System and Method for Forming Tufted Patterns
First Claim
1. A method of controlling a tufting machine to form tufts of yarn in a backing material passing through the tufting machine, to form tufted articles having a combination of varied pattern effects, the method comprising:
- creating a yarn feed effect tufting pattern having a first design;
creating a shifting needle bar effect tufting pattern of a second, different design;
determining and applying shift compensation for pattern steps of the shifting needle bar effect tufting pattern to create a revised shifting needle bar effect tufting pattern;
merging the yarn feed effect tufting pattern into the revised, shifting needle bar effect tufting pattern and creating a combination tufting pattern;
loading the combination tufting pattern into a control for the tufting machine;
moving the backing material through the tufting machine and reciprocating a needle bar carrying a series of needles therealong into the backing material to form the tufts of yarn therein according to steps of the combination tufting pattern;
when the combination tufting pattern calls for shifting of the needle bar, splitting the combination pattern into separate pattern steps of the underlying first and second patterns for yarn feed control and shifting, respectively; and
adjusting the yarn feed to compensate for shifting in the combination tufting pattern and keep the combination tufting pattern running substantially straight.
1 Assignment
0 Petitions
Accused Products
Abstract
A tufting machine and a method of controlling the tufting machine to form a tufted article having varying pattern effects, such as forming cut and loop pile tufts of yarn in a graphics type pattern, defining a yarn feed effect pattern and a shifting needle bar effect pattern, and combining the two patterns. The yarn feed of the tufting machine is controlled to compensate for pattern shifts while a hook assembly having a series of hooks/loopers and a series of clips independently moveable between extended and retraced positions is selectively controlled to cause a transition from cut pile tufts to loop pile tufts and loop pile tufts to cut pile tufts according to the programmed pattern information.
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Citations
15 Claims
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1. A method of controlling a tufting machine to form tufts of yarn in a backing material passing through the tufting machine, to form tufted articles having a combination of varied pattern effects, the method comprising:
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creating a yarn feed effect tufting pattern having a first design; creating a shifting needle bar effect tufting pattern of a second, different design; determining and applying shift compensation for pattern steps of the shifting needle bar effect tufting pattern to create a revised shifting needle bar effect tufting pattern; merging the yarn feed effect tufting pattern into the revised, shifting needle bar effect tufting pattern and creating a combination tufting pattern; loading the combination tufting pattern into a control for the tufting machine; moving the backing material through the tufting machine and reciprocating a needle bar carrying a series of needles therealong into the backing material to form the tufts of yarn therein according to steps of the combination tufting pattern; when the combination tufting pattern calls for shifting of the needle bar, splitting the combination pattern into separate pattern steps of the underlying first and second patterns for yarn feed control and shifting, respectively; and adjusting the yarn feed to compensate for shifting in the combination tufting pattern and keep the combination tufting pattern running substantially straight. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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9. A method of forming a tufted pattern, comprising:
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drawing a yarn feed effect pattern; drawing a shifting needle bar effect pattern; applying shift compensation for pattern steps of the shifting needle bar effect pattern involving shifting of the needle bar and copying the yarn feed effect pattern into the shifting needle bar effect pattern to create a combination pattern; moving a backing material through a tufting zone of a tufting machine and reciprocating a series of yarn carrying needles into the backing material to form tufts of yarn therein according to the combination pattern; for steps of the combination pattern requiring shifting of the needle bar, running corresponding steps of the underlying needle bar effect and yarn feed effect patterns separately; and adjusting feeding of the yarns in accordance with the yarn feed effect pattern step to compensate for the shifting of the needle bar so that the combination pattern is effectively run straight. - View Dependent Claims (10, 11, 12, 13, 14, 15)
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Specification