US3677206A - Apparatus for making tufted fabrics - Google Patents

Apparatus for making tufted fabrics Download PDF

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Publication number
US3677206A
US3677206A US110851A US3677206DA US3677206A US 3677206 A US3677206 A US 3677206A US 110851 A US110851 A US 110851A US 3677206D A US3677206D A US 3677206DA US 3677206 A US3677206 A US 3677206A
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pile
needles
tufting
backing fabric
latch
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US110851A
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English (en)
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John T Macisaac Jr
James E Troy
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FIELD CREST CANNON Inc
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Fieldcrest Mills Inc
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Assigned to FIRST NATIONAL BANK OF BOSTON THE reassignment FIRST NATIONAL BANK OF BOSTON THE SECURITY INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: FIELDCREST MILLS, INC., A CORP OF DE.
Assigned to FIELD CREST CANNON, INC. reassignment FIELD CREST CANNON, INC. MERGER (SEE DOCUMENT FOR DETAILS). Assignors: CANNON MILLS COMPANY, A NC CORP. (INTO), FIELDCREST MILLS, INC., A DE. CORP.
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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
    • D05C15/04—Tufting
    • D05C15/08—Tufting machines
    • D05C15/16—Arrangements or devices for manipulating threads
    • D05C15/22—Loop-catching arrangements, e.g. loopers; Driving mechanisms therefor

Definitions

  • the apparatus includes cooperating tutting needles, pile formers and latch needles for forming pile tufts on a backing fabric while positioning small locking threads through lower bight portions on the tufts being fonned to secure them to the backing fabric.
  • the tufiing yarns are under relatively high tension so that they are drawn upwardly relative to the backing fabric and so that portions of the locking threads passing through the lower bight portions are displaced upwardly into the backing fabric.
  • novel means are provided for guiding the locking threads into the hooks of the latch needles each time they enter through the tuft lower bight portions so that the latch needles will draw corresponding stitches of lockin thread through the respective lower bight portions.
  • This invention relates to an improved apparatus for making tufted pile fabrics, and is particularly devised for making fabrics of the type disclosed in our copending application Ser. No. 110,967 filed concurrently herewith and entitled 'IUFIED PILE FABRICS AND METHOD OF MAKING SAME.
  • tuf'ting needles insert pile yarns downwardly through a backing fabric in which pile loops are formed by loopers which enter the loops below the backing fabric and hold them a predetermined distance below the back of the fabric as the tufting needles subsequently withdraw upwardly from the backing fabric.
  • the loopers subsequently withdraw from the loops as the backing fabric is advanced so that a portion of each pile yarn is positioned upon the upper, back face, of the backing fabric as the needles are again lowered to form a succeeding transverse row of tufts.
  • Another object of the invention is to provide an apparatus for making tufted pile fabrics wherein the lower bight portions of pile yarns, inserted through a backing fabric by tutting needles, are secured to the backing fabric by moving complementary latch needles into the lower bight portions being presented by the tufting needles, and utilizing means for guiding a locking thread, preferably of substantially smaller size than the pile yarns, through the hook of each latch needle.
  • the hooks of the latch needles, with the locking thread therein, are then withdrawn from the respective pile yarn lower bight portions, so as to draw a loop locking thread through each lower bight portion.
  • FIG. 1 is a fragmentary vertical sectional view through the tuft-forming instrumentalities of the apparatus of this invention showing a tufting needle, a latch needle and a locking thread guide at the start of a cycle in an operation thereof;
  • FIGS. 2-7 are similar to FIG. 1, but showing successive stages in an operating cycle of the needles and the locking yarn guide;
  • FIG. 8 is a fragmentary plan view taken substantially along line 8-8 in FIG. 1;
  • FIG. 9 is a fragmentary plan view taken substantially line 9-9 in FIG. 7;
  • FIG. 10 is a front elevation of a tufting machine embodying the invention with parts broken away;
  • FIG. 11 is a side elevation looking at the right-hand side of the tufting machine of FIG. 10;
  • FIG. 12 is a fragmentary vertical sectional view taken substantially along line 12-12 in FIG. 10;
  • FIG. 13 is a side elevation of the tufling machine looking at the left-hand side of FIG. 10;
  • FIG. 14 is an enlarged fragmentary elevation, partially in section, taken substantially along line 14-14 in FIG. 10,
  • FIG. 15 is a fragmentary rear elevation looking at the Mthand side of FIG. 14 and also looking at the opposite side of the mechanism for imparting lateral movement to the pile formers from that shown in FIG. 10;
  • FIGS. 16 and 17 are enlarged fragmentary vertical sectional views taken substantially along the respective lines 16-16 and 17-17 in FIG. 10;
  • FIG. 18 is a detail of mechanism for imparting lateral and vertical reciprocating motions to the locking thread guides, taken substantially along line 18-18 in FIG. 1 7.
  • the tufling machine embodying the apparatus of the instant invention comprises tuft-forming instrumentalities including a row of plain tufting needles 20, a row of complementary latch needles 21, respective movable locking thread guides 22, and a row of pile formers 23, all of which rows extend laterally of the path of travel of a suitable backing fabric 24.
  • the backing fabric may be of woven or knitted construction and is shown in the form of a woven fabric formed from weft yarns 24a interwoven with warp yarns 24b and denoting respective transverse and longitudinal directions of the backing fabric 24.
  • the backing fabric is shown as being advanced in a substantially horizontal path of travel over a support means or bed plate 25 and past the tuftforming instrumentalities, with the pile formers 23 being positioned above the backing fabric, the tufiing needles 20 penetrating the backing fabric from above the same, and with the latch needles 21 and corresponding locking thread guides 22 positioned below the backing fabric 24.
  • the backing fabric 24 may be advanced through the machine at an incline or in a vertical direction, if desired, with corresponding changes being made in the location and attitude of the tuft-forming instrumentalities, without departing from the invention.
  • the front portion of bed plate 25 is suitably slotted to accommodate passage of tufting needles 20 therethrough while supporting the backing fabric adjacent the needles 20.
  • a tensioned tufting yarn or pile yarn 26 extends downwardly through the eye of each tufting needle 20, and the eye of each thread guide 22 has a separate stitching or locking thread 27 extending upwardly therethrough.
  • the locking threads 27 are under relatively lighter effective tension than pile yarns 26 and preferably are of a translucent synthetic material of substantially smaller size than the pile yarns 26 so as to be barely visible and present very little projection along the lower face of backing fabric 24.
  • Each latch 21 may be of a type generally used on circular knitting machines and comprises a shank 21a having a downwardly facing hook 2lb on its free rear end adapted to be engaged and thus closed by a latch 21c pivotally suspended from shank 21a.
  • the pile former 23 of FIGS. 1-7 includes two loop-forming stages or surfaces 23a, 23b of difl'erent effective heights selectively movable into and out of the tuft-forming zone or the plane of the vertically reciprocatory tufting needle 20.
  • each of the pile yarns 26 successively formed into a longitudinal row of pile loops or loop pile tufts 26 : on the upper face of backing fabric 24 as the tufting needles 20 successively penetrate backing fabric 24 and insert the pile yams through the backing fabric to form lower bight portions 26b on the loops.
  • each successive lower bight portion 26b is inserted through the backing fabric, latch needles 21 cooperate with locking thread guides 22 to position locking threads 27 alongside the lower face of the backing fabric and through the successive lower bight portions to secure the loops to the backing fabric. Additionally, each successive lower bight portion 26b of pile yarn 26 is displaced upwardly by drawing the pile yarns upwardly relative to the backing fabric so that portions of the locking threads passing through the corresponding lower bight portions are displaced upwardly into the backing fabric.
  • FIGS. 1-7 illustrating successive stages in one complete 360 cycle thereof.
  • tufling needle occupies its uppermost position above the plane of pile former 23, that as tufting needle 20 starts downwardly, the last previously formed lower bight portion 26b of pile yarn 26 and a loop 27a of locking thread 27 are looped beneath shank 21a of latch needle 21, and that the locking thread 27 extends rearwardly from the second last previously formed tuft lower bight portion 26b through the then open hook 21b of the latch needle, and through the eye of the corresponding thread guide 22 to the source, as further illusu'ated in FIG. 8. It should be noted that, whenever tufting needle 20 occupies its uppermost or 0-360 position, latch needle 21 will have completed a rearward stroke thereof to the broken-line position and will be in the course of a forward stroke thereof from right to left in FIG. 1.
  • FIG. 2 shows the position of the tuft-forming instrumentalities at about 45 in a cycle thereof in which pile former 23 has started a lateral shifting movement toward the observer, and latch needle 2] has withdrawn forwardly from the previously formed pile yarn lower bight portion 26b, pulling a succeeding loop 270 of locking thread 27 through the latter lower bight portion 261:.
  • pile former 23 has moved toward the observer sufficiently so that tufting needie 20 has started to move past the far side of pile former 23, thus looping pile yarn 26 across and above pile former 23.
  • latch needle 26 withdraws from and casts off the previous locking thread loop 270 while drawing the succeeding locking thread loop through the previous loop 27a as in the successive 60, I20" and 180 positions of FIGS. 3, 4 and 5.
  • tufting needle 29 will have pulled the last preceding lower bight portion 26b upwardly into backing fabric 24 so that the entire corresponding lower bight portion is positioned above the upper face of backing fabric 24 or at least the upper surface of the lower bight portion is positioned above the plane of the lower face of backing fabric 24.
  • the latter lower bight portion 26d aided in lifting the last locking thread loop 270 to be cast off of the latch needle and this, coupled with the tension being applied to the corresponding locking thread 27, causes the locking thread loop to be drawn upwardly against the lower face of backing fabric 24 to complete a stitch thereof while the portions of the locking thread passing through the corresponding lower bight portion are displaced upwardly into the backing fabric.
  • each locking thread 27 extending from a previously formed tuft lower bight portion 26b is looped around one leg of a next succeeding lower bight portion and then drawn through the latter bight portion and through a previously formed loop portion 270 of the same locking thread, also extending from the said previously formed lower bight portion, so as to form a stitch interconnecting the previously formed and next succeeding tuft lower bight portions 26b.
  • the tension means associated with pile yarns 26, and which will be later described, serves not only to maintain tension in the pile yarns but also serves to prevent slackening of the pile yarns during reciprocation of the tufting needles 20 so that the tufting needles will retract the previously formed lower bight portions of the pile yams into the backing fabric as the tufting needles penetrate the backing fabric and pull the pile yarns over adjacent pile formers while the tufting needles form succeeding lower bight portions adjacent the lower face of the backing fabric.
  • latch needle 21 starts a rearward stroke to the right from the position of FIG. 4 before tufting needle 20 reaches its lowermost position of FIG. 5.
  • latch needle 2l enters the new lower bight portion 26b of pile yarn 26, between one leg thereof and one side of tufting needle 20, as tufting needle 20 is moving upwardly as indicated in FIG. 6.
  • the latch needle 21 is moving rearwardly through the new lower bight portion 26b and through the new locking thread loop 27a, these loops swing the latch 21c to open the hook 21b as needles 20, 21 return to the 0-360 position of FIG. 1.
  • latch needle 21 While latch needle 21 is moving rearwardly, however, the corresponding thread guide 22 is moving downwardly and also laterally toward the observer so that, at about the 285 position of a cycle (FIG. 7), the thread guide 22 becomes positioned below and adjacent the opposite side of the longitudinal plane of latch needle 21 from that in which it was previously positioned, as shown in FIG. 9. With further rearward movement of latch needle 20, the locking thread guide 22 then moves upwardly and away from the observer so that by the time latch needle 21 has reached its rear-most position, such as that indicated in broken lines in FIG. I, the locking thread 27 is again inserted through the hook 21b of the latch needle 21 so as to be positioned as in FIGS. 1 and 8.
  • a repeat cycle of tufting needles 20, latch needles 21 and pile yarn guides 22 is then effected in the manner heretofore described with the exception that pile formers 23 move from right to left or away from the observer in FIGS. 1-7 so that pile yarns 26 are again looped over the corresponding stages of pile formers 23 but in the opposite direction from that in which they were looped during the immediately preceding cycle of needles 20, 21 and locking thread guides 22.
  • pile formers 23 move laterally in one direction, and during intervening cycles of needles 20, 21 and guides 22, pile formers 23 move laterally in the opposite direction.
  • pile formers 23 move laterally relative to needles 20, 21 and backing fabric 24, it follows that tufting needles 20 successively insert each pile yarn at substantially longitudinally aligned points in the advancing backing fabric 24 such that the lower bight portions 26b of each longitudinal row of loops 260 also are positioned in a corresponding row. Thus, a common locking thread 27 is positioned through the successive lower bight portions of each longitudinal row thereof.
  • the severing of the loops may be effected by use of conventional shearing apparatus and/or either or both of the loop-forming stages 23a, 23b of each of certain pile formers 23 or of all of the pile formers may be provided with suitable upwardly projecting cutter blades (not shown) on the free forward ends thereof. If a cutter blade is provided on a relatively low loopforrning stage 230 of any particular pile former 23, the cutter blade may project above stage 230 such a distance as to sever the low loops 26a only, or the blade may be of such height as to sever both the low loops and the high loops.
  • backing fabric 24 is drawn upwardly from a suitable supply roll 30 journalled on opposing composite side frame members 31a, 31b of a frame broadly designated at 31. From supply roll 30, backing fabric 24 passes over, under and over respective successive guide or tension rolls 32, 33, 34 (FIGS. 16 and 17) and then passes forwardly in a substantially horizontal path of travel over the fabric supporting means or bed plate 25 and through the tuft-forming instrumentalities. Bed plate 25 is carried by a transverse beam 31c of frame 31.
  • backing fabric 24 passes forwardly beneath and partially around a first take-up roll 35, then over a second take-up roll 36, then downwardly and beneath an idler roll 37 (FIGS. 11 and 13), and thence forwardly to a suitable cloth roll-up or take-up means, not shown.
  • Take-up rolls 35, 36 are joumalled in laterally spaced brackets 31d, 31: (FIGS. 10, 11 and 13) secured to front portions of side frame members 310 and 31b. Intenneshing gears 35a, 35b are provided on corresponding ends of the shafts of take-up rolls 35, 36.
  • the take-up rolls may be driven by an electric motor 40 (FIGS. and 11) carried by frame member 310 and connected by belt and pulley means 41, 42 to a main drive shafi 43 journalled in frame members 31a, 31b and extending through an upper housing portion 31f of frame 31.
  • Belt and pulley means 44 also connect main drive shaft 43 to the input side of a gear box 45 whose output side has the shaft of first take-up roll 35 connected thereto, thus, driving the take-up rolls at a speed proportional to that of the rate of rotation of main drive shaft 43.
  • Fabric tension roll 32 is joumalled in frame 31 and has a suitable braking device 46 (FIG. 13) thereon to maintain backing fabric 24 under predetermined tension as it is being advanced forwardly through the tuftforming instrumentalities.
  • the pile yarns 26 pass forwardly from a suitable source 50, such as a creel (FIG. 11), and over suitable rods 51, 52 between which individual weight members 53 are suspended on the pile yarns to maintain them under predetermined relatively high tension while preventing the occurrence of any slack therein. From rod 52, pile yarns 26 pass forwardly, then downwardly through suitable successively arranged pile yarn guide means 55, 56, 57 and thence through the eyes of the respective tufting needles (FIG. 16).
  • the two lower pile yarn guide means 56, 57 are mounted for substantially vertical reciprocation with tufting needle 20, and the upper pile yarn guide means 55 is carried by frame 31.
  • each post 61 is pivotally connected, by means of a link 62 (FIG. 16), to a corresponding crank arm 63 suitably secured to a tufting needle motion rocker shaft 64 journalled in housing portion 31f of frame 31.
  • a link 62 FIG. 16
  • crank arm 63 For oscillating needle motion crank shaft 64 to impart substantially vertical reciprocation to tufting needles 20, it will be observed in FIG. 12 that one end portion of rocker shaft 64 has another crank 65 fixed thereon.
  • cam-connecting arm 66 is pivotally and adjustably connected, as at 660, to crank 65.
  • the pivot 66a is adjustable along a slot 650 provided in the crank 65.
  • the other end of connecting arm 66 is mounted on an eccentric cam 67 fixed on main drive shafi 43.
  • the front portions of latch needles 2] are suitably secured in a common transverse latch needle support bar 70 positioned closely beneath the path of travel of backing fabric 24 and suitably secured to a plurality of transversely spaced guide blocks 71, only one of which is shown in FIGS. 16 and 17.
  • Each guide block 71 is mounted for forward and rearward sliding movement on a guide rod 72 whose forward portion is suitably secured to a corresponding bracket 73.
  • brackets 73 extend downwardly and are suitably secured to a transverse frame member 31 extending between and suitably secured to side frame members 31a, 31b.
  • the upper end of a crank arm 75 is pivotally connected to each guide block 71 (FIGS. 16 and 17).
  • the lower ends of crank arms 75 are mounted on a common transverse shaft 76 journalled on side frame members 31a, 31b (FIG. 10).
  • a latch needle rocker shaft 80 (FIGS. 16 and 17) is journalled in side frame members 31a, 31b rearwardly of crank arms 75.
  • Cranks B1 are fixed on and depend from rocker shaft 80 and are connected by respective links 82 to medial portions of the respective crank arms 75.
  • latch needle rocker shaft has at least one crank 85 fixed thereon and extending upwardly therefrom to which the lower portion of a cam-connecting arm 86 is pivotally and adjustably connected, as at 86a.
  • the upper portion of cam-connecting am 86 is loosely mounted on an eccentric cam 87 suitably secured to main drive shafi 43.
  • Crank 85 preferably is provided with an elongate adjustment slot 85a therein for adjustably receiving the pivot 86a of connecting arm 86 so as to permit adjusting the length of stroke of the latch needles.
  • rotation of shafi 43 transmits forward and rearward reciprocatory motion to latch needles 21 through the intervening connections heretofore described.
  • locking thread guides 22 should move both laterally and substantially vertically so as to position locking threads 27 in the hooks of respective latch needles 21. Accordingly, locking thread guides 22 are carried by a transverse bar 90 (FIGS. 16, 17 and 18).
  • a depending arm 91 supports each end of bar 90 and the lower portion of each arm 91 is suitably secured to a pair of tubular guide members 92 mounted for lateral, substantially horizontal, sliding movement on a respective pair of guide rods 93.
  • Guide rods 93 are carried by a bracket 94 having a substantially vertical guide rod 95 extending downwardly therefrom and mounted for su bstantially vertical sliding movement in a guide block 96 suitably secured to the corresponding side frame member of frame 31 (FIGS. 17 and 18).
  • each guide rod 95 has the front end of a corresponding lever 97 pivotally connected thereto.
  • the front ends of levers 97 are pivotally mounted on support brackets 100 suitably secured to the corresponding side frame members 31a, 31b (FIG. 10).
  • each link 101 is pivotally connected to a medial portion of each lever 97.
  • the lower end of each link 101 is pivotally connected to a forward portion of a corresponding cam follower lever 102 pivotally mounted, intennediate its ends, on the corresponding side frame member of frame 31.
  • the rear portion of each cam follower lever 102 has a follower 103 thereon engaging the irregular groove of a corresponding face cam 104.
  • Face cams 104 are mounted on a cam shaft 105 (FIGS. 10 and 13) journalled on side frame members 31a, 31b.
  • Cam shaft 105 is driven by belt and pulley means 106 drivingly connecting main driveshaft 43 to cam shaft 105.
  • face cams 104 transmit substantially vertical motion to supporting brackets 94 (FIGS. 17 and 18) and thus to locking thread guides 22, through the intervening connections therewith heretofore described, and in timed relation to reciprocation of tufiing needles 20 and latch needles 21.
  • a link 110 is pivotally connected to one of the depending arms 91 of thread guide supporting bar 90.
  • the outer end of link 110 is pivotally connected to the upper end of a follower lever 1 11 (FIGS. 10 and 18) which extends downwardly and is pivotally mounted intermediate its ends, as at 112, on side frame member 31b.
  • the lower portion of follower lever 111 has a follower 113 thereon engaging a peripheral groove of irregular configuration in a cam wheel 114 fixed on cam shaft 105. It is thus seen that rotation of cam wheel 114 imparts lateral reciprocatory motion to locking thread guides 22 through the intervening connections heretofore described.
  • the locking threads 27 are directed to and through the eyes of locking thread guides 22 from a suitable source independent of supply and are maintained under predetermined relatively light tension as compared to the tension in the pile yarns 26. Accordingly, it will be observed in FIG. 13 that the source of the locking threads 27 is shown, by way of example, in the form of a plurality of spools 22a arranged in a transverse row adjacent the rear portion of the machine and loosely mounted on corresponding stobs 22b.
  • the stobs 22b are mounted on a common transverse frame member 31!: adjacent the rear lower portion of frame 31 and project upwardly through a friction material 22c, such as natural or synthetic rubber, on which the spools rest in frictional engagement therewith.
  • Each spool has a weight member 22d resting thereupon which, coupled with the weight of the respective spool and the thread thereon determines the amount of frictional resistance to rotation applied to the spools by the friction material 22c, thus determining the amount of tension in threads 27.
  • the tension means embodied in the friction material 22c and the weight members 22d is shown by way of example only, it being understood that any suitable tension means may be provided for applying tension to the locking threads 27.
  • pile formers 23 are shifted a relatively short distance laterally in one direction during alternate cycles in the operation of needles 20, 2] and guides 22, and pile formers 23 are shifted laterally in the opposite direction during intervening cycles in the operation of the needles 20, 21 and thread guides 22.
  • pile formers 23, which are shown in a form of elongate, relatively thin pile wires, are mounted for longitudinal or forward and rearward sliding movement in a common pile former support bar 120 spaced closely above the path of travel of backing fabric 24 and over bed plate 25.
  • Support bar 120 overlies and serves as a stripper for the backing fabric 24 during upward strokes of tufting needles 20.
  • Each end portion of support bar 120 is suitably secured to a laterally movable bracket 121 supported for such movement on a pair of guide rods 122 (FIGS. l4, l5, l6, and 17) suitably secured to a corresponding stationary bracket 123.
  • Brackets 123 are suitably secured to he corresponding side frame members Ma, 3112.
  • One of the movable brackets I21 has the inner end of a link I25 (H68. 14 and 15) pivotally connected thereto.
  • the other end of link 125 is pivotally connected to a follower am 126 which extends forwardly adjacent the outer surface of frame member 3th and is pivotally connected, as at 127 (FIG. 14), to side frame member 31b.
  • a medial portion of follower arm I26 has a follower 130 thereon which engages the irregular peripheral groove of a cam wheel 131 fixed on a corresponding cam shaft 132 journalled in frame 31.
  • Cam shaft 132 and cam 131 are driven, to rotate one revolution during every two revolutions of main drive shafl 43, by suitable belt and pulley means 134 connecting drive shaft 43 to cm shaft 132, as best shown in FIGS. and 13.
  • cam wheel 131 transmits lateral reciprocatory motion to the pile formers 23 through the intervening connections heretofore described, with the walls of the peripheral groove in earn 131 being so shaped as to impart lateral movement to the pile formers in one direction during alternate cycles in the operation of needles 20, 21 and thread guides 22, and to impart lateral motion to the pile formers in the opposite direction during intervening cycles in the operation of the needles 20, 21 and thread guides 22.
  • pile formers 23 are provided with at least two pile forming stages 23a, 23b of relatively different heights so as to form pile tufts of different lengths according to a predetermined pattern by selectively presenting the loop-forming stages or surfaces 23a, 23b to the loop-forming position in alignment with the tufiing needles. Accordingly, it will be observed in FIGS. 16 and 17 that each pile former is biased in a forward direction by a corresponding compression spring 140, and the rear portion of each pile former 23 has one end of a control cord 142 connected thereto.
  • Control cords 142 extend rearwardly and then partially around and upwardly from a guide rod 143 whose opposing ends are carried by brackets 144 suitably secured to and extending rearwardly from side frame members 31a, 31b.
  • the control cords 142 are connected to and controlled by a suitable pattern device 146 shown schematically in FIG. II and which may be in the form of a Jacquard mechanism or dobby head. It is apparent that such pattern device will function to selectively lifi the control cords 142 so as to pull the respective pile formers rearwardly in opposition to the respective springs and, upon the selected cords being released.
  • the springs 140 will bias the corresponding pile wires forwardly so that the low pile forming stages or surfaces 230 thereof will move along the corresponding rows of loops previously formed thereon to position the higher loop forming stages 23b thereof in the tuft-forming position.
  • the needles 20 successively insert the lower bight portions 26b of each row of pile tufls at substantially longitudinally aligned points in the backing fabric 24, it will be observed in FIG.
  • the lower surfaces of the pile formers are spaced sufl'iciently above the backing fabric to permit the front ends of the lower stages 23a of the pile formers 23 to enter a few of the loops positioned forwardly thereof when the pattern device 146 calls for corresponding relatively high loop-forming stages 23b to be moved into operative position relative to tutting needles 20.
  • a tufting machine having reciprocating tufting needles for repeatedly penetrating a backing fabric from one face thereof to insert respective bight portions of loops of pile yarns therethrough; the combination therewith of reciprocating latch needles adjacent the opposite face of the backing fabric and extending generally transversely of the tufting needles, means for moving said latch needles to cause them to enter through and withdraw from the respective pile yarn bight portions presented by said tulting needles, means providing an independent source of supply of locking threads for said latch needles, and means operatively associated with said latch needles for guiding a locking thread from the source of supply thereof laterally across and into the hook of each latch needle whenever it has entered through a pile yarn bight portion such that each latch needle draws a loop of locking thread through each respective pile yarn bight portion thus presented during each withdrawal of said latch needles.
  • a tufiing machine including means for moving the backing fabric along a path above said latch needles in timed relation to reciprocation of said tufting needles and said latch needles, each latch needle including a shank on which the respective latch is pivotally suspended, the hook of each latch needle facing downwardly, said guiding means being operable to guide each respective locking thread, extending from a previously formed lower bight portion of pile yarn, partially around a subsequently presented pile yarn bight ponion and into the respective open hook, and the thus presented pile yarn bight portion serving to close the respective latch during subsequent withdrawal of the latch needles to prevent the presented pile yarn bight portions from becoming ensnared in the hooks of the latch needles during withdrawal of said latch needles.
  • a tufting machine including means for moving the backing fabric in one longitudinal direction in timed relation to the operation of said needles, a plurality of pile formers adjacent the respective tufting needles, and
  • a tufting machine comprising means to shift each pile former in one lateral direction during each alternate period in which said tufting needles are withdrawn and to shift each pile former in the opposite lateral direction during each intervening period in which said tufting needles are withdrawn.
  • each of at least some of said pile formers includes pile forming surfaces of different heights thereon, and means connected to said some of said pile formers for selectively presenting different height surfaces thereof to said tufting needles.
  • a tufting machine wherein the pile yarns extend from a source through said tufting needles to the backing fabric, and means engaging the pile yarns between their source and said needles and preventing slackening of the pile yarns during movement of the tufiing needles so that the tufting needles retract previously formed pile yarn bight portions into the backing fabric as the tuiting needles penetrate the backing fabric and pull the pile yarns over adjacent pile formers while the tufting needles form succeeding pile yarn bight portions adjacent said opposite face of the backing fabric.
  • a tufting machine including pile formers adjacent said one face of the backing fabric and over which said loops are formed by said tufting needles, and means for moving said tufting needles in timed relation to said latch needles so that, during the insertion of a succeeding pile yarn bight portion by each tufting needle, the respective latch needle is withdrawn from and will have released an immediately preceding pile yarn bight portion therefrom as the preceding pile yam bight portion is thus pulled toward the backing fabric by the tufting needle pulling the respective pile yarn over the pile former and into the backing fabric in the forming of the succeeding loop.
  • a tutting machine having means for advancing a backing fabric lengthwise thercthrough, and tufting needles for forming loop pile tufts from pile yarns on one face of the backing fabric by repeatedly inserting pile yarn bight portions of the tufts through to the opposite face of the backing fabric; the combination therewith of means for inserting locking threads through successive pile yarn bight portions as they are inserted through the backing fabric for securing the loop pile tufts to the backing fabric, a plurality of pile formers extending lengthwise of and adjacent said one face of the backing fabric and over which said loop pile tufts are formed by said tufting needles, at least some of said pile formers each including loop-forming surfaces of different heights thereon, and means for selectively moving said some of said pile formers longitudinally to present the different height surfaces thereof to said tufting needles and to form loop pile tufts thereover of corresponding different heights.
  • a tufling machine wherein said means for inserting locking threads through successive pile yarn bight portions comprises a reciprocating latch needle for each tufling needle and positioned adjacent the opposite face of the backing fabric for inserting through and withdrawing from the pile yarn bight portions presented by the tufting needles, an independent source of supply for the locking threads, and means operatively associated with said latch needles for guiding a locking thread from the independent source of supply laterally across and into the hook of each latch needle whenever it has entered through a pile yarn bight portion whereby each latch needle draws a loop of locking thread through each respective pile yarn bight portion thus presented during each withdrawalpf said latch needles.
  • a tufttng machine including means for moving said tufting needles and said latch needles in such timed relationship that, during the insertion of a succeeding pile yarn bight portion by each tufting needle, the respective latch needle is withdrawn from and will have released an immediately preceding pile yarn bight portion therefrom and the preceding bight portion is thus pulled toward the backing fabric by the tufiing needle pulling the respective pile yarn over the pile former and into the backing fabric in the forming of the succeeding loop pile tuft.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Textile Engineering (AREA)
  • Treatment Of Fiber Materials (AREA)
  • Knitting Of Fabric (AREA)
  • Preliminary Treatment Of Fibers (AREA)
US110851A 1971-01-29 1971-01-29 Apparatus for making tufted fabrics Expired - Lifetime US3677206A (en)

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WO1995006152A1 (en) * 1993-08-25 1995-03-02 Burlington Industries, Inc. Variable gauge fabric and method of manufacture
US5575228A (en) * 1993-08-25 1996-11-19 Tuftco, Inc. Variable gauge tufting apparatus
WO2000052245A1 (en) * 1999-03-02 2000-09-08 E.I. Du Pont De Nemours And Company Apparatus for producing a stitched pile surface structure
US6116058A (en) * 1993-01-19 2000-09-12 Textilma Ag Process and installation for producing textile net-like fabrics
US20020062905A1 (en) * 2000-11-30 2002-05-30 Zafiroglu Dimitri P. Process for bonding of stitched carpets
US20030082334A1 (en) * 1999-03-02 2003-05-01 Zafiroglu Dimitri Peter Stitched pile surface structure and process and system for producing the same
US20040065400A1 (en) * 2000-05-04 2004-04-08 Zafiroglu Dimitri Peter Stitched yarn surface structure and method of forming the same
US20040071926A1 (en) * 2002-10-15 2004-04-15 Dimitri Zafiroglu Stitched-bonded yarn surface structure
US6726976B2 (en) 1999-12-02 2004-04-27 E.I. Du Pont De Nemours And Company Tufted pile structure having binder concentrated beneath the backstitches
US6860120B1 (en) * 2001-05-16 2005-03-01 Invista North America S.A.R.L. Stitching apparatus for forming a cut pile surface structure
US20050066867A1 (en) * 2003-02-03 2005-03-31 Ian Beverly Tufting machine
US8162008B1 (en) * 2009-04-16 2012-04-24 Presnell Iii Samuel C Method and system for producing simulated hand-woven rugs
US10851484B2 (en) 2016-06-09 2020-12-01 Columbia Insurance Company Patterned tufted articles, and systems and methods for making same
WO2022246496A1 (en) * 2021-05-28 2022-12-01 Robert Gabor Pongrass Lock stitch, and method and system to form a lock stitch

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GB2277100A (en) * 1993-02-11 1994-10-19 Cobble Blackburn Ltd Yarn feed mechanism for tufting machine

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US3253426A (en) * 1957-03-28 1966-05-31 Nahwirkmaschb Malimo Veb Apparatus for producing plush fabrics
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US3421929A (en) * 1966-06-14 1969-01-14 Singer Co Tufting mechanism,method,stitches and article
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US1827614A (en) * 1928-09-20 1931-10-13 Union Special Machine Co Tufted fabric and method of making the same
GB821702A (en) * 1955-10-21 1959-10-14 Textimaprojekt Veb A method of producing plush-like goods such as carpets or the like and a machine for performing the same
GB813439A (en) * 1956-06-04 1959-05-13 Crabtree & Son Ltd D An improved method of and apparatus for making tufted carpets
US3253426A (en) * 1957-03-28 1966-05-31 Nahwirkmaschb Malimo Veb Apparatus for producing plush fabrics
US3428007A (en) * 1962-02-23 1969-02-18 United Merchants & Mfg Machine for forming pile loops and stitch formation
US3361096A (en) * 1965-12-23 1968-01-02 Singer Co Tufting machines for producing terrylike fabrics and fabrics produced thereby
US3421929A (en) * 1966-06-14 1969-01-14 Singer Co Tufting mechanism,method,stitches and article

Cited By (21)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6116058A (en) * 1993-01-19 2000-09-12 Textilma Ag Process and installation for producing textile net-like fabrics
US5575228A (en) * 1993-08-25 1996-11-19 Tuftco, Inc. Variable gauge tufting apparatus
WO1995006152A1 (en) * 1993-08-25 1995-03-02 Burlington Industries, Inc. Variable gauge fabric and method of manufacture
WO2000052245A1 (en) * 1999-03-02 2000-09-08 E.I. Du Pont De Nemours And Company Apparatus for producing a stitched pile surface structure
US6269759B1 (en) 1999-03-02 2001-08-07 E. I. Du Pont De Nemours And Company Apparatus for producing a stitched pile surface structure
AU757505B2 (en) * 1999-03-02 2003-02-20 E.I. Du Pont De Nemours And Company Apparatus for producing a stitched pile surface structure
US20030082334A1 (en) * 1999-03-02 2003-05-01 Zafiroglu Dimitri Peter Stitched pile surface structure and process and system for producing the same
US6951590B2 (en) 1999-03-02 2005-10-04 Invisia North America S.A.R.L. Stitched pile surface structure and process and system for producing the same
US6726976B2 (en) 1999-12-02 2004-04-27 E.I. Du Pont De Nemours And Company Tufted pile structure having binder concentrated beneath the backstitches
US20040065400A1 (en) * 2000-05-04 2004-04-08 Zafiroglu Dimitri Peter Stitched yarn surface structure and method of forming the same
US20020062905A1 (en) * 2000-11-30 2002-05-30 Zafiroglu Dimitri P. Process for bonding of stitched carpets
US20050155693A1 (en) * 2000-11-30 2005-07-21 Zafiroglu Dimitri P. Process for bonding of stitched carpets
US6860120B1 (en) * 2001-05-16 2005-03-01 Invista North America S.A.R.L. Stitching apparatus for forming a cut pile surface structure
US20040071926A1 (en) * 2002-10-15 2004-04-15 Dimitri Zafiroglu Stitched-bonded yarn surface structure
US6967052B2 (en) 2002-10-15 2005-11-22 Invista North America S.A.R.L. Stitched-bonded yarn surface structure
US20050066867A1 (en) * 2003-02-03 2005-03-31 Ian Beverly Tufting machine
US7296524B2 (en) * 2003-02-03 2007-11-20 Spencer Wright Industries, Inc. Tufting machine
US8162008B1 (en) * 2009-04-16 2012-04-24 Presnell Iii Samuel C Method and system for producing simulated hand-woven rugs
US10851484B2 (en) 2016-06-09 2020-12-01 Columbia Insurance Company Patterned tufted articles, and systems and methods for making same
US10961647B2 (en) 2016-06-09 2021-03-30 Columbia Insurance Company Patterned tufted articles, and systems and methods for making same
WO2022246496A1 (en) * 2021-05-28 2022-12-01 Robert Gabor Pongrass Lock stitch, and method and system to form a lock stitch

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DE2204123A1 (de) 1972-08-10
BE778678A (fr) 1972-07-28
DE7203221U (de) 1973-07-05
GB1375215A (zh) 1974-11-27
CA955801A (en) 1974-10-08

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