Textured surface effect fabric

• US 5,549,064 A
• Filed: 10/24/1994
• Issued: 08/27/1996
• Est. Priority Date: 12/21/1992
• Status: Expired due to Term

• Current Assignee: Mohawk Carpet Distribution Inc (Mohawk Industries Incorporated)
• Original Assignee: Burlington Industries LLC
• Inventors: Padgett, William P. III
• Primary Examiner(s): LEWIS, PAUL
• Application Number:
  US08/328,164
• Time in Patent Office: 673 Days
• Field of Search: 112/80.7, 112/80.73, 112/266.2, 112/410, 112/80.54, 112/475.23
• US Class Current: 112/410
• CPC Class Codes: D05C 15/18 Thread feeding or tensioning arrangements
• 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

Abstract

Tufting apparatus includes servomotors driving front and back yarn feed rolls for feeding yarns to the needles of the front and back needle bars, respectively. Incremental servomotor control for each stitch enables a height differential between immediately adjacent stitches in excess of 3/32 inch (2.38 mm). By providing yarns of multiple colors and textures, a variety of patterns and textured surface effects are provided in the surface of the tufted pile fabric.

Claims

1. A tufted pile fabric comprising:

a substrate;

a plurality of yarns stitched into said substrate in warpwise stitch rows and spaced weftwise from one another forming a tufted pile on one face of said substrate;

at least one pair of immediately-adjacent tufts having a difference in height in one stitch row greater than 3/32 inch without an intermediate tuft different in height than said pair of tufts.

2. A fabric according to claim 1 wherein each tuft of said pair of immediately-adjacent tufts is formed by the same yarn of said plurality of yarns.

3. A fabric according to claim 1 wherein each tuft of said pair of immediately-adjacent tufts is formed by different ones of said yarns of said plurality of yarns.

4. A fabric according to claim 1 wherein the difference in height between a pair of immediately-adjacent tufts in the weft direction is greater than 3/32 inch.

5. A fabric according to claim 1 wherein said tufts form a loop pile fabric.

6. A fabric according to claim 1 wherein said tufts form a cut pile fabric.

7. A fabric according to claim 1 wherein said tufts comprise a combination loop and cut pile fabric.

8. A fabric according to claim 1 wherein said plurality of yarns comprises yarns of different colors.

9. A fabric according to claim 1 wherein the difference in height is sufficient to substantially obscure from view the shorter of the pair of immediately-adjacent tufts.

10. A tufted pile fabric comprising:

a substrate;

a plurality of yarns stitched into said substrate in warpwise stitch rows and spaced weftwise from one another forming a tufted pile on one face of said substrate;

a first set of plural tufts formed by one of said yarns having a height above said substrate common to one another;

a second set of plural tufts formed by said one yarn and next succeeding said first set of tufts, said second set of plural tufts having a height above said substrate common to one another and in excess of 3/32 inch difference in height relative to the height of said first set of tufts;

said first and second sets of tufts having immediately-adjacent tufts, said immediately-adjacent tufts of said first and second sets of tufts having a difference in height greater than 3/32 inch without an intervening tuft different in height than the tufts of said first and second sets thereof.

11. A tufted pile fabric comprising:

a substrate;

a plurality of yarns stitched into said substrate in warpwise stitch rows and spaced weftwise from one another forming a tufted pile on one face of said substrate;

a first set of plural tufts in one stitch row having a height above said substrate common to one another;

a second set of plural tufts in said one stitch row and next succeeding said first set of tufts, said second pair of plural tufts having a height above said substrate common to one another and in excess of 3/32 inch difference in height relative to the height of said first set of tufts, said first and second sets of tufts having immediately-adjacent tufts, said immediately-adjacent tufts of said first and second sets of tufts having a difference in height in said one stitch row greater than 3/32 inch without an intervening tuft different in height than the tufts of said first and second sets thereof.