US3237578A - Machine for making pile fabric formed by tufts of yarn on a web of backing material - Google Patents

Machine for making pile fabric formed by tufts of yarn on a web of backing material Download PDF

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Publication number
US3237578A
US3237578A US157231A US15723161A US3237578A US 3237578 A US3237578 A US 3237578A US 157231 A US157231 A US 157231A US 15723161 A US15723161 A US 15723161A US 3237578 A US3237578 A US 3237578A
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Prior art keywords
needles
row
web
tufts
loop
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Expired - Lifetime
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US157231A
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English (en)
Inventor
Dietz Wolfgang
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Forbo Holding AG
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Deutsche Linoleum Werke AG
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    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05C—EMBROIDERING; TUFTING
    • D05C15/00—Making pile fabrics or articles having similar surface features by inserting loops into a base material

Definitions

  • the invention relates to a method and apparatus for applying rows of tufts to a backing material by means of cut pile and loop pile tufting machines.
  • Such tufting machines and needle pile machines have been used very widely recently for making needle pile blankets, upholstery materials, carpets, etc.
  • the needles of the machine fastened to a needle carriage, shoot the tufts into a backing material, foil or the like passing below the needle carriage perpendicularly to the row of needles.
  • One of the reasons for this is that the yarns have to pass through the eyes of the tufting needles, the size of which again depends on the spacing of the needles. The other reason is that the spacing and strength of the needles in turn depends on the loop holders and knives respectively to be accommodated and on the backing material.
  • Blended hair yarns which result in a particularly strong product, are hard to use with fine needles. Patches of latex and the like in the yarn are left in the eyes of the needles and lower productivity. Stoppages cause variations in the buckling of the thread, which often prejudices the appearance of the goods and lowers their value.
  • the finer needles, loop holders, knives, etc. are also particularly sensitive, especially in carpet cut pile tufting machines, and their constant servicing is responsible for frequent stoppages and hard wear on materials.
  • the tufts With a cut pile the tufts are juxtaposed parallel in both the longitudinal and the transverse direction, the perforations showing rectangular meshes. Thus the tufts support each other only laterally, so that interstices are formed in the space between four tufts, such as are found in all conventional carpets.
  • the present method eliminates the described disadvantages and achieves the desired purpose of thickening the pile and fibre section in conventional and knotted carpets.
  • the backing material passing under the needle carriage is fed obliquely to the direction of the row of needles.
  • the thickness of pile and fibre section enables the depth of the pile to be considerably decreased so as to save or restrict oneself to a specific weight of yarn.
  • FIGS. 1 and 2, 3 and 4, 5 and 6 are a side elevation and plan view respectively of different embodiments of apparatus of the present invention
  • FIG. 7 is a horizontal section through needles and obliquely held loop-formers for out pile;
  • FIGS. 8 and 8a illustrate the horizontally operating loop former carriage
  • FIG. 9 is a plan view of a knife carrier shaft with knife holder carrier
  • FIGS. 10, 11, 12 are front, side and plan views respectively of the course of a cut pile tuft row Where the backing is drawn obliquely and drops down after stitching;
  • FIG. 13 shows cut pile made in known manner
  • FIG. 14 shows cut pile made according to the invention
  • FIG. 15 shows loop pile made in known manner
  • FIG. 16 shows loop pile made according to the invention
  • FIGS. 17, 18 and 19 are front, side and plan views respectively of the course of a cut pile tuft row between obliquely-placed guide rods;
  • FIGS. 20, 21 and 22 are views from below, from the side and from behind respectively of the course of a loop pile tuft row between obliquely placed guide rods.
  • FIGS. 1 and 2 illustrate the guiding of a backing material 1 which is brought through under the diagrammatically shown needles 2 of the needle carriage 3 of a tufting machine 4 (partially shown in section in FIG. 1), the direction of its passage (seen in plan form in FIG. 2) being diagonal and oblique respectively to the direction in which the row (or rows) of needles of the needle carriage extend.
  • the unwinding roll 5 and the take-up roll 6 are arranged obliquely to the direction of the needle carriage and, together with the feed needle roller 7 and the delivery needle roller 8, lead the cloth through the machine obliquely to the row of needles. At the same time the cloth is stretched and transported longitudinally by the needle rollers during the tufting operation.
  • Pin chains 9, 10 or the like and width supports 11, 12 are provided at the selvedges respectively to guide the cloth laterally and to stretch it transversely. These also prevent any lateral deviation of the cloth due to the diagonal tufting, which is important particularly where cut pile is being made.
  • the loop formers hold only one loop at each stitch of the needle and release it again when the cloth is moved on, with cut pile several loops are held on the loop former before cutting. Depending on the tension of the yarn these loops endeavour more or less forcefully to lead the cloth in the direction of the loop formers.
  • FIG. 9 shows the knife holder carriage carrying blocks 41 with knives 42 mounted therein.
  • the knives are moved by the knife carrier shaft 43 in a slight upward are away from the needles.
  • the knife carrier shaft has lengths of screw thread 44 mounted in threaded bushes or nuts. The pitch is chosen so that the knife carrier shaft and the knives moved therewith move in the oblique direction of the cloth. This enables the oblique working of the loop formers and of the knives to coincide where there is a horizontally operating loop former carriage according to FIG. 8.
  • FIGS. 10, 11 and 12 the tuft row illustrated and the length of fabric 47 run obliquely to the right.
  • the reeds 48 slope downwardly immediately behind the needles, so that the advancing, longitudinally stretched backing can be resiliently drawn downwards.
  • the loop former 49 arranged vertically to the row of needles, secures the loops 50, 51 and 52 without effectively preventing the cloth from advancing obliquely, owing to its downward flexibility, in spite of the contrary pull of the loops -52 (FIG. 10).
  • FIGS. 3 and 4 the cloth is also led obliquely to the direction of the row of needles (shown in plan view in FIG. 4.)
  • the obliquely placed needle rollers 15, 16 transport and stretch the cloth longitudinally and draw it over guide rods 172-0, whereby servicing of the machine is facilitated by superposing a platform 21.
  • FIGS. 5 and 6 show cloth guides 22-24 and 2527 which, by forming loops of cloth, bring the cloth out of the normal direction of passage vertical to the row of needles-shown in plan viewinto an oblique direction.
  • the cloth is led to the machine by the needle roller 22 and stretched and led away by obliquely mounted (FIG. 6) needle rollers 28.
  • the drive (not shown) for the needle rollers, which may also perform the returning action, can be provided by bevel gears.
  • Combinations of the cloth guides shown or other known types can of course be set obliquely to transport and stretch the cloth.
  • the needle rollers for example, may comprise short, separate pieces arranged obliquely and offset like Venetian blinds.
  • the loop formers 29, constructed obliquely in accordance with the invention receive the looped yarn 31 brought by the needles 30 through the uppermost backing and lead the loops 32 to the knives 33, which cut them up into cut pile tufts 34.
  • the fact that the loops are guided obliquely by the loop formers means that the advancing backing is also guided obliquely or left in its oblique direction.
  • FIG. 8 shows diagrammatically the loop former carriage 35, carrying blocks 36 with loop formers 37 attached thereto.
  • the carriage is reciprocated by the toothed racks 38, the guides 39 making the [forward thrust occur obliquely to the direction (not shown) of the row of needles. This also results in the backing being guided obliquely through the loops on the loop former.
  • FIG. 13 shows cut pile tufts 54 seen as from the top of the needle pile carpet and made with a needle and tuft row spacing a and a stitch spacing b.
  • the centers 55 of the stitches are in the longitudinal direction of the row of needles, indicated by the dotted line 56.
  • the centres of the stitches form rectangular meshes, in the centre of which there are few fibers.
  • the opened tufts 54 of the pairs of yarn threads 57, 58 support each other only laterally.
  • the backing material runs in the direction of the arrow 59 perpendicularly to the direction of the row of needles.
  • FIG. 14 Shows the close pile and fibre density obtained with the same needle spacing by closing up the rows of tufts and offsetting them longitudinally as in FIG. 13 through the oblique direction of the backing material 60 in relation to the direction of the row of needles 61.
  • the tufts of the individual needles are placed in the space between the tufts put into the backing by the needles of the adjacent row of tufts.
  • the needles perforations form obliquely offset meshes, so that the tufts support each other not only laterally but also diagonally.
  • the oblique guiding of the cloth enables a much closer spacing c of the rows of tufts to be obtained.
  • the decrease in the strain on the weft threads of the backing makes it possible to have a closer stitch spacing d.
  • FIG. 15 shows loop tufts 62 made of twisted threads comprising three separate threads 63 (only partially illustrated).
  • the needles of the rows of needles 64 and 65 are arranged one behind the other and longitudinally displaced in such a way that the rows of tufts of the front needles come to rest between those of the back needles.
  • the spacing of the tuft rows e is accordingly half the needle spacing f.
  • the tuft row spacing g is only about one third of the same needle spacing f.
  • the individual threads are directed approximately in the diagonal direction of the carpet, which has a more pleasing effect.
  • FIGS. 17, 18 and 19 the illustrated row of tufts 66 and the associated length of fabric 67 run obliquely to the right.
  • the somewhat obliquely arranged reeds 68 slope downwardly immediately behind the needles.
  • guide rods or wires 70 are let into the reed plate under the dents. After stitching (shown in plan View) these are bent obliquely downwards and guide the as yet uncut loops and the out tuft bunches in an oblique direction. This results in the cloth extending in the prescribed oblique direction and not being drawn sideways by the as yet uncut loops by the loop formers moving vertically to the row of needles.
  • the dents and guide wires may also comprise a suitably stamped dropper.
  • the row 71 of loop tufts and the associated length of fabric 72 move to the righ-t, i.e. to the left as seen from below.
  • the presser foot 73 does not allow the cloth to diverge upwardly when, according to the invention, the loop guide rods and reeds 74 respectively, set obliquely to the needles in the view from below, guide the rows of loops and thereby the cloth in the prescribed oblique direction.
  • a machine for the manufacture of pile fabric formed by tufts of yarn arranged in rows longitudinally and transversely on a Web of backing material comprising a row of tuft forming means, including a needle bar and a row of tufting needles positioned on and aligned longitudinally of said bar, for passing yarn through said backing material from one side and retaining a loop on the opposite side for each tuft, and means to convey said web of backing material in a constant unidirectional path longitudinal of said web past said row of tuft forming means and at an acute angle to said row of needles and said needle bar, said row of needles extending across said web and reciprocating in one position through said web so that said row of tuft forming means forms successive rows of tufts extending entirely across said web at an acute angle to the length of said web upon reciprocation of said row of needles as said web moves through said path.
  • said means to convey said web of backing material includes needle roller means for transporting said material.
  • said means to convey said web of backing material includes separate obliquely positioned needle rollers on opposite sides of said row of needles for engaging and transporting said material.
  • said means to convey said web of backing material includes feeding pin chains running obliquely to said row of tuft forming means and parallel to the direction of movement of said web of material and in feeding engagement with the material.
  • said row of tuft forming means includes loop former means positioned obliquely to said row of tufting needles and adapted to retain loops to form said tufts.
  • said row of tuft forming means includes horizontally operating loop former carriage means directed obliquely to the said row of needles and having loop former means thereon to cooperate with said needles.
  • a machine as defined in claim 8 which includes knife carrier shaft means directed obliquely to the row of needles, knife means on the shaft, and means supporting said shaft means.
  • said tuft forming means includes loop guide reeds directed at an acute angle to said row of needles and a presser foot behind said row of needles.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Textile Engineering (AREA)
  • Knitting Machines (AREA)
  • Treatment Of Fiber Materials (AREA)
US157231A 1960-12-06 1961-12-05 Machine for making pile fabric formed by tufts of yarn on a web of backing material Expired - Lifetime US3237578A (en)

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DED0034886 1960-12-06

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US3237578A true US3237578A (en) 1966-03-01

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US (1) US3237578A (enrdf_load_stackoverflow)
BE (1) BE611201A (enrdf_load_stackoverflow)
GB (1) GB966242A (enrdf_load_stackoverflow)
NL (1) NL271970A (enrdf_load_stackoverflow)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3377973A (en) * 1965-07-07 1968-04-16 Grace W R & Co Tufting method and article
US3583346A (en) * 1968-12-27 1971-06-08 Elsie Coulson Bloch Tufted loop pile fabric

Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US257786A (en) * 1882-05-09 Joseph thomas
DE460728C (de) * 1927-09-21 1928-06-04 Heinrich Llg Rohner Einrichtung zur Herstellung von plueschartigen Stickereien auf Stoffbahnen
US1830463A (en) * 1928-01-19 1931-11-03 Mechanical Rubber Co Loop forming machine
US2335487A (en) * 1941-01-24 1943-11-30 Joe C Cobble Multiple needle tufting machine
US2411267A (en) * 1944-07-20 1946-11-19 Hamrick Lyman Multiple needle tufting machine
US2679218A (en) * 1951-03-31 1954-05-25 Clarence M Jones Chenille tufting machine
US2696181A (en) * 1950-04-04 1954-12-07 Russell Lacey Mfg Company Method for forming pile fabric
US2975736A (en) * 1958-06-23 1961-03-21 Singer Cobble Inc Loop shedder
US3017847A (en) * 1956-03-13 1962-01-23 Collins & Aikman Corp Tufted fabrics and methods of making same
US3056364A (en) * 1958-12-29 1962-10-02 Singer Cobble Inc Apparatus for sewing separate yarns into the same row of stitching
US3059598A (en) * 1955-03-14 1962-10-23 American Viscose Corp Tufted fabric

Patent Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US257786A (en) * 1882-05-09 Joseph thomas
DE460728C (de) * 1927-09-21 1928-06-04 Heinrich Llg Rohner Einrichtung zur Herstellung von plueschartigen Stickereien auf Stoffbahnen
US1830463A (en) * 1928-01-19 1931-11-03 Mechanical Rubber Co Loop forming machine
US2335487A (en) * 1941-01-24 1943-11-30 Joe C Cobble Multiple needle tufting machine
US2411267A (en) * 1944-07-20 1946-11-19 Hamrick Lyman Multiple needle tufting machine
US2696181A (en) * 1950-04-04 1954-12-07 Russell Lacey Mfg Company Method for forming pile fabric
US2679218A (en) * 1951-03-31 1954-05-25 Clarence M Jones Chenille tufting machine
US3059598A (en) * 1955-03-14 1962-10-23 American Viscose Corp Tufted fabric
US3017847A (en) * 1956-03-13 1962-01-23 Collins & Aikman Corp Tufted fabrics and methods of making same
US2975736A (en) * 1958-06-23 1961-03-21 Singer Cobble Inc Loop shedder
US3056364A (en) * 1958-12-29 1962-10-02 Singer Cobble Inc Apparatus for sewing separate yarns into the same row of stitching

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3377973A (en) * 1965-07-07 1968-04-16 Grace W R & Co Tufting method and article
US3583346A (en) * 1968-12-27 1971-06-08 Elsie Coulson Bloch Tufted loop pile fabric

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Publication number Publication date
NL271970A (enrdf_load_stackoverflow)
GB966242A (en) 1964-08-06
BE611201A (fr) 1962-03-30

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