US20050263054A1

US20050263054A1 - Flocking machine

Info

Publication number: US20050263054A1
Application number: US10/536,823
Authority: US
Inventors: Sei Kato
Original assignee: HOTTA KUNIO
Current assignee: HOTTA KUNIO
Priority date: 2002-11-28
Filing date: 2002-11-28
Publication date: 2005-12-01
Also published as: CN1694985A; AU2002349632A1; JPWO2004048669A1; WO2004048669A1

Abstract

The thread-implanting machine of this invention has a needle 51 which inserts thread 55 through a pinhole 51 a, and this needle 51 runs up and down through the surface and undersurface of base cloth 54. In addition, in response to the vertical movement of this needle 51, hook shaft 6 rotates. Then, the turning hook 1, which has the turning hook blade 5 and is attached to the hook shaft 6, and the ascending-descending blade 10 by the turn of said hook shaft 6 cut the thread 55, and sequentially, the thread is implanted.

Description

TECHNICAL FIELD

This invention relates to a thread-implanting machine to implant a number of threads into the base cloth and produce carpets and mats, etc.

BACKGROUND ART

For the thread-implanting machine of the base cloth, refer to FIG. 12 for the explanation of producing a carpet.
FIG. 12 shows the cross-section drawing, and to produce a carpet, implant thread 101 into base cloth 100 at a prescribed pitch while cutting every thread loop as well as implanting the thread 101 into the base cloth 100.
A needle 105 that moves up and down is placed in the body of the thread-implanting machine (not shown in the figure) and the thread 101 from a stock bobbin (not shown in the figure) is inserted through a pinhole 105 a that is at the tip of the needle 105. In addition, a pivot shaft 107 is placed underneath the needle 105 that oscillates by an oscillating mechanism (not shown in the figure) in response to the vertical movement of said needle 105, and an L-shaped shuttle hook 108 is attached to this pivot shaft 107. A sharp point 108 a of this shuttle hook 108 is inserted into an after-mentioned thread loop that is formed by the thread 105, and a cutting blade 108 b is placed underneath the point 108 a. Moreover, a thread cutting blade 112 that is able to slide against the cutting blade 108 b of said shuttle hook 108 moves up and down using an ascending-descending shaft 113 as a supporting point in response to the vertical movement of said needle 105.
Subsequently, for the mechanism of the needle 105, the shuttle hook 108 and the thread cutting blade 112 of said structure, refer to FIG. 12 for the explanation of the process of implanting the thread 101 into the base cloth 100.
(1) The needle 105 runs through the base cloth 100 from the top dead center and hits the lowest point through an ascending-descending apparatus (not shown in the figure) of the needle 105. At this time, the point 108 a of the L-shaped shuttle hook 108 moves close to the thread 101 by the oscillating mechanism (FIG. 12 (A)).
(2) Subsequently, when the needle 105 starts moving up, the thread 101 inserting through the pinhole 105 a loosens and forms a thread loop. Then, by said oscillating mechanism, the point 108 a of the L-shaped shuttle hook 108 is inserted into the thread loop of the thread 101 (FIG. 12 (B)).
(3) Moreover, when the needle 105 moves up, the length (distance) of the thread 101 between the base cloth 100 and the needle 105 is maintained at a certain length by the point 108 a of the L-shaped shuttle hook 108 that stays at the same position, and the needle moves further up and hits the top dead center above the base cloth 100. When the needle 105 hits the top dead center, the thread cutting blade 112 moves up and the thread is cut by the thread cutting blade 112 and the cutting blade 108 b that is formed on said shuttle hook 108 (FIG. 12 (C)).
After that, the thread 101 is implanted into the base cloth 100 and carpets etc. are produced by repeating said (1) to (3) with the base cloth 100 being moved by 1 pitch.
However, because it repeats the operation of stopping, oscillating, stopping and waiting to cut, cutting the thread, oscillating back to the original position and stopping by the oscillating movement of said shuttle hook 108, there is an impact shock at the time of stopping the oscillation when this sequence of operation is performed at high speeds, thus improvements on the noise problem are desired.

DISCLOSURE OF THE INVENTION

The needle on the thread-implanting machine of this invention has thread through its pinhole and runs up and down through the surface and undersurface of base cloth. In addition, the hook shaft turns in response to the vertical movement of this needle. Then, the turning hook, which has the turning hook blade and is attached to the hook shaft, and the ascending-descending blade by the turn of said hook shaft, cuts the thread, and sequentially, the thread is implanted. Therefore, because the turning hook (turning hook blade) cuts the thread with the ascending-descending blade while implanting, the noise is reduced.
Moreover, because the ascending-descending blade that is used for the thread-implanting machine of this invention has a mechanism that it moves up and down by the eccentric cam that is attached to the turning shaft or the eccentric cam that is placed on the outside of the hook shaft and synchronizes with the hook shaft, it can be easily configured.
In addition, because the thread-implanting machine of this invention has a rotary vane, attached, it can prevent the accumulation of thread waste and makes it possible to stitch at high speeds.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is the overall view of the thread-implanting machine.
FIG. 2 is a drawing of the components underneath the needle.
FIG. 3 is a drawing that shows the process of thread implantation.
FIG. 4 is a drawing that shows the process of thread implantation.
FIG. 5 is a drawing that shows the process of thread implantation.
FIG. 6 is a drawing that shows the process of thread implantation.
FIG. 7 is a drawing that shows the process of thread implantation.
FIG. 8 is a drawing that shows the process of thread implantation.
FIG. 9 is a cross-section drawing of implantation into the base cloth.
FIG. 10 is a drawing of the components of the thread-implanting machine that the rotary vane is attached.
FIG. 11 shows the other ascending-descending mechanism of the ascending-descending blade.
FIG. 12 is the basic concept of an existing thread-implanting machine.

BEST EMBODIMENT OF THE INVENTION

Explaining this invention in greater detail.
For the thread-implanting machine that produces carpets etc. by implanting into base cloth, refer to FIG. 1 that shows the entirety and FIG. 2 that shows components underneath the needle 51.
The ascending-descending mechanism that the needle 51 runs up and down through the surface 54 a and the undersurface 54 b of the base cloth 54 is built in the body of the thread-implanting machine 50, and thread 55 from the stock bobbin 52 is inserted through the pinhole 51 a that is formed on the tip of this needle 51.
Moreover, there is the hook turning extension arm 60 underneath the body of the thread-implanting machine 50, and the hook shaft 6 that turns in synchronization with the ascending-descending mechanism of said needle 51 is placed on the inside of this hook turning extension arm 60. In other words, it is a cycle in which the rotation is made from the top dead center of the needle 51 (on the surface of the implanting cloth 54) to the bottom dead center of the needle 51 (on the undersurface of the implanting cloth 54) to the top dead center of the needle 51 (on the surface of the implanting cloth 54).
The turning hook 1, which is semicircular, is composed of an arm part 7 that is placed extending towards the exterior edge from the center and a falcate hook 4 that extends on a quasi-half circle from this arm part 7, and an inductive groove 3 is formed between this hook 4 and the arm part 7. Then, this turning hook 1 is connected to the hook shaft 6 in the center part.
Additionally, the sharp point 2 of the hook 4 is able to insert into a thread loop that is formed by the later-mentioned thread 55 c and thread 55 w, and this thread 55 of the thread loop that has the hook inserting through is induced to a turning hook blade 5, which is one side of scissors that cut the thread 55 and are placed on the inside that is close to the arm part 7 of the hook 4, accompanying the turn of shuttle hook 1.
Moreover, an eccentric cam 8 that is in close contact with said arm part 7 is attached to said hook shaft 6. On the other hand, a plate-like ascending-descending blade 10 that is oscillatable is attached to a supporting shaft 10 j by a spring 11 in the state where it is always placed on said eccentric cam. Then, a cutting blade 10 a that is formed at the upper end of the ascending-descending blade 10 comprises the other side of the scissors for said shuttle hook blade 5.
Thus, turning hook 1 and eccentric cam 8 turn counterclockwise in synchronization with the vertical movement of the needle 51, and ascending-descending blade 10 moves up by the eccentric cam 8, and said turning hook blade 5 and the ascending-descending blade slide against each other, and cut thread as scissors.
Next, the process of sequentially implanting into the base cloth 54 accompanying the vertical movement of the needle 51 will be described with reference to FIG. 3-8.
The positions of the vertical movement of the needle 51 is defined as sin θ function depending on the turning angle of the shuttle hook 1, and the positions of the needle 51 and the point 2 of the turning hook 1 are recreated with a high degree of accuracy.
In addition, the hook shaft 6 makes one rotation with the cycle of needle 51, which is from the top dead center (on the surface 54 a) to the bottom dead center (on the undersurface 54 b) to the top dead center (on the surface 54 a), and the needle 51 runs up and down through the surface 54 a and the undersurface 54 b of the base cloth 54, and thread 55 is cut by the turning hook blade 5 of the turning hook and the ascending-descending blade 10 and sequentially implanted into the base cloth 54 by a pitch (P).
(1) FIG. 3 shows that the needle 51 that has thread 55 through its pinhole 51 a is on the surface 54 a of the base cloth 54 and is going down from the top dead center and also shows the state immediately before the pinhole 51 a sticks into the base cloth 54.
In addition, thread 55 that is threaded in the pinhole 51 a is connected to a stock bobbin 52, and with regard to the dropping of the needle 51, there is no sliding of thread 55 that is restrained by the pinhole 51 a and the needle 51 and thread 55 moved down together. Moreover, the slackness of thread 55 a is equivalent to the length of one implanted piece of thread, and with the downward movement of needle 51, the length of one implanted piece of thread is pulled from the stock bobbin 52.
(2) FIG. 4 shows the state that needle 51 drops further and needle 51 has run through base cloth 54 and is under the undersurface 54 b and has hit the bottom dead center. In addition, thread 55 c and 55 w that are through the pinhole 51 a are under tension of the friction of the base cloth 54 and closely attaching to needle 51.
(3) FIG. 5 shows that needle 51 moves slightly up from the bottom dead center, and the thread 55 c and 55 w at the tip of the needle loosen and also make a thread loop that spreads to the both sides of pinhole 51 a, and at the same time, point 2 of the turning hook inserts into the thread loop accompanying the turn of the turning shaft 6 and the thread is hooked by the hook 4.
In addition, because the thread loop of the thread 55 is hooked by the hook 4, this thread loop does not come through to the surface of the base cloth 54 even if needle 51 moves up.
(4) FIG. 6 shows that the shuttle hook has caracoled from the state FIG. 3, and the needle 51 is moving up through base cloth 54, and thread 55 c and 55 w are maintained by the hook 4, and thread 55 is moved up to the surface of base cloth 54 accompanying the upward movement of needle 51 while the thread loop that is formed with thread 55 c and 55 w is straightened.
(5) FIG. 7 shows that needle 51 has moved further up and almost hits the top dead center, the thread loop slides to the turning hook blade 5 held by the hook 4, and needle 51 is being pulled upward with thread 55 d sliding through pinhole 51 a, and the thread 55 d is put into a state of tension.
In addition, it shows that ascending-descending blade 10 moves up by eccentric cam 8 that is attached to hook shaft 6, and this is immediately before this ascending-descending blade 10 and the turning hook blade 5 of the turning hook 1 cut thread 55.
(6) In FIG. 8, needle 51 hits the top dead center, and the turning hook blade 5 and ascending-descending blade 10 move to the highest position, slide against each other, become scissors and cut thread 55 c and 55 w, and one cycle is completed. Then, the base cloth 54 is moved by one pitch (P), and the next thread implantation is prepared.
In addition, the timing to move said base cloth 54 by one pitch (P) is while the needle 51 is above the surface of the base cloth 54.
FIG. 9 (A) shows the implanted thread that has been implanted into the base cloth 54 when said cycle from (1) to (6) is sequentially performed using one piece of the thread 55, and each piece of implanting thread is cut into 55 g and 55 h and is implanted. Additionally, FIG. 9 (B) shows the state of one implanted thread, and shows the thread implantation state in which the thread is divided into two pieces on the undersurface of base cloth 54.
In addition, there is an explanation of an example that one piece of thread 55 is inserted through pinhole 51 a, however, several pieces of thread can be inserted through pinhole 51 a and implanted. For example, if three pieces of thread are inserted through pinhole 51 a, and said cycle (1)-(6) is performed, they are divided into three and three pieces as shown in FIG. 9 (C), which means that it can implant 6 pieces at a time.
As seen above, because the thread-implanting machine of this invention cuts thread with turning hook blade 5 and ascending-descending blade 10 when turning hook 1 turns, it moves smoothly unlike the oscillating movement of existing shuttle hooks and is able to implant quietly.
In addition, although ascending-descending blade 10 is a simple mechanism that moves up by eccentric cam 8, it can be comprised to oscillate as existing one and cut thread with the shuttle hook blade 5.
Moreover, FIG. 10 shows the components underneath the needle 51 that have another structure, but a component that is different from the thread-implanting machine shown in FIG. 2 is rotary vane 40. Additionally, a turning hook 1A is a discotic that has falcate hook 4 and the turning hook blade 5 and has a different shape than said turning hook 1, but it has the same function.
The rotary vane 40 is attached to the back of said ascending-descending blade 10 on the hook shaft 6, and blades 41 are attached to this rotary vane 40, and it turns along with the turn of hook shaft 6 and blows winds forwards (to the direction of ascending-descending blade 10) to cool the scissor part that is composed of ascending-descending blade 10 and the turning hook blade 5 as well as preventing thread waste from adhering and piling up.
In addition, this thread waste is made by the friction generated when the thread 55 goes through small pinhole 51 a, and the thread that goes through the small pinhole is peeled into micro fibers and scattered around, and this thread waste wraps around the turning hook 1 and, if left unattended, it becomes unable to operate.
Moreover, with regard to the cutting by turning hook blade 5 and the ascending-descending blade 10, because turning hook blade 5 and ascending-descending blade 10 cut thread by sliding against reciprocal, the turning hook blade 5 and ascending-descending blade 10 will burn due to frictional heat if the machine operates for a long time at high speed and is left unattended.
In this way, it is possible to prevent the accumulation of thread waste and the turning hook blade 5 and the ascending-descending blade 10 from burning and to continuously perform for a long time at high speeds by attaching the rotary vane 40 to the hook shaft 6.
In addition, this rotary vane 40 can be attached to the hook shaft that oscillates as well as the turning shaft 6 that turns to one direction, and it goes without saying that it is possible to apply this to various sorts of sewing machine etc. as well as thread-implanting machine. For example, the thread 55 is inserted through pinhole 51 a, and base cloth 54 is sewn by needle 51 that runs up and down through the surface and undersurface of base cloth 54 and the bobbin thread (not shown in the figure), in other words, for the thread-implanting machine that does not cut thread 55, because the accumulated thread waste can be removed by the winds from rotary vane 40 that is attached to a shaft that turns in one direction or oscillates, it is possible to stitch at high speeds.
Subsequently, FIG. 11 is a front elevation view that shows the other ascending-descending mechanism of ascending-descending blade 10A, and the structure has a different position of eccentric cam 8 from the one shown in FIG. 2.
A cam shaft 30 is placed on the outside of a turning hook 1A, and this cam shaft 30 and the hook shaft 6 have turning conduction in equal ratio by a wheel and are synchronized with each other, and an eccentric cam 31 is attached to cam shaft 30, and the ascending-descending blade 10A moves up by this eccentric cam 31. In other words, the eccentric cam 31 is placed on the outside of the hook shaft 6. Moreover, this ascending-descending blade 10A is supported roughly in the center by a pivot shaft 33, and a U-shaped fitting part 10 b that is formed on the heel of the ascending-descending blade 10A slides over the eccentric cam 31 and connects to it.
Therefore, as the turning hook 1A turns on the shuttle shaft 6, the ascending-descending blade 10A is moved up (oscillates) by eccentric cam 31 on the cam shaft 30, and said turning hook blade 5 and the cutting blade 10 a cut thread 55.
In this way, the ascending-descending blade 10A can be configured so that it can be moved up (oscillatable) by the eccentric cam 31 that is attached to the cam shaft 30 that is placed on the outside of the turning hook 1 as well as being comprised to attach the eccentric cam 8 to the hook shaft 6 shown in FIG. 2.

Claims

1-3. (canceled)

4. A flocking machine, comprising: a needle that runs up and down through the surface and undersurface of the base cloth and has a pinhole; a hook shaft that turns in response to the vertical movement of said needle; a turning hook that is attached to said hook shaft and has the turning hook blade; and an ascending-descending blade that has a cutting blade, wherein said turning hook blade and said cutting blade slide against each other at a designated position.

5. A flocking machine according to claim 4, wherein the ascending-descending blade moves up and down by either one of the eccentric cams: an eccentric cam that is attached to the hook shaft or an eccentric cam that is attached to the cam shaft that turns in synchronization with said hook shaft.

6. A flocking machine according to either claim 4, wherein a rotary vane is attached to the hook shaft.

7. A flocking machine according to either claim 5, wherein a rotary vane is attached to the hook shaft.

8. Scissors, comprising: a turning hook that has a hook, said hook comprising a sharp point and a turning hook blade; an eccentric cam; an ascending-descending blade that has a cutting blade, said ascending-descending blade oscillating by said eccentric cam; wherein said turning hook blade of said turning hook and said cutting blade slide against each other at a designated position.

9. A flocking machine that has a hook shaft and the scissors according to claim 8, wherein a turning hook, which said scissors have, is attached to said hook shaft and additionally a rotary vane is attached to said hook shaft.