Sewing – Special machines – Embroidering
Reexamination Certificate
1999-05-05
2001-03-20
Nerbun, Peter (Department: 3741)
Sewing
Special machines
Embroidering
Reexamination Certificate
active
06202580
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 a yarn feeding mechanism for use with such a tufting apparatus.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 4,549,496 to Kile discloses a tufting apparatus for producing patterned tufted goods using yarns of different colors. This apparatus is capable of selectively implanting yarns 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 yarn 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 and increased reliability.
SUMMARY OF THE INVENTION
This invention satisfies the foregoing need by providing an apparatus for feeding a yarn from a yarn supply to a reciprocating needle comprising a yarn pullback mechanism which is disposed intermediate a yarn feeder and a reciprocating needle and is mechanically linked to the yarn feeder. More particularly, the yarn feeding apparatus of this invention comprises a driven roller, a yarn feeder disposed for selectively moving into peripheral engagement with the driven roller, and alternatively, moving out of peripheral engagement with the driven roller, an actuator for moving the yarn feeder into and out of peripheral engagement with the driven roller so that when the yarn feeder is in peripheral engagement with the driven roller, the driven roller drives the yarn feeder and causes the yarn feeder to feed the yarn in a path from the yarn feeder to the reciprocating needle, and a yarn pullback mechanism. The yarn pullback mechanism is mechanically linked to the yarn feeder such that when the actuator moves the yarn feeder out of engagement with the driven roller, the yarn pullback mechanism lengthens the path between the yarn feeder and the reciprocating needle and draws the yarn back from the reciprocating needle, and when the actuator moves the yarn feeder into engagement with the driven roller, the yarn pullback mechanism shortens the path between the yarn feeder and the reciprocating needle.
Because the yarn feeding apparatus of the present invention includes a yarn pullback mechanism mechanically driven by a driven roller which also drives the yarn feeder, the yarn pullback mechanism does not require an independent pneumatic mechanism, such as an air solenoid, for power. The mechanical yarn pullpack apparatus of this invention can be made thinner than a pneumatic cylinder and consequently, with this invention, more yarn feed devices can be arranged in a tufting apparatus in less space. This allows spacing of the reciprocable needles of the tufting apparatus more closely together and increases the throughput of the tufting apparatus. Also, because the yarn pullback mechanism of this invention is mechanically linked to the yarn feed drive roller, the tufting apparatus of this invention tufts more accurately than a tufting apparatus having a pneumatically driven yarn pullback mechanism. In addition, because the yarn pullback mechanism of this invention is not pneumatic, the overall air supply requirements for the tufting apparatus is less than that for a tufting apparatus with a pneumatically driven yarn pullback apparatus.
Desirably, the yarn pullback mechanism comprises a yarn pullback member having a passageway through which the yarn passes. More particularly, the yarn pullback member is pivotally disposed, the yarn feeder is pivotally disposed, and the yarn pullback member and the yarn feeder are pivotally connected such that the actuator pivots the yarn feeder into and out of peripheral engagement with the driven roller, and, when the actuator pivots the yarn feeder out of engagement with the driven roller, the yarn pullback member pivots and moves the yarn passageway so as to lengthen the path between the yarn feeder and the reciprocating needle and draw the yarn back from the reciprocating needle, and when the actuator pivots the yarn feeder into engagement with the driven roller, the yarn pullback member returns the passageway so as to shorten the path between the yarn feeder and the reciprocating needle. According to a particular embodiment of this invention, the yarn pullback member comprises a leg which is pivotally disposed proximate one end and a foot extending from another end of the leg so that the yarn pullback membe
Nerbun Peter
Sutherland Asbill & Brennan
Tapistron International, Inc.
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