US3488245A - Means for manufacturing pile fabrics - Google Patents

Means for manufacturing pile fabrics Download PDF

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Publication number
US3488245A
US3488245A US518912A US3488245DA US3488245A US 3488245 A US3488245 A US 3488245A US 518912 A US518912 A US 518912A US 3488245D A US3488245D A US 3488245DA US 3488245 A US3488245 A US 3488245A
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United States
Prior art keywords
drum
cells
yarn
loops
pile
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Expired - Lifetime
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US518912A
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English (en)
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Irvine L Thatcher
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Individual
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Individual
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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H11/00—Non-woven pile fabrics
    • D04H11/04—Non-woven pile fabrics formed by zig-zag folding of a fleece or layer of staple fibres, filaments, or yarns, strengthened or consolidated at the folds

Definitions

  • each cell being of predetermined size, depth and pitch, means to deliver a measured quantity of liquid dye to each cell and a notched yarn inserting means which pushes a loop of yarn into the liquid-filled cell to imbibe the liquid dye by capillary action, a roller adjacent the drum to feed a farbic backing coated with adhesive to the dyed loops, and heating means which sets the adhesive and dries the pile.
  • a cutter may be used to cut the loops.
  • the invention pertains to pile fabrics such as carpets, rugs and similar floor coverings, upholstery materials and so forth.
  • the chief object of the invention is to obviate the need for conventional looms and all their necessary ancillary machinery and processes in the production of pile fabrics by providing a new or improved process and means or apparatus whereby pile fabrics can be simultaneously manufactured and dyed to any predetermined multicolour pattern or design of maximum clarity and delineation.
  • Another object of the invention is to render possible the production of simultaneously manufactured and dyed pile fabrics whose piles may be either looped or cut, as desired.
  • a still further object of the invention is to enable pile fabrics to be reinforced or strengthened during manufacture, if desired.
  • the apparatus or means for carrying the invention into effect includes a member, preferably comprising a rotary cylindrical or tubular drum, adapted to be intermittently rotated at predetermined speed through the medium of gear trains or other suitable means.
  • the outer face of the said member is covered with a multiplicity of cells or recesses of predetermined size, depth and pitch which cells are intended to serve a dual purpose, namely, to receive and contain dyestuif provided from a suitable source or sources of supply and to also co-act with means for insertion into the cells of ends of yarn from a suitable supply whereby the said yarn is simultaneously dyed and looped.
  • the looped yarn is thereafter passed into engagement with suitable pre-formed backing material suitably treated so that the outer ends of the loops become adhered or bonded to the said backing whereupon the now pile fabric is complete having a pile of uncut or looped nature.
  • suitable pre-formed backing material suitably treated so that the outer ends of the loops become adhered or bonded to the said backing whereupon the now pile fabric is complete having a pile of uncut or looped nature.
  • additional means may be associated with the apparatus for cutting the loops forming the pile to produce a cut pile fabric.
  • thermoelectric heaters for facilitating dyeing and for curing the bonding.
  • FIGURES 1a, 1b and 1c are a schematic arrangement of apparatus (not to scale) illustrating the principle of the invention.
  • FIGURE 2 is a schematic front view of a fragmental part of the preferably rotary member or drum employed in the process and apparatus according to the invention.
  • FIGURE 3 is a side elevation of the rotary member or drum of the apparatus and other associated parts whose functions will be hereinafter described.
  • FIGURE 4 is an enlarged side view of a detail of the apparatus.
  • FIGURE 5 is an elevation diagrammatically illustrating the means for inserting dyestuff into cells of the apparatus.
  • FIGURE 6 is a diagrammatic view of netted reinforcement used as the backing for the dyed pile fabric made in the apparatus of FIGS. l-S.
  • FIGURE 7 is a diagrammatic view of the latch mechanism linked to the dye dispenser and of the solenoid which operates the mechanism electrically.
  • the drum 1 is of hollow or tubular cross-section of any desired length according to the intended maximum width of the fabric to be produced, the said drum being mounted on an axial shaft 2 supported in suitable bearings.
  • Any suitable well known means such as gear trains and ratchet mechanism are related to the said drum and shaft assembly for intermittently rotating the drum for predetermined distances during operation, the gears being driven from any convenient or included power unit such as an electric motor.
  • the outer face or periphery of the drum 1 is covered with a multiplicity of cells or recesses 3 predetermined size, depth and pitch so that the said cells form rows in aligned positions across the drum and around the same.
  • each dispenser Located in proximity to the drum 1 is or are one or more rows of dye dispensers 4 corresponding in number and in pitch with the co-axial rows of cells in the drum.
  • the outlet end or nozzle of each dispenser is of less diameter than the cells 3 in order that the said nozzle may register with and enter for a predetermined distance into its related cell, means being provided for intermittently advancing and withdrawing the several dispensers in correct timed sequence relatively to the rotary motion of the drum.
  • a yarn insertion unit or units comprising a row of plungers 6 corresponding in number and pitch to the co-axial or transverse ro-ws of cells in the drum.
  • the plungers 6 are of slightly less diameter than the bores of the cells 3 and may have notched or otherwise suitably contoured extremities, the several plungers being arranged to intermittently engage and withdraw from the cells in correct timed relationship with respect to the intermittent rotary motion of the drum 1.
  • a source of yarn supply Arranged to co-act with the yarn insertion unit is a source of yarn supply of any suitable kind.
  • the supply may comprise a roller or beam upon which are wound ends of yarn corresponding in number to the number of cells in each transverse row of the drum, or the ends of yarn may be carried upon bobbins or like packages mounted on a.creel or equivalent device.
  • Any suitable roller or other guide means 7 may be provided for controlling passage of the ends of yarn to the apparatus.
  • a number of rollers 8 between which latter and the periphery of the drum 1 a continuous length of backing material is intended to be passed from a suitable source such as a rotary beam.
  • the backing material preferably consists of any suitable woven fabric but it must be understood that felt, knitted fabric, sheet plastics substance, rubber or any other suitable backing material could be employed. Secondary backing could be applied simultaneously or later, as preferred or if desired.
  • One surface of the backing material has a film or layer of suitable bonding agent applied thereto either prior to or during passage to the drum 1.
  • the bonding agent may consist of any suitable well known type of rubber-based substance or a suitable synthetic resin.
  • Heater means 9 are included in the apparatus to preheat the backing 11 from the under side between the guide means 7 and the first roller of the plural roller means 8 and a further heater means 49 is mounted inside the drum, for expediting the dyeing and drying actions and other heater means 29 is provided above the backing and after the last of the rollers in roller means 8 in proximity to the bonding station of the apparatus for curing the bond.
  • the heaters 49 and 29 serve to heat the bonding agent prior to contact with the yarn on the drum.
  • means for cooling hot-melt bonding agents after application may be provided.
  • the drum 1 When the apparatus or machine is started, the drum 1 is caused intermittently to rotate and sequentially advance the rows of cells 3 relatively to the dye dispensing and yarn insertion means 4 and 6. Then, as the rows of cells progressively pass the dye dispensers any or all of the cells in each row receives a charge of dyestuif 5 caused by the dispensers moving into engagement with the cells and automatically discharging measured quantities of dye. Preferably, this operation continues until the cells in a predetermined area of the drum are charged to produce a complete predetermined pattern.
  • the heater means 9 which preheats the backing and heater 49 in the drum which heats the dyed loops in the arrangement which is referred to above, the dyestuft' rapidly dries and the bonding action for the loops of yarn becomes complete.
  • suitable cutting means may be combined or associated with the aforesaid apparatus.
  • These means could comprise a plurality of cutter blades 12 of tapered Or other suitable configuration arranged in a row relativel to the passing fabric with the number of blades corresponding to the number of cells in each row of the drum and as shown in FIGURE 1b.
  • Revolving brushes or vacuum operated means could be provided for removing any dust or fly resulting from pile cutting or other operations.
  • a very effective manner for automatically dispensing dyestuff to the cells of the drum 1 as aforesaid is achieved by employing a row or rows of units, one of which units is illustrated in axial section in FIGURE 5 of the accompanying drawings.
  • a pipe or tube 15 is connected to a pipe 16 associated with a source of dyestuff supply.
  • a one-way valve in the form of a springloaded ball 17, suitably seated with respect to a seating in the pipe 16.
  • I Slidably mounted on the external wall of the tube 15 1s a secondary pipe or tube 18 furnished with an outlet nozzle 19 housing a one-way valve also in the form of a spring loaded ball 20.
  • the tube 18 is of greater length than that of the primary tube 15 to provide a chamber of predetermined volumetric capacity.
  • valve 17 When the secondary tube 18 is moved outwardly upon the relatively stationary tube 15 the valve 17 automatically opens and dyestuff from the supply pipe 16 flows into the aforesaid chamber. Immediately the direction of movement of the tube 18 is reversed the valve 17 automatically closes and the valve 20 automatically opens whereupon the predetermined charge of dyestutf contained in the chamber is expelled or discharged at the nozzle 19 into one of the cells of the drum 1 of the apparatus according to the invention.
  • the pipe 16 would carry a plurality of identical dispensing units corresponding in number and pitch or spaced relationship to the cells of the drum 1.
  • a useful possible addition to apparatus according to the invention are means for inserting reinforcement into the pile fabric being produced.
  • Such means could comprise a beam carrying any desired number of ends of strong yarn, string, wire or other suitable filaments adapted to be longitudinally introduced to the backing material immediately before the loops forming the pile are bonded to the backing.
  • a carrier or carriers could be mounted at either or both sides of the apparatus for inserting transverse reinforcing yarn, string, wire or other filaments into the pile fabric.
  • both longitudinal and transverse reinforcements may be employed.
  • a preferred kind of reinforcement would be in reticulated or netted form as diagrammatically illustrated in FIGURE 6 where the reinforcement comprises strong yarn, string, wire or other suitable filaments 22 inserted by any suitable means so that the loops of the pile are enclosed by the reticulated arrangement of the said filaments.
  • FIGURES 3 and 4 of the drawings A convenient manner of providing the aforesaid cells or recesses 3 in the rotary drum member 1 is illustrated in FIGURES 3 and 4 of the drawings Where the cells comprise identical tubular members ganged together in predetermined number and spaced relationship upon supporting devices 23 adapted to be secured to the periphery of the drum, the ends of the several devices being accurately located by providing lugs or keys 24 arranged to mate with recesses 25 formed in the drum.
  • FIGURE 3 it will be observed that thirty rows of dye dispensers are associated with the drum the dispensers of each row being connected by a pipe such as 16 (FIG- URE 5) to a supply of dyestuff of desired colour.
  • a pipe such as 16 (FIG- URE 5) to a supply of dyestuff of desired colour.
  • the uncharged cells of the drum sequentially pass to the dye dispensers and continue to function to repeat the pattern so that the production of dyed pile fabric is continuous and automatic.
  • the manner of advancing the dispensers towards the cells may be effected by electric solenoids, punched cards or any other suitable means.
  • the outer looped ends of the yarn may be treated with any suitable substance prior to the aforesaid bonding action.
  • FIGURE 5 One system of controlling the dye dispensers 4 according to the invention can be understood by referring to FIGURE 5.
  • One dispenser only is shown but any predetermined number are ganged together in a supporting head or unit located close to drum 1.
  • the supporting head is adapted to be moved towards the drum 1, when necessary, by a driven cam or other suitable means whereby every nozzle of the Whole of the dispensers 4 enters into the corresponding cell 3 in the said drum. During this movement of the unit every dispenser receives a charge of dyestuif.
  • FIGURE 7 there is shown the latch mechanism which is associated with the dye dispenser 4 and which is electrically actuated by a solenoid.
  • each dispenser 4 Associated with each dispenser 4, and as shown in FIG. 7, is a solenoid 30, a pivoted latch 31, a co-acting latch member 32 and a spring-loaded frame 33 linked to the dispenser.
  • Apparatus for manufacturing dyed pile fabrics comprising:
  • a gear and ratchet mechanism operatively related to said drum and shaft assembly for intermittent rotation of said drum
  • each of said cells having a predetermined size, depth and pitch for receiving a measured quantity of liquid dye of predetermined color prior to insertion of a yarn loop into said cell whereby the yarn loop imbibes said liquid dye by capillary action prior to assembling and bonding the dyed yarn to form the pile fabric;
  • said dye dispensing means located adjacent said drum in alignment with a row of said cells, said dye dispensing means including a supply pipe containing dyestuif in liquid form, at least one row of dye dispensers each of which is fed by liquid dyestuff from said pipe and each of which is fitted with a nozzle capable of extending into said cell and with a spring-loaded valve for delivering a predetermined amount of liquid into the cell upon rotation of the drum to bring a row of cells into alignment with said row of dispenser nozzles; and
  • said yarn inserting means located adjacent said drum and behind said dispensing means in relation to the direction of rotation of said drum, said yarn inserting means including a plurality of plungers arranged in a row for alignment with a row of said cells, notched means on said plungers adapted to engage a strand of yarn and, on reciprocation of said plunger, to bring said strand in loop form into a cell containing liquid dye dispensed from said dispensing means.
  • An apparatus as claimed in claim 2 including a plurality of cutter blades corresponding in number to the number of cells in each row of the drum, said blades cutting said loops after the backing is adhered and dried.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Treatment Of Fiber Materials (AREA)
  • Medicines Containing Material From Animals Or Micro-Organisms (AREA)
  • Knitting Of Fabric (AREA)
  • Woven Fabrics (AREA)
US518912A 1965-01-08 1966-01-05 Means for manufacturing pile fabrics Expired - Lifetime US3488245A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB866/65A GB1076651A (en) 1965-01-08 1965-01-08 Method of and means for manufacturing pile fabrics
GB2999265 1965-07-15

Publications (1)

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US3488245A true US3488245A (en) 1970-01-06

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US518912A Expired - Lifetime US3488245A (en) 1965-01-08 1966-01-05 Means for manufacturing pile fabrics

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US (1) US3488245A (xx)
BE (1) BE674848A (xx)
DE (1) DE1635661B1 (xx)
DK (1) DK127857B (xx)
ES (1) ES321539A1 (xx)
FR (1) FR1474820A (xx)
GB (1) GB1076651A (xx)
LU (1) LU50219A1 (xx)
NL (1) NL6600168A (xx)
NO (1) NO125539B (xx)
SE (1) SE317352B (xx)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4431429A (en) * 1981-12-24 1984-02-14 Rbi International Carpet Consultants Carpet dyeing system
US4472220A (en) * 1981-11-12 1984-09-18 Camac Corporation Textile detexturizing system

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1822510A (en) * 1927-08-09 1931-09-08 Lea Fabrics Inc Machine for the making of pile fabric
US3166465A (en) * 1960-05-27 1965-01-19 Int Latex Corp Bakced pile fabric and method of producing the same
US3173823A (en) * 1961-06-16 1965-03-16 John E Guinard Piled fabric and the method of and apparatus for manufacturing the same
US3235438A (en) * 1960-05-20 1966-02-15 American Biltrite Rubber Co Molded elastomeric product having integral flexible hair-like filaments

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1822510A (en) * 1927-08-09 1931-09-08 Lea Fabrics Inc Machine for the making of pile fabric
US3235438A (en) * 1960-05-20 1966-02-15 American Biltrite Rubber Co Molded elastomeric product having integral flexible hair-like filaments
US3166465A (en) * 1960-05-27 1965-01-19 Int Latex Corp Bakced pile fabric and method of producing the same
US3173823A (en) * 1961-06-16 1965-03-16 John E Guinard Piled fabric and the method of and apparatus for manufacturing the same

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4472220A (en) * 1981-11-12 1984-09-18 Camac Corporation Textile detexturizing system
US4431429A (en) * 1981-12-24 1984-02-14 Rbi International Carpet Consultants Carpet dyeing system

Also Published As

Publication number Publication date
SE317352B (xx) 1969-11-17
GB1076651A (en) 1967-07-19
LU50219A1 (xx) 1966-04-27
NL6600168A (xx) 1966-07-11
ES321539A1 (es) 1966-11-16
DK127857B (da) 1974-01-21
FR1474820A (fr) 1967-03-31
NO125539B (xx) 1972-09-25
DE1635661B1 (de) 1971-01-21
BE674848A (xx) 1966-05-03

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