IE901921A1 - Method of and apparatus for cutting carpet - Google Patents

Abstract

Patterned carpet is formed by implanting coloured lengths of yarn in a layer of adhesive on a pre-formed web (IO). Marginal portions of the web are marked in predetermined positions relative to the rows of tufts and the web is subseguently cut at predetermined positions relative to the marks to form tiles of carpet.

Description

The present invention concerns the cutting of ootterned corpet, for exompie to form corpet tiles which can subseguently he placed edge-to-edge to form a predetermined overall pattern.

Apparatus and a method for cutting patterned carpet is desorbed in Ir'sh specification no. 37114. he apparatus desorbed in the published specification includes indicators which overlie the pile of the carpet. The Indicators are marks, pins or similar elements and the positions of these are compared with the positions of predetermined tufts m the carpet. The carpet is adjusted relative to the indicators unt’l the predetermined tufts coincide with the indicators. The carpet hacking :s then cut bv cutting blades having a predetermined positional relation to the mdicators.

In a method In accordance with a first aspect of the present invention, the web of a carpet composing a web and a pile of tuf‘s on one face of the web, the tufts defining a pattern of the carpet, s marked m predetermined positions relative to the positions where the respective tufts are attached to the web and the web Is then cut along lines which hear a predetermined relation to the positions of the marks. ’he use of marks on the web leads to greater accuracv 'n the oos't’ons of the cuts than Is achieved by comparing the positions of mdiv'dual tufts with Indicator overlying the pile, 't'hilst the tofts of ‘he pile will generally be upstanding with respect to the web, the att:tude may differ from one toft to another within a piece of carpet and from one niece of carnet to another piece. Handling and stacking pieces of carpet, pr’or to cutting, may vary the attitudes of some tufts to an unpredictable degree.

In the establishment of a predetermined relation between the cuttina elements and the marks on the web, there mav be used one or more Indicator elements having a known positional relation to the cutting elements. There may be used one or more indicator elements which is in a nosltion beside the web, assuming the carpet to be resting on a generally horizontal surface with its pile uppermost, and/or one or more Indicator elements which \s at a level immediately below the level of the web, for example befnq present on a surface on which the carpet rests. Preferably, there is also provided one or more Indicator elements at a level above web so that a mark on the web can he brought into alignment with two indicator elements, one above the web and the other either at the same level as or below the web.

The marks on the web may he formed by applying a marking medium to the web or by modifying the web locally, for example severing the web or modifying the web to change its appearance. In a case where a marking medium is applied, it may be applied as a thin film or as an element which has a substantial thickness, relative to that of the weh. In a further alternative, a pre-formed marking element may be applied to the weh. ^he marking medium or marking element may have a character substantially different from that of the web, for example, a metallic character, so that the position of the mark can readily be identified by a sensing device.

According to a second aspect of the Invention, there is provided apparatus for use in cutting patterned carpet and comprising a support on which the carpet rests during positioning and durma cutting, cuttlna means for cutting the carpet whilst on the support and means for movinq the cutting means relative fo the support to effect cuttmg, wherein *he support ‘ncorporates Indicator elements x/hich lie In. on or close to 'he $urface on which the carpet rests.

The mdicator elements mav he formations, tor example apertures or grooves, may he marks on the support or may be protected onto the support by suitable protection devices.

According to a third aspect of the Invention, there 's provided a method of manufacturing carpet wherein a pre-formed web Is moved along a defined path through an attachina station, tuft-forming lengths of yarn are attached to the web at the attaching station and margins are cut from the veb whilst the web is In said defined oath.

The third aspect of the invention facilitates the production of carpet which has a predetermined width and wherein the tuffs occuov predetermined positions with respect to the lateral edges of the carpet.

There are preferably applied to the web, whilst the web is in said defined path, marks which occupy predetermined positions relative to *he tufts. These marks can then be used in positioning of the carpet for cutting.

According to a fourth aspect of the Invention, there Is provided apparatus for use in the manufacture of carpet and compr’sinq guide means defining n path through the apparatus, drive means for mov'ng a ore-formed web through the apparatus along said oath, tuft-attaching means for attaching tuft-forming lengths of varn to the web at an attaching station along said path and cutting means for cutting margins from the web whilst the web is in said path.

An example of apparatus embodying the second and fourth aspects of the invention and which is used in a method according to both the first and the third aspects of the Invention will now be described, with reference to the accompanying drawing, wherein:FIG' IRF I is a diagrammatic representation of apparatus for aoplvtnq tuf ts to a web, FIGURE 2 is a diagrammatic representation, on an enlarged scale, of a part of the apparatus of Figure I and of the tufted web formed therein.

FIGURE 3 is a diagram similar to figure 9 showing pos'tmning of the tufted web for cutting; and ~IGUPE 4 is a diagrammatic elevation of cutting apparatus.

Tie apparatus illustrated in F'gure I anodes tuft-forming lenaths of varn to a ore-cormed web !0. The web s supplied as a roll U which is supported 'n the apparatus of F'gure ’ in a known manner for unwinding, 'he apparatus Includes guide means for guidinq the web from the roll ’ ' along a defined path through a marking station 12. a heating station I 3. an attaching station '4 and a trmming station IS to a further roll I 6 formed on a take-up reel. The guide means mav Include rolls and other known guide elements arranged In a generally known manner for guidinq the web and will not he described In detail. Representative aulde elements are indicated in the drawing at IT. Rr've means is provided for mov’ng the web along the oath in a controlled manner to the take-up reel and for dr'vinq the take-uo reel. ror example, there may he provided downstream of the roll I I a known accumulator 18 including one or more rolls which is or are dr'ven when the length of web in the accumulator falls to a predetermined value. A further accumulator 13a, which may be identical with the accumulator 13, ;s provided upstream of the take-up reel. The fake up reel mav he driven in such a manner as to maintain tension in the web downstream of the second accumulator. The speed at which the web moves through the attaching station is controlled by a roll 17a which is driven inferm i f ten fly and which has a carded surface to avoid slip of the weh relative to the roll. Additional means for controlling the speed of the weh at selected positions along the path ταν he incorporated, if reauired.

At the marking station 12. there is provided a oair of marking devices I? which ore operated in co-ordination with ieedinq of the web '0 along its path to olace on respective margins of the web marks vhich are spaced at predetermined intervals along the margin of the web. The marks ore Dlaced on one face only of the web, called herein the upper face. The marking devices 19 may be known devices incorporating stamps which print on the web marks, each of which is a rectilinear line of ink, the length of the line being perpendicular to a longitudinal centreline of the web. Movement of the stamps onto the web is triggered by a photodetector which responds to movement of a yarn source or other member at the attaching stat'on which is moved intermittently.

The web in the roil I I has on its upper surface a 'aver of a thermoplastic adhesive. This layer extends between the margins of the web but preferably does not cover the margins. The marks applied by the devices lq may be applied only to those margins of the web which do not bear the layer of adhesive. Alternat’vefy, the marks mav extend onto the 'oyer of adhesive.

The marked web moves from the marking station I 2 over the surface of a heating element 2d at the heating station ! 3. element nd Has a surface of substantial area which Is In contact with the underside of the web !0 and transmits heat through the web to the laver of adhesive to soften the adhesive. This surface :s convex In a direction along the web and in a direction across the web. The web, bear'nq the laver of fluid adhesive, then moves Into the attaching station ' i.

At the attaching station, the web Ό is supported on a heatma bar 2I which engages the underside of the web and supplies additional heat to the laver of adhesive at a rate which is at least sufficient to compensate *or beat losses and maintain the adhesive in a fluid-condition. A slot rs defined between guide members 22 and 23 which are spaced upwardly from the web IO and the layer of adhesive thereon. Ty,e slot extends across the entire width of the web and lies directly above the heating bar 2I. Grippers 7'l are provided for drawing lengths of tuft-forming yarn from a yarn source 25 to respective positions overlying the slot and a oresser 26 is arranged for reciprocation towards and away from the web !0 through the slot to press the lengths of yarn through the slot between the mem,hers 22 and 23 into the layer of adhesive on the web IO. After the presser 26 has withdrawn into the slot, the implanted tuffs are pushed out of the slot bv reciprocation of a -5□usher 27 across the underside of the slot. Movement of *he veh ΤΠ throuqh the attaching station is stepwise and is co-ordinated with movement of the pusher 27.

The general arrangement of the yarn-attaching means may he as disclosed in GB 1,422,524, to which reference should be had for further details. The yarn source 25 may be a known source, For example an assembly of spools connected together in a chain so that yarn can he drawn from successive spools.

From the attaching station 14, the tufted web oasses through the trimming station 15 to the take-up roll 16. At the trimming station, there 's mounted a pair of cutting blades, one adjacent to each lateral marqin of the web. Each cutting blade is positioned to intersect the path of travel of the web and sever from the main body of the weh either an entire margin or a part of the margin. The blades are adjustable towards and away from each other according to the required separation between the lines along which the web is to be cut. AI ternaf'velv, a single blade may be provided to sever one margin only. pror to or after winding of the carpet onto the take-up reel, the carnet may be treated by re-heating as described in GP 1,432.574.

The carpet 's subsequently unrolled and the weh '3 's coated at its underside with a layer of bitumen or other settable mater'al in a known manner. In a case where the coated carpet ‘s relatively inflexible, the carnet may then be cut into pieces, called herein pelts, rather Fhan being reformed into a roil. Subsequently, there is cut from each pelt one or more tiles.

A press for cutting tiles from the pelt Is dlustrated In r'gure 4. The press comprises a Frame 29 on which there The carrier 32 carries one or more blades 73 for cutting the weh 10 of the pelt and a support 74 for the pelt. The support has a substantially flat, upwardly facing surface for receiving the pelt. This surface is interrupted bv slots containing the blades 37. The cutting edges of the blades normally lie within the slots and just below the level of the upwardly facing surface of the support. That surface of the support is displaceable relative to the carrier 32 and relative to the blades 33, from the position illustrated in Hgure 4 in a direction towards the base 30. The range of travel of the surface of the support is such that the cutting edges of the blades can protrude substantially above that surface, sufficiently to cut through the web 10 of a pelt of carpet lying on the support 34. The support may be formed of a resilientlv flexible material, for example a foamed plastics material or a latex foam. The support may have a continuous skin which provides the support surface for the carpet pelts. Downward movement of the pelt and the upoer surface of the support 34 is effected by means of the platen 31, when the carrier 37 and supoort are positioned directly beneath the platen.

The carrier 32 and support 34 are withdrawn from beneath the platen 31 to facilitate removal of carpet tiles from the support and placing of a further pelt on the support.

Indicating means is provided for indicating a required position of the pelt relative to the blades 33 and thereby facilitate placing of the pelt In a predetermined oosif’on relative to the blades. in a case where the lateral extent of the supoort 34 Is substantially greater than the corresponding dimension of each pelt, the indicating means Includes marks or other Indicating elements on the upwardlv faclna surface of Mne support 34 at positions which are overlapped bv margins of the web IT bearing the marks applied at the marking station 12. ’’’he indicating elements on the support 34 are preferably rectilinear lines which are at r'aht angles to the direction of travel of the carrier 32 relative to the base 7Π.

Alternatively, in a case where all pelts to be cut have the same width, there may be provided immediately adiacent to the uoper surface of the supoort 34 guide elements which engage oooosite marqins of the oelt, when the pei't Is placed on the support 34. In this case, the indicatinq elements may he provided in the guide elements. In this case, the ‘ndicatina elements may be at substantially the same level as the marks on the margin of the web 10. In a case where the indicating elements are on the support 34, those elements would lie slightly below the level of the marks on the web 10.

The indicating means further comprises a member 35 of plate-like form which can be moved relative to the frame 2? between a lowered position illustrated in Figure 4, In which the Indicator member lies above and close to or rests on the upwardly facing surface of the carpet pelt, and a raised position in which the indicating member 35 Is spaced upwardly from the pelt. In its raised position, the member does not impede removal of the carpet tile or files from the support and placing of the pelt on the suppor*.

The indicating member 35 is adapted to permit the caroet pelt to be viewed through the indicator member, when the latter is in its lowered position. The indicator member may be transparent or mav include a transparent part. Alternatively, there may be formed in the indicator member one or more apertures through which the carpet pelt can be viewed.

In the particular example illustrated, the indicator member 35 is connected with the frame 29 for pivoting relative thereto about a horizontal pivot axis 36. Alternatively, the indicator member may be arranged for reciprocation upwardly and downwardly. The pivot axis 36 Is at a level somewhat above that occupied by the carpet pelt and is preferably spaced from the carpet pelt, when the carrier 32 is fully withdrawn from beneath the platen 31, in a direction towards the path of travel of the platen.

The indicator member has marks or indicator elements corresponding to marks and/or pile tufts of the carpet. The marks or other indicat'nq elements on the member 35 include elements which, when the member ‘s in its lowered position, lie directly above the marks on the support 79 or on the guide elements, be web 10 of the oelt lies between the supDort 79 and the indicator member 35 and accurate positioning of the pelt in one direction, called herein the fore and aft direction can be achieved bv aligning each of the marks on the web 10 with the corresponding mark on the support 39 and with the corresDonding mark on the support 35. ror facilitating positioning of the caroet pelt in a direction transverse to the fore and aft direction, there are provided on the indicator member 75 marks, pins or other indicating elements which, when the oelt Is in the required position, are aligned w:th predetermined tufts of the carpet pile. 5uch tufts may be of a colour different ?rom the colour of adlacent tufts and may be in that part of the pelt which is cut awav when the t:le Is formed from the pelt.

It will be noted that the tufts are comprised by ’J-shaped pieces of pile varn, the base of the U being implanted in the layer of adhesive on the web 10 and the limbs of the IJ extending away from the web. These limbs are aligned in the fore and aft direction, that is a direction parallel to the trimmed margins of the web. If the tufts are subjected to downward pressure or other action which tends to cause the tufts to lean from an upright attitude relative to the web, they are likely to lean In a fore and aft direction and unlikely to lean in any lateral direction. Accordingly, the positions of -8free-ends of the tufts can he retied upon in posi+loning the web ΙΠ m a lateral direction; whereas the position of the free-end of the tuft is unreliable for positioning of the web In the fore and aft directions.

An operator may position each carpet pelt on the support 3A manually, viewing the marks and indicator elements to decide when the pelt is 'n the required position relative to the blades 33. To facilitate grioDing of the pelt by the operator, the indicator member 35 and the support may he cutaway in a central region of a front edge of the indicator member and support, so that a front edge portion of the pelt is exposed and readily accessible.

In an alternative arrangement, the indicator means provided on the member 35 is adapted to respond to the presence in respective predetermined positions relative to the indicator member of certain tufts or certain pattern elements and of the marks applied at the marking station 17. ror example, the indicator means may compr'se optical sensing devices which respond to tufts of a certain colour or fluorescent tufts. Alternatively, the indicator means may be electro-magnetic and be adapted to respond to the presence of a metallic tuft or of a metallic medium applied to the margin of the web ΙΠ. The indicating means mav incorporate lights or other means for providing a signal to an operator, when he has correctlv positioned the pelt. Alternatively, positioning may be carr;ed out automatically ov means of grippers which grip the pelt and are moved In a predetermined manner bv suitable drive means until the indicating means signals that the carnet pelt 's in the required position.

'Ve have mentioned hereinbefore that the marking devices mav be known devices which apply to the web rectilinear lines, the lengths of these lines being perpendicular to a lonqitudinai centreline of the web. Additionally or alternatively, there may be provided at the marking station 12 known devices incorporating stamps which print on the web marks, each of which is a rectilinear line of ink with the length of the line exfendinq alonq the web. Printing on the web in this wav a line which extends along the weh and bears a predetermined relation to the rows of tufts applied to the web facilitates cutting the web alonq lines parallel to a longitudinal centreline of the web in a predetermined relation to the rows of tuffs. Printing on the web lines of ink, the lengths of which are perpendicular to the longitudinal centreline of the web facilitates cutting of the web along lines perpendicular to that centreline in predetermined relation to the lines of tufts, ’’’he lines of ink remain in the pelts which are cut from the carpet and are used durnq positioning of each pelt in the press illustrated in Figure i. There mav be 9provided in the press one set of indicator elements for comparison with marks on the web which are lines perpendicular to the longitudinal centreline of the web and a further set of indicator elements for comparison with marks on the web which are lines parallel to the longitudinal centreline of the web. Alternatively, indicator elements of one set may he adaoted for comparTson with both longitudinal and transverse marks on the web.

Claims (14)

1. !. A method of cutting patterned carpet comprising a web and a pile of tufts on one face of the web which define the pattern of the carnet, wherein the web 's marked in predetermined positions relative to the positions where respective tuffs are attached to the web and the web is cut along lines which bear a predetermined relation to the positions of the marks.

2. A method according to Claim l wherein, in preparation for cutting, the carpet is moved to bring said marks into respective predetermined positions relative to indicator elements which are distinct from cutting elements which cut the web.

3. 4 method according to Claim 2 wherein the ‘ndicator elements ‘nclude elements which are spaced apart in the direction of the thickness of the carpet and wherein one of the marks on the web Is moved into alignment vith said spaced indicator elements.

4. A method according to Claim 3 wherein the mark on the web lies in the space between the indicator elements.

5. A method according to any preceding Claim wherein the marks are applied to the web m apparatus which attachs the tufts to the web.

6. A method according to Claim 5 wherein the marks are applied to the web prior to application of the tufts to the web.

7. A method according to any preceding Oaim wherein marginal portions are trimmed from the web after marking of the web and before cutting. 3. A method according to Claim 7 wherein the marginal portions are trimmed from the web in apparatus which applies the tufts to the web.

8. 9. A method according to any precedina Claim wherein a fur + her layer 's applied to an underside of the web after marking of the web and before cutting of the web. IO. A method according to any preceding Claim wherein the tufts are upstanding limbs of 'J-shaped pieces of yarn. I I. Apparatus for use in cutting patterned carpet and comprising a support on which the carpet rests during positioning and cutting, cutting means for cutting the carpet whilst on the support and means for moving the cutt'nq means relative to the support to effect cutting, wherein the support incorporates indicator elements which lie in, on or close to the surface of the support on which the carpet rests.

9. 12. Apparatus according to Claim I! further comprising an indicator member which overlies the carpet when the carpet rests on the support, the indicator member having or constituting a further indicator element aliqned with a corresponding one of said indicator elements which lie in, on or close to the surface on which the carpet rests. !3. A method of manufacturing carpet wherein a pre-formed veb : s moved along a defined path through an attaching station, tuft-forming lengths of yarn are attached to the web at the attaching station and margins are cut from the web whilst the web is in said defined path. I'i. A method according to Claim 13 wherein, whilst the web is in said defined path, marginal portions of the web are marked at positions which bear a predetermined relation to the positions at which the tuft forming lengths of vqrn are attached to the web.

10. 15. A method according to ^laim 14 wherein the marginal portions of the web are marked before the lengths of yarn are attached to the veb.

11. 16. Apparatus for use in the manufacture of carpet and comprlsinq quide means defining a path through the apparatus, dr’ve means for moving a preformed web through the apparatus along said path, tuft-attachinq means for attaching lengths of yarn to the web at an attaching station and cutting means for cutting marginal portions from the web whilst the web is In said -I2path. I 7. Apparatus according to Claim 16 wherein the cutting means is arranged for cutting the marginal portions from the web after the web Has passed through the attaching station.

12. 18. Apparatus for use in cutting patterned carpet substantially as hereinbefore described with reference to the accompanying drawings.

13. 19. A method of cutting patterned carpet substantially as hereinbefore described with reference to the accompanying drawings.

14. 20. Carpet tiles whenever made by a method as claimed in any of