US3812799A

US3812799A - Method and means of tufting

Info

Publication number: US3812799A
Application number: US00246305A
Authority: US
Inventors: B Wittler; N Leszczak; A Spanel
Original assignee: Individual
Current assignee: SPANEL INTERNATIONAL Ltd A CORP OF DELAWARE
Priority date: 1972-04-21
Filing date: 1972-04-21
Publication date: 1974-05-28
Anticipated expiration: 1991-05-28

Abstract

A method and means for use in pneumatic multi-color tufting and other tufting systems wherein at each tufting needle station three needles with linearly aligned eyes are disposed to receive yarn for tufting. In a preferred embodiment the yarn is cut into a discrete yarn bit prior to tufting and may be clamped at the central needle which, of the three needles, may be the first to descend through the backing. The central needle descent is followed by the descent of the two outer needles which pull the remainder of the yarn bit through the backing layer thereby implanting a series of tufts in the backing layer. The central needle may have an open eye for creating loop tufts or it may have a closed eye in which case a knife member will be used to release the yarn from the central needle to form cut tufts. A single member may serve dual functions; first as a clamp until the yarn is deposited in the backing to a desired point and then serving as a knife when the yarn is to be cut and released from the eye of the central needle.

Description

United States Patent 191 Spanel et al.

[ 3,812,799 1 May 28, 1974 METHOD AND MEANS OF TUFTING [75] Inventors: Abram N. Spanel, 344 Stockton St.,

Princeton, NJ. 08540; Bernard H. Wittler, Dover; Nicholas Leszczak, Point Pleasant, both of NJ.

[73] Assignee: sa'id Spanel, by said Lesczak and Wittler [22] Filed: Apr. 21, 1972,

[21] Appl. No.: 246,305

[52] US. Cl 112/79 R [51] Int. Cl. D05c 15/10 [58] Field of Search 112/79 R, 266, 79.5, 262,

[56] References Cited UNITED STATES PATENTS R27,l6 5 s/1971 5 711161 et al. 1. 112/791; l,844,435 211932 Myers 112/79 A 2,3 s7 ,9 5/1959 Felton 112/795 3,415,209 l2/l968 Ellison etal.... 112/79,R 3,554,l47 l/l97l Spanel 112/79 R 3,670,672 6/l972 Spanel et al. 112 79 R FOREIGN PATENTS'OR APPLICATIONS 37,378 10/1965 Germany 66/85 A Primary Examiner-James R. Boler Assistant Examiner-Peter Nerbun Attorney, Agent, or Firm-Woodcock, Washburn, Kurtz & Mackiewicz A [5 7 ABSTRACT A method and means for use in pneumatic multi-color tufting and othertufting systems wherein at each tufting needle station three needles with linearly aligned eyes are disposed to receive yarn for tufting. In a preferred embodiment the yarn is cut into a discrete yarn bit prior to tufting and may be clamped at the central needle which, of the three needles, may be the first to descend through the backing. The central needle descent is followed by the descent of the two outer needles which pull the remainder of the yarn bit through the backing layer thereby implanting a series of tufts in the. backing layer. The central needle may have an open eye'for creating loop tufts or it may have a I closed eye in which case a knife member will be used to release the yarn from the central needle to form cut tufts. A single member may serve dual functions; first as a clamp until the yarn is deposited in the backing to a desired point and then serving as a knife when the yarnis to be cut and released from the eye of the central needle.

20 Claims, 19 Drawing Figures PATENTED m2 8 1974 sum 31]? 5 1 METHOD AND MEANS OF TUFTING BACKGROUND OF THE INVENTION 1. Field of the Invention The subject invention relates to the tufting of rugs, carpets, and the like and provides a needle system which may be used for implanting tufts into a backing layer where the yarn is cut into discrete bits prior to tufting. The invention has particular utility in the Spanel et al pneumatic transfer multi-color selection systern, but is not to be limited to either pneumatic systems or multi-color selection systems.

2. Prior Art The subject invention may be used in conjunction with many of the embodiments disclosed in U.S. Pat. No. 3,554,147 which issued to Abram N. Spanel and George I. Brennan on Jan. 12, 1971 and Reissue U.S. Pat. No. 27,165 which issued Aug. 10, 1971 to Abram N. Spanel and Loy E. Barton. Reissue U.S. Pat. No. 27,165 discloses a pneumatic system in which yarn strands and discrete bits of yarn may be transported pneumatically to a loading station where they are applied by a bit-applying element to the backing layer. A double needle is disclosed as the bit-applying element in a number of the embodiments. U.S. Pat. No. 3,554,147 discloses an alternative system to Reissue U.S. Pat. No. 27,165 and provides for the simultaneous selection of bit-lengths of yarn of different colors for each tufting cycle at each individual needle station. Double needles may be used with the apparatus of U.S. Pat. No. 3,554,147 also.

While double needles with closed eyes can be used efficiently in tufting systems which produce cut-pile products, a modified needle may be desirable to produce loop pile rugs. Also, with double needles, flexibility in producing a combination of loop and cut-pile products is lacking.

A clamping means is required in several of the embodiments of the subject invention and in one particu lar embodiment an example of a clamping member which is internally disposed within the needle shank, is disclosed. While U.S. Pat. No. 2,785,644 which issued to W. W. Freedle et al. on Mar. 19, 1957 discloses an internally disposed, plunger member, there is neither intent nor disclosure of the operablecombination of a synchronized needle and clamp necessary for automatic operation in the subject tufting machine inventron.

SUMMARY OF THE INVENTION with the systems disclosed in aforementioned U.S. Pat.

No. 3,554,147 and Reissue U.S. Pat. No. 27,165 and discloses a method and means of tufting utilizing three needles which act cooperatively to produce a-series of tufts one of which may be a looped-pile tuft while the others may be cut-pile tufts. In a preferred embodiment, the yarn may be clamped at the central needle which then withdraws through the backing layer to form a central tuft. The needles on the right and left of the central needle then descend and the yarn bit passes through the eyes of the left and right needles after these needles draw the yarn bit through the backing layer. The central needle may have an open eye with a camming surface at least for casting off a loop tuft, or it may have a closed eye with a cutting means arranged to operate in cooperation therewith to cut the yarn loop to form a cut-pile tuft. In some of the embodiments the same member serves as both a clamp and a cutting member.

In another preferred embodiment the central needle has a closed eye and is rotatable through to enable the use of conventional looper and cutter devices to cut the loop of yarn free from the eye.

BRIEF DESCRIPTION OF THE DRAWINGS For a more detailed understanding of the invention, reference is made in the following description to the accompanying drawings in which:

FIG. 1 is a schematic view of a tufting machine in which the herein described needle system may be used;

FIG. 2 is an isometric view of the three needle tufting station showing the central needle as having an internal clamp;

FIG. 3 is an isometric view similar to FIG. 2 and showing the clamp pin in its clamping position;

FIG. 4 is an isometric view similar to FIG. 3 and showing the central needle pulling the yarn through the backing layer;

FIG. 5 is an isometric view similar to FIG. 4 but showing the central needle reaching a desired down position;

FIG. 6 is an isometric view similar to FIG. 5 but also showing the outer needles beginning their downward descent;

FIG. 7 is an isometric view similar to FIG. 6 but showing the outer needles in their desired down position with the ends of the yarn bit free from the outer needles;

FIG. 8 is an isometric view showing a yarn loop being cast-off by the central needle;

FIG. 9 is an isometric view of an embodiment in which the internal clamp pin is replaced by a knife member which may also serve as a clamp;

F 16.10 is a cross-sectional side'view showing the embodiment of FIG. 9 with the central needle beginning its downward descent;

FIG. 11 is a cross-sectional side view of the embodiment of FIG. 9 showing the central needle in its desired down position with the outer needles descending;

FIG. 1 1A is a cross-sectional side view of the embodiment of FIG. 9 showing the cutting of the yarn;

FIG. 12 is a cross-sectional side view of the embodiment of FIG. 9 showing the cutting of the center loop;

FIG. 13 is an isometric view of another knife and clamp combination embodiment;

FIG. 14 is a crosssectional side view of the embodimentof FIG. 13 showing the central needle in its descending position;

FIG. is a cross-sectional side view of the embodiment of FIG. 13 showing the yarn tuft after being cut by the knife;

FIG. 16 is a cross-sectional side view of an embodiment which utilizes conventional looper and cutting means;

FIG. 17 is a cross-sectional side view of the embodiment of FIG. 16 showing the center yarn loop being cut; and

FIG. 18 is a plan view taken along the lines 1818 of FIG. 16.

DESCRIPTION OF THE PREFERRED EMBODIMENT With reference to FIG. 1, tufting apparatus is shown with which the three needle system of the subject invention may be utilized. Yarn supply means 10 is located adjacent yarn-metering device 12 in which yarn of selected lengths and colors is pneumatically fed through collator 16 to loading station 20. A separate color yarn strand may be fed through each of the

channels

16R, 16W, 168 which lead into common passageway 18. The yarn is selected and supplied in the manner described in the aforementioned US. Pat. No. 3,554,147.

Once the yarn is fed to loading station 20, a cutter means 30 which may be adjustable to provide the deshown being fed from supply roll 42 over idler roller 44 to drive roller 46 which is operated by a ratch and pawl mechanism 48. A suction pump 50 is shown for creating negative pressure for the pneumatic transfer of yarn from yarn-metering device 12 to loading station 20.

Motor 52 is shown as driving the entire device through a suitable transmission 54 which may be a train of gears, timing chains, or the like. The metering device 12 and the cutting device 30are shown operating off of shaft 25 while needle means cam 40, 41, clamp 35 and backing drive ratch and pawl 48 are shown operating off of shaft 27 along with the schematic symbol 56 for the clock pulses for the pattern read-out. Thus, the schematic of FIG. 1 shows the means where desired bitlengths of yarn are fed to the loading station where they are cut into discrete bits after threading into

needles

60, 61, 62 when the needles are in their loading position as shown by the dotted lines. It is to be clearly understood that the invention disclosed herein is not'limited to this particular tufting system and has utility with any type of pneumatic pressure flow system, either positive or negative, or a combination of the two, or where mechanical means are used to present the yarn in a loading position for tufting.

With reference to FIG. 2,, one embodiment of the needle system is shown. Three needles are shown comprising a series with conventional closed eye needles shown as

outer needles

60 and 61 and an open eye needle 62 shown as the central needle. With respect to central needle 62 the camming surface 64 of needle eye 63 which extends belowneedle eye opening 65 will be noted. Needle shank 67 of needle 62 extends to a drive bar means 68 which is separate from the drive bar 38 which operates the outer two

needles

60 and 61. Disposed within needle shank 67 is a clamp pin 56 which extends down into drive bar 68 where it terminates in a plunger 69 which is biased downward by a return spring 70. An air-pressure cavity 71 is shown as providing the means by which said clamp pin 66 is forced to its upward position by the plunger 69 thereby overcoming the bias of spring which will cause clamp pin 66 to clamp a yarn strand against the top of needle eye 63. It will be recognized that this means of operating clamp 66 may be used as an alternative to the cam operated means of FIG. 1.

The outer needles 60 and 61 are shown as being driven by needle bar 38 as shown in FIG. 2 which has a slot 72 for the central needle shank 67 to extend through. In the loading position,- as shown, the needles are piercing the backing B and aligned to receive a yarn bit or yarn strand Y as shown. The yarn Y may be fed to its loading position, as shown, and then cut or it may be cut prior to the threading of the needles and fed as a discrete bit as disclosed in aforementioned Reissue US. Pat. No. 27,165. While FIG. 2 and succeeding figures do not show the yarn as being contained in a passageway such as passageway 18 of FIG. 1, it should be understood that this could be the case particularly if pneumatic means are used to transport the yarn into its loading position of threading the needles. It will be noted that eye 63 of central needle 62 must be aligned with the

eyes

73 and 74 of outer needles 60'and 61 respectively.

With reference to FlG. 3, clamp pin 66 is shown moving to its clamping position whereby the yarn will be clamped against the interior top of needle eye 63 of central needle 62. In this position, clamp pin 66 is being forced up by air-pressure from a compressor, not shown, in cavity 71 which acts against plunger 69 to overcome the bias of spring 70.

While FIG. 3 shows the yarn being clamped after it has been cut by cutter 30 in the case where pneumatic pressure is used for transporting the yarn, it might be desirable to clamp the yarn prior to cutting to prevent it from being shifted by the pneumatic pressure subsequent to cutting.

In FIG. 4 central needle 62 is seen beginning its descent through backing B with yarn Y clamped firmly in place by clamp pin 66. It will beobserved that clamp pin 66 serves to cause yarn to be drawn equally by needle 62 from boththe direction of needle 60 and the. direction of needle 61 thereby insuring equal length tufts as will become evident, provided, of course, the yarn bit is properly'centered with respect to needle 62 at the time of clamping. The centering may be accomplished by a number of methods such as the yarn-metering technique of aforementioned US. Pat. No. 3,554,147, for example.

The central needle 62 is shownreacliing its desired total down position in FIG. 5 with the yarn still clamped in place by clamp pin 66. The loop that is herein legs C and D of the yarn bit are left free of the needles having slipped out of

needle eyes

73 and 74. At this point, the air pressure in chamber 71 may be turned off to enable spring-biased plunger 69 to return downward to retract the clamp pin 66 from its yarn-locking position.

As shown in FIG. 8, central needle 62 moves upwardly and yarn loop A is cast-off the inclined cam surface 64 which, in effect, cams the yarn loop out of the needle eye 63 through opening 65. It is to be noted that clamp pin 66 retracts to a position below the cam surface 64 so that it cannot interfere with this cast-off function. When yarn loop A is free of central needle 62, its ascent may momentarily stop and with the tufted yarn now free of all needles, 60, 61, 62, backing B may forward. This allows rugs of varying density to be produced without unwanted gaps, since a better looking rug can be made by having needle 60 penetrate very close to the tuft formed by needle 61 in the preceding cycle. This would give a pattern of a looped tuft and two cut-pile tufts (from different piercing points in the backing) close together, then another loop, then another two cut-piles, etc. On the other hand, the backing could be moved a greater distance to increase the spacing between cycles so that when needle 60 next penetrates the backing, it is at a distance .from the tuft formed by the last stroke of needle 61 on the order of the distance between

needles

61 and 62 and between 62 and 60. Thus, with this type of tufting, the pattern is essentially: single cut-pile tuft, single cut-pile tuft, loop-pile tuft, single cut-pile tuft, single cut-pile tuft, loop-pile tuft, etc., with approximately the same spacing between each of the above tufts.

With reference to FIG. 9, a different embodiment is shown wherein

outer needles

60 and 61 and their drive means 38 remain of the same type as earlier described.

However, central needle 80 has a closed-eye 85 and has no internal clamp pin 66 and accompanying airactuating means. Needle 80 may be driven by needle drive bar 81 in the manner of needle drive bar 68 of the embodiment of FIG. 2(Member 82 is a combination clamping and cutting member and is coextensive in v part with needle 80. Member 82 is driven by knife drive bar 83 through arm member 84. g

In the initial steps of the operation of this embodiment, clamp-knife member 82 acts .as clamp member 66 did in the embodiment of FIG. 2. That is to say, once serving to prevent an unequal pull of yarn either from the right or left needles by keeping the yarn in a clamped or pinched condition as shown in FIG. 10.

Needle 80 continues to withdraw until itreaches a first down position at which time the formed loop is ex tended to its desired nap height. Once this position has been reached with the yarn bit pinched between member 82 and a corner 86 of the top surface of the eye 85 of the needle 80, needles 60 and 61 start their descents, pulling the outer legs of the yarn bit through the backing B as shown in FIG. 11. With reference to FIG. 11A, once the ends of the yarn bits have been released by

needles

60 and 61, all three

needles

60, 61, 80 may stroke down in unison to their full down positions. As needle 80 descends further, member 82 may either remain stationary or ascend whichever is most feasible; but in any event it now serves as a knife, cutting loop A against the upper portion 86 of needle eye 85 which surface is sharp enough to aid in the accomplishment of this act. After the cut has been made (FIG. 12), the backing B may move to its next position and the new tufting cycle begins again as needles 60, 61, 80 all ascend to their loading position with their eyes aligned.

With reference to'FlG. 13, another embodiment is shown which once again utilizes

outer needles

60 and 61 and their driving means 38. Central needle 88 is driven by drive bar 89, which is similar to drive bar 81 of the embodiment shown in FIG. 9. However, the clamp-knife mechanism of FIG. 9 is replaced with a device of an alternate design although one member once again may serve as both a clamp and a knife. Member 90 which is an extended shank, is coextensive in part with needle 88 and has a rounded concave top portion 91 which may serve to clamp the yarn bit against the top of needle eye 92. Shank 90 extends to a separate drive bar 93 for the knife-clamp combination.

The steps of operation are similar to the previously described embodiment. Member 90 is driven up by drive means 93 to clamp the yarn bit while the

needles

60, 61, 88 are in their loading position. Central needle 88 then withdraws through the backing B carrying with it the center portion of the yarn bit which is pinched and held between member 90 which descends in cooperation with needle 88 and the top edge 94 of the needle eye 92 as shown in FIG. 14. Both needle 88 and knife-clamp member 90 continue downward together maintaining the yarn in a clamped or pinched condition until needle 88 reaches a first down position which effectively sets the desired height of the pile nap. With needle 88 holding this position and the yarn bit clamped or pinched by member 90, the two outer needles and 61 withdraw, pulling the end legs of the yarn bit through the backing B. Needles 60 and 61 continue downward until the leg ends of the bit are released from their needle eyes. At this point, see FIG. 15, all three

needles

60, 61, 88 move downward with knife member remaining in a stationary position or moving upward thus causing the yarn bit to be severed between edges 91 of member 90 and the upper cutting edge 94 of needle eye 92. When the cutting is completed and theneedles are free of the tufts, the backing B moves to the next position and the needles then penetrate through the backing B into loading position for the next bit of yarn.

The three needle tufting concept also has utility in a system where conventional looper and knife attachments may be used. With reference to FIG. 16, three closed eye needles 60, 61, 95 are shown in loading position with a yarn bit Y inserted in

needle eyes

103, 104,

105.

Needles

60, 61 operate off of needle bar mechanism 38 as shown. This may be a single unit or comprise separate mechanisms. Needle 95 is connected to staff 108 which receives its reciprocating drive force from drive bar means 109 which encompasses extension 107 her 113 by means '1 14. Member 113 extends widthwise across the machine, and studs 112 from each of the needles are connected to individual arms 111, as best shown from the sectional view in FIG. 18. As best seen in FIG. 18, as the member 113 reciprocates back and forth, arms 111 extending from the stud connections 112 will cause the needle staffs 108 to rotate a desired amount. in this case, it is desirable for the needle staffs to rotate 90, the reason for which will be hereinafter described. A conventional tufting looper 120 with conventional knife means 122 may be placed adjacent each of the needle stations.

The operation of this embodiment can best be seen from FIG. 17. As in the case of the earlier embodiments, central needle 95 withdraws through the backing pulling with it equal amounts of yarn through

needle eyes

103, 104 of the two

outer needles

60, 61. A clamp is not shown in this embodiment, but one may be used as in earlier embodiments. Once central needle 95 reaches its desired down position, needles 60, 61 withdraw pulling with them the two legs of the yarn bit.

Needles

60, 61 descent to a desired down position preferably below that of needle 95 thereby causing the release of the two yarn legs that were in their eyes, 103 and 104. At this time member 113 of the rotating device 110 shifts to cause needle staff 108 to enable needle 95 to rotate 90. At the completion of the rotation, looper 120 advances to the right and hooks the loop extending out of needle eye 105 which has been rotated to a position where it may be hooked by needle looper 120. Knife 122 cuts the loop in the conventional manner to provide cut pile. Looper 120 and knife 122 move away from the

needles

60, 61, 95 to their pre-cutting position and the backing B moves to its next position with

needles

60, 61, 95 penetrating the backing B for the next cycle.

While various embodiments of the inventionhave been shown and described, it will be understood that other modifications may be made. The appended claims are, therefore, intended to define the scope of the invention.

We claim: 1. A method of tufting comprising the steps of: positioning a yarn bit at a loadingstation into bitapplying position relative to a series of more than two linearly aligned bit-applying elements;

operating a first of said bit-applying elements to place -a portion of said yarn bit into tufting relationship with a backing layer leaving sufficientyarn in bitapplying position for tufting thereof by the other bit-applying elements;

thereafter operating said other bit-applying elements to place the remaining portions of said yarn bit in tufting relationship with the backing layer; and

returning said bit-applying elements to said loading station to receive another yarn bit preparatory to the next tufting operation.

2. A tuft bit-applying system comprising:

i a series of at least three individual bit-applying elements aligned with each other to receive a yarn bit common to said series and operable in synchronized manner to place said yarn bit in tufting relationship with a backing layer; I

mounting means for said bit-applying elements for independent movement of at least two of said bitapplying elements relative to the remaining bitapplying elements to and from a loading station;

means for moving each intermediate bit-applying element of the series to place a portion of said yarn bit into tufting relationship to the backing layer, which portion of said yarn bit has in part been pulled from bit-applying elements to the right and left of each said intermediate bit-applying element;

means for moving the remaining bit-applying elements to place the remaining portions of said yarn bit into tufting relationship with the backing; and

means to return said bit-applying elements to said loading station to receive another yarn bit preparatory to the next tufting operation.

3. A method of tufting comprising the steps of:

positioning a yarn bit in eyes of three linearly aligned needles;

clamping the yarn bit at the central needle;

movingthe central needle through a backing layer with said yarn clamped thereby pulling a portion of said yarn bit therethrough and leaving remaining portions of the yarn bit in the eyes of the outer needies;

thereafter moving the outer needles through the backing layer thereby pulling the remaining portions of said yarn bit therethrough; and

releasing said yarn bit from the central needle thereby leaving a series of tufts in the backing layer.

4. A method of tufting comprising the steps of:

positioning a yarn bit in the eyes of three linearly aligned needles; v

clamping said yarn bit at the central needle;

moving the central needle through a backing layer thereby to move a middle portion of said yarn bit therethrough and leaving desired end portions of said yarn bit in the eyes of the outer needles;

thereafter moving the outer needles through the backing layer thereby moving said end portions of said yarn bit therethrough, said ends of said yarn bit being released from said needles as said needles move away from the backing layer; and

releasing the middle portion of said yarn bit from the central needle by severing said yarn bit in the region intermediate said outer needles.

5. A method of tufting comprising the steps of:

positioning a ,yarn bit in the eyes of three linearly aligned needles including a central open-eye needle;

clamping said yarn bit at said central needle;

moving said central needle through a backing layer thereby implanting a portion of said .yarn bit therein to form a'loop and leaving desired end por- -tions of said yarn bit in the eyes of the outer needles;

thereafter moving the outer needles through the backing layer thereby implanting said end portions of said yarn bittherein, said yarn bit ends being released from said needles as said needles complete their stroke through the backing layer; and

releasing the middle portion of said yarn bit from said central needle by allowing the loop to slip through said open-eye.

6. A tufting machine comprising:

reciprocating needle means in which a series of three needles having aligned eyes are disposed at each loading station;

means for placing a discrete bit of yarn in said eyes of said needles;

mounting means for said needle means for reciprocating movement of the central needle independent of reciprocating movement of the two outer needles;

means for moving said central needle through the backing;

means for thereafter moving the two outer threaded needles through the backing; and

means for returning said needles'to the loading station to receive another yarn bit preparatory to the next tufting operation.

7. A tufting machine comprising:

means for placing a discrete bit of yarn in said eyes of said needles;

means for clamping the yarn bit to said central needle;

means for moving the central needle through the backing;

means for thereafter moving the two outer needles through the backing;

means for releasing said clamping means to release said yarn bit from said needles upon completion of their movement through the backing; and

means for returning said needles to the loading station to receive another yarn bit preparatory to the next tufting operation.

8. A tufting machine comprising:

reciprocating needle means in which a series of three needles having aligned eyes are disposed at eachneedle station; yarn clamping means associated with said central needle; mounting means for said needle for reciprocatin movement of said central needle independent of reciprocating movement of the two outer needles;

means for placing a discrete bit of yarn in said eyes of said needles;

means for moving said central needle through the backing;

means for moving the two outside threaded needles through the backing; and

means'for operating said clamping means to release the yarn bit from said central needle after it has been moved through the backing, the remainder of said yarn bit being freed from the outside two needles as the ends of said yarn bit are pulled from the eyes thereof.

9. A needle system as set forth in claim 2 for a tufting machine wherein:

said central needle has an open eye with a cam surface disposed along the bottom of said eye to facilitate the casting off of tufted loops.

10. A needle system as set forth in claim 2 for a tuft- 5 ing machine wherein:

at least one of the needles has an open eye and includes a means to cast off a yarn loop that has been tufted and further includes a clamp means for clamping yarn disposed within said needle and designed to project into and withdraw out of said open eye.

11. A tufting machine comprising:

means to load a yarn bit in said eyes of said needle means;

a single element combination yam-clamp and knife means associated with said central needle;

mounting means for said needle means for reciprocating movement of said central needle independent of reciprocating movement of the two outer needles;

operating means for operating said combination yarn-clamp and knife means in timed relation with said reciprocating movement of said needle means; and

means for operating said mounting means to move said yarn bit through said backing by first the central needle and secondly by said outside two needles while said yarn bit is clamped by said combination means, the ends of said yarn bit sliding through the eyes of the outside needles as they move through the backing, said operating means then actuating said knife means to cut said yarn bit at said central needle to release said yarn bit from the eye of that needle.

12. A tufting machine comprising:

.means to load a yarn bit in said eyes of said needle means;

a single element combination yarn-clamp and knife means associated with the central needle,- said combination .means having a shank coextensive with the central needle shank;

means for operating said mounting means successively to move said yarn bit through said backing first by said'central needle and secondly by the outside two needles; and

means for operating said shank of said combination means to clamp said yarn bit during said successive movements of said needle means and upon completion of said successive movements for further operating said shank to cut said yarn bit at the central needle to release said yarn bit from the eye of the central needle.

13. A tufting machine comprising:

reciprocating needle means in which a series of three loading station;

means to load a yarn bit in said eyes of said needle means;

a single element combination yarn-clamp and knife means associated with said central needle, said combination means being positioned externally of 5 said central needle;

means for operating said mounting means to move said yarn bit through said backing by first the central needle and secondly by said outside two needles, while said yarn bit is clamped by said combination means, the ends of said yarn bit sliding through the eyes of the outside needles as they move through the backing, said operating means then actuating said knife means to out said yarn bit at said central needle to release said yarn bit from the eye of that needle;

means for operating said mounting means to move said yarn bit through said backing by first the central needle and secondly by said outside two needles while said yarn bit is clamped by said combination means, said operating means then serving as a cutting means in conjunction with a surface of said central needle to out said yarn bit to release said yarn bit from the eye of that needle.

14. A tufting needle system for a tufting machine comprising:

needle means including needle moving means in A which at least one needle has associated therewith a single element combination clamp knife means which operates against a surface of said needle to first, in one position of the needle, clamp the yarn against said needle surface and when said needle is moved to a second position, cut the yarn by an additional movement against said needle surface.

15. A tufting machine comprising:

means, to load a yarn bit in said eyes of said needle means;

mounting means for saidneedle means for reciprocating movement of said central needle independent of reciprocating movement of the two outer needles;

means for operating said mounting means to move said yarn bit through said backing in three places by first the central needle followed by the two outer needles;

means to rotate said central needle to facilitate the severing of the yarnimplanted in said backingby said central needle; and

means to sever said yarn implanted by said central needle while said central needle is in its rotated position.

16. A tufting machine comprising:

means to load a yarn bit in said eyes of said needle means;

mounting means for said needle means for reciprocating movement of said centralneedle indepenby link means to a bar whereby the longitudinal I movement of said bar causes said needle to rotate; and

cutting means including a hook and knife combination operable to first hook the tufted yarn loop after the central needle has been rotated and then to cut the loop by said knife.

17. A method of tufting comprising the steps of:

placing yarn in loading position relative to a series of more than two successively aligned yarn-tufting elements;

operating a first of said yamtufting elements to place a portion of the yarn into tufting relationship with a backing layer and leaving sufficient yarn in loading position for the other yarn-tufting elements;

thereafter operating other yarn-tufting elements to place the remaining portions of the yarn in tufting relationship with the backing layer; and

releasing the yarn from the yarn-tufting elements.

18. A tufting machine comprising:

a first needle bar means and a central needle supported thereon;

a second needle bar means and two outer needles supported thereon;

said central and outer needles having aligned eyes;

said second needle bar means having an aperture formed therethrough between said outer needles and receiving said central needle;

first reciprocating means actuating said central needle between said outer needles so that relative motion may occur between said first and said outer needles;

means to place a single bit of yarn inthe aligned eyes of said first and outer needles;

said first reciprocating means adapted to move said threaded central needle through the backing;

second reciprocating means adapted to move said two outer threaded needles through the backing subsequent to the movement of said central needle through the backing; and

means to cause the yarn bit to be released from said first and outer needles after it has been drawn through the backing.

19. A tufting machine comprising:

a first needle bar means and a central needle supported thereon;

a second needle bar means and two outer needles supported thereon, said central and outer needles having aligned eyes;

said second needle bar means having a configuration providing an unobstructed frame path for said central needle;

means to place a single bit of yarn in the aligned eyes of said first and outer needles;

means to cause the yarn bit to be released from said first and outer needles after it has been moved through the backing.

20. A tufting machine comprising:

a first needle support means and a central needle supported thereon;

a second needle support means and two outer needles supported thereon, said central and outer needles having aligned eyes;

first reciprocating means actuating said central needie between said outer needles so that relative motion may occur between said first and said outer needles;

Claims

1. A method of tufting comprising the steps of: positioning a yarn bit at a loading station into bit-applying position relative to a series of more than two linearly aligned bit-applying elements; operating a first of said bit-applying elements to place a portion of said yarn bit into tufting relationship with a backing layer leaving sufficient yarn in bit-applying position for tufting thereof by the other bit-applying elements; thereafter operating said other bit-applying elements to place the remaining portions of said yarn bit in tufting relationship with the backing layer; and returning said bit-applying elements to said loading station to receive another yarn bit preparatory to the next tufting operation.

2. A tuft bit-applying system comprising: a series of at least three individual bit-applying elements aligned with each other to receive a yarn bit common to said series and operable in synchronized manner to place said yarn bit in tufting relationship with a backing layer; mounting means for said bit-applying elements for independent movement of at least two of said bit-applying elements relative to the remaining bit-applying elements to and from a loading station; means for moving each intermediate bit-applying element of the series to place a portion of said yarn bit into tufting relationship to the backing layer, which portion of said yarn bit has in part been pulled from bit-applying elements to the right and left of each said intermediate bit-applying element; means for moving the remaining bit-applying elements to place the remaining portions of said yarn bit into tufting relationship with the backing; and means to return said bit-applying elements to said loading station to receive another yarn bit preparatory to the next tufting operation.

3. A method of tufting comprising the steps of: positioning a yarn bit in eyes of three linearly aligned needles; clamping the yarn bit at the central needle; moving the central needle through a backing layer with said yarn clamped thereby pulling a portion of said yarn bit therethrough and leaving remaining portions of the yarn bit in the eyes of the outer needles; thereafter moving the outer needles through the backing layer thereby pulling the remaining portions of said yarn bit therethrough; and releasing said yarn bit from the central needle thereby leaving a series of tufts in the backing layer.

4. A method of tufting comprising the steps of: positioning a yarn bit in the eyes of three linearly aligned needles; clamping said yarn bit at the central needle; moving the central needle through a backing layer thereby to move a middle portion of said yarn bit therethrough and leaving desired end portions of said yarn bit in the eyes of the outer needles; thereafter moving the outer needles through the backing layer thereby moving said end portions of said yarn bit therethrough, said ends of said yarn bit being released from said needles as said needles move away from the backing layer; and releasing the middle portion of said yarn bit from the central needle by severing said yarn bit in the region intermediate said outer needles.

5. A method of tufting comprising the steps of: positioning a yarn bit in the eyes of three linearly aligned needles including a central open-eye needle; clamping said yarn bit at said central needle; moving said central needle through a backing layer thereby implanting a portion of said yarn bit therein to form a loop and leaving desired end portions of said yarn bit in the eyes of the outer needles; thereafter moving the outer needles through the backing layeR thereby implanting said end portions of said yarn bit therein, said yarn bit ends being released from said needles as said needles complete their stroke through the backing layer; and releasing the middle portion of said yarn bit from said central needle by allowing the loop to slip through said open-eye.

6. A tufting machine comprising: reciprocating needle means in which a series of three needles having aligned eyes are disposed at each loading station; means for placing a discrete bit of yarn in said eyes of said needles; mounting means for said needle means for reciprocating movement of the central needle independent of reciprocating movement of the two outer needles; means for moving said central needle through the backing; means for thereafter moving the two outer threaded needles through the backing; and means for returning said needles to the loading station to receive another yarn bit preparatory to the next tufting operation.

7. A tufting machine comprising: reciprocating needle means in which a series of three needles having aligned eyes are disposed at each loading station; means for placing a discrete bit of yarn in said eyes of said needles; mounting means for said needle means for reciprocating movement of the central needle independent of reciprocating movement of the two outer needles; means for clamping the yarn bit to said central needle; means for moving the central needle through the backing; means for thereafter moving the two outer needles through the backing; means for releasing said clamping means to release said yarn bit from said needles upon completion of their movement through the backing; and means for returning said needles to the loading station to receive another yarn bit preparatory to the next tufting operation.

8. A tufting machine comprising: reciprocating needle means in which a series of three needles having aligned eyes are disposed at each needle station; yarn clamping means associated with said central needle; mounting means for said needle for reciprocating movement of said central needle independent of reciprocating movement of the two outer needles; means for placing a discrete bit of yarn in said eyes of said needles; means for moving said central needle through the backing; means for moving the two outside threaded needles through the backing; and means for operating said clamping means to release the yarn bit from said central needle after it has been moved through the backing, the remainder of said yarn bit being freed from the outside two needles as the ends of said yarn bit are pulled from the eyes thereof.

9. A needle system as set forth in claim 2 for a tufting machine wherein: said central needle has an open eye with a cam surface disposed along the bottom of said eye to facilitate the casting off of tufted loops.

10. A needle system as set forth in claim 2 for a tufting machine wherein: at least one of the needles has an open eye and includes a means to cast off a yarn loop that has been tufted and further includes a clamp means for clamping yarn disposed within said needle and designed to project into and withdraw out of said open eye.

11. A tufting machine comprising: reciprocating needle means in which a series of three needles having aligned eyes are disposed at each loading station; means to load a yarn bit in said eyes of said needle means; a single element combination yarn-clamp and knife means associated with said central needle; mounting means for said needle means for reciprocating movement of said central needle independent of reciprocating movement of the two outer needles; operating means for operating said combination yarn-clamp and knife means in timed relation with said reciprocating movement of said needle means; and means for operating said mounting means to move said yarn bit through said backing by first the central needle and Secondly by said outside two needles while said yarn bit is clamped by said combination means, the ends of said yarn bit sliding through the eyes of the outside needles as they move through the backing, said operating means then actuating said knife means to cut said yarn bit at said central needle to release said yarn bit from the eye of that needle.

12. A tufting machine comprising: reciprocating needle means in which a series of three needles having aligned eyes are disposed at each loading station; means to load a yarn bit in said eyes of said needle means; a single element combination yarn-clamp and knife means associated with the central needle, said combination means having a shank coextensive with the central needle shank; mounting means for said needle means for reciprocating movement of said central needle independent of reciprocating movement of the two outer needles; means for operating said mounting means successively to move said yarn bit through said backing first by said central needle and secondly by the outside two needles; and means for operating said shank of said combination means to clamp said yarn bit during said successive movements of said needle means and upon completion of said successive movements for further operating said shank to cut said yarn bit at the central needle to release said yarn bit from the eye of the central needle.

13. A tufting machine comprising: reciprocating needle means in which a series of three needles having aligned eyes are disposed at each loading station; means to load a yarn bit in said eyes of said needle means; a single element combination yarn-clamp and knife means associated with said central needle, said combination means being positioned externally of said central needle; mounting means for said needle means for reciprocating movement of said central needle independent of reciprocating movement of the two outer needles; means for operating said mounting means to move said yarn bit through said backing by first the central needle and secondly by said outside two needles, while said yarn bit is clamped by said combination means, the ends of said yarn bit sliding through the eyes of the outside needles as they move through the backing, said operating means then actuating said knife means to cut said yarn bit at said central needle to release said yarn bit from the eye of that needle; means for operating said mounting means to move said yarn bit through said backing by first the central needle and secondly by said outside two needles while said yarn bit is clamped by said combination means, said operating means then serving as a cutting means in conjunction with a surface of said central needle to cut said yarn bit to release said yarn bit from the eye of that needle.

14. A tufting needle system for a tufting machine comprising: needle means including needle moving means in which at least one needle has associated therewith a single element combination clamp knife means which operates against a surface of said needle to first, in one position of the needle, clamp the yarn against said needle surface and when said needle is moved to a second position, cut the yarn by an additional movement against said needle surface.

15. A tufting machine comprising: reciprocating needle means in which a series of three needles having aligned eyes are disposed at each loading station; means to load a yarn bit in said eyes of said needle means; mounting means for said needle means for reciprocating movement of said central needle independent of reciprocating movement of the two outer needles; means for operating said mounting means to move said yarn bit through said backing in three places by first the central needle followed by the two outer needles; means to rotate said central needle to facilitate the severing of the yarn implanted in said backing by said central needle; and means to sever said yarn implanted by said ceNtral needle while said central needle is in its rotated position.

16. A tufting machine comprising: reciprocating needle means in which a series of three needles having aligned eyes are disposed at each loading station; means to load a yarn bit in said eyes of said needle means; mounting means for said needle means for reciprocating movement of said central needle independent of reciprocating movement of the two outer needles; means for operating said mounting means to move said yarn bit through said backing by first the central needle followed by the two outer needles; means to rotate said central needle to cause a tufted loop to rotate including an arm extending from the base of the central needle staff which is connected by link means to a bar whereby the longitudinal movement of said bar causes said needle to rotate; and cutting means including a hook and knife combination operable to first hook the tufted yarn loop after the central needle has been rotated and then to cut the loop by said knife.

17. A method of tufting comprising the steps of: placing yarn in loading position relative to a series of more than two successively aligned yarn-tufting elements; operating a first of said yarn-tufting elements to place a portion of the yarn into tufting relationship with a backing layer and leaving sufficient yarn in loading position for the other yarn-tufting elements; thereafter operating other yarn-tufting elements to place the remaining portions of the yarn in tufting relationship with the backing layer; and releasing the yarn from the yarn-tufting elements.

18. A tufting machine comprising: a first needle bar means and a central needle supported thereon; a second needle bar means and two outer needles supported thereon; said central and outer needles having aligned eyes; said second needle bar means having an aperture formed therethrough between said outer needles and receiving said central needle; first reciprocating means actuating said central needle between said outer needles so that relative motion may occur between said first and said outer needles; means to place a single bit of yarn in the aligned eyes of said first and outer needles; said first reciprocating means adapted to move said threaded central needle through the backing; second reciprocating means adapted to move said two outer threaded needles through the backing subsequent to the movement of said central needle through the backing; and means to cause the yarn bit to be released from said first and outer needles after it has been drawn through the backing.

19. A tufting machine comprising: a first needle bar means and a central needle supported thereon; a second needle bar means and two outer needles supported thereon, said central and outer needles having aligned eyes; said second needle bar means having a configuration providing an unobstructed frame path for said central needle; first reciprocating means actuating said central needle between said outer needles so that relative motion may occur between said first and said outer needles; means to place a single bit of yarn in the aligned eyes of said first and outer needles; said first reciprocating means adapted to move said threaded central needle through the backing; second reciprocating means adapted to move said two outer threaded needles through the backing subsequent to the movement of said central needle through the backing; and means to cause the yarn bit to be released from said first and outer needles after it has been moved through the backing.

20. A tufting machine comprising: a first needle support means and a central needle supported thereon; a second needle support means and two outer needles supported thereon, said central and outer needles having aligned eyes; first reciprocating means actuating said central needle between said outer needles so that relative motion may occUr between said first and said outer needles; means to place a single bit of yarn in the aligned eyes of said first and outer needles; said first reciprocating means adapted to move said threaded central needle through the backing; second reciprocating means adapted to move said two outer threaded needles through the backing subsequent to the movement of said central needle through the backing; and means to cause the yarn bit to be released from said first and outer needles after it has been moved through the backing.