Sewing – Special machines – Embroidering
Reexamination Certificate
2000-02-11
2001-09-25
Nerbun, Peter (Department: 3741)
Sewing
Special machines
Embroidering
C112S080230, C112S080300, C112S475230
Reexamination Certificate
active
06293211
ABSTRACT:
TECHNICAL FIELD
This invention relates generally to tufting apparatus for producing patterned textile goods such as carpet, upholstery, and the like, and more particularly to tufting apparatus for producing tufted goods having a multicolor pattern by selectively feeding different yarns to a row of reciprocating hollow needles which implant the yarns into a transversely shifting backing material. More particularly, this invention relates to such a tufting apparatus which can produce tufted goods with a variety of yarn color patterns and cut/loop patterns, tufted goods with patterns of differing pile heights, and tufted goods having tight or loose tufts.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 4,549,496 to Kile discloses a tufting apparatus for producing patterned tufted goods using yams of different colors. This apparatus is capable of selectively implanting yams of different colors into a backing to produce a tufted product having a predetermined multicolored pattern. The patent apparatus employs multiple heads spaced across the width of a backing material. Each head comprises a hollow needle for penetrating the backing and implanting yarn tufts in the backing by reciprocating the head and feeding yarn through the needle pneumatically. This device uses a system of gears and rollers to select the desired yarn for implantation into the backing for each penetration by the needle. The multiple heads are stepped in synchronism across the backing for a distance corresponding to the spacing between the heads in order to implant a transverse row of yam tufts. This process is repeated as the backing is advanced to complete the product. A computer controls the selection of yarn implanted by each needle for each penetration of the backing in order to reproduce the desired pattern in the finished goods.
The apparatus disclosed in the Kile patent and its method of operation have been subsequently modified. Such modifications are disclosed in U.S. Pat. Nos. 4,991,523; 5,080,028; 5,165,352; 5,158,027; 5,205,233; and 5,267,520, all to Ingram., and U.S. Pat. No. 5,588,383 to Davis et al. These subsequent patents disclose an apparatus in which the backing is shifted transversely relative to the reciprocating needles while the backing advances through the apparatus. Thus, rather than the multiple heads which carry the hollow needles being moved across the backing, the subsequent patents disclose an apparatus wherein the backing rather than the heads is shifted transversely. In addition, the device disclosed in the Ingram patents comprises a plurality of hollow needles carried on a widthwise extending member. As the yarn is implanted by the reciprocating needles, the backing is shifted in the transverse direction by an amount corresponding to the spacing between adjacent needles in order to implant a transverse row of tufts. A knife blade is associated with each needle and positioned on the opposite of the backing for cutting the yarn at the lower position of the needle.
The apparatus disclosed in the Ingram patents further includes a mechanism for supplying continuous lengths of the different yarns to the needles comprising a system of gears. More specifically, this yarn supply mechanism includes a main rotatable gear shaft tied to and driven by the main drive shaft that reciprocates the needles. A plurality of small gears extending along the length of the main gear shaft are selectively engagable with the main gear shaft to feed the desired yarns to the needles. The individual gears for feeding the yarns are selectively shifted in and out of meshing cooperation with the main gear shaft by air solenoids. Once the yarn is fed by the gear system, the yarn is drawn to and out of the needle by pressurized air from a manifold mounted to the reciprocating needle mounting bar.
U.S. Pat. No. 5,080,028 discloses a mechanical system for retracting yarns from the needles when other yarns are desired to be implanted. The retraction mechanism includes a reciprocating plunger disposed between two yarn guides. The reciprocating plunger pulls the yarn to be retracted out of the needle and an independent pneumatic mechanism, such as an air solenoid, drives the reciprocating plunger. The reciprocating plunger operates in unison with the pneumatic mechanism which feeds the yarn to the needles.
Although the tufting apparatus disclosed in the Kile and Ingram patents performs well, there is a need for a tufting apparatus for producing patterned textile goods with increased throughput, increased reliability, and greater pattern variety.
SUMMARY OF THE INVENTION
This invention satisfies the foregoing need by providing a system for producing patterned tufted goods comprising independent control systems for a yarn supplier and a yarn cutting system. This allows for yarn color patterns and cut/loop patterns to be stored and implemented independently so that different colored yarn patterns can be used with different cut/loop patterns. More particularly, the apparatus of this invention comprises a tufting frame, a backing transport system mounted to the frame for advancing of backing in a direction past a yarn applying region, a yarn applicator disposed at the yarn applying region, a yarn supplier for supplying a plurality of continuous lengths of different yarns to the yarn applicator, a yarn cutting system for selectively cutting the yarn implanted in the backing, a first control system for controlling the yarn supplier, and a second control system independent of the first control system for controlling the yarn cutting system. The yarn applicator penetrates the backing and implants 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 first control system for controlling the yarn supplier does so in accordance with a color pattern so as to select which of the continuous lengths of yarn, if any, is implanted in the backing at each penetration of the yarn applicator. The second control system for controlling the yarn cutting system does so 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 the tufted good has both cut tufts and loop tufts.
Desirably, the first control system for controlling the yarn supplier comprises a first programmable computer and the second control system for controlling the yarn cutting system comprises a second programmable computer independently programmable from the first computer. Although the first and second control systems are independently programmable, their operation is synchronized so that the yarn applicator and yarn cutting system are synchronized.
The yarn applicator desirably comprises a plurality of hollow tufting needles and the yarn cutting system desirably 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.
According to another aspect of the present invention, a method for producing patterned tufted carpet is provided comprising advancing the backing in a direction past the yarn applying region, supplying a plurality of continuous lengths of different yarns to a yarn applicator, penetrating the backing with a reciprocating yarn applicator, controlling the supplying of the yarn in accordance with a color pattern, and selectively cutting with a yarn cutter. The yarn is implanted in the backing at each penetration by engaging the yarn cutter with the yarn applicator before the yarn applicator begins an upstroke. The reciprocating yarn applicator implants yarn in the backing successively along a row during movement of the backing to form a plurality of yarn tufts in the backing and the yarn is supplied in accordance with a color pattern so as to select which of the continuous lengths of yarn, if any, is implanted in the backing at each penetration. By engaging the yarn cutter with the yarn applicator before the yarn applicator
Nerbun Peter
Sutherland & Asbill & Brennan LLP
Tapistron International, Inc.
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