US2478743A - Tufting machine - Google Patents

Description

A. E. CHARLES Aug. 9, 1949.

TUFTING MACHINE 5 Sheets-Sheet 1 Filed April 2, 1947 b 2. .N w v I N A I I I I 1 I l I I I I I I 1 I I I 1 ll .v a. J 0 nm R ma. Q? 3 W um Q E 3 Fl m. j Er I l E. 1 n q m m IN .FM 0 v v v 1 W- 0 mo INVENTOR.

ARTIS ELMER CHARLES ATTORNEY.

A. E. CHARLES TUFTING MACHINE Aug. 9, 1949.

3 Sheets-Sheet 2 Filed April 2, 1947 INVENTOR.

AR-rls ELMER CHARLES ATTORNEY.

A. E. CHARLES TUFTING MACHINE Aug. 9, 1949.

Filed April 2, v 1947 3 Sheets-Sheet 3 INVENTOR. A RTIS ELME CHARLES.

AT TORNEY- Patented Aug. 9, 1949 UNITED FT N Artis Elmer Charles, Guntersville,-Ala., assignor to Carolyn Chenilles, Inc., New corporation of- New York York, N. Y., a

Application April 2, 1947, serial ze. 73am 1 This invention relates to a process and machine forproducing tufts on a base material, and relates more particularly to a novel process and machine for simultaneously producing a plurality of tufts on a web of textile, which tufts'may be spaced from each other a predetermined distance.

In Patent No. 2,335,487 to Cobble et al. there is shown and described a multiple needle tufting machine which is designed to produce in a single operation up to over two hundred stitches, or tufts, running laterally of the machine. By omitting certain of the needles on said machine, the lateral spacing of the tufts is easily effected. It is an important object of this invention to provide a novel process and means for longitudinally spacing the tufts which may be formed of one or more stitches.

Another object of this invention is the provision of auxiliary drive means for the feed shaft of a multiple needle tufting machine so that, at a predetermined interval in the normal feed of the fabric web, the rate of rotation of the feed shaft is increased momentarily, thus causing a greater than normal length of fabric to be fed past the needles, whereby a space of predetermined extent is formed between the tufts being produced longitudinally of the fabric web, without affecting the normal reciprocation of the needle bank.

A further object of this invention is to provide means for relieving the tension on the yarns being led to the needles of the needle bank during the operation of the auxiliary drive means on the drive means.

Still another object of this invention is to provide a means for progressively unwinding textile web from the web supply and a longer length of web concomitantly with the operation of the auxiliary drive means on the drive shaft to feed the textile web past the needle bank.

' Other objects and advantages of this invention, together with certain details of construction and combinations of parts, will appear from the following detailed description and will be pointed out in the appended claims.

In the drawings, wherein a preferred embodiment of my invention is shown,

Fig. l is a front elevational view of a multiple needle tufting machine modified in accordance with my invention;

Fig. 2 is a rear elevational view thereof;

Figs. 3 and 4 are detail views, on an enlarged scale of the mechanism for operating the clutch for superimposing an auxiliary fabric web feeding movement on the feed shaft; and

Fig. 5 is a fragmentary view of the means for i 4 Claims. (Cl.'112-79) 2 unrolling fabric from the supply T011, porting the same.

Like reference numerals indicate like par throughout the several views of the drawings.

Since 'the multiple needle tufting machine, which I have modified, is fully shown amidescribed in the above-mentioned Cobble et al. patent, I will describe this well-known mechanism only to such extent as is necessary to disclose the present inventive features.

Referring particularly to Figs. 1 and 2 of the drawings, themultiple needle tufting machine is shown as comprising a drive shaft 6 which is driven by a motor 1 through a belt 8 connecting a pulley 9 fixed to drive shaft 6 and a pulley H carried by motor shaft H. The motor 1 is supported on a bracket I3 suitably fixed to the framework m-or the tuftingmachine.

The driveshaft 6, 'whichis journaled in bearings l5 mounted on the top of the tufting "machine, actuates the bar supporting the needle bank of the machine (not shown) the fabric web feed mechanism, generally indicated by reference numeral 16, through a'connecting rodll, and the looping and loop cutting mechanisms of the machine (not shown) through connecting rod l8.

More specifically, the fabric web feed mechanism comprises a shaft H! which is journaled in bearings 2| attached to the framework M of the machine. Along shaft I9 are fixed suitably spaced, serrated or toothed discs 22 over which the fabric web 23'being tufted is trained after it is fed under the needle band; For holding the fabric web against the serrated discs 22 there are provided grippers 24, one for each disc, which are mountedon a bar 25 extending across the width of-themachine. The bar 25 is fixed to a rodf'ie'rotatably mounted in bearings, such as bearing 21, on the framework llof the machine. A handle 28 is'fixed to rod 26 and 'is adapted simultaneously to move all of the grippers 24 to and from the serrated discs 22. Fingers 30 carried on a bracket 30 fit in between the serrated discs 22 to keep the fabric web from being fouled between said discs.

The fabric web 23' is taken from a supply'roll 29 carried by a support and unrolling arrangement generally indicated by reference numeral 3| (see Figs. 2 and 5) This arrangement comprises two idler rollers 32 and 33 carried by shafts 34 and 35, respectively, journaled in bearings, such as bearings 36, on and between which idler rollers is supported the supply roll 29. Between and below said idler rollers 32 and 33 is ashaft 3T, journaled in bearings 38, on which are fixed spaced serrated or toothed discs 39. At one end of shaft 31 is fixed a pulley 4|, which is connected by means of a belt 42 to a pulley 43 fixed to a stub shaft 44 journaled in bearing 45 integral with hearing bracket 46 suitably fixed to a block 41 which may be attached to the floor. A pulley 48 is fixed to the other end of stub shaft 44 and is operatively connected to a pulley 49 fixed to shaft [9 by a belt 50. By this arrangement, the fabric web is unrolled from the supply roll 29 a length of fabric web equal in length to the length fed by the feed shaft [6 upon each rotation thereof. Discs are fixed to shaft 31 to prevent the supply roll from moving laterally out of desired position.

29 over a roller 52, mounted on a shaft 53 journaled in bearing brackets 54 fixed to framework l4 by bolts 55, then under the needle bank of the machine and then trained over serrated discs 22 on feed shaft l9. On the surface of roller 52 are helical ribs 56 which are oppositely directed from substantially the center of the roller. The roller may be turned by the fabric web passing over the same, or it may be turned by the drive shaft 6 of the machine. For the latter purpose, a pulley 51 is fixed to one end of shaft 53, a pulley 58 fixed to the corresponding end of drive shaft 6 and these pulleys connected by a belt 59.

Operatively connected to connecting rod [1 is a rocker arm 6| which is attached to a clutch mechanism 62 and reciprocates the same giving intermittent rotational movement to feed shaft 19. This rotational movement of shaft I5 moves serrated discs 39 on shaft 31 as well as serrated discs 22 on shaft l9, thus unrolling the fabric web from the supply roll and pulling the same past the needle bank a stitch length, usually about one-sixteenth of an inch, while the needle bank is in raised position. Thus, the stitches or loops will be equally spaced and relatively close together to form a tuft of the desired number of stitches or loops.

In order to produce tufts which are spaced longitudinally from each other, the fabric web, after a tuft of any predetermined number of stitches or loops is completed, is caused to be fed past the raised needle bank a distance greater than the stitch length normally caused to be fed by clutch 62, thereby providing a space between the tufts in the fabric web. This space may be of any length. To give the effect of a candlewick spread, the space may be one and oneeighth inches, but may be greater or less as desired. To effect the variation in the feed of the fabric web, I have provided an auxiliary feed mechanism which may readily bemounted on the multiple needle tufting machine referred to above with little modification of the elements thereof, as will hereinafter appear.

On drive shaft 6 is fixed a gear 63 which is adapted to mesh with and rotate a gear 64 fixed to a stub shaft 65 journaled in bearing bracket 66 suitably mounted on top of the machine. Also carried on stub shaft 65 is a cam 61 which is held thereon by set screws and collar 69. The cam 61 cooperates with a cam follower ll pivotally mounted at the upper end of a lever arm 72. Fixed to the lever arm 12 is a stubshaft 13 which is journaled in a bearing 14 carried by a bracket, generally indicated by reference numeral 15, mounted on the framework of the machine. The lower end of lever arm 12 is attached; as by a linkl6, to the arm ll of a clutch mechanism 18. The arm "I1 is slotted at 19 to receive link The fabric web 23 is led from the supply roll;v

4 16 so that the throw of the clutch may be adjusted to the degree of auxiliary rotation of the feed shaft desired.

Referring to Fig. 3 of the drawings, the cam 61 is shown as having been rotated to the position where the point 8| of the cam 61 is in contact with cam follower H and has moved lever arm 12 to give the clutch 18 an operative movement. The. clutch 18 at this point has superimposed on feed shaft I 6 an auxiliary feeding movement which is far in excess of the normal stitch length feeding movement thereof. At the same time, the shaft 31 is also caused to turn to unroll from the supply roll a length of fabric web equal to that pulled past the raised needle bank by the rotational movement of the feed shaft. Thus, regardless of the size of the supply roll there will be no drag on the fabric web being fed by the feed shaft and, therefore, there will be no variation in the length of the spaces between the tufts.

In Fig. 4 of the drawings, the point M of cam 61 is shown as having moved away from the cam follower on lever arm 12, permitting the latter to be moved backward to inoperative position by the action of the springs 82 and 83 which also act to maintain the cam follower in contact with the cam surface.

Since the auxiliary movement of the fabric web causes yarns 84 to be pulled along with the fabric web, thus putting an undue tension thereon which may cause the same to break, I have provided means for relieving the tension thereon. Thus, the yarns 34', after they pass tension guides 85 on their way to the needles of the needle bank, are caused to pass under a guide rod 86 and over a, guide rod 81 to which guide rod 86 is attached as by links 88. Guide rod 81 is journaled at one end in a bracket 89 and the other end thereof is fixed to an arm 9| which is pivotally attached to a lever 92, which is in turn connected to a lever 93. Lever 93 is fixed to a shaft 94 journaled in bearings 95 fixed to a bracket 96 mounted on the framework of the machine. To shaft 94 is fixed an arm 91 carrying a cam follower 98 adapted to cooperate with a cam 99. This cam is fixed to a gear I00 mounted on a stub shaft IUI carried by the framework. Gear lfll meshes with and is rotated by a gear I02 fixed to drive shaft 6.

During the stitch length feeding of the fabric web, the bars 86 and 81 are in a position such as to form a loop or bulge in the yarns being fed to the needle. At the moment that clutch I8 is moved to rotate feed shaft l9, cam 99 causes cam follower 98 to move to rotate shaft 94 and thus through levers 93 and 82 cause the rocking of arm M. This movement of arm 6| momentarily moves the guide rods 86 and 61 away from the yarns, leaving a length of each yarn to be taken up by movement of the fabric web. Further movement of the cam slowly moves the guide rods 86 and 81 back to their extended position.

As indicated above, the tuft may be composed of any number of stitches or loops. Where it is desired to have'four stitches or loops in each tuft, the gears 63 and 64 are of such dimension that the point 8! of the cam '61 is caused to strike cam follower ll after the fourth complete rotation of gear 63.

The extent of the auxiliary rotational movement of the feed shaft may be varied or adjusted by changing the position of the link 16 in the slot 19 of clutch arm 11. i A

It is believed that the operation of the multiple needle tufting machine as modified in accordance with my invention will be readily apparent from the above description.

The embodiment of my invention shown and described herein is to be considered merely as illustrative, as my invention is susceptible to variation, modification and change within the spirit and scope of the appended claims.

What is claimed is:

1. In a machine for forming in a fabric web a plurality of tufts each composed of a predetermined number of stitches or loops, wherein a plurality of yarns are stitched by a bank of needles into said fabric web progressively fed to the needle bank from a supply roll a stitch length at a time by a feed shaft intermittently rotated by means operatively connected to the drive shaft of the machine, the combination therewith of means for unrolling said web from said supply roll at the same rate as it is fed past the needle bank by said feed shaft, said latter means comprising a roller on which said supply roll is mounted, and means operatively connected to said feed shaft for rotating said roller.

2. In a machine for forming in a fabric web a plurality of tufts each composed of a predetermined number of stitches or loops, wherein a plurality of yarns are stitched by a bank of needles into said fabric web progressively fed to the needle bank from a supply roll a stitch length at a time by a feed shaft intermittently rotated by means operatively connected to the drive shaft of the machine, means for spacing said tufts longitudinally of said web comprising a clutch mounted on said feed shaft, means, in cluding a lever arm attached to said clutch, a cam for moving said lever arm, a gear on which said cam is mounted for rotation therewith and a gear fixed to said drive shaft for meshing with and driving said first-mentioned gear, for reciprocating said clutch to rotate said feed shaft to move said web a distance greater than a stitch length, and means for unrolling said web from said supply roll at the same rate as it is fed past the needle bank by said feed shaft, said latter means comprising a roller on which said supply roll is mounted, and mean-s operatively connected to said feed shaft for rotating said roller.

3. In a machine for forming in a fabric web a plurality of tufts each composed of a predetermined number of stitches or loops, wherein a plurality of yarns are stitched by a bank of needles into said fabric web progressively fed to the needle bank from a supply roll a stitch length at a time by a feed shaft intermittently rotated by means operatively connected to the drive shaft of the machine, means for spacing said tufts longitudinally of said web comprising a clutch mounted on said feed shaft, means, including a lever arm attached to said clutch, a cam for moving said lever arm, a gear on which said cam is mounted for rotation therewith and a gear fixed to said drive shaft for meshing with and driving said first-mentioned gear, for reciprocating said clutch to rotate said feed shaft to move said web a distance greater than a stitch length, means for unrolling said web from said supply roll at the same rate as it is fed past the needle bank by said feed shaft, said latter means comprising a roller on which said supply roll is mounted, and means, operatively connected to said feed shaft for rotating said roller, bars for applying tension on said yarns, and means for moving said bars at predetermined spaced intervals for relieving the tension on said yarns.

4. In a machine for forming in a fabric web a plurality of tufts each composed of a predetermined number of stitches or loops, wherein a plurality of yarns are stitched by a bank of needles into said fabric web progressively fed to the needle bank from a supply roll a stitch length at a time by a feed shaft intermittently rotated by means operatively connected to the drive shaft of the machine, means for spacing said tufts longitudinally of said web comprising a. clutch mounted on said feed shaft, means, including a lever arm attached to said clutch, a cam for movin said lever arm, a gear on which said cam is mounted for rotation therewith and a gear fixed to said drive shaft for meshing with and driving said first-mentioned gear, for reciprocating said clutch to rotate said feed shaft to move said web a distance greater than a stitch length, means for unrolling said web from said supply roll at the same rate as it is fed past the needle bank by said feed shaft, said latter means comprising a roller on which said supply roll is mounted, and means, operatively connected to said feed shaft for rotating said roller, bars for applying tension on said yarns, and means for moving said bars at predetermined spaced intervals for relieving the tension on said yarns comprising a cam driven from said drive shaft, a cam follower movable by said cam and levers connected to said cam follower and said bars.

ARTIS ELMER CHARLES.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 1,794,644 Roesen Mar. 3, 1931 1,796,912 Wood Mar. 17, 1931 1,805,122 Weinheim Ma 12, 1931 2,016,909 Sakellarides Oct. 8, 1935 2,062,027 Hofmann et al Nov. 24, 1936 2,090,022 Baynton et a1 Aug. 17, 1937 2,112,512 Windham et al Mar. 29, 1938 2,223,445 Doble Dec. 3, 1940 2,359,050 Patey Sept. 26, 1944 2,389,914 Kile Nov. 27, 1945 2,411,883 Kile Dec. 3, 1946

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