US2887966A - Production of tufted fabrics - Google Patents

Description

May 26, 1959 w. FELTON PRODUCTION OF TUFTED FABRICS 4 Sheets-Sheet 1 Filed Nov. 28, 1955 Inventor WILLIAM 551.70 1/ QMMWL 55M 53mm Attorney Filed Nov 28', 1955- 4 Sheets-Sheet 2 FIG. 2

Inventor WILL/AM FELTON 4 By 7 QMMM SAM sac-Lawn Attorney May 26, 1959 WpFELTON 2,887,966

PRODUCTION OF TUFTED FABRICS Filed Nov. 28, 1955 4 Sheets-Sheet 3 FIG. 4

Imenlor WILL/AM FELTON By Altar/20y w. FELTON PRODUCTION OF TUFTED FABRICS May 26, 19 59 4 Sheets-Sheet 4 Filed Nov. 28, 1955 Inuenlor WILL/HM FE LTON Altomq n met United States Paten 2,887,966 PRODUCTION OF TUFTED FABRICS William Felton, Bradford, England Application November 28, 1955, Serial No. 549,464

Claims priority, application Great Britain December 17, 1954 x 15 Claims. 01. 112-795 This invention relates to that kind of loom for producing tufted fabrics, such as carpets, by the application of Patented May 26, 1959. I

. said end by a stop.

' The means also preferably include an additional support which operates betweenthe needles to support the fabric at right angles to the support provided by a comblike support and thereby additionally support the fabric against the drag exerted thereon by the pulling of the tail.

yarn or thread to an already produced fabric, such as canvas. 'The main object of the invention is to provide a novel'process and means for that purpose which result in the secure attachment of the tufts to the fabric with' out-having yarn extending from one tuft to another and ends of the tuft lengths through the fabric.

In the more or less diagrammatic drawings- Figure 1 is a fragmentary side view in section of a part of a machine for tufting. v Figure 2 is a fragmentary plan view illustrating a de- Figure 3 is a fragmentary plan view illustrating another detail.

Figures 4 and 5 together represent a fragmentary rear" view partly insection.

therefore without the using of more thread or yarn than is necessary to produce the tufts themselves. I

A process of producing a tufted fabric consists in supporting separate tuft lengths, supporting a piece of fabric, forming holes in the said fabric and drawing the ends of the said lengths through separate of the said holes so that each length remains attached to the fabric-whilst the ends project from the holes at one side of the fabric.

The process also consists in feeding the supported tuft lengths and the fabrics so that holes are made in succes- Referring to the drawings, in the construction shown therein, there is an intermittently rotatable transporting orfeed ing means for the filament memberl which is on a shaft 10 and which can also be subjected to a small 1, amount of axial displacement when required. The mem- I her has pairs of supports or blades 2 placed circularly around it at predetermined distances apart, the blades of each pair) also being placed at uniform predetermined distances apart. Each blade is provided with a series of notches 3 spaced at suitable distances apart along its sive parts of the fabric, and the tuft lengths are opposed to. said successive parts preparatory to having their ends drawn through the holes.

The process furthermore preferably consists in foreing' one projecting end towards the other and thereupon holding projecting ends from interfering with the ends of further tuft lengths inserted into the fabric.'

The process furthermore consists in drawing both ends of each tuft length simultaneously through diiferent holes 1 length and each adapted to have a different continuous length 4 of=thread or yarn pressed into it for example" by means of one of a series of discs 5 mounted at the requisite distances apart on a shaft 6' which can be rotatedby yarn 'or thread or'other means.

in=the fabric as distinguished from pushing the said ends therethrough. Means for performing the said process p'referablyin cludes a feed member which holds-tuft lengths, means for" moving a piece of fabric, pairs of needles, points for",

piercing the'fabric from that side which is distal from the tuft lengths, notches or holes in the-needles for simul taneous engagement by the tuft lengths, and means for closing the notches or holes to facilitate withdrawal of the needles from the fabric, the withdrawal of thene'edles causing the ends of the tuft lengths to be pulled from the" near side of the fabric through the fabric tothe distal side thereof whilst'leaving an intermediate part of each tuft length at the said near side.

The feed member may be adapted to take and hold yarn'or thread in continuous length and there may be The, different. continuous lengths 4 of thread or yarn, drawmfor example'from acreel, are forced in a continuousjmanner into the notches 3 and fed as the said member 1 'and discs 5 rotate.

A series of'cutter blades 6 is mounted in a holder 7 which (is longitudinally slidably mounted on a slide 8 laterally slidably mounted on a stationary bed 9, whereby the holder 7 can be moved axially relative to the member 1 and simultaneously towards or away from the said member thus imparting to each cutter 6 a localised rotary 'movement which causes the cutters to enter between each' successive pair of blades 2 as each pair comes into register therewith and sever the lengths 4 of yarn at the places I where 'they 'are stretched between the said pair of blades 2. The combined movement of the holder 7 and therefore the; blades '6] is obtained from an eccentric 11 which reciprocatesarod 12 guided in a part 13 of the bed 9 and having la'rolle'r 14which engages a slot 15 in a'pa rt 16 of the holder 7, and from eccentrics 17 each connected by a part 1 8to the slide 8. The eccentric 11 thus produces the relative; axial movement and the eccentrics 17 produce cutting means to cut the held yarn or thread into tuft lengths.

The said means furthermore preferably include driving means which drive the feed means and fabric synchronously and intermittently in order to produce dwells in the motion thereof during which the said needles pass 1 through the fabric, are engaged with the tuft lengths and are Withdrawn from the fabric.

The said means furthermore preferably include a comb-like support for the fabric, Where the needles pass through it, the needles being adapted'to pass through the gaps in the support.

Thelmeans also preferably. include a stop which is adjacent? pair.

the relative advancing and receding movement. Intermittent rotation of the said member 1 causes each pair of blades 2 successively to register with the cutters 6 and v the lengths 4 of yarn or thread are therefore cut by successiye cutsinto shorter lengths each of which is about equal .to a tuft length, the said shorter lengths still being held stretched by the blades 2 so that each length extends from the;blade of one pair to the adjacent blade ;of an? Nearthe rotary member 1 there is a support 19. in S which a row of thread gripping means or'pairs of needlesv 20'. are mounted-radially to the rotary 'member 1. A II combz-likefrest 21is arranged between the support moved to theends' of already'inserted lengths... the rotaminember with each gaplzof the rest in-registei' 14 with one pair of the needles and allowing the said pair simultaneously to be pushed and pulled through it.

The support 19 is first control means or mechanism comprising a pair of cams 23 which cause the needles sior notch 25 facing in a direction opposite to that in which the rotary member 1 is axially displaced. Each slide 24 has a point 26 and the slides are all mounted on a carrying frame 27 having parts 28 slidable in stationary members 29 and reciprocated by second control means or cams 30 so as to cause them to allow the mouths of the notches 25 to remain uncovered whilst the needles 20 are projected between the adjacent pair of blades 2 and the rotary member 1 is being displaced axially, and thereupon to cover the said mouths and keep them covered until the needles have been drawn back to the distal side of the sup? port 21. The projection of the needles into the space between adjacent pairs of blades 2 and the axial displacement of the rotary member causes one piececut from the continuous length of yarn or thread to be brought into the notches of both needles of each pair of needles, whilst the said piece is still held stretched by the adjacent blades of two adjacent pairs of blades 2. In Figure l, a piece cut by one of the cutters 6 is shown and marked 31'. Each pair of needles 2t is in a different plane which is at right angles to the axis of rotation of the member 1 and each pair of needles therefore engages a different cut off piece at two spaced places one behind the other. A let-off mechanism is provided to control a shaft on which a roll of fabric, for example canvas is mounted and there are guide and tension members over which the fabric passes before it passes over the support 21 at that side of the support which is nearest the rotary member 1. Some of the fabric is shown in Figure 1 and is marked 32. From the support 21 the fabric passes beneath a stationary guide block 33 to suitable transporting means such as a pair of feed rollers A and B, with the roller A shown as being in driven connection with roller B by a chain E while a chain F passes around a sprocket wheel G secured to roller B and sprocket Wheel H on shaft 10 of rotary member 1. A pawl C connected to an arm D rests on a ratchet wheel R fixed to roller B so that when the arm D is oscillated as by a cam 38, the fabric 32 is progressed. Thus, the feed rollers A and B are rotated intermittently to move the fabric 32 at a linear speed which is synchronous with the linear speed at which the cut pieces of the filament or thread are fed by the rotary member to the needles. The interruption in the linear motion of the fabric 32 and the rotary motion of the member 1 is synchronous. That is to say, the first transporting means or rotary member 1 and the second transporting means or feed rollers A and B are thus operatively connected for synchronous intermittent movement so that each pair of thread supports 2 is at a standstill when located opposite the associated fabric portion which is at a standstill. The axial displacement of the member 1 occurs whilst the fabric is stationary and the rotary member is not rotating.

The points 26 of the tubular slides 24 enable the slides 24 to readily penetrate through the fabric 32,0n the support 21 when projected through the gaps of the sup,- port 21 into position between adjacent pairs of blades 2, this projection taking place whilst the fabric and rotary member are momentarily stationary. The said projection is accompanied by a movement of the needles 20 in the same direction whilst the upper ends of the needlesare retracted into the slides 24. The needles thus pass with the slides through the fabric, whereupon.the needles-and slides thenremain projecting from the near sideiof the 4. j fabric but the slides move to uncover the notches 25 so that the cut piece can be made to enter the notches 25 by axial displacement of the member 1. After the piece has been engaged, the slides 24 move to cover the notches 25 and grip the piece between them and the needles of the pair. The needles and slides are thereupon simultaneously withdrawn back again to the distal side of the support 21. This withdrawl results in each end of each cut piece engaged in a notch 25 and gripped by the corresponding slide 24 against Withdrawal from the notches being pulled through a separate hole of the holes made in the fabric by the slides 24, with the result that a portion of each piece remains at that side of the fabric 32 nearest the rotary member 1 whilst the remainder projects from the other side of the fabric to form the projecting part of a tuft. The slides 24 may be operated thereupon to release the ends or the needles be operated so as to forcibly withdraw them from the said ends. Thus a row of. tufts is produced in the fabric. To assist the support 211. insupporting the fabric 32 against the pull exerted thereon when the ends are pulled therethrough by the needles 20, there is an auxiliary supporting member 34 having a comb-like upper part to mesh with the comb-like partof the support 21 and adapted to be projected radially-into meshing position and withdrawn therefrom by an operating mechanism including cams 35 so as to support the fabric 32 at places which are in register with the gaps 22 .of, the support and are situated between the needles 20 of each pair.

When a row of tufts has been thus inserted, the fabric 32 and the rotary member 1 are fed a step further. so as to bring a fresh part of the fabric into position above the needles 20 and a fresh row of cut off pieces into.

position for engagement with the needles. To ensure that the already inserted row of tufts shall not interfere with x the insertion of the next further row now to be inserted,

there is a rocking comb 36 which is suitably driven so,-

that whilst the needles and slides 24 are retracted, the trailing .ends of the tufts are pushed by the comb in the direction of travel of the fabric 32 indicated by arrow 37 in Figure. 1 but at a greater speed. There is also a bar 37a carried by arm D operated for example by cam 38 so that whilst it is out of the path of the produced row of tufts it moves into a position in front of the trailing end of the lastproduced row of tufts, is thereupon caused to rise and arrive behind the said trailing ends and finally is,caused to travel substantially in the same direction as the fabric at substantially the same speed as the fabric, the oscillating comb 36 assisting the bar 37 in the collection of the ends of the row of tufts in order to ensure that all the said ends shall be out of the way of the needles.

when they are next moved to project again through the support 21 and fabric 32 into position between one of the I said ad acent pair of blades 2 and another adjacent'pair of blades 2., The operations repeat themselves to makev further rows of tufts.

As all of the necessary motions or nearly all of them can be readily obtained by means of rotary earns, the herembefore described machine is capable of operating at speeds which enable an economic output of tufted fabric to ,beobtained.

Wherever the term fabric hereinbefore or hereinafter appears it is to be understood that it includes sheet materials, such as sheet rubber, paper and so forth and sheet fabrics such as felt fabric, woven fabric, knitted placing the rotatable member 1 and therefore also the blades 2, there may be means for axially displacing they.

pairs of blades 2 only.

In another alternative which may be employed with or without displacement of the rotary member 1 or blades 2, thei ends' of the needles may be shaped-to displacethe" stretched shorter lengths laterally against their own resil- -iency so that they will snap automatically into the notches when the mouths thereof come into register with the said shorter lengths.

-I claim:

'1. An apparatus for producing tufted fabric comprising, 'in combination, supporting means for supporting a backing fabric; at least one pair of supports adapted to releasably hold a tuftlength at the ends thereof so that the respective tuft length extends straight beween said supports, said pair of supports and said supporting means being located relative to each other in such a position that the tuft length extends parallel to and'on one side of the supporting means for the backing fabric and opposite to the supporting means; gripping means located opposite said supports; and operating means for reciprocating said gripping means and being located on the side of said fabric supporting means remote from said pair of supports, said operating means moving said gripping means from the other side of said fabric through the same' for gripping the tuft length, and moving said gripping means back to the other side of said fabric so that said ends of'said tuft length are released by said pair of supports and drawn to the other side of said fabric to form a pilethereon. I

2. An apparatus for producing tufted fabric comprising, in combination, supporting means for supporting a backing fabric; at least one pair of supports adapted to releasably hold a tuft length at the ends thereof so that the respective tuft length extends straight beween said supports, said pair of supports and said supporting means being located relative to each other in such a position that the tuft length extends parallel to and on one side of the supporting means for the backing fabric and opposite to the supporting means; a pair of pointed gripping means spaced from each other a distance shorter than said supports and being located opposite said supports; and operating means for reciprocating said gripping means and being located on the side of said fabric supporting means remote from said pair of supports, said operating means moving said pair of gripping means from the other side of said fabric through the same for gripping the tuft length, and moving said pair of gripping means back to the other side of said fabric so that said ends of said tuft length are released by said pair of supports and drawn to the other side of said fabric to form a pile thereon.

3. An apparatus as set forth in claim 2 wherein said operating means include cam means.

4. An apparatus as set forth in claim 2 wherein each of said gripping means includes a pointed needle having a transverse notch adjacent the point thereof and a tubular member having a pointed edge and slidably housing the respective needle and being movable along the same for closing and opening said notch, said tubular members being controlled by said operating means to close said notches when said notches engage the tuft length, and to open said notches when said supports have released said tuft lengths.

5. An apparatus for producing tufted fabric comprising, in combination, supporting means for supporting a backing fabric; at least one pair of supports adapted to releasably hold a tuft length at the ends thereof so that the respective tuft length extends straight between said supports, said pair of supports and said supporting means being located relative to each other in such a position that the tuft length extends parallel to and on one side of the supporting means for the backing fabric and opposite to the supporting means; a pair of pointed gripping means spaced from each other a distance shorter than said supports and being located opposite said supports, each of said gripping means including a needle having a notch and a closure member movable relative to the respective needle for closing and opening the respective notch; operating means located on the side of said fabric support ing means remote from said pair of supports, said operating means including first and second control means for controlling the movement of said pair of needles and of said pair of closure members, said operating means moving said pair of gripping means from the other side of said fabric through the same, moving said closure members to notch-closing position when a tuft length is engaged in said notches, retracting said gripping means'to the other side of said fabric to cause release of the respective tuft length by said supports, and moving said closure members to notch-opening position so that the ends of the tuft lengths form a pile on the other side of the fabric.

6. An apparatus as set forth in claim 5 wherein said closure members are tubular members having pointed edges, each tubular closure member slidably housing the respective needle.

7. An apparatus for'producing tufted fabric comprising, in combination, supporting means for supporting a backing fabric; at least one pair of supports adapted to releasably hold a tuft length at the ends thereof so that the respective tuft length extends straight beween said supports, said pair of supports and said supporting means being located relative to each other in such a position that the tuft length extends parallel to and on one side of the supporting means for the backing fabric and opposite to the supporting means, said pair of supports being movable in a direction transverse to the-plane of said supports; shifting means for shifting said pair of supports in said transverse direction; a pair of pointed gripping means spaced from each other a distance shorter than the distance between said supports and being locatedopposite said supports, each of said gripping means including a needle having a notch and a closure member movable relative to the respective needle for closing and opening the respective notch; operating means located on the side of said fabric supporting means remote from said pair of supports, said operating means including first and second control means for controlling the movement of said pair of needles and of said pair of closure members, said operating means moving said pair of gripping means from the other side of said fabric through the same, moving said closure members to notch-closing position when a tuft length is engaged in said notches, retracting said gripping means to the other side of said fabric to cause release of the respective tuft length by said supports, and moving said closure members to notch-opening position so that the ends of the tuft lengths form a pile on the other side of the fabric; and actuating means for actuating said first and second control means and said shifting means in a timed sequence so the pair of supports is shifted for inserting a tuft length into said notches when said gripping members are in notch-opening position.

8. An apparatus as set forth in claim 7 wherein said first and second control means include cam means.

9. An apparatus as set forth in claim 5 and including first intermittently movable transporting means, and a plurality of pairs of supports mounted on said transporting means so that upon movement of said first transport- 1ng means each of said pairs of supports is successively placed opposite said gripping means; and second intemiittently movable transporting means for intermittently transporting said backing fabric so that successive portions of said backing fabric are successively placed opposite said gripping means, said first and second transporting means being connected to each other for movement synchronously and intermittently so that each pair of supports is at a standstill when located opposite the associated fabric portion which is at a standstill.

10. An apparatus as set forth in claim 9 and including a rocking comb located in the region of said gripping means trailing the same in direction of movement of said second transporting means and adapted to be located on the other side of the fabric and being movable in direction of movement of said second transporting means for pushing the ends of tuft lengths projecting from said other 7 side .of said fabric in direction of travel of the fabric and out .of the way of said gripping means.

11. Anapparatus as set forth in claim 9 and includinga bar reciprocable in direction of movement of said sec ond transporting meansleading in direction of movement of the same with respect to said gripping means for moving tuft lengths projecting from said other side of said fabric out of the way of said gripping means.

12. An apparatus as set forth in claim 7 and including first intermittently movable transporting means, and a plurality of pairs of supports mounted on said transporting means so that upon movement of said first transporting means each of said pairs of supports is successively placed opposite said gripping means; and second intermittently movable transporting means for intermittently transporting said backing fabric so that successive portions of said backing fabric are successively placed opposite said gripping means, said first and second transporting means being connected to each other for movement in a timed sequence so that each pair of supports is at a standstill when located opposite the associated fabric portion which is at a standstill.

13. An apparatus as set forth in claim 12 wherein said closure members are tubular members having pointed annular edges, each closure member slidably housing the respective needle.

14. An apparatus as set forth in claim 13 wherein said first and second control means include cams.

15. An apparatus for producing tufted fabric comprising, in combination, supporting means for supporting a backing fabric, means for intermittently moving a backing fabric in one direction so that consecutive fabric pors.) tionssuccessively assume a predetermined position feed-. ing means including a plurality of pairsof supports, each pair of supports being adapted to releasably support a tuft length at the ends thereof so that the respective'tufL .length extends straight between the respective-pain of means for engaging said lengths of tuft and-being spaced from each other a distance shorter than the distance;

between the supports of said pairs of supports, said grip. pingmeans being movable between a retracted position; located on the other side of the fabricto an advanced position; operating means for moving said pair. of-gripping means from retracted position on the other side of said fabric through each ofsaid portions of said fabric to-said advanced position for gripping the respectivetuft length, and for moving said pair of gripping means backtozthem otherside of said fabric so that said ends of the respective,

tuft length are released by said pair of supports and,

drawn to the other, side of said fabric to form a pile)- thereon.

ReferencesCited in the file of this patent,

UNITED STATES PATENTS,

1,714,928 Sigoda May 28,,1929; 1,863,049 Hermann June 14, 1932; 1,960,118 Mathewson May 22, .1934, 2,667,879 Mann et a1. Feb. 2, 1954

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