US3157554A

US3157554A - Apparatus for making patterned pile fabric

Info

Publication number: US3157554A
Application number: US61766A
Authority: US
Inventors: Max M Beasley
Original assignee: Singer Co
Current assignee: SPENCER WRIGHT INDUSTRIES Inc A CORP OF TENNESSEE; Singer Co
Priority date: 1960-10-10
Filing date: 1960-10-10
Publication date: 1964-11-17
Anticipated expiration: 1981-11-17

Description

Nov. 17, 1964 M. M. BEASLEY 3,157,554

APPARATUS FOR MAKING PATTERNED PILE FABRIC Filed Oct. 10, 1960 2 Sheets-Sheet 1 INVENTOR lllllllll'f'" Nov. 17, 1964 M, M. BEAsLL-:Y 3,157,554

APPARATUS FOR 'MAKING PATTERNED PILE FABRIC Filed Oct. l0, 1960 2 Sheets-Sheet 2 ATl'OgiEY United States Patent C) 3,157,554 APPARATUS FOR MAKING PATTERNED PILE FABRIC Max M. Beasley, Chattanooga, Tenn., assigner, by mesne assignments, to The Singer Company, New York, NX.,

a corporation of New Jersey Filed Get. 10, 1960, Ser. No. 61,766 4 Claims. (Cl. 156-435) This invention relates to an apparatus for making patterned pile fabric, and more particularly for making a pile fabric having pile loops of selectively dilferent heights without employing the methods of weaving or tufting.

Although the art of making pile fabric by introducing loops of yarn or other fibrous material between transverse blades or slats and cementing the loops together is known, this art has been practiced Very little and certainly does not enjoy the wide recognition of .the weaving or tufting industries. It is believed that one reason this method of forming loops between slats is not very popular is that machines and methods heretofore conceived have only been capable of forming loop piles of a uniform height, and consequently cannot complete with the varied patterned fabrics of the weaving and tufting industry.

It is therefore an object of this invention to provide an apparatus for selectively varying the pile height in accord ance with a predetermined pattern in a loop pile fabric produced without the use of looms or tufting needles.

Another object of this invention is to provide an apparatus for selectively forming loops of different heights between spaced transverse slats in which a separate individually controlled plunger is provided for each yarn.

Another object of this invention is to provide an apparatus for making an infinite variety of patterns by selectively forming high and low loops between uniformly spaced transverse slats.

Another object of this invention is to provide a novel method of making patterned loop pile fabrics with a minimum of material and equipment and more economically than can be produced by weaving or tufting.

Further objects and advantages of this invention will be apparent from `the following description, taken in conjunction with the drawings, wherein:-

FIG. l is a sectional elevation of the apparatus made in Aaccordance with this invention;

FIG. 2 is an enlarged sectional elevation of the loop forming member in raised position preparatory to forming a high loop;

FIG. 3 is a view similar to FIG. 2, but with the loop forming member in its lowermost position to form a high loop;

FIG. 4 is a View similar to FIG. 2 with the loop forming member in raised position preparatory to forming a low loop; and

FIG. 5 is a view similar to FIG. 4 with the loop forming member in its lowermost position to form a low loop.

Referring now to the drawings in more detail and par ticularly to FIG. l, the apparatus comprises a main frame or housing upon which is journaled a horizontally disposed rotary shaft 11 supporting a drum or roll 12. Spaced to the rear of the housing 16 is another similar shaft 13 supporting a roll 14. Adapted to engage the peripheries of both rolls 12 'and 14 for rotary movement therewith is an endless belt or belts 15. Mounted transversely of the frame 10 on the outside of the endless belt 15 is a plurality of uniformly spaced straight transverse slats or bars 16 of uniform size. These slats 16 may be formed integrally with the belt 15 and made of a hard plastic material, such -as rubber, or any other convenient material which will cause them to iex as the belt l5 travels around the peripheries of the rolls 12 and 14. To

ice

assist in supporting the upper'leg of the belt 15 as it travels beneath the operating elements of the apparatus, is a platform 17. ln order to move the belt 15 in the direction of the arrow, the shaft ll may be driven by any convenient means, such as a motor, not shown. The shaft 13 may be journaled for rotary movement in any convenient means, not shown.

Mounted on the upper part of the main frame or housing 10 is the main drive shaft 20 to which is iXed one or more eccentrics 21, each of which is linked by a connecting rod 22 to a push rod 23 in such a manner that rotation of the main drive shaft 20 will cause the push rod 23 to reciprocate at a uniform stroke. The push rod 23 is supported for vertical reciprocation by the push rod housing 24. Mounted on the lower end of the push rod 23 is the loop forming member 25 comprising a carrier including an upper carrier plate 26 supporting a transverse carrier bar 27.

The carrier bar 27 includes a plurality of uniformly spaced vertical guideways 28 in transverse alignment, only one of which is shown. Slidably mounted in each guideway is a plunger 29 having a flat lower end or blade 30 of a thickness adapted to penetrate between any pair of adjacent slats 16 in the path of the reciprocable blade and simultaneously to carry a portion of yarn 32 snugly between the slats. In order to hold each plunger 29 Within its guideway 28 and to permit limited reciprocation of the plunger 29 relative to the guideway 2S, a keyway or flat 34 is formed in one side of the plunger 29. A stationary key or dog 35 extends from the guideway wall into `the keyway 34. The difference between the depth ofthe keyway 34 and the key 35 is equal to the difference in the depth of penetration of the loop forming blade 30 between the adjacent slats 16.

In order to lock the plunger 29 in its extended position for deepest penetration, a hole 36 is formed in the front of the carrier bar 27 to intersect the plunger guideway 28. Adapted to reciprocate from front to rear within the hole 36 s a latch pin 37. It can be seen from FIGS. 2 -and 3 that when the latch pin 37 has been moved to the left into the guideway 28 and above the plunger 29, the plunger 29 will be locked in its extended position between the latch pin 37 and the key 35. Thus, when the push rod 23 is reciprocated to its lowermost position, the loop forming blade 30 will penetrate to its greatest depth and form a high loop 40 between an adjacent pair of slats 16, as best disclosed in FIGS. 2 and 3.

When the latch pin 37 is withdrawn toward the front of the machine or to the right in FIGS. 4 and 5, the plunger 29 is free to reciprocate within its guideway 28 to the limits permitted by the engagement of the key 35 within the keyway 34. Thus in FIG. 4, when the 'push rod 23 is moving upwardly, the plunger 29 will assume its lowermost position because of gravity and inertia. On the other hand, when the push rod 23 is descending at a rather rapid rate, the inertia of the plunger 29 plus the pressure of the yarn 32 against the tip of the blade 30 will cause the plunger 29 to move to its uppermost position within the guideway 28, as best disclosed in FIG. 5. In such a position, the blade 30 will form a low or short loop 41.

In order to control the movements of the latch pin 37, it is linked by means of a connecting rod 44 to the armature 45 of a solenoid 46. Each solenoid 46 is controlled by an electrical lead 47 which terminates in a switch 48. The switch 48 is opened and closed by means of a pivoted finger 49 which is adapted to be pvoted by means of engagement or disengagement with grooves 50 in a pattern sheet 5l mounted on a pattern drum 52 which is continuously and synchronously rotated on shaft 53 by means such as a motor, not shown. l

In order to prevent yarn 32 from being robbed from previously formed loops by the peneration of the loop pile fabric.

forming blade 30 between slatsV 16, a presser foot 55V is provided including a platel 56 for Vengaging thebase portions `ofthe previously formed

loops

40, 41. The plate 56is supported at` the lower end of a vertical rod 57 adapted to freely reciprocate in an opening in the carrier plate 26. A coil spring VS8 is disposed between vthe carrier plate Zo and the presser foot plate Soin order to urge the presser plate 56 Vaway from the carrier and down into holding engagement against the base portions of the Aloops 40 and 41. Downward movement of the presser foot 55 relativeto 'the loop forming member 25 is limited by the ange 59 on top of the rod 57. Thus, it can be seenvfrom Vthe sequence of operations disclosed in FIGS..2 and 3 or FIGS. 4 and 5, the presser foot plate 56 will be suspended above the loops When'the loop forming member is in its uppermost position, but ask the member 25descends, thepresser foot platef willenga'ge the baseportions of theloops 40 and'41 andthe Y pressure between the plate S6 and the loops will gradually increase to hold the loops in place as the blade descends with a loop portion of yarn SZ'between slats 16. Uponascent of the loop forming member 25, the pressure between the presser foot plate 56 and thefloops completely disengages the yarns in theV uppermost position of the loop forming member 25 (FIGS. 2 and 4).

VIn order/to secure the

loops

49, 41 in their pile-formed position, a hopper 6i? is located behind the loop forming member 25 for dispensing a plastic adhesive material 61,V such as polyvinyl chloride paste, which is slowly metered out upon the upper base portions of the

loops

49 and 41. A spreader orl doctor blade 62 may also be mounted behind the hopper t'to'level, the material 61y to a uniform backing.- An infra red'heater 6,3 is located behind the'spreader 62` in order to dry the plasticY material 61 and cause it to set to form a backing material VKforthe After the plastic coating 61 has set,V the slats 16 separate by virtue of their travel around Vthe peripheryy of the drun'i14 in order to release the loops 40 and 4l. The completed fabric may thenbe con- Vveyed to a subsequentrstation to be rolled for storage or apparent. v The drum shaft 11, the main drive shaft 20,V

the pattern drum shaft 53 and the Vyarn feed rolls 65 and 66 may all be rotatedl synchronously from'arcommon power source, such as a motor, not shown. As the belt '15 and the slats 16 move toward the rear of the machine,

yarn 32 is fed in the same direction acrosstheV slats and in the path of the reciprocating plunger blade 30.- Assum- V ing that the pivoted iinger'49V engages momentarily the surface-of the pattern sheet 51 to open the switch '48,

' the'solenoids 46 will remain inactivated soth'at'the latch pin V3 7 remains 4in its extended locking position'in the guideway 2S to maintain the plunger 29 inV its extended 1 positionY fordeepest penetration between the slats 16. Rotation of the main drive shaft 2li will therefore cause the loop forming'member ZS'tojmove from its upper position disclosed in FIG. 2 to its'lowermost position disclosedlin FIG. 3Q whereby 'the ,presserV foot 55 will firmlyV gripV the. baseV portions of the previously formed .loops "and the v plunger blade V36 will descend to its lowermost position between the adjacent slats 16 to form aY high loopy dil. The loop forming VelementZS reciprocates upward'to again assume its position in FIG. 2, and

f 1Assurningrithat theV pivo'ted pattern'inger 49 falls into Y agroove ofapattern sheet 51 to close the switch V4S andthereby'actuatel the solenoid'fioto withdraw the latch i Y pin 37fto the positionv disclosed in FIG. 4, downwardY re-VY V4d, 41V will gradually decrease until the presser Vfoot 55 f 1 the belt 15 continues to move toward the left so that the j V-vnext/successive pair ofadjacent slats16 willalign themselves in the path of the plunger blade Sill.

Y the'diference 4 Y ciprocation of the loop'forming element 25 Awill cause the plunger 29 to move from its position disclosed in FIG, 4 to its raised or withdrawn position disclosed in FIG. 5 and thereby form a short loop 41. The presser foot 55 operates in the sameY manner regardless of the relative position of the plunger 29 with respect Vto the ,loop forming element 25.

Both high loops 4i) and low loops 41 are held Vbetween the slats 16 as they pass beneath the hopper 6tlptheY doctor blade 62 and the infra red dryer 63; By the time the loops have reached the rear end of the yplatform 17, the plastic coating 61 has set to form a backing material for the fabric and the loops are released by the separation of the slats 16 rotating around the drum 14.

Y. It will be understood that, even though only asideY elevation" of one plunger 29, yarn 32 and solenoid'46 have been disclosed, this machine is particularly adapted for a plurality of similarunitsdisposed transverselyrof the machine so that each yarnV 32 i's individually Vcontrolled to form a high loop or a low loop at any point in the fabric to create an innite variety of patternsfof high loops and low loops in a pile fabric made in accord;- ance with this invention. It is also possible. under this invention to provide aV plunger bladev 39 whose transverse v width is equal Vto the gauge of the fabric or toV a multiple of the gauge. vFor example, a plunger blade 30 could have a width sufcient to control two, three or four adjacent yarns. Y

lt will be apparent to those skilled in the art that varv ious changes may be made in the invention, without departing from the spirit and vscope thereofi and therefore the vinvention. is not limited to that which is shown lin the drawings and described in the specifications, but only as indicated in the appended claims. Y Y

Nhatis claimed is: Y l f 1. Anapparatus for making .patterned Ypile fabric comprising a plurality of uniformly andlongi'tudinally spaced transverse slats, means,A for moving said slats in one longitudinal direction, meansfor Vfeeding a yarn across said slats in said one direction, apile forming carrier, means for continuously reciprocating said carrier in a direction normal to'the plane of movement of said Y said plunger in said carrier to reciprocaterelative to saidYV carrier in said normal direction, first means for positioning said plunger in said carrier to carry aportion of said yarn to a first deep position between a pair of adjacent slats to form a high loop'when saidcarrier is inoperative postion; second means for positioning said plunger in said carrierfto carry a portion of said yarn Vto a secondV Vshallow positionbetween a pair of adjacent slats to"fo`rm a low loop when said carrier is in operative position,

and means for coating the yarn portions connecting saidV Y loops to form a backing for said pile'fabric.

2. The invention according to claim 1 in. whichrsaid iirst positioningrvmeans comprises latch means reciprocably mounted in said carrier, Vand means forrecipf.v rocating said latch means selectively to latch said plungerV v in said firstV position Vand to unlatch said plunger.

v 3; The invention according" to claimfl in which said second positioning means comprises a keyway formed on i one side of said plunger and a key in said'carrier extending into said keyway, the dimension Vof said keyway'par- Y allel to saidnormal directionbeing greater'thanthe cor.-

responding dimension of said key by afjdistance equal toY in depth between saidjfirstv and vsecond posi.

Y 4. An 'apparatus for making'patternedpile Vfalririccorn,`V prising a plurality of uniformly andlongitudinally spacedV transverse slats,"means Yfor moving said slats in one lon? Y Vgitudinal direction,means,forV feeding a yarn'across fsaiclY slats inKsaid one direction, a pile forming carrier,fnnzansV for continuously receprocating said carrier in a direction normal to the plane of movement of said slats between an operative position adjacent said slats and an inoperative posit-ion remote from said slats, a guideway in said carrier having an axis parallel to said normal direction, a plunger adapted to carry a portion of said yarn snugly between a pair of adjacent slats, said plunger being received in said guideway for reciprocable axial movement therein, a latch pin, means in said carrier for slidably receiving said latch pin for selectively latching said plunger in said carrier to carry a portion of said yarn to a irst deep position between a pair of adjacent slats to form a high loop when said carrier is in operative position and for unlatching said plunger, a keyway formed on one side of said plunger and a key in said carrier extending into said keyway, the axial dimension of said keyway being greater than the axial dimension of said key by a distance equal to the difference in the depth between said first deep position and a second shallow position of said plunger, said key being adapted to engage one end of said keyway to maintain said plunger in said shallow position when said plunger is unlatched and when said carrier is in operative position, and means for coating the yarn portions conneeting said loops to form a backing for said pile fabric.

References Cited by the Examiner UNITED STATES PATENTS 1,984,330 12/34 Boyce 112-221 2,116,048 5/38 Smith 154-78 EARL M. BERGERT, Primary Examiner.

Claims

4. AN APPARATUS FOR MAKING PATTERNED PILE FAVRIC OCMPRISING A PLURALITY OF UNIFORMLY AND LONGITUDINALLY SPACED TRANSVERSE SLATS, MEANS FOR MOVING SAID SLATS IN ONE LONGITUDINAL DIRECTION, MEANS FOR FEEDING A YARN ACROSS SAID SLATS IN SAID ONE DIRECTION, A PILE FORMING CARRIER, MEANS FOR CONTINUOUSLY RECEPROCATING SAID CARRIER IN A DIRECTION NORMAL TO THE PLANT OF MOVEMENT OF SAID SLATS BETWEEN AN OPERATIVE POSITION ADJACENT SAID SLATW AND AN INOPERATIVE POSITION REMOTE FROM SAID SLATS, A GUIDEWAY IN SAID CARRIER HAVING AN AXIS PARALLEL TO SAID NRMAL DIRECTION, A PLUNGER ADAPTED TO CARRY A PORTION OF SAID YARN SNUGLY BETWEEN A PAIR OF ADJACENT SLATS, SAID PLUNGER BEING RECEIVED IN SAID GUIDEWAY FOR RECIPROCABLE AXIAL MOVEMENT THEREIN, A LATCH PIN, MEANS IN SAID CARRIER FOR SLIDABLY RECEIVING SAID LATCH PIN FOR SELECTIVELY LATCHING SAID PLUNGER IN SAID CARRIER TO CARRY A PORTION OF SAID YARN TO A FIRST DEEP POSITION BETWEEN A PAIR OF ADJACENT SLATS TO FORM A HIGH LOOP WHEN SAID CARRIER IS IN OPERATIVE POSITION AND FOR UNLATCHING SAID PLUNGER, A KEYWAY FORMED ON ONE SIDE OF SAID PLUNGER AND A KEY IN SAID CARRIER EXTENDING INTO SAID KEYWAY, THE AXIAL DIMENSION OF SID KEYWAY BEING GREATER THAN THE AXIAL DIMENSION OF SAID KEY BY A DISTANCE EQUAL TO THE DIFFERENCE IN THE DEPTH BETWEEN SAID FIRST DEEP POSITION AND A SECOND SHALLOW POSITION OF SAID PLUNGER, SAID KEY BEING ADAPTED TO ENGAGE ONE END OF SAID KEYWAY TO MAINTAIN SAID PLUNGER IN SAID SHALLOW POSITION WHEN SAID PLUNGER IS UNLATCHED AND WHEN SAID CARRIER IN IN OPERATIVE POSITION, AND MEANS FOR COATING THE YARN PORTIONS CONNECTING SAID LOOPS TO FORM A BACKING FOR SAID PILE FABRIC.