycle of the needles 10, 11. By way of
example, twelve successive tufts are formed of each pile yarn P-1,
P-2 during the formation of each cylical pattern repeat of the pile
yarns in forming the rows of pile tufts, but the path traced by
each first pile yarn P-1 is shown to be 60.degree. out-of-phase
with the path traced by each second pile yarn P-2 in each pattern
repeat. In other words, the distance between the starting point of
each repeat cycle of the first set of pile yarns P-1 and that of
the second set of pile yarns P-2 is shown as being equivalent to
twice the space between two adjacent tufts in any given
longitudinal row.
For purposes of clarity, the first and second row of needles 10, 11
are shown in FIGS. 1A-3A with their centers spaced apart
longitudinally of the direction of travel of the base material B a
distance equivalent to the amount of longitudinal movement imparted
to the base material B incident to the formation of ten successive
pile tufts by each needle 10, 11. That is, the needle rows 10, 11
are shown 300.degree. out-of-phase in FIGS. 1A-3A. It is preferred,
however, that the first row of needles 10 is positioned the
equivalent of two tufts forwardly or rearwardly of the second row
of tufting needles 11 so that the needle rows are 60.degree.
out-of-phase with respect to the tuft pattern being formed. Also,
in forming the fabric sections 40, 41, 42 tufting needles 10, 11
may be mounted on a common needle bar controlled by a single
control cam, if desired.
Referring now to FIGS. 1-3, it will be observed that each fabric
section 40-42 includes alternate rows of pile tufts T' with
intervening rows of pile tufts T" between the alternate rows. The
alternate and intervening tuft rows T', T" are formed of the
respective first and second sets of pile yarns P-1, P-2. However,
each row of tufts is formed of several different pile yarns of the
same respective set because, at predetermined intervals, and
between the formation of successive tufts, each pile yarn in each
set P-1, P-2 (FIGS. 1, 2 and 3) is shogged or shifted laterally two
gauges in one direction or in the opposite direction so that the
pile yarns of one set extend across the back of the rows of tufts
formed of the pile yarns of the other set, and vice versa. It
should be noted that none of the tufts in the alternate rows of
tufts T' are formed of the pile yarns in the second set P-2 and
none of the tufts in the intervening rows of tufts T" are formed of
the pile yarns in the first set P-1.
As the base material B advances toward the top of the drawing in
FIGS. 1A, 2A and 3A, each pile yarn is caused to trace a
predetermined irregular path of the same shape over the back side
of the base material, although the path of each pile yarn of the
first set P-1 is out-of-phase with respect to the path of each pile
yarn of the second set P-2. Therefore, for purposes of clarity,
only the paths traced by one pile yarn in each set will be
described with reference to FIGS. 1 and 1A, such pile yarn of the
first set P-1 being identified as P-1' and such pile yarn of the
second set P-2 being identified as P-2'.
At the start of a repeat cycle, it may be assumed that one of the
needles 10 has inserted pile yarn P-1' through the base material B
at point a in FIG. 1A and, at the same time, one of the needles 11
has inserted the pile yarn P-2' through the base material B at
point a' which is 300.degree. of a pattern repeat or cycle ahead of
the point a. Thus, all of the pile yarns in the first set 10 will
have previously been formed into the alternate rows of tufts T'
(FIGS. 1, 2 and 3) in that portion of each fabric section 40, 41,
42 located forwardly of the point a in FIGS. 1 and 1A.
During formation of the tufts at points a, a' as well as the next
succeeding tufts, the low surfaces 21 (FIG. 5) of the respective
cams 16, 17 are in engagement with followers 25, 26. Thereupon, the
corresponding intermediate surfaces 22 of cams 16, 17 move into
engagement with followers 25, 26 and thus shift both needle bars
12, 13 to the right in FIGS. 1A, 2A and 3A (to the left in FIGS.
1-3) for two gauges so that all of the pile yarns in the second set
are caused to extend across the adjacent pile yarns P-1 which had
previously formed the alternate rows of pile tufts T' forwardly of
the rearward or first needle bar 12.
Each of the needles 10, 11 in each set then forms a group of tufts
comprising a series of three successive pile tufts of the same
respective pile yarn, during which the followers 25, 26 dwell in
engagement with cam surfaces 22. The succeeding high surfaces 23 of
cams 16, 17 then move into engagment with followers 25, 26 to again
shift both needle bars 12, 13 tow gauges to the right in FIGS.
1A-3A, whereupon a series of three additional successive pile tufts
are formed in the base material from each respective pile yarn by
each of the tufting needles 10, 11, and during which the high
surfaces 23 of the cams 16, 17 remain in engagement with the
respective followers 25, 26. Thereupon, the next succeeding
intermediate surfaces 22 of cams 16, 17 move into engagement with
the respective followers 25, 26 to shift needle bars 12, 13 two
gauges to the left in FIGS. 1A-3A, and three more pile tufts then
are formed of each respective pile yarn P-1, P-2.
The low surfaces 21 of cams 16, 17 then again move into engagement
with followers 25, 26 to again shog or shift both needle bars 12,
13 two gauges to the left and to their original positions.
Thereafter, an additional tuft is formed of each of the pile yarns
P-2 to complete a cycle in the patterend manipulation of the pile
yarns. It should be noted that, each time that needle bars 12, 13
are shifted laterally for two gauges, in the manner heretofore
described, the second row of needles 11 lays the second pile yarns
P-2 across the adjacent, alternate, rows of tufts T' of the first
pile yarns P-1, and this also causes the pile yarns of the first
set P-1 to cross the intervening rows T" formed of the pile yarns
of the second set P-2. In so doing, tufts of each first pile yarn
are caused to be positioned adjacent opposite sides of tufts formed
of each second pile yarn P-2, and vice versa.
Additionally, since needle bars 12, 13 dwell in predetermined
positions during a formation of longitudinal series of three tufts
by each tufting needle 10, 11 and following each time that needle
bars 12, 13 are shifted laterally for two gauges, each longitudinal
row of pile tufts comprises successive groups of pile tufts each
having a series of three pile tufts therein. Also, the pile tufts
in any given group are formed of the same pile yarn, but adjacent
groups of pile tufts in each longitudinal row are formed of
different pile yarns.
This may be more clearly understood with reference to the upper
portion of FIG. 1 wherein it is shown, for example, that there are
longitudinally spaced groups b of shaded or colored tufts in each
of three adjacent alternate rows T' in the central portion of
fabric section 40, but adjacent groups of the shaded tufts b in the
same longitudinal row are separated by groups of at least three
white or uncolored tufts which are formed from different pile yarns
from that of which the groups of shaded tufts b are formed in the
same alternate rows T'. All of the tufts in any given group b are
formed of the same pile yarn and, as a matter of fact, all of the
particular groups of tuft b in the central portion of FIG. 1 are
formed of the same pile yarn in this instance.
Because of the fact that the needles 10, 11 are staggered and the
tufts formed of any given pile yarn are formed in succession as the
base material B is advanced past the row of tufting needles 10, 11,
it will be observed in the upper central portion of FIG. 1 that the
successive groups of shaded pile tufts b in a given one of the
alternate rows T' are offset with respect to the groups of shaded
pile tufts b in other adjacent alternate rows T'. Also, it is
apparent in the upper central portion of FIG. 1A that the offset
pile tufts in adjacent alternate rows of interconnected by the
respective pile yarn extending across the back of the intervening
rows T" along the back of the base material B. It follows from the
foregoing description that offset pile tufts in adjacent
intervening rows T" also are interconnected by the respective pile
yarn extending across the back of the alternate rows T' along the
back of the base material.
As heretofore indicated, fabric sections 41, 42 are formed in the
same manner as, and may even be formed integral with fabric section
40. The fabric sections 41, 42 differ from fabric section 40 simply
by the choice of pile yarns. For illustrative purposes, it will be
observed in FIG. 1A that the majority of the pile yarns are white,
with only one of the pile yarns P-1 which forms one of the
aforementioned alternate rows of pile tufts T' being a shaded or
black yarn along the approximate central portion of fabric section
40. Also, only two of the pile yarns P-2 of the second set, and
which form portions of corresponding intervening rows of pile tufts
T", are shaded or black pile yarns spaced substantial distances to
either side of the aforementioned shaded or black pile yarn in the
first set P-1.
Although fabric section 41 is formed in the same manner as fabric
section 40, it will be observed in FIG. 2A that alternate pile
yarns c of the first set P-1 are colored yarns; e.g., green, and
intervening pile yarns d of the first set P-1 are white. Also, all
of the pile yarns of the second set P-2 are of the same color as
the alternate pile yarns c of the first set P-1. Thus, it will be
observed in FIG. 2 that, on the pile face of fabric section 41,
alternate rows of tufts T' each have longitudinally spaced groups
of three colored tufts C therein with groups of three white tufts D
disposed therebetween and formed of the respective pile yarns c, d
(FIG. 2A) of the first set P-1. Also, the colored tuft groups C are
offset in adjacent alternate rows T'. On the other hand, all of the
tufts are of the same color throughout the length of each
intervening row of tufts T", since all of the pile yarns P-2 in
FIG. 2A are of the same color.
Although the fabric section 42 in FIGS. 3 and 3A also is formed in
the same manner as fabric sections 40, 41, the pile face of fabric
section 42 (FIG. 3) has a substantially different aesthetic
appearance than the pile faces of fabric sections 40, 41 (FIGS. 1
and 2), because of a different arrangement of colored pile yarns.
Accordingly, it will be observed in FIG. 3A that alternate pile
yarns e of the first set P-1 may be gray yarns, for example, and
intervening pile yarns f of the first set P-1 are white yarns.
Additionally, alternate pile yarns g in the second set P-2 are
green yarns, for example, and intervening pile yarns h in the
second set P-2 are black yarns, for example. Thus, it will be
observed in FIGS. 3 that, on the pile face of fabric section 42,
alternate rows of tufts T' each have longitudinally spaced groups
of three gray tufts E therein with groups of three white tufts F
therebetween formed of the respective pile yarns e, f (FIG. 3A) of
the first set P-1, and wherein the groups of gray tufts E are
offset in adjacent alternate rows T'.
Also, it will be observed in FIG. 3 that intervening rows of tufts
T" each have longitudinally spaced groups of green tufts G therein
with groups of three black tufts H therebetween formed of the
respective pile yarns g, h (FIG. 3A) of the second set P-2, and
wherein the groups of green tufts G are offset in adjacent
intervening rows T". It will be noted in FIG. 3 that adjacent
groups of gray and white tufts E, F in alternate rows T' are
partially offset with respect to adjacent groups of green and black
tufts G, H in the intervening rows T". Thus, although a pattern of
pile tufts is presented, the different colors of tufts are somewhat
randomly disposed throughout the pattern.
As heretofore described, the needle bars 12, 13 are positioned
out-of-phase with respect to the pattern of tufts being formed and
are shifted laterally in a unitary manner to produce fabric
sections 40, 41, 42 as shown in FIGS. 1, 2 and 3. Thus, in forming
fabric sections 40, 41, 42, a single cam may be utilized, instead
of the two cams 16, 17 of FIGS. 4 and 5, for shifting the needle
bars 12, 13 laterally of the path of travel of the base material B,
if desired. However, the two cams 16, 17 are provided in FIG. 4 to
facilitate lateral shifting of needle bars 12, 13 independently of
each other, as may be desirable in forming some tuft patterns.
Also, by changing the relative angular positions of control cams so
that they are 60.degree. out-of-phase, for example, needle bars 12,
13 may be located in in-phase relationship for producing the fabric
sections 40, 41, 42, if desired.
Referring now to FIGS. 6 and 7, there is shown a single pattern
repeat in a fabric section 43 which may be formed by arranging the
needle rows 10, 11 in out-of-phase relation substantially as
described with respect to fabric sections 40-42, but wherein the
needle rows 10, 11 would be 80.degree. out-of-phase and the
sequence of the lateral stepwise movements of the needle bars 12,
13 is different from that described with respect to the forming of
fabric sections 40-42. Of course, the configuration of the grooves
in cams 16, 17 would be different from that shown in FIG. 5 for
forming the fabric section 43.
As is the case with respect to FIGS. 1A, 2A, 3A, the first and
second sets of pile yarns shown in FIG. 7 are broadly designated at
P-1 and P-2, respectively. The first pile yarn set P-1 in FIG. 7
may include a lateral series of red, green black and gray pile
yarns i, j, k, m in each lateral repeat and all of the pile yarns
of the second set P-2 may be white yarns. Reading upwardly from the
bottom of FIG. 7, it can be seen that a group of three successive
tufts is formed from each pile yarn in each set P-1, P-2, whereupon
the needle bars are shifted laterally two gauges to the left. A
single tuft then is formed from each pile yarn, and the needle bars
then shift two gauges to the right and another tuft is formed from
each pile yarn. Thereafter, the needle bars are again shifted two
gauges to the right, whereupon two successive tufts are formed of
each pile yarn longitudinally of the fabric. The needles bars 12,
13 then move to the left for two successive steps of two gauges
each with a tuft being formed from each pile yarn at the end of
each step. Thereafter, needle bars 12, 13 are again shogged two
gauges to the right to complete the pattern cycle.
Thus, it will be observed in FIG. 6 that, on the pile face of
fabric section 43, each of the alternate rows T' includes pile
tufts of three different colors formed of the pile yarns in set
P-1, and all of the tufts in each intervening row T" are white
tufts formed from the second set of pile yarns P-2. The tufts
corresponding to the respective pile yarns i, j, k, m of the first
set P-1 in FIG. 7, are indicated respectively at I, J, K and M in
FIG. 6.
Because of the paths taken by each pile yarn in thte pile yarn set
P-1 in FIG. 7, and as indicated in broken lines in FIG. 6, the
various colors of tufts are arranged in different sequences in the
alternate rows of tufts T' in the pattern repeat shown in FIG. 6.
More specifically, the right-hand row T' includes three tufts I,
one tuft J, one tuft I, two tufts M, one tuft I and one tuft J in
that order. The second alternate row T' from the right in FIG. 6
includes three tufts J, one tuft K, one tuft J, two tufts I, one
tuft J, and one tuft K in that order. The third alternate row T'
from the right in FIG. 6 includes three tufts K, one tuft M, one
tuft K, two tufts J, one tuft K and one tuft M, in that order. The
last or fourth alternate row of tufts T' from the right in FIG. 6
includes three tufts M, one tuft I, one tuft M, two tufts K, one
tuft M and one tube I in that order.
The term "tufts" is used herein generically to mean loop pile tufts
or cut pile tufts as the case may be, it being understood that, if
desired, the tufting machine may be equipped with conventional
cutting blades associated with the loopers thereof for cutting the
pile loops on the machine, or the pile surfaces may be sheared
after the fabric is removed from the tufting machine.
It is apparent from the foregoing disclosure that a wide variety of
patterns of pile tufts of different colors or kinds may be obtained
in tufted fabrics in accordance with this invention and, therefore,
further illustrative examples of the fabrics of this invention is
deemed unnecessary.
In the drawings and specification, there has been set forth a
preferred embodiment of the invention and, although specific terms
are employed, they are used in a generic and descriptive sense
only.
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