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US2985124A - Method and apparatus for making tufted pile fabrics - Google Patents

Method and apparatus for making tufted pile fabrics Download PDF

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Publication number
US2985124A
US2985124A US836360A US83636059A US2985124A US 2985124 A US2985124 A US 2985124A US 836360 A US836360 A US 836360A US 83636059 A US83636059 A US 83636059A US 2985124 A US2985124 A US 2985124A
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US
United States
Prior art keywords
loops
yarn
pile
needle
sheet
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
US836360A
Other languages
English (en)
Inventor
Walter A Rice
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Mohasco Industries Inc
Original Assignee
Mohasco Industries Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Mohasco Industries Inc filed Critical Mohasco Industries Inc
Priority to US836360A priority Critical patent/US2985124A/en
Priority to GB14015/60A priority patent/GB910848A/en
Priority to FR828016A priority patent/FR1262773A/fr
Priority to BE591264A priority patent/BE591264A/fr
Priority to ES0259169A priority patent/ES259169A1/es
Priority to ES0259170A priority patent/ES259170A1/es
Priority to CH782060A priority patent/CH371411A/fr
Application granted granted Critical
Publication of US2985124A publication Critical patent/US2985124A/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • 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
    • D05C15/26—Tufting machines with provision for producing patterns
    • D05C15/36—Tufting machines with provision for producing patterns by selective cutting of loops

Definitions

  • This invention relates to the production of pile fabrics of the type made by a tufting operation, in which loops of pile yarn are passed through a backing sheet by means of needles. More particularly, the invention is concerned with a novel method of making such fabrics in which the pile is composed of loops and cut loops of yarn distributed in accordance with a pattern, and with an apparatus by which such a fabric can be produced as rapidly and at as low cost as ordinary tufted fabrics.
  • Tufting machines constructed for the production of pile fabrics having loops and cut loops in the pile have been disclosed heretofore in patents but the machines of the patents with which I am familiar are complicated and do not appear to be capable of operation at the high speeds at which ordinary tufting machines are usually run. Also, the pattern control means in the patented machines is primitive and it, seems doubtful that the machines are practical for commercial operation.
  • the present invention is directed to the provision of a method for the production of tufted pile fabrics having a pile containing loops or cut loops arranged in accordance with the pattern and of an apparatus on which the method can be advantageously practiced.
  • a backing sheet is advanced with a step-by-step motion and, during each period of rest of the sheet, a transverse row of loops extending from one face of the sheet is formed by passing looped portions of the pile yarns through the sheet from the opposite side.
  • the loops in such a transverse row vary in height in accordance with the pattern and, upon the completion of the formation of the row of loops, the fabric is advanced in the direction of its length.
  • FIG. 1 is a diagrammatic view in vertical section of a tufting machine constructed in accordance with the invention
  • I Figs. 2-5, inclusive are diagrammatic views showing diflerent stages in the operation of the machine when used to practice the method of the invention.
  • the tufting machine illustrated comprises a frame structure provided with a bed plate 11 formed with a plurality of slots 11a and a backing sheet 12 is advanced with a step'by-step motion from a supply over the top of the plate lengthwise of the slots by means of rolls 13, 14, 15, 16, and 17, some of which are driven.
  • a shaft 18 mounted above the bed plate and driven by suitable means reciprocates a needle bar 19 through suitable connections including a plurality of eccentric disks 20, straps 21 encircling the eccentrics, and push rods 22-connected to the straps and attached to the needle bar, the rods being movable in guides 23.
  • the needle aten t bar carries a plurality of needles 24 and a pair of spaced pile yarn guides 25, 26 are mounted on the push rod guides 23 opposite each needle.
  • the needles pass loops of the pile yarns through the backing sheet and through respective slots 11a in the bed plate.
  • a plurality of loopers 27, one for each needle are mounted on a bar 28 carried by arms on a rock shaft 29 and, when the needles have reached the end of their downstrokes, the associated loopers enter the loops of yarn carried by the needles and hold the loops momentarily as the needles rise.
  • the action of the needles and loopers produce pile loops of maximum height.
  • the pile yarns are drawn from individual supplies thereof in the form of packages 30 in a creel and pass from the packages through respective guides 31 to a mechanism 32 which draws the yarns from the packages and feeds the yarns in increments toward the needles.
  • the feed mechanism illustrated is of the construction shown in the-Crawford Patent 2,853,034, issued September 23, 1958, and the mechanism includes a lower set of chains 33, the corresponding links of which are connected by fiat wires 34 extending across the sheet of yarns traveling-from the guides 31 to the guides 35 which lie between the feed mechanism and the guides 26.
  • the chains 33 are trained about sprocket wheels on shafts 36 carried on brackets 37 attached to the frame of the tufting machine.
  • the feed mechanism also includes an upper set of chains 38, the corresponding links of which are connected by flat wires 39 extending transverse to the sheet of yarns.
  • the wires 39 have sections thereon adapted to engage individual yarns in the sheet and the height of these sections varies in accordance with the pattern to be'produced in the pile.
  • the chains 38 are trained about sprocket wheels on shafts 40 and one of the shafts 36 and one of the shafts 40 are coupled together and driven in unison with the mechanism by which the backing sheet is advanced stepwise.
  • the chains of the two sets are guided by the sprocket Wheels on the shafts 36, 40 so that the chains have parallel stretches in which the wires 34, 39 intermesh and, as the backing sheet is advanced one step, the chains are advanced by the distance between adjacent wires on the chains.
  • the yarns traveling between guides 31, 35 are engaged by the intermeshing wires on the parallel stretches of the chains and deviated from a rectilinear path to form waves.
  • the length of yarn in each wave forms an increment which is fed during a needle cycle, and the length of such an increment of any yarn depends on the height of the section of the wire 39 engaging the yarn in that increment.
  • a stationary cutting member 41 is mounted below the bed plate 11 in alignment with each needle and the member has a pointed portion 41a extending in a direction opposite to the direction of travel of the fabric and lying close to the path of vertical travel of the associated needle.
  • the lower edge of the pointed portion of each cutting element 41 is formed to make a shear cut with a cutting element 42 lying against the side of the element'41 and movable by suitable means.
  • a stationary loop holder 43 in the form of a thin plate is secured at one end to the under surface of the bed plate and extends downwardly at an angle to terminate in a free end lying close to the path of vertical travel of each needle and above the top of the looper 27 co-operating with the needle.
  • a deflecting bar 44 is mounted on arms 45 attached to the needle bar and is adapted to engage the yarns be tween guides 25, 26 as the needle rises, and to deflect the yarns upwardly out of a rectilinear path and into a storage space between guides 25, 26.
  • the bar 44 rises to the same height on each ascent of the needles, constant lengths of the yarns are introduced into the storage space during each cycle.
  • the bar is disengaged from the yarns between the guides 25, 26 and the yarns pass directly from one guide to the other.
  • the constant lengths of the yarns are thus withdrawn from the storage space, each such constant length being the difference between the length of a yarn deflected into the storage space between guides 25, 26 and the length of a yarn passing in a straight line from one guide to the other.
  • Such a constant length of a yarn is suflicient for the formation of a loop of maximum height.
  • the needle 24 is at the upper limit of its travel after having passed a loop L of the pile yarn P through the backing sheet 12.
  • the deflecting bar 44 is also at the upper limit of its travel and has deflected the yarn into the storage space between the guides 25, 26.
  • the increment of the yarn which was fed during the descent and ascent of the needle was relatively short since the wire 39' of the upper set which deflected the yarn to form the increment is relatively low.
  • the increment fed was insufficient for the formation of a loop of maximum height and, after the loop passed through the backing sheet by the needle was momentarily held by the looper 27 and then released, the rise of the deflecting bar between guides 25, 26 to deflect the yarn into the storage space caused yarn to be withdrawn from the inserted loop to reduce its height.
  • the fabric is advanced one step and the shortened loop L passes over the top of the pointed end portion 41a of the stationary cutting element 41 associated with the needle 24.
  • the needle again descends and the deflecting bar 44 moves down with it. In such movement, the deflecting bar is disengaged from the yarn P and the constant length of yarn in the storage space is available for passage through the backing sheet by the needle.
  • looper 27 enters the doubled portion of the yarn carried through the sheet by the needle and holds the loop as the needle rises.
  • the increment of yarn fed during the cycle shown in Fig. 3 was sufficiently long for the formation of a loop of maximum height and, when the needle and the deflecting bar rise, the deflection of the yarn into the storage space between guides 25, 26, as shown in Fig. 4, does not withdraw yarn from the loop and a loop L' of maximum height is formed.
  • the loop L Upon being released by the looper 27, the loop L lies against the free edge of the loop holder 43 and is thus held against twisting out of a plane transverse to the direction of travel of the sheet.
  • the backing sheet 12 is advanced one step and this causes the loop L to encircle the pointed portion 41a of the stationary cutting element 41.
  • the needle and the deflecting bar then descend to form a third loop and, as this operation takes place, the movable cutting element 42 is moved in relation to the 4 cutting edge on the pointed portion 41a of the element 41 to cut the loop L.
  • a transverse row of pile loops extending from one face of the backing sheet is formed by passing doubled portions of the pile yarns through the sheet in each cycle of operation of the machine. Increments of the pile yarns are fed toward the needles during each cycle and these increments vary in length in accordance with the pattern.
  • a constant length of each yarn is released from the storage space in each cycle by the descent of the deflecting bar and constant lengths of the yarns are returned to the storage space as the needles and deflecting bar rise at the end of each cycle.
  • a method of making a fabric having a pile formed of transverse rows of loops and cut loops of pile yarns, the loops and cut loops being arranged in sequence in the rows in accordance with a pattern which comprises carrying'out a cycle made up of the steps of advancing the backing sheet stepwise, during a single period of rest of the sheet, inserting doubled portions of the pile yarns through the sheet from one side to form a transverse row of loops of uniform height projecting from the opposite side of the sheet, simultaneously with the insertion of the loops, feeding increments of pile yarns'toward the place of insertion of the loops, the increments varying in length in accordance with the pattern with some of the increments shorter than the length of yarn in one of said uniform loops, and withdrawing lengths of yarn from the just-formed inserted loops of the yarns, of which the increments fed during the insertion of the uniform loops were insutn'cient in length for formation of one of said uniform loops, the length of the withdrawn portion of each yarn
  • An apparatus for making a fabric having ;a-pile formed of transverse rows of loops and cut loops of pile yarns, the loops and cut loops being arranged in sequence in the rows in accordance with a pattern which comprises a support for a backing sheet, means for advancing the sheet lengthwise over the support step by step, a plurality of needles mounted above the support in a row transverse to the fabric and reciprocable in a vertical direction only, means for reciprocating the needles to cause the needles to pass loops of pile yarns carried thereby through the sheet, a plurality of loopers co-operating with respective needles to enter and retain momentarily the loops of pile yarns carried through the sheet by the needles to form pile loops of maximum height, means operating during each complete reciprocation of the needles to feed an increment of each pile yarn toward its needle, the increments of the several yarns varying in length in accordance with a pattern, means for holding constant lengths of the pile yarns in a storage space between the feeding means and the needles, means for holding constant
  • the engaging means includes a stationary cutting element aligned longitudinally of the fabric with each needle, each element having a pointed portion extending in a direction opposite to the direction of movement of the sheet and adapted to enter loops of more than a selected height formed by its looper, the pointed portion having a shearing edge.
  • the cutting means includes a movable cutting element co-operating with the stationary cutting element to shear loops entered by the pointed portion of the stationary element.
  • the loop holder is a plate secured at one end and extending toward the path of travel of a needle, the opposite end of the plate being free and terminating close to the needle path above the path of the looper co-operating with the needle.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Textile Engineering (AREA)
  • Treatment Of Fiber Materials (AREA)
  • Automatic Embroidering For Embroidered Or Tufted Products (AREA)
  • Sewing Machines And Sewing (AREA)
  • Carpets (AREA)
US836360A 1959-08-27 1959-08-27 Method and apparatus for making tufted pile fabrics Expired - Lifetime US2985124A (en)

Priority Applications (7)

Application Number Priority Date Filing Date Title
US836360A US2985124A (en) 1959-08-27 1959-08-27 Method and apparatus for making tufted pile fabrics
GB14015/60A GB910848A (en) 1959-08-27 1960-04-21 Improvements in method and apparatus for making tufted pile fabrics
FR828016A FR1262773A (fr) 1959-08-27 1960-05-23 Procédé et métier de fabrication de tissu à poils
BE591264A BE591264A (fr) 1959-08-27 1960-05-27 Procédé et métier de fabrication de tissu à poils.
ES0259169A ES259169A1 (es) 1959-08-27 1960-06-23 Un metodo de hacer un tejido de pelo
ES0259170A ES259170A1 (es) 1959-08-27 1960-06-23 Un aparato para hacer un tejido de pelo
CH782060A CH371411A (fr) 1959-08-27 1960-07-08 Procédé de fabrication d'un tissu à poils et métier pour la mise en oeuvre de ce procédé

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US836360A US2985124A (en) 1959-08-27 1959-08-27 Method and apparatus for making tufted pile fabrics

Publications (1)

Publication Number Publication Date
US2985124A true US2985124A (en) 1961-05-23

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ID=25271799

Family Applications (1)

Application Number Title Priority Date Filing Date
US836360A Expired - Lifetime US2985124A (en) 1959-08-27 1959-08-27 Method and apparatus for making tufted pile fabrics

Country Status (6)

Country Link
US (1) US2985124A (fr)
BE (1) BE591264A (fr)
CH (1) CH371411A (fr)
ES (2) ES259169A1 (fr)
FR (1) FR1262773A (fr)
GB (1) GB910848A (fr)

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3100467A (en) * 1961-05-19 1963-08-13 Mohasco Ind Inc Machine for making tufted fabric with cut and uncut pile loops
US3138126A (en) * 1961-04-13 1964-06-23 Singer Co Apparatus for tufting high and low cut pile
US3241507A (en) * 1960-12-05 1966-03-22 George D Dedmon Apparatus for and method of forming patterns by high-loop tufts and lowcut tufts in a pile fabric
US3257981A (en) * 1963-04-30 1966-06-28 Callaway Mills Co Tufting machine method and apparatus
US10233578B2 (en) 2016-03-17 2019-03-19 Card-Monroe Corp. Tufting machine and method of tufting
US11193225B2 (en) 2016-03-17 2021-12-07 Card-Monroe Corp. Tufting machine and method of tufting
US11585029B2 (en) 2021-02-16 2023-02-21 Card-Monroe Corp. Tufting maching and method of tufting
US12234587B2 (en) 2023-05-19 2025-02-25 Card-Monroe Corp. Tufting machine and method of tufting

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4127078A (en) * 1977-06-30 1978-11-28 Abram N. Spanel Yarn adjuster for controlling evenness of yarn tufts

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1907292A (en) * 1928-07-07 1933-05-02 Valway Rug Mills Inc Loop and pile forming machine
US2260896A (en) * 1939-02-04 1941-10-28 Shapiro & Son Curtain Corp Tufting mechanism for sewing machines
GB635817A (en) * 1948-04-22 1950-04-19 Fred Greenwood Method of and apparatus for the manufacture of rugs, carpets and pile fabrics
US2836134A (en) * 1955-09-12 1958-05-27 John B Harrison Loop guard for tufting machine
US2853034A (en) * 1954-11-10 1958-09-23 Mohasco Ind Inc Method of making pile fabrics with loops of different height and apparatus for practicing the method
US2879728A (en) * 1956-01-26 1959-03-31 Joseph K Mccutchen Tufting machine and method
US2879729A (en) * 1956-04-10 1959-03-31 Mccutchen Joseph Kelly Method of and apparatus for producing tufted product having unsevered and severed loops
US2882845A (en) * 1955-07-05 1959-04-21 Masland C H & Sons Tufting pattern controlled by looper

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1907292A (en) * 1928-07-07 1933-05-02 Valway Rug Mills Inc Loop and pile forming machine
US2260896A (en) * 1939-02-04 1941-10-28 Shapiro & Son Curtain Corp Tufting mechanism for sewing machines
GB635817A (en) * 1948-04-22 1950-04-19 Fred Greenwood Method of and apparatus for the manufacture of rugs, carpets and pile fabrics
US2853034A (en) * 1954-11-10 1958-09-23 Mohasco Ind Inc Method of making pile fabrics with loops of different height and apparatus for practicing the method
US2882845A (en) * 1955-07-05 1959-04-21 Masland C H & Sons Tufting pattern controlled by looper
US2836134A (en) * 1955-09-12 1958-05-27 John B Harrison Loop guard for tufting machine
US2879728A (en) * 1956-01-26 1959-03-31 Joseph K Mccutchen Tufting machine and method
US2879729A (en) * 1956-04-10 1959-03-31 Mccutchen Joseph Kelly Method of and apparatus for producing tufted product having unsevered and severed loops

Cited By (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3241507A (en) * 1960-12-05 1966-03-22 George D Dedmon Apparatus for and method of forming patterns by high-loop tufts and lowcut tufts in a pile fabric
US3138126A (en) * 1961-04-13 1964-06-23 Singer Co Apparatus for tufting high and low cut pile
US3100467A (en) * 1961-05-19 1963-08-13 Mohasco Ind Inc Machine for making tufted fabric with cut and uncut pile loops
US3257981A (en) * 1963-04-30 1966-06-28 Callaway Mills Co Tufting machine method and apparatus
US11193225B2 (en) 2016-03-17 2021-12-07 Card-Monroe Corp. Tufting machine and method of tufting
US10995440B2 (en) 2016-03-17 2021-05-04 Card-Monroe Corp. Tufting machine and method of tufting
US10233578B2 (en) 2016-03-17 2019-03-19 Card-Monroe Corp. Tufting machine and method of tufting
US11702782B2 (en) 2016-03-17 2023-07-18 Card-Monroe Corp. Tufting machine and method of tufting
US11708654B2 (en) 2016-03-17 2023-07-25 Card-Monroe Corp. Tufting machine and method of tufting
US12146251B2 (en) 2016-03-17 2024-11-19 Card-Monroe, Corp. Tufting machine and method of tufting
US12173439B2 (en) 2016-03-17 2024-12-24 Card-Monroe Corp. Tufting machine and method of tufting
US11585029B2 (en) 2021-02-16 2023-02-21 Card-Monroe Corp. Tufting maching and method of tufting
US12129586B2 (en) 2021-02-16 2024-10-29 Card-Monroe Corp. Tufting machine and method of tufting
US12234587B2 (en) 2023-05-19 2025-02-25 Card-Monroe Corp. Tufting machine and method of tufting

Also Published As

Publication number Publication date
BE591264A (fr) 1960-09-16
GB910848A (en) 1962-11-21
CH371411A (fr) 1963-08-15
FR1262773A (fr) 1961-06-05
ES259169A1 (es) 1960-12-01
ES259170A1 (es) 1960-12-16

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