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Re. 27,165

TUF'TING APPARATUS FOR. THE MANUFACTURE OF CARPETS. BUGS. AND THE LIKE

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Re. 27,165 _

18 Sheets-Sheet 12

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A. N. SPANEL EI'AL TUFTING APPARATUS FOR THE MANUFACTURE OF

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CARPETS, RUGS, AND THE LIKE Original Filed Oct. 23, 1965

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CARPETS, :RUGS, AND THE LIKE Original Filed Oct. 25. vi965 ' ‘v18 Sheets-Sheet 18

Re. 27,165

United States Patent Office

Reissued Aug, 10,1971

1

2 bits, the yarn-bits are centered, as by reciprocable pneu matic stops before movement of the needles from loading

27,165

TUFTING APPARATUS FOR THE MANUFACTURE OF CARPETS, RUGS, AND THE LIKE

position and a shutter valve normally sealing a vacuum

Abram N. Spanel, 344 Stockton St., Princeton, NJ. 08540, and Loy E. Barton, Bradenton, Fla.; said Barton assignor to said Spanel Original No. 3,387,577, dated June 11, 1968, Ser. No. 503,342, Oct. 23, 1965. Application for reissue Sept. 17, 1969, Ser. No. 866,416

their loading position, through the backing layer, and

manifold for the discharge ends of the transfer tubes is retracted to permit passage of the loaded needles from

then back to loading position. In another arrangement using needles for applying the yarn-bits, the eye ends of the empty needles pass through the backing layer to the Int. Cl. D05c 15/16 US. Cl. 112-79 38 Claims 10 bit-loading position, and after loading are returned through the backing layer for transfer of the bits thereto. Matter enclosed in heavy brackets [] appears in the The invention further resides in a tufting machine hav original patent but forms no part of this reissue speci? ing features of construction, combination and arrange cation; matter printed in italics indicates the additions ment hereinafter described and claimed. made by reissue. 15

ABSTRACT OF THE DISCLOSURE Yarn bits are cut from yarn strands and pneumatically

transported [by suction] to bit-loading stations where

For a more detailed understanding of the invention,

reference is made to the following description of preferred methods and apparatus and to the accompanying drawings in which:

.

FIG. 1 is a ?ow diagram illustrating the yarn and

backing-layer paths and identifying components of the they are positioned by stop means for transfer to a backing 20 preferred apparatus; layer by bit-applying elements as provided by needles, FIGS. 1A and 1B are explanatory ?gures referred to narrow blunt-edged blades, or a single [wide] blunt-edged in discussion of the tufting operation; blade. FIG. 2 schematically and in perspective illustrates the 25 yarn-feed capstan of FIG. 1 and associated drive This invention relates to mechanisms and methods for mechanism; manufacturing carpets, rugs, pile textiles and the like by FIG. 3 schematically and in perspective illustrates one application of yarn-bits to a backing layer in location and of the Presser-feet of FIG. 1 and its drive mechanism; FIG. 4 schematically and in perspective illustrates the color to reproduce any desired pattern. In accordance with the present invention, the bit 30 yarn cut-0d knife of FIG. 1 and associated drive applying elements of a tufting machine (speci?cally the mechanism; FIG. 5 schematically and in perspective illustrates a needles, for example), are supplied in each cycle of the yarn-bit magazine of FIG. 1 and mechanism for effecting machine with yarn-bits of color and position, to reproduce its linear motion; the corresponding line of a desired pattern by a pneu FIG. 6 schematically and in perspective illustrates the matic transmission arranged speci?cally comprising at 35 magazine of FIG. 5 and mechanism for effecting its lateral least one pair of associated guide and magazine structures. Each magazine structure has an array of passages respec

tively forming part of a path for pneumatic transmission

motion; FIG. 7 schematically and in perspective illustrates a

suction control valve of FIG. 1 and its operating of a yarn-bit to a corresponding needle or other bit-apply ing element. Each guide structure or means for receiving 40 mechanism; FIG. 8 schematically and in perspective illustrates a the ends of yarn strands has an array of similarly spaced bit-centering stop of FIG. 1 and its operating mechanism; passages for threading, in a repeated color sequence, with

FIG. 9 schematically and in perspective illustrates the the yarn strands; the number of colors in each sequence shutter-valve of FIG. 1 and its operating mechanism; should be not less than, and is preferably equal to, the FIG. 10 schematically and in perspective illustrates the total number of colors required by all lines of the pattern. 45 needle-bar of FIG. 1 and its operating mechanism; The number of yarn passages, per guide structure, should FIG. 11 schematically and in perspective illustrates a preferably exceed the number of needles to be supplied pin roll of FIG. 1 and its driving mechanism; therefrom to accommodate an additional color sequence FIGS. 12A and 12B jointly provide a front elevational of yarn strands. During a cycle of the machine as used for two or more 50 view of a tufting machine incorporating mechanisms schematically shown in FIGS. 1 to 11 with parts omitted color operation, each passage of the magazine effectively for clarity of illustration; scans, step-by-step, a complete color sequence of the ' FIG. 13 is a side elevational view of FIG. 12A as guide-structure passages. For each step position of the viewed from the left; scan, the magazine passages are each in alignment with a guide-passage corresponding with that step position and 55 FIG. 14 is a rear elevational view of mechanism shown independent feed-means for the yarn strands are selec in FIG. 13;

tively controllable in accordance with patern require

FIG. 15 is a side elevational view of FIG. 12B as viewed

ments so that one or more or none of the magazine pas

from the right;

sages receive a yarn end fed from the ten aligned guide passage. In the interval between successive scan steps and

in FIG. 15;

after the time for operation of the feed-means, all yarn

FIG. 16 is a rear elevational view of mechanism shown I

FIG. 17 is a detail view, on enlarged scale, of the strands then extending between the guide and magazine Presser-foot mechanism and some associated components; FIGS. 18A and 18B are detail views, on enlarged scale, structures are severed, as by timed knife means, so to leave yarn-bits of‘ selected color in predetermined pas 65 of the drives of the needle-manifold valve, the bit stops and the shutter-valve of the needle manifold; sages of the magazine. FIGS. 19 and 20 are front and side elevational views, During the machine-cycle, the yarn bits are, transferred on enlarged scale, of part of a bank of control solenoids from the magazine by pneumatic means applied to hit transfer tubes, each having a receiving end aligned with for the yarn-feed mechanisms; FIGS. 21A-21D are explanatory charts referred to in a magazine passage and a discharge end adjacent the bit discussion of various modes of operation of machines loading position of the corresponding bit-applying ele ment. In one arrangement using needles for applying the embodying the invention;

' 27,165

FIGS. 22A-22D illustrate the construction and steps of operation of a modi?ed needle-loading and bit-applying

Assuming that a command signal has been given to

FIGS. 24 and 25 respectively illustrate, in front eleva tion, multi-blade and uni-blade constructions suited for the bit»applying arrangement of FIGS. 23A, 23B. Referring to FIGS. 1 and 3, the magazine 10‘ has a longitudinal row of spaced chambers 11 each with its discharge end in alignment with the receiving end of a

to the corresponding needle by suction applied to its transfer tube 12 via the manifold 21. The timing of the bit-transfer suction is controlled by valve 22. The yarn-bit B as propelled from the delivery end of tube 12‘ into the then aligned eyes of the forked needle (FIG. 1A) is pref erably centered by a reciprocable stop 23. After delivery of a yam-bit to needle 13, the shutter 24, which seals off the needle passages in the bottom of manifold 21, is

supply a bit-length of yarn from a particular spool 12 to arrangement; ' the magazine chamber 11 for a particular needle, such FIGS. 23A and 23B schematically illustrate, in side bit-length is cut upon conclusion of the aforesaid feed elevation, the construction and steps of operation of an~ 5 ing operation by a timed movement of the knife 1'5. The other loading and bit-applying arrangement; and yarn-bit so cut off and left in the magazine is transferred

bit-transfer tube 12, serving as a pneumatic communica tion means. The discharge end of each of tubes 12 is ad jacent the path of a corresponding one of the forked tutt 15 retracted so to permit unobstructed movement of the

ing needles 13 carried by a reciprocable needle-bar 14.

While'each needle is at rest at the top of its stroke,'a yarn bit B is pneumatically delivered to it from the corre

sponding transfer tube 12 and centered (FIG. 1A). The suction system hereinafter described in detail is illustra tive of one form of pneumatic means for producing a dif ferential of pressure for transport of the yarn-bits, it be ing understood that other forms of pneumatic means may be utilized. During the subsequent down-stroke of the needles, the ends of the yarn-bits in them are pushed 25

through the backing layer L (FIG. IE) to project from the lower face of the layer. In other words, during the subsequent down-stroke of the needles, the centered bits

in the double or forked needles are pushed through the

needle ?rst through the backing layer L and then back to its original position. Although it is possible to use a single magazine for all needles, it is desirable principally for economy of space

to use two or more magazines. In the particular tufting

machine herein illustrated and described, two magazines 10 and 10A are used. The transfer tubes 12 from the upper magazine 10 extend from its chambers 11 to say the odd-numbered tufting needles and the transfer tubes 12A from the chambers of the lower magazine 110A ex tend to the even-numbered tufting needles. Both sets of transfer tubes connect to the common suction manifold

21, each adjacent its corresponding tufting needle. The yarn-feeding and cutting mechanisms associated with the

backing layer L (FIG. 1B) to form initially a vertical U 30 lower magazine are the same as for the upper magazine which is held by a portion of the backing layer straddled and are identi?ed by the same reference characters plus by the forked needles. For continued downward motion the suffix A to avoid unnecessary repetition of their de of the needles, the free ends of the bit ride out of the eyes scription. of the needles before the end of the down-stroke (FIG. A suitable mechanism for driving the yarn-feed capstan 1B) to form an inverted U. The empty needles return to 35 18 is schematically shown in FIG. 2. Because of the their original position, each to receive another yarn-bit horizontal space needed by the yarn strands on a capstan, and the backing layer L, with its new line of tufting, is several capstans may be used. Each capstan then has a advanced one step in readiness to receive the next line of groove for each thread of yarn. The capstan shaft 30 is inverted U tufts. driven via sprocket 31, chain 32 and sprocket 33 from In the interval between successive reciprocations of the 40 cam shaft 34, which in turn is driven via gear 35, idler needle-bar, as effected by the one-time shaft 25, each of gear 316 and gear 37 from shaft 318. The yarn-guide cap the chambers '11 of magazine 10 is loaded with a yarn stan drum 39 adjacent the capstan 18 is driven by gears bit B cut by knife 15 from a yarn strand S, whose end 41 on their respective shafts. The drive shaft 38 for this

positioned by a corresponding passage 16 in guide means or structure 17, is opposite the receiving end of the

yam-feed mechanism is coupled by means, including sprocket 42 and chain 43, to the one-time shaft 25 of the

chamber to serve as means for receiving ends of yarn 45 complete machine. The capstan drums 1'8 and 39 serve as strands. Each yarn strand S is looped (FIGS. 1 and 2) a common torque ampli?er for feeding yarn on demand about a series of one or more capstan drums 18‘ between from any one or more of all spools 19 of the upper tier.

its supply spool 19 and its guide passage 16. Between the A suitable operating mechanism for each presser-foot capstan and guide passage 16, the strand S passes beneath 20 is schematically shown in FIG. 3. The lower ends a reciprocating presser-foot 20. When a bit-length of 50 of links 45, 46, are pivotally connected to the respective yarn is to be fed from a spool 19, the associated presser end of a guide block 47 for the presser-foot. The pin 48 foot is permitted to drop, in response to a command sig extending from the supporting rod 49 of the pr'esser nal, for engagement with strand S at the beginning of a foot is received by an arcuate slot 50 in the right-hand forward feeding stroke. The resulting tension on the yarn or rod-guiding end 51 of lever 52. Intermediate its ends, tightens the yarn loop on the capstans, so to pull an addi 55 the lever 52 is pivotally connected at v53 to the link 45. tional length of yarn from the spool. The resulting slack The other end of lever 52 is coupled via link 54 and in the yarn strand in front of presser-foot 20‘ is taken -

rocker plate ‘55 to the biased movable element or arma

up by suction supplied, as later described, through the ture 56 of solenoid-motor 57 or equivalent. Normally, magazine chamber 11. In consequence, a bit-length of the Presser-foot 20‘ is out of engagement with the yarn yarn is pulled through passage 16 in the guide 17 and into 60 strand S for all angular positions of the parallel-link the chamber 11. motion provided by links 45, 46 and their interconnect In a modi?cation of the strand-feed arrangement just ing guide block 47. The upper end of link 46 is attached described, the forward motion of the presser-foot 20‘ and to rock shaft 62 which is oscillated under control of the the mechanism for effecting such forward motion are eccentric 58 via cam-follower 59, link 60 and arm 61. omitted. In such modi?ed feed arrangement, suction ap 65 The eccentric ‘58 is attached to and driven by the shaft plied through the magazine chamber is effective to tighten 34 which is also part of the capstan driving mechanism. the strand as looped over the capstans; the element 20

To feed a bit-length of the strand S, the solenoid 57 is normally engages the yarn strand and is lifted therefrom energized by a command signal at the beginning of a when that strand is to be fed to a magazine chamber. The length of the bit out from the end of the strand re 70 counter-clockwise motion of links 45, 46. The resulting clockwise movement of lever 52 about its pivot 53 lowers ceived by the magazine chamber may be controlled either

by presetting the interval for which the cutter 15 opens the suction path from the magazine to the yarn guide or by presetting the interval for which the presser-foot 20 is up while the cutter 15 has opened such suction path. 75

the presser-foot 20 into engagement with strand S. Such engagement is maintained until, at the end of the forward or feeding stroke of the presser-foot, the solenoid 5-7 is deenergized as by a limit switch. As later explained in