System and method for forming tufted patterns

• US 7,634,326 B2
• Filed: 09/12/2006
• Issued: 12/15/2009
• Est. Priority Date: 05/23/2006
• Status: Active Grant

• Current Assignee: Card-Monroe Corporation
• Original Assignee: Card-Monroe Corporation
• Inventors: Christman, William M. Jr., Hall, Wilton
• Primary Examiner(s): Welch; Gary L
• Assistant Examiner(s): Durham; Nathan E
• Application Number:
  US11/531,029
• Publication Number:
  US 20070272137A1
• Time in Patent Office: 1,190 Days
• Field of Search: 700/130, 700/131, 700/136, 700/138, 112/80.01, 112/470.01, 112/470.06, 112/475.18, 112/475.19, 112/475.23
• US Class Current: 700/131
• CPC Class Codes: D05C 15/26 with provision for producing patterns

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.

Claims

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.

2. The method of claim 1 and wherein creating the yarn feed effect tufting pattern comprises creating a roll or scroll pattern.

3. The method of claim 1 and wherein creating a shifting needle bar effect tufting pattern comprises creating a graphics type pattern.

4. The method of claim 1 and wherein adjusting the yarn feed to compensate for shifting comprises internally shifting the pattern yarn feed opposite the movement of the shifting of the needle bar.

5. The method of claim 1 and wherein creating the yarn feed effect pattern comprises creating a level cut loop pattern.

6. The method of claim 5 and further comprising setting the level-cut-loop pattern to run straight during shifting.

7. The method of claim 1 and further comprising adding yarn feed shift compensation for varying pile heights of the tufts during shifting of the needle bar.

8. The method of claim 1 and further comprising copying the revised shifting needle bar effect pattern to create pattern repeats for the revised shifting needle bar effect pattern.

9. A method of forming a tufted pattern, comprising:

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.

10. The method of claim 9 and wherein creating the yarn feed effect tufting pattern comprises creating a roll or scroll pattern.

11. The method of claim 9 and wherein creating a shifting needle bar effect tufting pattern comprises creating a graphics type pattern.

12. The method of claim 9 and wherein adjusting the yarn feed to compensate for shifting comprises internally shifting the yarn feed required by the underlying yarn feed effect pattern step opposite the movement of the shifting of the needle bar.

13. The method of claim 9 and further comprising controlling a level cut loop looper assembly of the tufting machine to run straight during shifting of the needle bar.

14. The method of claim 9 and further comprising controlling the operation of a level cut loop looper assembly to shift in accordance with the shifting of the needle bar.

15. The method of claim 9 and further comprising adding yarn feed shift compensation for varying pile heights of the tufts during shifting of the needle bar.