JPH083860A - Production of tufted carpet and tufting device - Google Patents

Abstract

PURPOSE:To readily form a low pile and a high pile and easily set and change difference in length of both the piles at several stages. CONSTITUTION:As a substrate 18 is advanced, a pile yarn 8 is thrust into the substrate 18 by a vertically moving needle 6 at a stitch position P before a finger plate 3 and piles 19 and 20 are formed by the pile yarn 8 latched by a looper R and the substrate is tufted to provide a method for producing a tufted carpet. A finger 5 capable of moving forward and backward to a supporting place capable of holding the substrate 18 and a nonsupporting place incapable of holding the substrate at the stitch position P is properly advanced and retreated to carry out tufting. When the finger is retreated to the nonsupporting place, the feed amount of the pile yarn 8 is smaller than that in advancing the finger 5 to the supporting place and tufting is carried out.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a tufted carpet manufacturing method and tufting apparatus capable of forming a low pile having a low pile length and a high pile having a high pile length.

[0002]

2. Description of the Related Art For example, a conventional tufting method using a one-step looper type tufting apparatus for forming a cut pile is shown in FIG.
Describing with reference to (C), the pile fabric 8 is pierced through the base cloth 18 placed on the finger plate 3 from above by the needle 6 that moves up and down at the stitch position P in synchronization with the forward movement thereof. At this time, a large number of fingers 5 projecting forward from the finger plate 3 beyond the stitch position P are positioned so that the needles 6 pass between the adjacent fingers 5, so that the needles 6 hold the base cloth 18. The base cloth 18 is pushed downward until it penetrates, but the base cloth 18 is supported by the fingers 5 and its lowering is prevented.
In the conventional tufting device, each finger is immovably fixed to the finger plate.

When the needle 6 descends, the looper R enters the pile 19 of the pile yarn 8 pierced by the base fabric 18. When the needle 6 is raised and the hole of the needle 6 and the tip of the looper R are substantially horizontal, the looper R takes the most advanced position, and when the needle 6 is further raised, the looper R is piled at the tip. The hooks 19 start to be retracted, and the knife K rises accordingly to cut the piles 19 locked on the looper R to form cut piles 19 '.

As described above, the pile yarn 8 pierced through the base fabric 18 supported by the fingers 5 at the stitch position P.
Is locked to the looper R to form the pile 19, so that the length of the pile 19 is determined by the distance between the upper edge of the finger 5 and the lower edge of the looper R. Therefore, in order to form a cut pile with a short pile length, it is sufficient to shorten the distance between the fingers and the looper, but in the conventional one-step looper tufting device, the distance is constant, so the amount of yarn supplied is reduced. If it is increased, the yarn will be loose before the needle, the adjacent yarns will be entangled and cause yarn breakage, and if the supply amount of yarn is reduced, the yarn shortage will occur,
The thread will be too tight and will be torn off immediately,
Only this balanced and constant pile length can be formed.

Further, conventionally, a two-stage looper type tufting in which a low pile looper and a high pile looper are arranged in upper and lower two stages and the both loopers are selectively operated to form a low pile and a high pile. Although a device is also known, even in this tufting device, since the distance between the finger and the first-stage looper, the distance between the finger and the second-stage looper, and the distance between both loopers are constant, The height difference between the pile lengths of the low pile and the high pile cannot be changed, and at the same time, the height difference must be increased.

The present invention uses a single-step looper for forming a cut pile or a loop pile, or a plain cut loop type looper commonly called PCL, and uses the same base cloth to have a low pile length and a high pile length. It is an object of the present invention to provide a tufting method and a tufting device that can easily form a high pile and can easily set and change the height difference between the low pile and the high pile in several steps.

[0007]

According to the first aspect of the present invention, the base cloth 18 placed on the finger plate 3 of the tufting device is moved forward at a constant speed, and the base cloth 18 is attached to the front side of the finger plate 3. In the method for manufacturing a tufted carpet, the pile yarn 8 is pierced by the needle 6 that moves up and down at the stitch position P, and the piles 19 and 20 are formed by the pile yarn 8 that is locked to the loopers R and R '. The finger 5 provided on the finger plate 3 so as to be movable back and forth and capable of advancing and retracting between a supporting position capable of supporting the base fabric 18 at the stitch position P and a non-supporting position not capable of supporting the base fabric 18 is referred to as the supporting position. When tufting is performed by appropriately advancing and retracting to and from the non-supporting position, the feed amount of the pile yarn 8 is set to the finger 5 when retracting to the non-supporting position.
Is advanced to the support position to reduce the supply amount when performing tufting.

According to the second aspect of the present invention, the needle 6 which moves up and down on the base cloth 18 at the stitch position P in front of the finger plate 3 while advancing the base cloth 18 placed on the finger plate 3 at a constant speed. Pile thread 8 is pierced through with the pile thread 8 and pile thread 8 is retained by the loopers R and R '.
It is a tufting device configured to form 9, 20, and a plurality of fingers 5 respectively provided on the finger plate 3 so as to be movable back and forth, and interlockingly connected to each finger 5, Finger driving means 1 for driving the base cloth 18 at the stitch position P to move back and forth between a supporting position capable of supporting the base fabric 18 and a non-supporting position not capable of supporting it.
1 and a yarn supply amount control means 1 for controlling the supply amount of pile yarn
It is characterized by having 0 and.

[0009]

In the method according to claim 1 of the present invention, when forming a cut pile or a loop pile having a high pile length, the base cloth 18 placed on the finger plate 3 is formed.
When the pile yarn 8 is supplied at a predetermined supply amount while feeding the pile yarn 8 at a predetermined speed, the pile yarn 8 is pierced from above by the needle 6 that moves up and down at the stitch position P in the base cloth 18. 5 by advancing 5 to a supporting position capable of supporting the base cloth 18 at the stitch position P.
Is supported by the fingers 5 in this supporting position, and its lowering is blocked. Then, the pile yarn 8 pierced through the base cloth 18 is locked by the looper R or R'to form a high pile 19 or 22 having a high pile length, and the high pile 19 or 22 is cut by the knife K. As a result, the high cut pile 19 'or 21 is formed.

On the other hand, when forming a cut pile having a short pile length, the fingers 5 are retracted to the non-supporting position, and the amount of the pile yarn 8 supplied at this time is tough when the fingers 5 are in the supporting position. Since the base cloth 18 is not supported by the fingers 5 in the vicinity of the stitch position P by reducing the supply amount to a required supply amount that is smaller than the supply amount when the yarn is tinged, the base fabric 18 is pulled downward with a decrease in the yarn supply amount. From the state in which the base cloth 18 descends by a predetermined height near the stitch position P, the needle 6
Is lowered and the pile yarn 8 pierced through the base cloth 18 is locked by the looper R, and the low pile 20 shortened by the amount by which the base cloth 18 is lowered can be formed. The low pile 20 is cut by the knife K to form a low cut pile 20 '.

Further, in the case of forming a loop pile having a short pile length, if only the yarn supply amount is reduced while holding the fingers 5 at the base cloth supporting position, the fingers 5 do not move from the base cloth supporting position. Therefore, the base cloth 18 is not pulled downward near the stitch position P. Therefore,
The length of the pile yarn that is locked by the looper R ′ and forms the pile 22 does not change. Therefore, due to the decrease in the yarn supply amount, the pile 2 locked to the looper R'is
The pile yarn forming the pile 23 on the traveling direction side by 2 stitches is pulled back, and as a result, the height of the pile is lowered, and the low loop pile 23 is formed.

In the tufting device according to the second aspect, each finger 5 is moved by the finger driving means 11.
Can be automatically moved back and forth at the stitch position P to a supporting position capable of supporting the base fabric 18 and a non-supporting position not capable of supporting the base fabric 18, and the yarn supply amount control means 10 controls the supply amount of the pile yarn. , Can be easily set and changed in multiple steps or steplessly.

[0013]

EXAMPLES Examples will be described with reference to the drawings.
1 and 2 show a tufting device used in the present invention. In these figures, 1 is a bed frame and 2 is a bed frame.
Is a finger plate support base provided on the front surface of the bed frame 1, and 3 is a horizontally long finger plate fixed horizontally on the finger plate support base 2. The finger plate 3 is provided with a number of guide holes 4 penetrating the plate 3 in the front-rear direction at regular intervals in the left-right direction, and the fingers 5 can slide back and forth in the respective guide holes 4. It has been inserted.

Reference numeral 6 denotes a needle that moves up and down in synchronization with the movement of the base cloth 18 (see FIG. 3 and subsequent figures) at the stitch position P in front of the finger plate 3. Below the needle 6, shown in FIG. Not, but a one-step looper R for cut pile
And a knife K (see FIGS. 3 to 6) or a plain cut loop type looper R ′ (see FIG. 8). Reference numeral 7 denotes a cone, and the pile yarn 8 is supplied from the cone 7 to the needle 6 via a feed roller mechanism 9. The feed roller mechanism 9 is provided with a yarn supply amount control means 10 for increasing / decreasing the supply amount of the pile yarn 8. The yarn supply amount control means 10 electrically controls the yarn feed amount of the feed roller 9, for example. It is composed of a speed controller controlled by a signal, and it is possible to easily set and change the supply amount of pile yarn in multiple stages or infinitely.

The fingers 5 are driven by the finger driving means 11 to move back and forth between a supporting position capable of supporting the base fabric 18 at the stitch position P and a non-supporting position not capable of supporting the base fabric 18. . Finger drive means 11
Is provided for each finger 5, and is composed of, for example, an air cylinder 13 with a solenoid valve 12 and a push / pull wire 14, and the tip of the push / pull wire 14 is a rear end of the finger 5 via a joint 15. The rear end of the wire 14 is interlockingly connected to the air cylinder 13. The push-pull wire 14 is slidably supported by the guide members 16a, 16b, 16c and the guide through hole 16d provided in the bed frame 1. Therefore, each finger 5 advances to a predetermined position via the wire 14 by pushing in one direction of the air cylinder 13 that reciprocates a predetermined stroke, and moves to a predetermined position via the wire 14 by pushing in the other direction. fall back. The forward / backward movement of the fingers 5 by each finger driving means 11 can be controlled by the control means 17 which is, for example, a microcomputer.

As described above, each finger 5 is moved to the base cloth 1 at the stitch position P by each finger driving means 11.
8 is driven to move back and forth between a supporting position capable of supporting 8 and a non-supporting position not capable of supporting it, but FIG. 1 shows a state in which the finger 5 has advanced to the supporting position, and FIG. The finger 5 group has advanced to the supporting position, and a part of the other finger groups 5 has retracted to the non-supporting position. As shown in FIG. 1, the finger plate support base 2 is vertically movable with respect to the bed frame 1 by a rack and pinion mechanism L interposed between the finger plate support base 2 and the bed frame 1, and is fixed by a bolt M. It

A method of manufacturing a tufted carpet for forming high cut and low cut piles by using the tufting device having the above-described structure will be described with reference to FIGS.
It will be described based on. First, a tufting method for forming a high cut pile will be described with reference to FIGS. 3A to 3C, and subsequently, a tufting method for forming a low cut pile will be described with reference to FIGS. 4 to 7.

First, as shown in FIGS. 3 (A) to 3 (C),
While starting the operation of the tufting device and advancing the base cloth 18 placed on the finger plate 3 at a predetermined speed,
When the pile yarn 8 is supplied at a predetermined speed, that is, at a predetermined supply amount, the pile yarn 8 is pierced from above by the needle 6 that moves up and down at the stitch position P in synchronization with the progress thereof. At this time, the finger 5 projects from the tip of the finger plate 3 to the front of the stitch position P and is in a supporting position capable of supporting the base cloth 18 at this stitch position P. Therefore, the base cloth 18 is in the finger located in this supporting position. 5
Supported by and prevented from descending. Then, when the needle 6 descends, the looper R enters the pile 19 of the pile yarn 8 pierced by the base cloth 18. When the needle 6 rises, the looper R hooks the pile 19 at its tip and retreats, and the knife K rises accordingly and cuts the pile 19 locked to the looper R to form a cut pile 19 '. To do. Thereafter, the same operation is repeated to form a pile row of high-cut piles 19 'having a high pile length.

When the last pile 19 is caught on the tip of the looper R and the needle 6 rises as shown in FIG.
The finger driving means 11 retracts to the unsupported position as shown in FIG.
The yarn supply amount control means 10 reduces the finger 5 to a required supply amount that is smaller than the initial yarn supply amount at the supporting position. Then, as shown in FIG. 5, since the base cloth 18 is no longer supported by the fingers 5 near the stitch position P, the base cloth 18 is pulled downward as the yarn supply amount decreases, and descends by a predetermined height as illustrated. .

From the state where the base cloth 18 is lowered by a predetermined height near the stitch position P in this way, the needle 6 is lowered and the base cloth 18 is lowered.
When the needle 6 rises after the looper R has entered the pile 20 of the pile thread 8 that has been pierced in the end, the length of the pile 20 hooked at the tip of the looper R is as shown in FIGS. 4 and 5. The cloth 18 is shortened by the amount that the cloth 18 is lowered to form the low pile 20. This low pile 20 is a looper R
Is cut by the knife K that rises when it is hooked and retracted to form a low-cut pile 20 '. After that, by repeating the same operation, the pile row of the low-cut pile 20 'is formed. FIG. 7 shows the same base cloth 1
8, following the pile row of high cut pile 19 ',
It shows a state in which a row of low-cut piles 20 'is formed.

After forming the row of low-cut piles 20 'as described above, when the fingers 5 are advanced to the supporting position again, the base cloth 18 is supported by the fingers 5 near the stitch position P. And its descent is blocked, and therefore the high cut pile 1 described above is
9'can be formed.

FIG. 8 shows a tufting method for forming a loop pile by using a plane cut loop type looper R '. In this case, the finger 5 is advanced to a supporting position capable of supporting the base fabric 18 at the stitch position P as shown in FIG. Then, after the needle 6 descends and the looper R ′ enters the pile 22 of the pile yarn 8 pierced through the base fabric 18, and the needle 6 rises,
The amount of pile yarn 8 supplied is controlled by the yarn supply amount control means 10.
When the yarn feed amount is reduced below the normal amount as in the case of forming the high loop pile, the fingers 5 are still held at the base cloth supporting position, so that the base cloth 18 is not pulled downward near the stitch position P. . As a result, the pile length of the pile 22 locked by the looper R ′ does not change, and the yarn of the pile on the traveling direction side for one stitch of this pile 22 is pulled back to form the low loop pile 23.
When the high loop pile 22 is formed, the fingers 5 are held at the base cloth supporting position, and the supply amount of the pile yarn 8 is a normal supply amount, that is, larger than when the low loop pile is formed. The supply amount may be set.

Also, by using this plain cut loop type looper R ', the position of the finger 5 is set to the forward position, the supply amount of the yarn 8 is increased, and further the cut loop sorting slide provided on the looper R'. When the position of the spring plate J is set to the cut position, the high cut pile 21 can be formed, and the position of the finger 5 is set to the retracted position to reduce the supply amount of the thread 8 and to cut the position of the spring plate J. Once in position, the low cut pile 24 can be formed. In FIG. 8, K indicates a knife. FIG. 9 shows the same base fabric 18 with the high loop pile 2 described above.
2 shows a state in which each pile row of the low loop pile 23, the high cut pile 21, and the low cut pile 24 is formed.

In the above, a large number of fingers 5 supported by the finger plate 3 so as to be movable back and forth are simultaneously advanced and retracted between a supporting position and a non-supporting position, and a high pile and a low pile are required in the advancing direction of the base cloth 18. Although a simple example in which lengths are alternately formed has been described, the feature of the present invention is that
Since each finger 5 can be moved back and forth individually to the supporting position and the non-supporting position, each finger 5
The time when the support moves from the unsupported position to the supported position or from the supported position to the unsupported position according to the progress of the base fabric 18,
By appropriately changing each finger 5 or a plurality of fingers 5, for example, as shown in FIG. 10, a tufted structure in which circular or diamond-shaped low pile regions Y and Z are formed in a high pile region X is formed. It is possible to manufacture carpets. That is, it is possible to perform an arbitrary pattern by combining the high pile region and the low pile region of arbitrary shapes. In addition, a low pile having an arbitrary pile length can be obtained only by changing the setting of the reduction of the yarn supply amount when the fingers 5 are retracted to the non-supporting position, and the height difference between the high pile and the low pile is small. It is easy to change from the big one to the big one, and stepless change is possible.

[0025]

According to the method of claim 1 of the present invention,
When forming a loop pile, it is possible to form a low loop pile simply by reducing the yarn supply amount while holding the fingers at the supporting position, and when forming a cut pile, it is possible to form a high cut pile by advancing the fingers to the supporting position. By moving the fingers back to the non-supporting position and reducing the amount of pile yarn supplied at that time from the amount when the fingers are in the supporting position, the base fabric is lowered near the stitch position. ,
A low-cut pile can be formed, and a high-pile and a low-pile are formed on the same base fabric by using a simple one-step looper without using a conventional two-step looper consisting of a low pile looper and a high pile looper. By controlling the yarn supply amount, the height difference between the pile lengths of the low pile and the high pile can be reduced,
You can easily set and change small to large items that cannot be done with a two-stage looper, and you can change steplessly.

In particular, according to this method, since each finger can be individually moved forward and backward to the supporting position and the non-supporting position, a high pile region and a low pile region having an arbitrary shape such as a circle or a triangle can be formed. With
Various patterns can be obtained by combining them. Further, of course, it is possible to manufacture a tufted carpet made of only a low pile or a high pile formed in an arbitrary pile length without moving the fingers back and forth.

According to the tufting device of the second aspect, by using, for example, a plane cut loop type looper, a low loop pile, a low cut pile, and a high cut pile having arbitrary pile lengths in the width direction and the length direction, respectively. If the loop pile, the high cut pile, and the yarn supply amount are set in three stages, it is possible to manufacture a tufted carpet including a middle loop pile and a middle cut pile, and in particular, a patterned tufted carpet by combining these high and low piles.

[Brief description of drawings]

FIG. 1 is a side sectional view showing a tufting device according to the present invention.

FIG. 2 is a perspective view showing a finger plate and fingers.

3 (A), (B) and (C) are explanatory views showing a tufting step of a cut pile in a state where fingers are projected to a supporting position.

FIG. 4 is an explanatory diagram showing a first stage of a tufting process of the cut pile in a state where the fingers are retracted to the unsupported position.

FIG. 5 is an explanatory diagram showing a second stage of the tufting process.

FIG. 6 is an explanatory diagram showing a third stage of the tufting process.

FIG. 7 is an explanatory diagram showing a state in which a high cut pile and a low cut pile are formed.

FIG. 8 is an explanatory diagram showing a tufting method for forming a high pile and a low pile of a loop and a cut, respectively.

FIG. 9 is an explanatory diagram showing a state in which a high loop pile, a low loop pile, a high cut pile and a low cut pile are formed.

FIG. 10 is a plan view showing an example of a tufted carpet formed according to the present invention.

[Explanation of symbols]

 3 Finger Plate 5 Finger 6 Needle P Stitch Position 8 Pile Thread 10 Thread Supply Amount Control Means 11 Finger Driving Means 12 Solenoid Valve 13 Air Cylinder 14 Push / Pull Wire 18 Base Fabric 19 High Pile 19 'High Cut Pile 20 Low Pile 20' Low Cut Pile 21 High-cut pile 22 High-loop pile 23 Low-loop pile 24 Low-cut pile R Single-step looper R'Plain-cut loop type looper J Cut-loop sorting slide spring plate K knife X High-pile area Y Low-pile area Z Low-pile area

Claims (2)

[Claims] 1. A looper is pierced by a pile thread pierced by a needle that moves up and down at a stitch position in front of the finger plate, while advancing a base cloth placed on a finger plate of a tufting device at a constant speed. A method of manufacturing a tufted carpet for forming tufting by forming a pile with a pile yarn locked to a supporting position, which is provided on a finger plate so as to be movable back and forth and can support a base cloth at the stitch position. A finger capable of advancing and retracting to a non-supporting position that cannot be supported, and tufting by appropriately advancing and retracting to and from the support position and the non-support position.
When retracted to the unsupported position,
A method of manufacturing a tufted carpet, characterized in that the finger is advanced to a support position to reduce the supply amount when tufting. 2. A pile thread is pierced through a base cloth placed on a finger plate at a constant speed, and a pile thread is pierced through the base cloth by a needle that moves up and down at a stitch position in front of the finger plate, and is locked to a looper. A tufting device configured to form a pile by pile yarns, wherein a plurality of fingers are provided on a finger plate so as to be movable back and forth, and the fingers are interlockingly connected to each other, and each finger is connected to the stitch position. The tufting is characterized by having finger driving means for driving the base cloth back and forth to a supporting position capable of supporting the base cloth and a non-supporting position not capable of supporting it, and a yarn supply amount control means for controlling the supply amount of the pile yarn. apparatus.