US3220371A

US3220371A - Method of making textiles

Info

Publication number: US3220371A
Application number: US284396A
Authority: US
Inventors: Joe T Short; Jasper C Gaulding; Pike Howard
Original assignee: Callaway Mills Co
Current assignee: Callaway Mills Co
Priority date: 1962-08-17
Filing date: 1963-05-31
Publication date: 1965-11-30
Anticipated expiration: 1982-11-30
Also published as: BE636295A; CH430614A; GB1050681A; DE1485468A1; GB1050682A

Description

Nov. 30, 1965 SHO T ETA. 3,220,371

METHOD OF MAKING TEXTILES ori inal Filed Aug. 17, 1962 s Sheets-Sheet 1 o O O o o 5 c o o o 0 I f O o o o o O 24 o O O o h 0 i 64 1:1 3 i 22 I so 7 ME-"A 38 E E a a a I l4 20 v 20 I TI B I;

. Pa. 5.]- v I 3 a'- a 1 ll G 1 l 64 IL 1| e 6 v I 22 fF-u INVENIORS 24 JOE T. SHORT JASPER C. GAULDING HOWARD PlKE BY flaw-4 Ma, ATTORNEYS Nov, 30, 1965 J. 1'. SHORT .ETAL 3,220,371 union or MAKING TEXTILES I Original Filed AugQ lT. 196 2 s Sheets-Sheet 2 INVENTORS JOE T. SHORT' 'JASPER C. GAULDING HOWARD PIKE f ATTORNEYS Nov. 30, 1965 1'. SHORT ETAL 3,220,371

METHOD OF MAKING TEXTILES briginal Filed Aug. 17. 1962 s Sheets-Sheet s ."F'EE -15 INVENTORS JOE T. SHORT JASPER c. GAULDING' HOWARD PIKE BY 4%,, am, W, Wadi-1% ATTORNEYS 3,220,371 IMETHOD OF MAKING TEXTILES Joe T. Short, West Point, Jasper C. Gaulding, Hogansville,

and Howard Pike, La Grange, Ga., assignors, by mesne assignments, to Callaway Mills Company, La Grange, Ga., a corporation of Georgia Original application Aug. 17, 1962, Ser. No. 217,712.

Divided and this 13 Claims. (Cl. 112-266) application May 31, 1963, Ser. No.

. techniques for the production of pile fabrics such as floor covering materials. In a typical process of the type used commercially priorto the present invention, the fo'mation of pile loops or tufts is accomplished through the interaction of needle and looper elements disposed on opposite sides of a backing. Both the needles and the loopers are arranged in long rows extending transversely of the backing and the backing is advanced longitudinally. Each of the needles has an eye in its free end through which a pileyarn is threaded. All of the needles move together toward and away from the backing. As aneedle moves toward the backing it carries with it a pile yarn and projects or inserts a loop of this pile yarn throughthe backing. and then the looper element moves into the pile loop to hold the loop as the needle is withdrawn from the backing.

Various attempts were made using this general process to produce multicolor effects. However, the success achieved was limited, particularly in loop pile fabrics.

It is an object of this invention to produce a tufted pile fabric having a longitudinal row of pile tufts in which different pile yarns predominate at the face of the fabric at different points along the row. By using differently colored pile yarns in such a row and selectively controlling the heights of the loops formed from these yarns, one can obtain novel pattern effects.

In a preferred embodiment of the invention,a backing is moved along a path and controlled lengths of a plurality of pile yarns having different appearance characteristics are released to a hollow needle which is reciprocated back and forth to insert the tip thereof through a backing. Air i'smoved through the needle in a stream that tends to project the pile yarns from the tip of the needle as these yarns are supplied to the needle. At each point where the tip of the needle enters the backing, it is possible to form a pile loop of any desired height from any one or all of the pile yarns passing through that needle. If it is desired that a given pile yarnextend along the backing without forming a pile loop at a given penetration pointof the needle, the amount of that yarn made available to the needle can be made to correspond to the length of I the backstitch. During the same time period, a greater amount ofanother yarn may be supplied to the needle to form a pile loop extending through the backing. A plurality of pile loops of the same or different heights also may extend through the backing at any given point of penetration of the needle. The selectivity necessary for producing figured patterns and the like maybe obtairled by selectively controlling the relative amount of different yarns that are supplied to a given needle during the loop-forming cycles.

United States Patent ice A more complete understanding of the invention will be gained from consideration ofthe accompanying drawings. in which:

FIGURE 1 is a somewhat diagrammatic cross-sectional view of a multiple needle tufting machine for carrying out a method of the invention;. 7 Y a j I FIGURE 2 is a diagrammatic view illustrating generally the paths of the pile yarns supplied to the needles of the illustrating pile loop-forming operations carried out in ai:- v

cordance with the invention; I

FIGURE. 11 is a diagrammatic perspective view of a face portion of a fabric embodying the invention;

FIGURE 12 is a diagrammatic perspective view of the bottom of a floor covering embodying the invention, with a portion of a cover fabric being lifted to reveal the disposition of the pile yarns along the backing;

FIGURES 13, 14 and 15 are diagrammatic views illustrating loop forming operations in accordance with the invention performed by passing the needle tip a. shorter distance through the backing than is illustrated in FIG- URES 5, 7 and 9; and

FIGURE 16 is a partial cross-sectional view taken along the line 16-16 in FIGURE 1. v

The tufting machine of FIGURE 1 is provided with suitable fabric feeding and guiding means, including rollers 2 and 4, for advancing a backing 6 across the bed 8 of the machine in a conventional manner. The backing 6 ordinarily is a woven fabric of jute or cotton, but any suitable material may be used.

As the backing 6 is advanced, it moves through a tufting zone Where pile loops are inserted therethrough. In this zone, the backing sheet 6 is supported from below by a plurality of tine or finger elements 10 secured to the bed 8 and it is held against substantial upward movement by a presser member 12 carried by bracket means 14 secured to an upper housing unit 16 of the machine. The presser member 12 is provided with openings 18 in vertical alignmerit with the spaces between adjacent ones of the tines 10 and also in vertical alignment with the needles 20 of the machine.

Each of the needles 20 is provided with an axial passageway 21 of sufiicient size to accommodate a pluralitycarrier 26 is a simple reciprocating motion. With this typeof needle motion; it is desirable that the advance of thebacking 6 be intermittent so that it need not move during the portion of the machine cycle when the tips of the needles 20 are inserted into the backing. It is preferred that the needles 20 be disposed in a plurality of rows extending across the path of the backing 6 and that the needles 20 of one row be staggered with respect to the needles 20 of the other rows. Two transverse rows 2%; and 20b of the needles 20 are shown in FIGURE 16.

The drive for the needle carrier 26 may include an eccentric 28 rotatable with a driven shaft 30 within a bear ing member 32. The bearing member 32 is pivotally cortnected at 34 to the upper end of a push rod 36 mounted for vertical sliding movement in a bearing member 3% azzasri carried by the upper housing unit 16 of the machine. The

' lower end of. the push rod 36 is connected rigidly to the needle carrier 26 so that the needle carrier 26 willmove up and down as the eccentric 28 rotates about the axis of the drivenshaft 30.

' The pile yarns 22 and'24 are fed through the axial passageways 21 in the needles 20 by fluid streams. As illustrated, the needle carrier 26 includes a largev air chamber 40 to which air under pressure may besupplied through one or more flexible tubes 42 leading from a suitablepressurized air s'ource'44 suchas the discharge.

chamber of a compressor. Each of the needles 20 is .mounted on the needle carrier 26 by set screws 45 or other'suitablemeans, and each passes through the air 1 chamber 40.. The wall ofeach needle has orifice. means 46in communication with the air chamber 40. Air is prevented from escaping around the. exterior wall of each needle by suitable O-rings 48 or other sealing means.

-:'Ihe, orifices 46 are inclined downwardly and inwardly tocause air from the chamber 40 to flow into the axial passageway 21 of the needle in the form of a high velocity downwardly directed stream. It is desirable that the orifice means 46 be such as to reduce the pressure of the air below atmospheric pressure at the outletof the orifice means. With this arrangement an additional draft of air downwardly through the open, upper end of the axial passageway 21 in the needle is induced, and threading of the needle may beaccomplished by delivering-a yarn end to the upper end of the passage- .way 21. t

"The high. velocity air stream flowing downwardly through a needle 20 exerts drag forces on the pile yarns '22 and 24 tending to project these yarns from the lower end oi the needle; The air stream will pull through a needle 20 whatever length of yarn is released to the needle. It is important to note also that the forces are applied to the yarns in such a way that the'individual yarns may be fed atdifferent' rates. For example, dur- ,ing a given timeinterval there may be fed. through the axial'passageway 21 of a given'needle 20 a small length of pileyarn 22' and a greaterlength of another pile yarn 24. :When a plurality'of pile yarns pass together through a single yarn passageway 21. ina needle 20 their surfaces contact, andunder some conditions it would be possible for one yarn to interfere with the feeding of another. For thisreason it is desirable to use synthetic filament pile yarns, such as multifilament nylon yarns, in practicing the invention. Such yarns are relatively smooth, and since they are held'under tension by the air stream flowing' downwardly through the passageway 21, there is 'no dangerof one interfering with the delivery of the other.

;'When other, types of yarns are-used, it may be advisable to provide additional assurance that interference will not .occur.

For, example, the yarns may be given a temporary treatment, such as a coating of starch, to improve their surface characteristics during the tuftingprocess, or'the passageway through the needle may be subdivided or partitioned soas to minimizecontact between the yarns. v V

The supplying of pile yarns to the needles 20 is accomplished in the machine illustrated-in the drawings by..a feed mechanism 50 of the notched bar type. However, other suitable feed mechanisms capable of selec- ..:tively varying the rate of delivery of individual ones or ;.groups of the pile yarns may be used if desired. The

mechanism 50 is well known, and it need not be de- It will sutfice to point out that As shown in FIG- assembly 58 have shallow notches 60, intermediate depth notches 61,-and deep notches 62 in their edges for receiving pairs of the pile yarns. Hence, in the yarn feeding zone where the pattern bars 52 and '54 .are dis ,posed in intermeshing relationship, the pile yarns are carried along; undulating paths of different lengths. When the endless chains 56 and.58 move a-pair of pattern bars 52 and 54 out of the zone of intermeshing, the amountof a given yarn released depends upon whether that yarn passed through a shallow notch'60, an inter mediate depth notch 61, 'or a de'ep notch 62in that bar 54. from a shallow notch 60.

In "order .that' the width of the feed mechanismSO may be minimized, it is preferred that a plurality of pile yarns be disposed .ineach of the notches60, 61 and 62. As shown, pairs of the yarns 22 of one color pass through alternate ones of the notches and pairs or the yarns 24 of another color pass through intermediate ones of the notches. This arrangement isnot essential however, and

1 other feed systems may be used.

' From the feed mechanism theyarns pass to the needles 20 of the tuf'ting machine through guides such as

openings

64 and 66 in a plate member 68 attached to the housing unit 16. In the illustrated machine there are two of the

guide openings

64 and 66 for each of the needles 20.- However, if more than two yarns are to be supplied to each of the needles 20, the guide means would include more guide openings per needle.

.Where multicolor effects are to beproduced, the pile yarns 22 and 24passing to a given needle 20 have different appearance characteristics. They may differ in vcolor or texture or'both. This is suggested in the drawings by the stippling applied to the yarn 22.

FIGURES 5 through 10 illustrate a sequence of' three needle penetrations during which three distinctlytdiffer ent appearance effects are produced. on the surface-of the fabric by a single needle 20. Only two "pile yarns are shown in their views, but it will be understood that 7 that cycle an amount of the yarn, 24 greater than the during the next cycle.

amount of the yarn 22.. Referring again to FIGURES 3 and 4 and visualizing the passage of a single pair. of the

bars

52 and 54 out of the yarn feeding zone, it will be understood that the dilferent loop lengths suggested in FIGURE 6 would result if the yarn 24 were in a shallow notch 60 and the yarn 22 were in an intermediate depth notch 61 in' the bar 54. v

FIGURES 7 and 8 are similar to FIGURES 5 and 6 with respect to the illustrated positions of theneedle 20. However, these views illustrate the conditions that .exist During this cycle, the amount of the yarn'24 that is supplied to the needle 20 is suf ficient to permit the formation of a short loop 74: The

amountof the yarn 22 that is relased to the needle 20 is sufficient to permit this yarn to extend aroundthe edge ofthe opening in the tip of the needle. Sucha short yarn feed takes place for example when a yarn :is released from a deep notch 62 in a pattern bar 54. v When the needle tip is projected far enough to expose the entire opening beneath the backing 6 as illustrated in FIG- URES 5, 7 and 9, a very short loop 76 may extend temporarily from the face of the backing 6. However this loop may be withdrawn from the backing duringwthe advance of the backing 6 or during the next downstroke of the needle 20 by limiting the additional amount .ot'r. .yarn 22 released to the needle during this pcriodloyn' value less than that required for the yarn 22 to extend freely along the backing and around the edge of the Less'yarn is released'from a deep notch 62 than opening in the needle tip This condition is suggested in FIGURE 9, where the seed loop 76 has been com pletely withdrawn so that the pile yarn 22 extends along the backing from the point at which

loops

70 and 72 were formed, over the point where loop 74 was formed and on to the point where the needle next penetrates the backing 6.

FIGURES 9 and 10 illustrates athird cycle, in which equal amounts of the

yarns

22 and 24 are released to the needle-20 to form long loops from both of the pile yarns. Only one such loop 78 is visible in these views because the other is directly behind it.

It win be observed also in'FIGURES 9 and 10 that the two

yarns

22 and 24 have shifted laterally with re-' without difficulty. At onepoint in a longitudinal row of'loops the pile yarn 22 may be disposed to the left "of the pile yarn 24 and at another point the pile yarn 22may be disposed to the right of the pile yarn 24. The crossing of the yarns may be allowed to occur in a random manner or it may be controlled where desired.

Various pattern effects obtainable in accordance with the invention are incorporated in the fabric shown diagrammatically in FIGURE 11 where the points A, B, C,'D

and E represent successive penetrations of a needle that forms a longitudinal row of loops. Let it be assumed that the stippled yarns in this view are brown in color and that the other-yarns are white. The two loops that protrude through the same opening in the backing 6 at the point A are of unequal heights with the brown loop being longer than the white loop. At this point the color of the brown yarn will predominate on the face of the fabric, and the brown yarn will overlie and partially conceal the w'hite'yarn. At point B the two loops projecting from the backing 6 are again of unequal heights, but the white loop is higher than the brown loop so that the white yarn willpartially overlie and conceal the brown yarn. At point C the two loops are of equal height, both being high or long loops. At this point both yarns will contribute equally to the color effect produced at the surface of the fabric. A similar color effect is achieved at point D where both of the loops projecting from the fabric are low loops. At point E only the white yarn extends through 1 the backing to form a pile loop, it being understood that at this point the brown yarn passes along the rear face of I the backing as indicated at 81 in FIGURE 9.

Variations in color effects within any given transverse row of loop pile also are contemplated. The point P is 'in transverse alignment with the point C. At point C the brown and white loops are of equal heights and contribute equally to the appearance of the face of the fabric, but at point F the brown-loop is higher than the white loop so that the'white loop is at least partially concealed.

' Hence, it will be apparent that by using two differently colored yarns, a number of different visual-effects may be produced in a single longitudinal row of loop pile. Blends of the two colors may be obtained in either high or low "loops, or one color maybe caused to predominate over the other. Additionally, it should be observed that variations in mechanical characteristics, such as the deformability'of the pile surface of the fabric, result from the with any desired pattern.

In fabricating floor coverings, it is preferred that a binder and a cover sheet be applied to the rear face of the fabric formed on the tufting machine. A latex coating 6 over the backing 6 and the

pile yarns

22 and 24 securely locks the pile yarns in place and serves as a means for 'securing a cover sheet 82 to the backing 6 as suggested in FIGURE 12. The cover sheet preferably is a loosely woven fabric of jute or cotton. It gives the floor covering enhanced dimensional stability and abrasion resistance characteristics. FIGURE 12 also serves to clarify the relationship of the

pile yarns

22 and 24 of a set to each other as they extend along the backing 6. They run generally in side-by-side:

relation, but one may cross laterally over the other'as indicated at 80 or one may pass through the backing to form a loop at av point where the other remains on the rear of the backing as indicated at 81. If it is desired that no loops at all be formed at some particular point where conditions it maybe preferable to pass only a part of the tapered portion of the tip through the backing as shown diagrammatically in FIGURES 13-15. The taper of the tip of the needle 84 in these views is greater than that of the needles 20 and the verticalstroke isshorter. With such an arrangement it is not necessary that a seed loop be formed at a point in the fabric where a yarn is not to appear on the face of the final product. example, FIGURES l3 and 14 illustrate the formation of a high loop 86 from the yarn 22 at a point where the yarn 24 never enters the opening in backing 6. Yet, a plurality of loops 88 and 90 may be formcd,'as indicated in FIGURE 15, at any needle penetration point wherethey may be desired.

Still other modifications and variations will suggest themselves to persons skilled in the art. It isintended, 4

1. A method of making tufted fabric comprising carry ing out a first cycle including inserting a hollow needle through a backing and feeding through said needlc a length of a first pile yarn and a different length of a sec-- ond pile yarn having an appearance different from said first pile yarn, and then subsequently carrying out another cycle including inserting said needle-through the backing and feeding through said needle a length of said first pilefl yarn and a length of said second pile yarn different from the length of said second pile yarn fed through said' needle during said first cycle.

2. A method of making tufted fabric comprisingcarrying out a first cycle including inserting a plurality of hollow needles simultancously through a backing and feeding through each of said needles a set of pile yarns, controlling the length fed of a first pile yarn of each set so as to bedifferent from the length fed of a second pile yarn of such set, and then repeating said cycle while feeding in at least some of said sets different lengths of said pile yarns than were fed during said first cycle.

g 3. A method of making tufted fabric comprising carry-J ing out a first cycle including supplying to a'hollow needlea length of a first pile yarn and a longer length of a second pile yarn, creating relative movement between said hollow needle and a backing by moving said hollow needle-with respect to said backing back and forth through said back-= ing and fiowing fluid through said needle to feed said lengths of yarn through said needle and to form pile loops of different length; and then subsequently carrying-out a second cycle including supplying to said needle a length of said first pile yarn longer than the length of said first pile yarn supplied during said first cycle and a lengthof.

said second pile yarn shorter than the length of said sec 0nd pile yarn supplied during said first cycle, continuing the relative movement between said needle and said backing by moving said needle with respect to said backing back and forth through the backing and flowing fluid through said needle to feed the lengths of yarn supplied! thereto through said needle to form pile loops of lengths different from those formed during said first cycle.

4.- A method of making patterned tufted fabric comprising carrying outa first cycle including supplying to a single passageway in a hollow needle a length of a first synthetic filament pile yarn andjalonger length of a sec-i ond'synthetic filament pile yarn having an appearance different from that of said first pile yarn, inserting said hollow needle through a backing and flowing air .through said passageway to feed said lengths of yarn through'said needle and form pile loops of different lengths; and then pile loops 'of different lengths and colors'with the individual loops of said transverse rows being disposed in longisubsequently carrying out a second cycle including supplying to said passageway a length of said first pile'yarn longer than the length of said-first pile yarn supplied during said first cycle and a length of said second pile yarn shorter than the length of said second pile yarn supplied during said first cycle, inserting said needle through the backing and flowing air through said needle to feed the lengths of yarn supplied thereto through said needle to form pile loops of lengths different from those formed during said first cycle.

5. A method of making patterned multicolor tufted fabric comprising carrying out a first cycle including supso as to at least partially conceal said loop of said first pile yarn; and then subsequently carrying outa second cycle including supplying to said needle a length of said first pile yarn and a shorter length of said second pile yarn, inserting said needle through the backing and flowing fluid through said needle to'feed the lengths of yarn supplied thereto through said needle to form pile loops of different lengths with the loop of said first pile yarn extending beyond the loop of said second pile'yarn so as to at least partially conceal said loop of said second pile yarn.

6. A method of making tufted fabric comprisingcarrying'out a first cycle' including supplying to each of a pluralityof hollow needles a length of a first pile yarn and a longer length of a second pile yarn, inserting said hollow needles through a backing and flowing fluid through said needles to feed said lengths of yarn through said needles and form pile loops of different lengths; and then subsequently carrying out a second cycle including supplying lengths of said pile yarns to said needles with the lengths of said first pile yarn supplied to at least some of said needles during the second cycle being longer than the lengths of said first pile yarnsupplied to such needles during said first cycle and with the lengths of said second pile yarn supplied to such needles during the second cycle being shorter than the length of said second pile yarn supplied to such needles during saidfirst cycle, inserting said needles'through the backing and flowing fluid through, said needles to feed the lengths of yarn supplied thereto through said needles to form pile loops of lengths different from those formed during said first cycle.

7. A method of making patterned tufted fabric having .pile loops of different lengths and colors in longitudinal and transverse rows comprising carrying out a first cycle including supplying to each of a plurality of transversely,

' plying to at least some of said needles a'length of a pile yarn of said first color longer than the length of pile yarn of said first color supplied during said first cycle and a tudinal alignment to form .longitudinal rows of loops of different lengths and colors. v

8. A method of making a tufted fabric comprising carrying out a first cycle including inserting the tip of a hollow needle through a backing and withdrawing the tip of the needle from the backing, feeding through said needle lengths of at least two pile yarns,and advancing said backing realtive to said needle; and then carrying out immediately thereafter avsecond cycle including inserting the tip of a hollow needle through a backing and withdrawing the tip of the needle from the backing, feeding through said needle lengths of at least two pile yarns, and advancing said backing relative to said needle; the length of one of said pile yarns fed during said second cycle being suflicient to form a pile loop andthe total length of said one of said pile yarns fed during said successive cycles being substantially equal to the sum of the length of yarn contained in said loop and twice the distance between the penetration points of said needle.

In a method of making tufted fabric, the steps of passing a plurality of yarns simultaneously through the same hole in a backing to the same extent for creating a pile having loops formed from said yarns, and selectively elongating either one ofQsaid loops beyond the length of the other loop which other loop remains at said same extent according to a prescribed pattern.

10. In a method'of making tufted fabric, the steps of holding the material of a backing open for creating a hole therein, simultaneously inserting a pair of yarns through said hole in said backing as said hole is held open for creating a tuft, and selectively manipulating the length of either one of said yarns by moving'a portion thereof while continuing to hold said hole open and without the moving portion engaging said material for creating loops of different lengths in a single tuft.

and manipulating said increment of at least one of said yarns for elongating the length of the loop thereof while continuing to hold said portions away from each other.

12. In a method of tufting of the type wherein a backing is passed along a path of travel and a plurality of hollow needles disposed transversely; to said path of travel on one side of the backing with their ends adjacent said backing-are upon relative movement of said backing and said needles caused to'be inserted during successive cycles through successive transverse portions of said backing so that said ends of said needles are disposed during a portion of each cycle on the other side of said backing and wherein individual first yarns are respectively passed through hollow portions of said needles and protrude from the ends of said needles for being inserted with said ends of said needles through said backing for forming loops of first yarns and wherein a fluid pressure differential is applied to said hollow'portions of said needles for urging said yarns out of said ends to increase the lengths of said loops during that portion of the cycle in which such loops are formed and the feed of said yarns to said needles is controlled for regulating according to a prescribed pattern the amounts of yarns respectively urged from said ends of said needles when said ends of said needles are disposed on said other'side of said backing so that longitudinal parallel rows of tufts of first yarns are produced on said other side of said backing respectively by said first yarns, the steps of passing second yarns respectively through said needles and out of said ends of said needles along corresponding paths with said first yarns and respectively through the same ends of said needlesjwith said first yarns so that the second yarns are also inserted to approximately the same extent with said first yarns through said backing and simultaneously with second loops in-the same pile and said fiuid pressure differential applied to said hollow portions of said needles 1 varied with respect to each other along said longitudinal -the insertion of said first yarns therethr'ough for forming 10 rows of piles to an extent sufiicient for the longer loop essentially to hide from view the shorter loop.

13. In a method of making'tufted fabric, the steps of simultaneously inserting a pair of yarns through-the same hole in a backing and selectively arresting the penetration .of. one of said pair of yarns while continuing the penetration of the other of said pair of yarns through said backing. 1

Reierences Cited hy'the Examiner UNITED STATES PATENTS 7 2,990,792 7/1961 Nowicki et al 11279.6 3,089,442 5/1963 Short 11279 3,091,199 5/1963 Ballard 112-79 3,095,840 7/1963 Ballard l12--79 FOREIGN PATENTS 618,165 2/ 1949 Great Britain.

20 JORDAN FRANKLIN, Primary Examiner.

Claims

1. A METHOD OF MAKING TUFTED FABRIC COMPRISING CARRYING OUT A FIRST CYCLE INCLUDING INSERTING A HOLLOW NEEDLE THROUGH A BACKING AND FEEDING THROUGH SAID NEEDLE A LENGTH OF A FIRST PILE YARN AND A DIFFERENT LENGTH OF A SECOND PILE YARN HAVING AN APPEARANCE DIFFERENT FROM SAID FIRST PILE YARN, AND THEN SUBSEQUENTLY CARRYING OUT ANOTHER CYCLE INCLUDING INSERTING SAID NEEDLE THROUGH THE BACKING AND FEEDING THROUGH SAID NEEDLE A LENGTH OF SAID FIRST PILE YARN AND A LENGTH OF SAID SECOND PILE YARN DIFFERENT FROM THE LENGTH OF SAID SECOND PILE YARN FED THROUGH SAID NEEDLE DURING SAID FIRST CYCLE.