Tufting machine with pattern yarn feed and distribution device

• US 5,983,815 A
• Filed: 03/10/1998
• Issued: 11/16/1999
• Est. Priority Date: 03/11/1997
• Status: Expired due to Term

• Current Assignee: Card-Monroe Corporation
• Original Assignee: Card-Monroe Corporation
• Inventors: Card, Roy T.
• Primary Examiner(s): Izaguirre, Ismael
• Application Number:
  US09/038,042
• Time in Patent Office: 616 Days
• Field of Search: 112/80.23, 112/80.7, 112/80.73, 112/163, 112/302
• US Class Current: 112/80.73
• CPC Class Codes: D05C 15/18 Thread feeding or tensioning arrangements
• CPC Class Codes: D05C 15/32 by altering the loop length

Abstract

A tufting machine with an improved pattern yarn feed and distribution device for use in tufting a graphic pattern into the face of a tufted article. An improved pattern yarn feed drive is provided with at least two separate yarn drive control sections which together provide an increased number of controls such that any one control is adapted to drive a predetermined number of tufting yarns selectively passed thereabout for minimizing the length between any one of the tufting yarns and its respective tufting needle. An improved tube bank configuration is used with the pattern yarn drive assembly, and comprises at least two tube bank sections, each of which is also constructed and arranged to minimize the length of the yarns passed therethrough from a respective one of the yarn drive controls to a respective one of the tufting needles. This improved construction minimizes the problems of yarn elasticity and yarn lag when feeding the yarns to the needles of the tufting machine, thus greatly reducing the likelihood of a loss of pattern definition occurring in the graphic pattern being tufted in the face of the tufted article on the tufting machine.

Claims

1. A tufting machine with pattern yarn feed and distribution device used to produce a tufted article having a graphic pattern defined in its face, the tufting machine having an elongate frame, the frame including a base and a head supported on the frame above the base, the head and the base of the tufting machine defining a tufting zone therebetween, and a supply of tufting yarn, said tufting machine comprising:

at least one elongate needle bar extending in the lengthwise direction of the tufting machine and supported on the head of the tufting machine for reciprocating movement toward and away from the tufting zone, said at least one needle bar having a predetermined number of tufting needles mounted thereon in aligned series and extending at least partially along the length of said at least one needle bar;

a pattern yarn feed drive assembly supported on the head of the tufting machine with respect to said at least one needle bar, said yarn feed drive assembly having at least two separate yarn drive control sections, each said yarn drive control section having a plurality of yarn drive controls about which selected ones of the yarns are selectively passed, each said yarn drive control being constructed and arranged to selectively feed the selected ones of the tufting yarns to selected ones of said needles to form multiple repeats of recurring predetermined numbers of yarns in series across the tufting machine to form the desired graphic pattern in the tufted article; and

a yarn feed tube bank constructed and arranged to guide a respective one of the yarns to each said needle, respectively, said tube bank having a predetermined number of elongate yarn tubes, one each of said yarn tubes being provided for each said needle of the tufting machine;

said tube bank being comprised of at least two separate tube bank sections, each said tube bank section being constructed and arranged to guide yarns to each of the needles of each of the multiple repeats extending across the tufting machine with the lengths of the yarns passed therethrough from the respective ones of said yarn drive controls to said needles of said multiple repeats being minimized, and with at least one of said at least two tube bank sections being provided for each respective one of said at least two yarn drive control sections;

whereby each of the tufting yarns is selectively passed about a selected one of the yarn drive controls and is then passed through a respective one of the yarn tubes for being guided to a respective one of the tufting needles, and is selectively fed to its respective needle by its yarn drive control in accordance with the graphic pattern being tufted in the face of the tufted article.

2. The tufting machine of claim 1, wherein said pattern yarn feed drive assembly comprises two of said yarn drive control sections.

3. The tufting machine of claim 2, wherein said at least two separate tube bank sections comprises two separate tube bank sections, and wherein one of said two tube bank sections is provided for each said yarn drive control section.

4. The tufting machine of claim 1, wherein each of said two tube bank sections guides the yarns to one-half of said predetermined number of needles.

5. A tufting machine having a pattern yarn feed and distribution device used to produce a tufted article having a graphic pattern defined in its face, the tufting machine having an elongate frame defining a tufting zone, and a supply of tufting yarn, said tufting machine comprising:

at least one elongated needle bar extending in the lengthwise direction of the tufting machine and movable toward and away from the tufting zone, said at least one needle bar having a predetermined number of needles mounted at least partially along the length of said at least one needle bar;

a pattern yarn feed drive assembly supported on the frame of the tufting machine and a first center yarn drive control section having a first predetermined number of said yarn drive controls;

a second yarn drive control section positioned at one end of said first yarn drive control section; and

a third yarn drive control section positioned at the other one end of said first yarn drive control section and being spaced from said second yarn drive control section;

said second and said third yarn drive control sections each having a second predetermined number of said yarn drive controls which is a fractional number of said first predetermined number of yarn drive controls;

each said yarn drive control being constructed and arranged to selectively feed the yarns to selected ones of said needles; and

a yarn feed tube bank for guiding respective ones of the yarns to each said needle, respectively, said tube bank having a predetermined number of elongate yarn tubes, one of each of said yarn tubes being provided for each said needle of the tufting machine;

said tube bank being comprised of at least two separate tube bank sections, each said tube bank section being constructed and arranged to minimize the length of the yarns passed therethrough to each said needle, respectively, with at least one of said tube bank sections being provided for one of said yarn drive control sections;

whereby each of the yarns is selectively passed about a selected one of said yarn drive controls and through one of said yarn tubes for being guided to one of said needles, and each yarn is selectively fed to its needle by its selected yarn drive control in accordance with the graphic pattern being tufted in the face of the tufted article.

6. The tufting machine of claim 5, wherein said at least two separate tube bank sections comprises a first center tube bank section, a second tube bank section at one end of said first tube bank section, and a third tube bank section at the other end of said first tube bank section, each of said tube bank sections being separate of the other.

7. The tufting machine of claim 6, wherein said second and said third tube bank sections each comprises an identical number of yarn tubes, and where said first tube bank section has a greater number of yarn tubes than either of said second and said third tube bank sections.

8. The tufting machine of claim 6, wherein said second and said third tube bank sections each guides a respective one of the yarns to one each of a second predetermined number of needles mounted on said at least one needle bar at each of the opposed ends of said predetermined number of needles for tufting one of a pair of opposed selvedges extending the length of the tufted article being produced on the tufting machine.

9. The tufting machine of claim 6, wherein said second and said third tube bank sections each guides a number of yarns less than first tube bank section.

10. A tufting machine with a pattern yarn feed and distribution device used to produce a tufted article having a graphic pattern defined in its face, the tufting machine having a frame including a base and a head, the head and the base of the tufting machine defining a tufting zone therebetween, and a supply of tufting yarn, said tufting machine comprising:

at least one elongated needle bar extending transversely and supported on the head of the tufting machine for reciprocating movement toward and away from the tufting zone, said at least one needle bar having a predetermined number of needles mounted thereon;

a pattern yarn feed drive assembly supported on the head of the tufting machine and having at least two yarn drive control sections, each said yarn drive control section having a plurality of yarn drive controls about which selected ones of the yarns are received, each said yarn drive control being constructed and arranged to selectively feed the yarns to selected ones of said needles; and

a yarn feed tube bank for guiding respective ones of the yarns to each said needle, respectively, said tube bank having a predetermined number of elongate yarn tubes, one each of said yarn tubes being provided for each said needle of the tufting machine;

said tube bank being comprised of at least two separate tube bank sections, each said tube bank section being substantially identical to and in reverse hand with respect to one another and constructed and arranged to minimize the lengths of the yarns passed therethrough to each said needle, with one of said two tube bank sections being provided for each respective one of said yarn drive control sections, and

wherein said tube bank sections each guide yarns to a second predetermined number of needles mounted on said at least one needle bar at the opposed ends of said predetermined number of needles for tufting one of a pair of opposed selvedges extending the length of the tufted article being produced on the tufting machine,

whereby each of the yarns is passed about a selected one of said yarn drive controls and through said yarn tubes so as to be guided to one of said needles, with each yarn selectively fed to its respective needle by its yarn drive control in accordance with the graphic pattern being tufted in the face of the tufted article.

11. A tufting machine with pattern yarn feed and distribution device used to produce a tufted article having a graphic pattern defined in its face, the tufting machine having an elongate frame, including a base and a head defining a tufting zone therebetween, and a supply of yarn, said tufting machine comprising:

at least one elongated needle bar extending transversely across the tufting machine and supported on the head of the tufting machine for reciprocating movement toward and away from the tufting zone, said at least one needle bar having a predetermined number of needles mounted thereon;

a pattern yarn feed drive assembly supported on the head of the tufting machine and having at least two separate yarn drive control sections, each said yarn drive control section having a plurality of yarn drive controls about which selected ones of the yarns are passed, each said yarn drive control being constructed and arranged to selectively feed the yarns to selected ones of said needles; and

a yarn feed tube bank constructed and arranged to guide the yarns to said needles, said tube bank having a predetermined number of elongated yarn tubes, one each of said yarn tubes being provided for each said needle of the tufting machine;

said tube bank being comprised of at least two separate tube bank sections, each of said tube bank sections comprising a separate scrambled tube bank and being constructed and arranged to minimize the length of the yarns passed therethrough from the respective ones of said yarn drive controls to each said needle, with one of said tube bank sections being provided for each one of said at least two yarn drive control sections;

whereby each of the yarns is passed about a selected one of said yarn drive controls and through a respective one of said yarn tubes so as to be guided to one of said needles, so that each yarn is selectively fed to its respective needle by its yarn drive control in accordance with the graphic pattern being tufted in the face of the tufted article.

12. A tufting machine having a pattern yarn feed and distribution device for producing a tufted article having a graphic pattern defined in its face, the tufting machine having an frame including a base and a head defining a tufting zone therebetween, at least one elongated needle bar extending transversely and movable toward and away from the tufting zone, and having a predetermined number of tufting needles mounted thereon, and a supply of tufting yarn, said tufting machine comprising:

a pattern yarn feed drive assembly supported on the head of the tufting machine with respect to the at least one needle bar, said yarn feed drive assembly having a first yarn drive control section and a separate second yarn drive control section, each said yarn drive control section having a plurality of yarn drive controls about which selected yarns are passed, each said yarn drive control being constructed and arranged to feed the selected ones of the tufting yarns to selected ones of said needles to form multiple repeats of recurring predetermined numbers of yarns in series across the tufting machine for forming the desired graphic pattern; and

a yarn feed tube bank for guiding a respective one of the yarns to each needle, respectively, said tube bank having a predetermined number of elongated yarn tubes, one each of said yarn tubes being provided for each one of the needles of the tufting machine;

wherein said tube bank comprises a first tube bank section for guiding the yarns fed by said first yarn drive control section and a separate second tube bank section for guiding the yarns fed by said second yarn drive control section, each said tube bank section being constructed and arranged to guide the yarns to each needle of the multiple repeats extending across the tufting machine with the lengths of the yarns passed therethrough from the respective ones of said yarn drive controls to each needle, respectively, being minimized.

13. The tufting machine of claim 12, wherein said first and said second tube bank sections are identical to and in reverse hand with respect to one another, each said tube bank section having an identical number of said yarn tubes.

14. The tufting machine of claim 12, wherein said first and said second tube bank sections each guides yarns to one-half of said predetermined number of needles.

15. A tufting machine with an improved pattern yarn feed and distribution device used to produce a tufted article having a graphic pattern defined in its face, the tufting machine having an elongate frame, the frame including a base and a head supported on the frame above the base, the head and the base of the tufting machine defining a tufting zone therebetween, at least one elongate needle bar extending in the lengthwise direction of the tufting machine and supported on the head of the tufting machine for reciprocating movement toward and away from the tufting zone, a predetermined number of tufting needles mounted on the at least one needle bar in aligned series and extending at least partially along the length thereof, and a supply of tufting yarn, said tufting machine comprising:

a pattern yarn feed drive assembly supported on the head of the tufting machine with respect to the at least one needle bar, said yarn feed drive assembly including;

i) a plurality of yarn drive controls;

ii) a first center yarn drive control section having a first predetermined number of said yarn drive controls;

iii) a second yarn drive control section positioned at one end of said first yarn drive control section;

iv) a third yarn drive control section positioned at the other one end of said first yarn drive control section and being spaced from said second yarn drive control section;

wherein selected ones of the yarns are selectively passed about said yarn drive controls, each said yarn drive control being constructed and arranged to selectively feed the selected ones of the tufting yarns to selected ones of said needles; and

a yarn feed tube bank for guiding a respective one of the yarns to each needle, respectively, said tube bank having a predetermined number of elongate yarn tubes, one each of said yarn tubes being provided for each one of the needles of the tufting machine, said tube bank comprising at least two separate tube bank sections, each of said at least two tube bank sections being constructed separately of the other and also being constructed and arranged to minimize the length of the yarns passed therethrough from respective ones of said yarn drive controls to the needles of the tufting machine.

16. The tufting machine of claim 15, wherein said at least two tube bank sections comprises a first center tube bank section, a second tube bank section at one end of said first tube bank section, and a third tube bank section at the other end of said first tube bank section.

17. The tufting machine of claim 16, wherein said first center tube bank section is constructed and arranged to guide the yarns fed by said first yarn drive control section to the needles of the tufting machine, said second tube bank section is constructed and arranged to guide at least some the yarns of said first yarn drive control section and all of the yarns fed by said second yarn drive control section to the needles of the tufting machine, and said third tube bank section is constructed and arranged to guide at least some the yarns of said first yarn drive control section and all of the yarns fed by said third yarn drive control section to the needles of the tufting machine.

18. The tufting machine of claim 15, wherein said second and said third yarn drive control sections each has a second predetermined number of yarn drive controls which is a fractional number of said first predetermined number of said yarn drive controls.