GB1597734A

GB1597734A - Tufting machine needles

Info

Publication number: GB1597734A
Application number: GB2747977A
Authority: GB
Original assignee: Spencer Wright Industries Inc
Current assignee: Spencer Wright Industries Inc
Priority date: 1977-06-30
Filing date: 1977-06-30
Publication date: 1981-09-09
Also published as: DE2828246C2; DE2828246A1; DE7819305U1

Description

(54) TUFTING MACHINE NEEDLES (71) We, SPENCER WRIGHT IN DUSTRIES INC., a Corporation organised and existing under the laws of the State of Tennessee, United States of America, of 1501 Riverside Drive, Chattanooga, State of Tennessee, United States of America, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: The invention concerns tufting machine needles, and has particular reference to a needle of application in the context of needle modules for use in tufting machines.

In our copending British Patent Application No. 27478/77 (Serial No. 1597733) we have described and illustrated a needle module for the needle arrangement of a tufting machine which comprises a body part adapted to be attached to the needle bar of the said tufting machine and having a plurality of needles formed integrally therewith to depend in spaced parallel, side-byside disposition therefrom, the length of the module being equal to or substantially equal to a multiple of the pitch of the needles supported by such module and the number of needles being equal to such multiple.

The primary object of the present invention is to provide a needle of particular use in the production of such a needle module.

According to the present invention, there is proposed a tufting machine needle adapted for mounting in a matrix with a plurality of like needles to provide a module comprising a body part and a plurality of needles arranged in spaced apart, side-byside disposition therein, the needle comprising a generally flat elongate element having a yarn receiving eye adjacent one end thereof, a first region of non-uniform crosssectional form within that longitudinal extent of the needle intended for positive location of the needle within the body part of the module, being a part of the element remote from the said eye, a pick-up area adjacent the eye, and a second region having, in at least one direction, a predetermined transverse dimension and being intermediate the said first region and the said pick-up area, the said element being twisted intermediate the said second region and the pick-up area to provide a set whereby that part of the element which provides the pick-up area lies in a plane inclined to the plane of the remainder of the element.

Preferably that part of the element which provides the pick-up area lies at an angle of approximately 6" with respect to the remainder of the element.

The invention also includes a needle module comprising a body part having embedded therein a spaced apart parallel disposition and at predetermined centres a plurality of needles as aforesaid.

The invention will now be described further, by way of example only, with reference to the drawing filed with the provisional specification which illustrates one embodiment thereof, and in which: Figure 1 is a plan view of a needle in accordance with the invention; and Figure 2 is a section on line X-X of Figure 1; and with reference to the accompanying drawings in which: Figure 3 is a diagrammatic side sectional elevation of a part of a tufting machine in which the needle arrangement has a single row of modular needle units each incorporating a plurality of needles of the kind shown in Figure 1; Figure 4 is a front elevation of a part of the arrangement shown in Figure 3; Figure 5 is a front elevation of a corresponding pair of needle modules; Figure 6 is a section taken on line VI-VI of Figure 5; and Figure 7 is a section taken on line VII-VII of Figure 6.

Referring now to the drawings, and particularly to Figures 1 and 2 thereof, a needle for incorporation in a needle module for the needle arrangement of a tufting machine comprises a flat elongate element 11 having an eye 12 adjacent one end and an enlargement 13 at the opposite end of the said element, the said element being twisted at a position, indicated at 14, approximately mid-way between its ends to introduce a "set" whereby the plane of that part of the element wherein the pick-up area is formed is inclined in relation to the plane of the remainder of the element at an angle of approximately 6".

The element 11 is approximately 1.875 inches long, 0.1 inches wide and 0..05 inches thick, the enlargement 13 extending over a distance of approximately 0.125 inches in the axial direction of the element and arising from a flattening of the end of the element to increase the width and reduce the thickness of such element in such region.

At a position approximately 0.875 inches from the enlarged end of the element the same is twisted, as at 14, to provide the 6" set before referred to, the transverse dimension of the element in closely spaced disposition relative to the region of twist and at that side thereof remote from the needle eye 12 being maintained to predermined tolerances over a longitudinal extent of, say, 0.3125 inches to provide a location means 15 for use in accurately positioning the element in a suitable tool (not shown) during the subsequent moulding or casting operation in the formation of the ultimate needle module.

The surface of the element is ground adjacent to the eye, as at 16, in order to provide an increased target area on the needle for engagement by the looper.

By providing a needle in the form hereinproposed we are able readily to introduce any "set" appropriate to the specific requirements of the tufting machine by a simple twisting operation, which set is reproduced in the module on inclusion of the needle therein by utilisation of the location means in setting up the needles as a preliminary to casting or moulding.

A further, and important, advantage lies in the possibility with needle shanks of the flattened form herein proposed, of arranging the needle in position within a matrix in spaced disposition relative to other like needles in the manner proposed in our co-pending application aforesaid at greater separation for a given needle pitch than is the case with conventional needles having cylindrical shanks of like strength, thereby to provide for the ready movement of metal between adjacent shanks and an increased strength in the matrix. Thus, the need to utilise reduced diameter shanks, with a resultant diminution in shank strength so as to ensure adequate strength in the matrix is avoided, this being particularly important in small gauge situations.

Whilst the needle described and illustrated is produced from stock rod or bar of circular section using conventinal die pressing and/or grinding techniques, alternative starting elements may be used, if preferred, and in this regard a stock strip material may be of application.

The needle hereinproposed is of particular application in the context of a needle module of the kind described and illustrated in our copending application No. 27478/77, (Serial No. 1597733) such module and the manner of its application being shown in Figures 2 to 7 of the accompanying drawings.

Referring now to the accompanying drawings, and particularly to Figure 3 thereof, a tufting machine hook or looper 20 is supported in a looper block 21 for oscillating motion to pick up a loop of yarn from a needle 22 supported on a needle bar 23, the needle bar 23 being reciprocable in the axial direction of the needle in conventional manner. The looper 20 is co-operable with a knife mechanism 24 oscillating in timed relationship therewith for cutting the loop of yarn to form cut pile.

The needles are of the kind shown in Figure 1 and are provided in modular units 25 attachable to the needle bar, such modular units being shown generally in Figure 4 and in detail in Figures 5 to 7.

Referring now to Figures 5 to 7, each modular unit 25 is generally rectangular, being approximately 1.25 inches long, 1.0 inches high and 0.25 inches thick, and supports five tufting needles 22 depending from the underside thereof, the modular units 25 being arranged as two rows of units 26, 27, the individual units 25 of each row being in end-to-end abutting disposition and the two rows 26, 27 being arranged one behind the other. The individual modular units 25 are each of integral form and of moulded or cast construction. At its front lower edge the body part 25a, whilst at the opposite lower edge the body part includes an integral lip or flange 25c of like dimensions to the said rebate. An elongate aperture 25d is formed in the body part 25a in the upper region thereof, the major axis of such aperture being parallel to the longitudinal edges of the body part and the minor axis lying in the medium plane thereof. Two truncated conical protruberances 25e are provided in the front face of the body part, such protruberances being arranged one at either side of the elongate aperture 25d and slightly below the line of the major axis thereof, whilst two truncated conical reces ses 25f are provided in the rear face of the body part in like disposition relative to the line of the said major axis as the protruberances and at like spacing to the spacing of the said protruberances, the said recesses and protruberances being arranged in offset disposition in the longitudinal direction of the body part by an amount equal to the intended pitch of the needles 22 of the two rows of modular units when considered collectively.

As can best be seen from Figures 6 and 7, in practice the individual modular units 25 are arranged in two rows of such units disposed one behind the other, the units of one row being offset slightly in the longitudinal direction of the needle bar in relation to the corresponding modules of the other row, and corresponding pairs of modules of the two rows being attached to the needle bar by a common screw 28 which passes through the aligned elongate apertures 25d in the two units and engages a respective screw-threaded hole 29 in the needle bar 23.

The extent to which the individual ones of each pair of corresponding modular units are offset is determined by the relative positions of the protruberances 25e and recesses 25f in the front and rear faces respectively of the body parts 25a, and such positions are so arranged as to give a relative displacement as between the corresponding units upon engagement of the protruberances on the front face of the rearmost modular units with the recesses in the rear face of the foremost unit equal to the intended needle pitch of the needle assembly as a whole.

The needles 22 in each modular unit 25 are symmetrically arranged on such unit, the axis of the extreme needle in each case being spaced from the end of the body part by a distance equal to the intended pitch of the needle assembly as a whole.

By providing the needles in groups on separate modular units, so we are able to replace broken or damaged needles simply by replacing the modular unit concerned, which operation can be effected in a ready and rapid manner, the setting of the needles in relation to the remaining needle being automatically effected by virtue of the geometry of the unit.

The rigidty of the needle assembly as a whole is enhanced by the co-operating protruberances and recesses of the corresponding modular units and by the cooperating rebates and flanges of such units, and a total structure well fitted for its purpose results.

The accuracy with which the modular units might be produced, and the facility with which such units might be assembled together avoids various of the problems met with in connection with the conventional arrangements.

Any tolerance as between the cooperating male and female formations will provide a facility for relative adjustment as between corresponding modular units in the longitudinal direction of the needle bar within the limits of such tolerances.

Whilst, in the embodiment disclosed in Figures 5 to 7, the modular units are provided in pairs each for inclusion in a respective one of two rows of units arranged one behind the other, a single row only of such units may be used in a coarse gauge tufting machine in the matter illustrated in Figures 3 and 4, the double row concept as envisaged in Figures 5 to 7 providing for the mounting of the modular units on the needle bar in analogous manner to that shown in Figures 3 and 4.

The needle of the present invention is not restricted in the exact details of the embodiment hereindisclosed, since alternatives will readily present themselves to one skilled in the art. Thus, for example, the enlargement may take any form other than that shown which will preclude withdrawal of the needle from the body part of the module in the axial direction of such needle, rotation of the needle in such body part being prevented by the non-circular character of the shank of such needle.

Furthermore, co-operating male and female formations other than the cooperating truncated conical protruberances 5. and recesses provided on the body part described and illustrated may be preferred in some instances.

Attention is drawn to our co-pending Patent Application No. 14252/80 divided from this present Application (Serial No.

1597735).

WHAT WE CLAIM IS: 1. A tufting machine needle adapted for mounting in a matrix with a plurality of like needles to provide a module comprising a body part and a plurality of needles arranged in spaced apart, side-by-side disposition therein, the needle comprising a generally flat elongate element having a yarn receiving eye adjacent one end thereof, a first region of non-uniform cross-section form within that longitudinal extent of the needle intended for positive location of the needle within the body part of the module, being a part of the element remote from the said eye, a pick-up area adjacent the eye, and a second region having, in at least one direction, a predetermined transverse dimension and being intermediate the said first region and the said pick-up area, the said element being twisted intermediate the said second region and the pick-up area to provide a set whereby that part of the element which provides the pick-up area lies in a plane inclined to the plane of the

**WARNING** end of DESC field may overlap start of CLMS **.

Claims

**WARNING** start of CLMS field may overlap end of DESC **.

ses 25f are provided in the rear face of the body part in like disposition relative to the line of the said major axis as the protruberances and at like spacing to the spacing of the said protruberances, the said recesses and protruberances being arranged in offset disposition in the longitudinal direction of the body part by an amount equal to the intended pitch of the needles 22 of the two rows of modular units when considered collectively.

As can best be seen from Figures 6 and 7, in practice the individual modular units 25 are arranged in two rows of such units disposed one behind the other, the units of one row being offset slightly in the longitudinal direction of the needle bar in relation to the corresponding modules of the other row, and corresponding pairs of modules of the two rows being attached to the needle bar by a common screw 28 which passes through the aligned elongate apertures 25d in the two units and engages a respective screw-threaded hole 29 in the needle bar 23.

The extent to which the individual ones of each pair of corresponding modular units are offset is determined by the relative positions of the protruberances 25e and recesses 25f in the front and rear faces respectively of the body parts 25a, and such positions are so arranged as to give a relative displacement as between the corresponding units upon engagement of the protruberances on the front face of the rearmost modular units with the recesses in the rear face of the foremost unit equal to the intended needle pitch of the needle assembly as a whole.

The needles 22 in each modular unit 25 are symmetrically arranged on such unit, the axis of the extreme needle in each case being spaced from the end of the body part by a distance equal to the intended pitch of the needle assembly as a whole.

By providing the needles in groups on separate modular units, so we are able to replace broken or damaged needles simply by replacing the modular unit concerned, which operation can be effected in a ready and rapid manner, the setting of the needles in relation to the remaining needle being automatically effected by virtue of the geometry of the unit.

The rigidty of the needle assembly as a whole is enhanced by the co-operating protruberances and recesses of the corresponding modular units and by the cooperating rebates and flanges of such units, and a total structure well fitted for its purpose results.

The accuracy with which the modular units might be produced, and the facility with which such units might be assembled together avoids various of the problems met with in connection with the conventional arrangements.

Any tolerance as between the cooperating male and female formations will provide a facility for relative adjustment as between corresponding modular units in the longitudinal direction of the needle bar within the limits of such tolerances.

Whilst, in the embodiment disclosed in Figures 5 to 7, the modular units are provided in pairs each for inclusion in a respective one of two rows of units arranged one behind the other, a single row only of such units may be used in a coarse gauge tufting machine in the matter illustrated in Figures 3 and 4, the double row concept as envisaged in Figures 5 to 7 providing for the mounting of the modular units on the needle bar in analogous manner to that shown in Figures 3 and 4.

The needle of the present invention is not restricted in the exact details of the embodiment hereindisclosed, since alternatives will readily present themselves to one skilled in the art. Thus, for example, the enlargement may take any form other than that shown which will preclude withdrawal of the needle from the body part of the module in the axial direction of such needle, rotation of the needle in such body part being prevented by the non-circular character of the shank of such needle.

Furthermore, co-operating male and female formations other than the cooperating truncated conical protruberances 5. and recesses provided on the body part described and illustrated may be preferred in some instances.

Attention is drawn to our co-pending Patent Application No. 14252/80 divided from this present Application (Serial No.

1597735).

WHAT WE CLAIM IS: 1. A tufting machine needle adapted for mounting in a matrix with a plurality of like needles to provide a module comprising a body part and a plurality of needles arranged in spaced apart, side-by-side disposition therein, the needle comprising a generally flat elongate element having a yarn receiving eye adjacent one end thereof, a first region of non-uniform cross-section form within that longitudinal extent of the needle intended for positive location of the needle within the body part of the module, being a part of the element remote from the said eye, a pick-up area adjacent the eye, and a second region having, in at least one direction, a predetermined transverse dimension and being intermediate the said first region and the said pick-up area, the said element being twisted intermediate the said second region and the pick-up area to provide a set whereby that part of the element which provides the pick-up area lies in a plane inclined to the plane of the

remainder of the element.
2. A needle as claimed in claim 1, wherein that part of the element which provides the pick-up area lies in a plane inclined at an angle of approximately 6" with respect to the remainder of the element.
3. A needle as claimed in claim 1 or 2, wherein the said first region comprises a localised region of increased or reduced transverse dimensions relative to the transverse dimensions of an adjacent part of the elongate element, thereby to prevent withdrawal of the needle from the body part of a module of which the needle forms a part and within which body part the needle is partially embedded.
4. A needle as claimed in any one of the preceding claims, wherein the elongate element is formed from stock rod or bar by die-pressing or grinding.
5. A needle for a tufting machine substantially as hereinbefore described with reference to and as illustrated in the drawings filed with the provisional specification.
6. A needle module comprising a body part having embedded therein in spaced apart parallel disposition and at predetermined centres a plurality of needles as claimed in any one of the preceding claims.
7. A needle module as claimed in claim 6, wherein the said body part includes formations thereon adapted for engagement with respective cooperating formations on the body part of another like module on mounting the said modules in corresponding disposition one behind the other on or relative to a needle bar, thereby to locate the needles of one module in offset disposition longitudinally of the needle bar relative to the needle of the other module by a distance equal to one half of the pitch of the needles as they exist in a module.
8. A needle module as claimed in claim 6 or 7, wherein the needles are symmetrically disposed on the said bodv part.
9. A needle module as claimed in any one of claims 6 to 8, wherein the body part includes co-operable male and female formations on the front and rear faces of the body part, the said formations being at like spacing in a direction transverse to the needle axes and the formations at one face being offset in relation to those at the other face by a distance equal to one half the pitch of the needle carried by such body part or an odd number multiple of such one half pitch.
10. A needle module as claimed in claim 9, wherein the cooperable male and female formations comprise truncated conical protruberances and recesses, respectively.
11. A needle module as claimed in claim 9 or 10, wherein the male and female formations are provided at respective opposite faces of the body part, with the female formations at that face of the body part intended to engage the needle bar of the tufting machine.
12. A needle module as claimed in any one of claims 6 to 11, wherein the edges of that face of the body part from which the needles extend formed with complementary rebate and flange formations, the flange formation being at that face of the body part intended to engage the needle bar of the tufting machine.
13. A needle module as claimed in any one of claims 6 to 12, wherein an elongate aperture is formed in the body part to provide clearance for the shank of a screw whereby the module is secured in position relative to the needle bar.
14. A needle module as claimed in claim 13, wherein the dimension of the major axis of the elongate aperture exceeds that of the minor axis by at least one half of the pitch of the needles in the module.
15. A needle assembly comprising a multiplicity of needle modules as claimed in any one of claims 6 to 14 arranged in end-to-end disposition on and secured to the needle bar of a tufting machine.
16. A needle assembly as claimed in claim 15, wherein the needle modules are arranged in two rows arranged one behind the other, the modules in one row being offset in relation to the respective corresponding modules in the other row by one half of the pitch of the needles on the module.