US3623440A

US3623440A - Tufting

Info

Publication number: US3623440A
Application number: US771936A
Authority: US
Inventors: Robert Spedding; William Sandford Hasler; Raymond Victor Evans
Original assignee: Singer-Cobble Ltd
Current assignee: Singer-Cobble Ltd
Priority date: 1967-10-31
Filing date: 1968-10-30
Publication date: 1971-11-30
Anticipated expiration: 1988-11-30
Also published as: NL6815547A; BE723161A; FR1590333A; DE1804856A1; GB1228580A

Abstract

In order to maintain pattern register between moving yarns having dyestuffs applied thereto at intervals therealong during the transverse rearrangement of such yarns, as, say, to give a pattern repeat, the yarns are all caused to move through a like distance as measured in the longitudinal direction of the yarn, during the rearrangement by providing a guide tube for each yarn through which the yarn passes, the said tubes all being of constant length and each serving to transfer a respective yarn from an initial position transversely of a yarn sheet or sheets issuing from a dyeing means to a final position transversely of a yarn sheet or sheets proceeding to a tufting machine or other combining means.

Description

United States Patent Inventors Robert Spedding 3,395,432 8/l968 Hasler et al 112/79 X ig Blackburn; 3,447,215 6/1969 Tillotson 112/79 x Wilham Sandford 11992119, 3,396,687 8/1968 Nowicki 112/790 Blmfkbumi Raymond V1919! Evans, 3,415,209 12/1968 121115011 m1. 1 12/79 Fenlscowles, Blackburn, all of England [21] Appl. 771,936 Primary Examiner-Jordan Franklin [22] Filed Oct 30, 1968 Assistant Examiner-Geo. V. Larkin [45] Patented No 30 1971 Attorneys-Marshall J. Breen, Chester A. Williams and Julian 731 Assignee Singer-Cobble Limited Blackburn, England [32] Priority Oct. 31,1967 [33] United Kingdom [3|] 49,362/67 TUNING ABSTRACT: In order to maintain pattern register between moving yarns havlng dyestuffs applied thereto at mtervals 7 Claims, 2 Drawing Figs.

therealong during the transverse rearrangement of such yarns, [52] US. Cl 112/79 A as, say, to give a pattern repeat, the yarns are all caused to [5 l] lnt. CL ..D05c 15/00, move through a like distance as measured in the longitudinal DOSc 15/18 direction of the yarn, during the rearrangement by providing a [50] Field of Search ll2/79, guide tube for each yarn through which the yarn passes. the 79.5, 79.6, 118 said tubes all being of constant length and each serving to transfer a respective yarn from an initial position transversely [56] Reierences Cited of a yarn sheet or sheets issuing from a dyeing means to a final UNITED STATES PATENTS position transversely of a yarn sheet or sheets proceeding to a 1,990,907 2 1935 Kellogg 1 12/79 tuftins machine or other combining means- PATENTEnunv 30 I97! 3, 623 ,440

sum 1 or =3 23 13 13 fly INVENTORS= Robert Spedding, William S. Hosler, and Raymond V. Evans BY KW ATTORNEY PATENTEmmv 30 Ian sum 2 BF 2 INVENTORS:

ATTORNEY TUFTING This invention concerns the production of tufted fabrics, and has more particular reference to a method of and a means for maintaining pattern register between the individual yarns of a multiplicity thereof passing from a dyeing means to a tufting machine.

In the production of a tufted fabric having a pattern in the pile due to a variation in pile height, which pattern has a repeat transversely of the fabric, corresponding yarns of each repeat are distributed across the fabric subsequent to passage through a patterning means, the patterning means controlling the rate of yarn feed, and thus the pile height, according to the required pattern. Having regard to the fact that the pattern is derived from a difference in pile height of adjacent yarns as distinct from being a pattern in color and is formed at the tufting needles by withdrawal of yarn from previously inserted tufts, the relative longitudinal positions of the individual yarns is of no consequence.

However, if the pattern is in color and the individual pile yarns are dyed at intervals therealong, the regions of color on adjacent yarns must be maintained in their respective relative positions longitudinally of the yarn if the intended pattern is to appear in the finished fabric. Unfortunately the distribution of corresponding yarns of each pattern repeat transversely of the sheet of pile yarns at the tufting needles, which corresponding yarns are conveniently dyed simultaneously at a common dyestuff applicator, disturbs the relative positions of the regions of dyestuff on the individual yarns at the needles and thus disturbs the pattern in the finished product.

The primary object of the present invention is to provide a means whereby pattern register as between adjacent yarns can be maintained and even this during distribution of corresponding yarns widthwise of the fabric to produce a pattern repeat in such fabric.

Thus, according to the present invention, in producing a tufted product having a pattern in color transversely thereof and wherein yarns are fed from a supply thereof, are dyed at spaced intervals longitudinally thereof and are tufted as a part ofa continuous process, we include the step of maintaining a constant path length for all yarns between the dyeing section and the tufting machine thereby to maintain a necessary level of pattern register between the dyestuff applied to the respective individual yarns throughout the full transverse extent of the product.

The invention also includes apparatus for practicing the method aforesaid, which apparatus includes a guide means intermediate a dyeing section and a tufting machine, the said guide means defining a path therein for each yarn passing therethrough which is of sensibly constant length independently of the point of entry into and exit from such means of the yarn, such guide means being adapted to receive yarns from the dyeing section at a relative disposition consistent with the grouping of such yarns for dyeing purposes and to deliver such yarns as a sheet or sheets thereof wherein the yarns are arranged in a relative disposition consistent with a pattern or pattern repeat requirement for feeding to the tufting machine.

The invention will now be described further, by way of example only, with reference to the accompanying drawings illustrating one embodiment thereof and in which:

FIG. l is a diagrammatic representation of the distribution within a guide means of the yarns from a plurality of treatment modules so as to ensure a constant path length for all yarns between such modules and a tufting machine;

FIG. 2 is a diagrammatic perspective view ofa typical guide means and shows the form taken by the individual tubes which collectively define the guide means.

Referring now to the drawing, and particularly to FIG. 1 thereof, yarns II from a plurality of creel modules 12 are fed to a corresponding number of dyeing modules 13, dyestuff being applied and fixed at such modules and the yarn also being washed and subsequently dried thereat, and from the modules 13, such yarns 11 pass to the tufting machine 14 via a guide means 15 adapted to maintain a constant path length for each yarn between the dyeing modules the tufting machine 14.

Each respective dyeing module 13 will receive those yarns which are to be similarly treated, for example, the corresponding yarns of each pattern repeat of the tufted fabric and will be provided with means arranged in tandem one behind the other to apply the dyestufi to the yarns in any convenient manner, to fix such dyestuff, wash the yarn and to dry same. The guide means 15 disposed between the dyeing modules and the needles of the tufting machine comprises a multiplicity of tube members 15a, one for each yarn, the said tube members all being of equal length thus to ensure a constant path length for all yarns between the dyeing modules and the needles, it being assumed that the path length between the dyeing modules 13 and the input side 15b of the guide means 15 and between the output side of such means and the needles is the same for all yarns. It has been found that the passage of the yarns through the tubes is facilitated if any necessary changes in direction thereof are acute, the radius of curvature at each such change being small.

In the arrangement illustrated in FIG. 1 the yarns are considered to be divided into eight groups, each group of yarns being intended to be subjected to a different color application, a single yarn from each group being taken to give a full pattern repeat and the remaining yarns of each group being distributed across the width of the tufting machine thus to give a corresponding number of repeats. If the dyestufi' as applied to a yarn is so applied at a correct position longitudinally thereof relative to dyestuff applied to other yarns of the same or another group, then to maintain this relative disposition at the tufting needles notwithstanding the distribution of the yarns widthwise of the tufting machine, all of the yarns must have the same actual path length between the dyeing module and the respective needles, such pattern length being achieved by causing the yarns to pass through the constant length tube members. While the transverse distribution of the individual yarns at the input side of the guide means is not important, since the yarns are parallel and thus their path lengths between spaced transverse planes equal, the distribution at the output side is important and should correspond to the gauge setting of the tufting machine, the yarns passing to such machine as a sheet or sheets of parallel yarns.

In the particular arrangement illustrated in FIG. 2 yarns are shown as progressing from modules, not shown, arranged at two different levels, the yarns from the upper module (or group thereof) being passed to tubes 20 having their lower ends carried by tube plate 2l while the yarns from the lower module (or group thereof) are passed to tubes 22 having their lower ends carried by tube plate 23. The upper ends of all of the

tubes

20, 22 are carried by a guide plate 24 from which the yarns pass, wither directly or indirectly, to the needles of the tufting machine. The tubes are all of constant length but each tube has its own unique shape determined by the entry and exit positions on the

plate

21, 23 and the guide plate 24 respectively.

The guide means shown in FIG. 2 is intended to handle a tufted fabric having 11 pattern repeats throughout its full width, while each repeat contains thereby two individual yarns. This arrangement requires that 32 groups of yarns, each group being subjected to a respective dyestuff application sequence such that all yarns in a given group are alike as regards pattern while the different groups each exhibit a respective and unique pattern characteristic, are provided, and that ll yarns, one for each pattern repeat, are included within each group. The groups are divided equally between the upper and

lower tube plates

21, 23 and appear on such plates as a corresponding number of inlets groups 25. Within each inlet group 25 are l l inlets 26, each being coupled to a

respective tube

20, 22 and each being intended to receive a single yarn.

The invention is not restricted to the exact features of the embodiment disclosed since alternatives will readily present themselves to one skilled in the art. Thus, for example, instead of providing a guide tube for each yarn, a series of spaced l3 and the needles of apertured guide members may be provided, the yarns being threaded through said members in a manner appropriate to give the necessary constant path length. Alternatively the yarns may be guided by eyelets or like means located at appropriate relative disposition.

Furthermore, the invention is not limited in its application to the context of producing tufted fabrics since it is of equal application in any other context where yarn is passed to a combining machine in sheet form.

What we claim is:

1. In the production of a product having a pattern in color transversely thereof and wherein a plurality of individual yarns is fed from a supply, a color-influencing medium is selectively applied to the yarns at spaced intervals longitudinally thereof and the yarns from at least a pattern in the said product, some of the yarns proceeding along paths having at least a part thereof arranged in nonparallel disposition relative to those of other yarns at or subsequent to the point of first color-influencing medium application and wherein the yarns are redistributed in the transverse direction thereof between the steps of medium application and fonning of the pattern, the step of maintaining a constant path length for the said yarns between the point of application of medium and the point of forming the pattern from the yarns thereby to maintain a necessary level of pattern register between the medium applied to the respective individual yarns throughout the full transverse extent of the product.

2. The method as claimed in claim 1 wherein the product is a tufted product and is comprised of the formation of tufts in a backing fabric.

3. Apparatus comprising a guide means for location intermediate a color-influencing medium applicator and a pattern forming means to guide the yarns between the aforesaid applicator and an apparatus for forming a pattern from said yarns, the said guide means defining a path therein for each yarn passing therethrough which is of sensibly constant length independently of the point of entry into and exit from said guide means, said guide means being adapted to receive yarns from the applicator at a relative disposition consistent with their disposition for application purposes and to deliver said yams as a sheet or sheets thereof wherein the yarns are arranged in a relative disposition consistent with a pattern requirement for feeding to the apparatus for forming the pattern.

4. Apparatus as claimed in claim 3 wherein the guide means is adapted to receive the said yarns in a relative disposition consistent with the grouping of like yarns for application purposes and to effect a redistribution of the yarns in the transverse direction thereof consistent with a pattern repeat requirement.

5. Apparatus as claimed in claim 3 wherein the guide means includes a plurality of guide tubes, one for each yarn, extending between spaced feed and delivery points, the said tubes all being ofa like length and having bends therein determined by the relative disposition of the said points.

6. Apparatus as claimed in claim 5 wherein the guide tubes all have corresponding bends therein.

7. Apparatus as claimed in claim 6 wherein the tubes are grouped to define a plurality of inlet levels, each such inlet level having a common outlet level.

Claims

1. In the production of a product having a pattern in color transversely thereof and wherein a plurality of individual yarns is fed from a supply, a color-influencing medium is selectively applied to the yarns at spaced intervals longitudinally thereof and the yarns from at least a pattern in the said product, some of the yarns proceeding along paths having at least a part thereof arranged in nonparallel disposition relative to those of other yarns at or subsequent to the point of first colorinfluencing medium application and wherein the yarns are redistributed in the transverse direction thereof between the steps of medium application and forming of the pattern, the step of maintaining a constant path length for the said yarns between the point of application of medium and the point of forming the pattern from the yarns thereby to maintain a necessary level of pattern register between the medium applied to the respective individual yarns throughout the full transverse extent of the product.

3. Apparatus comprising a guide means for location intermediate a color-influencing medium applicator and a pattern forming means to guide the yarns between the aforesaid applicator and an apparatus for forming a pattern from said yarns, the said guide means defining a path therein for each yarn passing therethrough which is of sensibly constant length indepEndently of the point of entry into and exit from said guide means, said guide means being adapted to receive yarns from the applicator at a relative disposition consistent with their disposition for application purposes and to deliver said yarns as a sheet or sheets thereof wherein the yarns are arranged in a relative disposition consistent with a pattern requirement for feeding to the apparatus for forming the pattern.

5. Apparatus as claimed in claim 3 wherein the guide means includes a plurality of guide tubes, one for each yarn, extending between spaced feed and delivery points, the said tubes all being of a like length and having bends therein determined by the relative disposition of the said points.