Method and apparatus for producing patterned tufted goods

• US 6,293,211 B1
• Filed: 02/11/2000
• Issued: 09/25/2001
• Est. Priority Date: 05/05/1999
• Status: Expired due to Term

• Current Assignee: CYP Technologies, LLC
• Original Assignee: Tapistron International, Inc.
• Inventors: Samilo, John S.
• Primary Examiner(s): NERBUN, PETER P
• Application Number:
  US09/502,914
• Time in Patent Office: 592 Days
• Field of Search: 112/80.16, 112/80.23, 112/80.3, 112/80.31, 112/80.32, 112/80.42, 112/80.54, 112/80.55, 112/80.56, 112/80.57, 112/80.58, 112/80.59, 112/80.6, 112/80.72, 112/80.73, 112/80.05, 112/80.08, 112/475.23
• US Class Current: 112/80.16
• CPC Class Codes: D05C 15/18 Thread feeding or tensioning arrangements
• CPC Class Codes: D05C 15/24 Loop cutters; Driving mechanisms therefor
• CPC Class Codes: D05C 15/26 with provision for producing patterns
• CPC Class Codes: D05C 15/32 by altering the loop length
• CPC Class Codes: D05C 15/34 by inserting loops of different nature or colour
• CPC Class Codes: D05C 15/36 by selective cutting of loops

Abstract

Apparatus for producing pattern tufted goods, such as pattern tufted carpet, produces cut and loop pattern carpet using independent yarn colored pattern and cutting pattern process controllers, colored pattern carpet having differential pile heights, and colored pattern carpet with tight or loose tufts. In addition, an apparatus for making color patterned tufted carpet has a yarn cutting system which more reliably cuts yarn when cut tufts are desired.

Claims

1. Apparatus for producing patterned tufted goods comprising:

a tufting frame;

a backing transport system mounted to the frame for advancing a backing in a direction past a yarn applying region;

a yarn applicator disposed at the yarn applying region and mounted to the frame for penetrating the backing and implanting the yarn in the backing successively along a row during movement of the backing to form a plurality of yam tufts in the backing;

a yarn supplier for supplying a plurality of continuous lengths of different yarns to the yarn applicator,

a yarn cutter for selectively cutting the yarn implanted in the backing;

a first control system for controlling the yarn supplier in accordance with a color pattern so as to select which of the continuous lengths of yarns, if any, is implanted in the backing at each penetration; and

a second control system independent of the first control system for controlling the yarn cutter in accordance with a cut/loop pattern so as to selectively cut the yarn implanted in the backing to form a cut tuft or alternatively form a loop tuft, so that a tufted good has both cut tufts and loop tufts.

2. Apparatus as in claim 1 wherein the first control system comprises a first programmable computer and the second control system comprises a second programmable computer independently programmable from the first computer.

3. Apparatus as in claim 1 wherein the yarn applicator comprises a plurality of hollow tufting needles and the yarn cutting system comprises a plurality of cutting elements for selectively engaging respective hollow tufting needles so as to cut the yarn in response to a signal from the second control system as the hollow tufting needles implant the yarn in the backing.

4. Apparatus as in claim 1 wherein the first control system is synchronized with the second control system.

5. Apparatus as in claim 1 further comprising a motion controller for controlling the motion of the yarn applicator and the backing transport system.

6. Apparatus as in claim 1 wherein the backing transport system moves the backing transversely to the direction of advancement of the backing such that the yarn is implanted in the backing successively along a transverse row during transverse movement of the backing to form the plurality of yarn tufts.

9. Method as in claim 1 wherein the yarn applicator comprises a plurality of hollow tufting needles, the yarn cutting system comprises a plurality of cutting elements, the step of controlling the cutting of the yarn comprises sending a signal to the yarn cutting system, and the cutting step comprises selectively engaging the cutting elements with respective hollow tufting needles in response to the signal as the hollow tufting needles implant the yarn in the backing so as to cut the yarn.

7. Method for producing patterned tufted goods comprising:

advancing a backing in a direction past a yarn applying region and moving the backing transversely to the direction of advancement of the backing;

supplying a plurality of continuous lengths of different yarns to a yarn applicator,

penetrating the backing with the yarn applicator and implanting a yarn therein successively along a transverse row during transverse movement of the backing to form a plurality of yarn tufts in the backing;

selectively cutting the yarn implanted in the backing at each penetration;

controlling the supplying of the yarn in accordance with a color pattern so as to select which of the continuous lengths of yarns, if any, is implanted in the backing at each penetration; and

independently of controlling the yarn supplier, controlling the cutting of the yarn in accordance with a cut/loop pattern so as to select whether the yarn implanted in the backing at each penetration forms a loop tuft or is cut and forms a cut tuft.

8. Method as in claim 7 wherein a first programmable computer controls the supplying of the yarn and a second programmable computer independently programmable from the first computer controls the cutting of the yarn.

10. Method as in claim 7 wherein the step of controlling the yarn applicator is synchronized with the step of controlling the yarn cutting.

11. Method as in claim 7 further comprising controlling the motion of the yarn applicator and the backing transport system with a motion controller.

12. Method as in claim 7 wherein the step of advancing the backing includes moving the backing transversely to the direction of advancement of the backing such that the yarn is implanted in the backing successively along a transverse row during transverse movement of the backing to form the plurality of yarn tufts.

13. Method for producing patterned tufted goods comprising:

advancing a backing in a direction past a yarn applying region;

supplying a plurality of continuous lengths of different yarns to a yarn applicator,

penetrating the backing with a reciprocating yarn applicator and implanting a yarn in the backing successively along a row during movement of the backing to form a plurality of yarn tufts in the backing;

controlling the supplying of yarn in accordance with a color pattern so as to select which of the continuous lengths of yarns, if any, is implanted in the backing at each penetration; and

selectively cutting with a yarn cutter the yarn implanted in the backing at each penetration by engaging the yarn cutter with the yarn applicator before the yarn applicator begins an upstroke.

14. Method as in claim 13 wherein the penetrating step includes reciprocating the yarn applicator between a top position and a bottom position such that each stroke of the yarn applicator includes a downstroke from the top position to the bottom position and an upstroke from the bottom position to the top position, and the cutting step includes engaging the yarn cutter with the yarn applicator during a stroke of the yarn applicator after the yarn applicator penetrates the backing and before the yarn applicator begins an upstroke.

15. Method as in claim 14 wherein the cutting step includes engaging the yarn cutter with the yarn applicator during a stroke of the yarn applicator as the yarn applicator reaches the bottom position on the downstroke of the yarn applicator cycle.

16. Method as in claim 14 further comprising generating a timing signal during the yarn applicator cycle and controlling the yarn cutter so that the yarn cutter engages the yarn applicator in response to the timing signal.

17. Method as in claim 14 wherein the timing signal is generated when the yarn applicator reaches the top position on the upstroke.

18. Method as in claim 13 wherein the yarn applicator comprises a plurality of hollow tufting needles, the yarn cutter comprises a plurality of corresponding cutting elements, and the cutting step comprises selectively engaging the cutting elements with respective hollow tufting needles.

19. Method as in claim 18 wherein the cutting step includes selectively reciprocating the cutting elements into engagement with the hollow tufting needles.

20. Method as in claim 16 wherein the cutting step includes selectively reciprocating the yarn cutter into engagement with the yarn applicator so that, in response to the timing signal, the yarn cutter moves toward the yarn applicator as the yarn applicator is on the downstroke.

21. Method as in claim 20 wherein the cutting step includes reciprocating the yarn cutter between a bottom position and a top position such that each stroke of the yarn cutter includes an upstroke from the bottom position to the top position and a downstroke from the top position to the bottom position, the timing signal is generated when the yarn applicator reaches the top position on the upstroke, and the cutting step includes engaging the yarn cutter with the yarn applicator in response to the timing signal during a stroke of the yarn applicator as the yarn applicator reaches the bottom position on the downstroke of the yarn applicator cycle and the yarn cutter reaches the top position of the yarn cutter stroke.

22. Method as in claim 13 wherein the step of advancing the backing includes moving the backing transversely to the direction of advancement of the backing such that the yarn is implanted in the backing successively along a transverse row during transverse movement of the backing to form the plurality of yarn tufts.

23. Apparatus for producing patterned tufted goods having differing pile heights comprising:

a tufting frame;

a backing transport system mounted to the frame for advancing a backing in a direction past a yarn applying region;

a yarn applicator disposed at the yarn applying region and mounted to the frame for penetrating the backing and implanting a yarn therein successively along a row during movement of the backing to form a plurality of yarn tufts in the backing;

a first yarn supplier for supplying a continuous length of at least one yarn to the yarn applicator at a first linear rate so that tufts formed by yarn supplied by the first yarn supplier has a first pile height; and

a second yarn supplier for supplying a continuous length of at least one yarn to the yarn applicator at a second linear rate different then the first linear rate so that tufts formed by yarn supplied by the second yarn supplier has a second pile height different than the first pile height.

24. Apparatus as in claim 23 wherein the first yarn supplier supplies a plurality of continuous lengths of different yarns to the yarn applicator and the second yarn supplier supplies a plurality of continuous lengths of different yarns to the yarn applicator.

25. Apparatus as in claim 23 further comprising a control system for controlling the first and second yarn suppliers in accordance with a color pattern so as to select which of the continuous lengths of yarns, if any, is implanted in the backing at each penetration.

26. Apparatus as in claim 23 wherein the first yarn supplier is disposed along one side of the tufting frame and the second yarn supplier is disposed along an opposite side of the tufting frame.

27. Apparatus as in claim 23 wherein the yarn applicator comprises a plurality of hollow tufting needles.

28. Apparatus as in claim 23 wherein the first yarn supplier comprises a first geared drive shaft and a first motor capable of rotating the first geared drive shaft at a first speed and the second yarn supplier comprises a second geared drive shaft and a second motor capable of rotating the second geared drive shaft at a second speed different from the first speed.

29. Apparatus as in claim 23 wherein the backing transport system moves the backing transversely to the direction of advancement of the backing such that the yarn is implanted in the backing successively along a transverse row during transverse movement of the backing to form the plurality of yarn tufts.

30. Apparatus as in claim 23 further comprising a yarn cutter for selectively cutting the yarn implanted in the backing at each penetration.

31. Method for producing patterned tufted goods having differing pile heights comprising:

advancing a backing in a direction past a yarn applying region;

penetrating the backing with a reciprocating yarn applicator and implanting a yarn in the backing successively along a row during movement of the backing to form a plurality of yarn tufts in the backing;

supplying a continuous length of at least one yarn with a first yarn supplier to the yarn applicator at a first linear rate so that tufts formed by yarn supplied by the first yarn supplier has a first pile height; and

supplying a continuous length of at least one yarn with a second yarn supplier to the yarn applicator at a second linear rate different then the first linear rate so that tufts formed by yarn supplied by the second yarn supplier has a second pile height different than the first pile height.

32. Method as in claim 31 wherein the first yarn supplier supplies a plurality of continuous lengths of different yarns to the yarn applicator and the second yarn supplier supplies a plurality of continuous lengths of different yarns to the yarn applicator.

33. Method as in claim 31 further comprising controlling the first and second yarn suppliers in accordance with a color pattern so as to select which of the continuous lengths of yarns, if any, is implanted in the backing at each penetration.

34. Method as in claim 31 wherein the yarn applicator comprises a plurality of hollow tufting needles.

35. Method as in claim 31 wherein the first yarn supplier comprises a first geared drive shaft, the second yarn supplier comprises a second geared drive shaft, the step of supplying yarn with the first yarn supplier includes rotating the first geared drive shaft at a first speed, and the step of supplying yarn with the second yarn supplier includes rotating the second geared drive shaft at a second speed different from the first speed.

36. Method as in claim 31 wherein the step of advancing the backing includes moving the backing transversely to the direction of advancement of the backing such that the yarn is implanted in the backing successively along a transverse row during transverse movement of the backing to form the plurality of yarn tufts.

37. Method as in claim 31 further comprising the step of selectively cutting the yarn implanted in the backing at each penetration.

38. Method for producing tufted goods comprising:

advancing a backing in a direction past a yarn applying region;

supplying a continuous length of yarn to a yarn applicator; and

reciprocating a yarn applicator, which comprises a plurality of hollow tufting needles, between a top position above the backing and a bottom position below the backing such that the hollow tufting needles penetrate the backing and implant the yarn in the backing successively along a row during movement of the backing to form a plurality of yarn tufts in the backing, the hollow tufting needles traveling a displacement distance on each stroke from the backing to the bottom position and back to the backing when forming a tuft,

wherein a length of the yarn is supplied on each stroke of the yarn applicator, the length of yarn being different than the displacement distance.

39. Method as in claim 38 wherein the step of supplying the yarn includes supplying a plurality of continuous lengths of different yarns to the yarn applicator, and the method further comprises controlling the supplying of the yarn in accordance with a color pattern so as to select which of the continuous lengths of yarns, if any, is implanted in the backing at each penetration so as to form a patterned tufted product.

40. Method as in claim 39 wherein the step of advancing the backing includes moving the backing transversely to the direction of advancement of the backing such that the yarn is implanted in the backing successively along a transverse row during transverse movement of the backing to form the plurality of yarn tufts.

41. Method as in claim 38 further comprising the step of selectively cutting the yarn implanted in the backing at each penetration.

42. Method as in claim 38 wherein the length of the yarn supplied on each stroke of the yarn applicator is less than the displacement distance so that the tufts are tight.

43. Method as in claim 38 wherein the length of the yarn supplied on each stroke of the yarn applicator is greater than the displacement distance so that the tufts are loose.