Patent Application
20250154701
This disclosure relates to systems and methods for forming tufted articles, such as turf, using hollow needle tufting machines.
Hollow needle tufting machines can deliver multiple colors or types of yarn to a single tufted article. Conventional hollow needle tufting machines typically include a plurality of yarns that can be held above and fed through a single hollow tufting needle. One known hollow needle tufting machine is disclosed in U.S. Pat. No. 10,961,647, granted Mar. 30, 2021, the entirety of which is hereby incorporated by reference herein for all purposes.
Conventional hollow needle tufting machines are unsuitable for many types of yarn, including staple fiber, wool, turf yarns, large yarns, and yarns that do not include or maintain a yarn twist. Accordingly, conventional hollow needle tufting machines are incapable of forming various types of tufted articles.
Described herein are various systems and methods for forming tufted articles using a hollow needle tufting machine. The systems and methods can be used for tufting different types of yarns, such as turf yarns, staple yarns, or yarns having a denier greater than 5000.
In one aspect, a system includes a pair of guides. A clevis is movable between the pair of guides. The clevis defines an opening therethrough. Yarn extends through the opening through the clevis. The yarn is configured to contact only exterior surfaces of the pair of guides.
Also disclosed herein is a system including a manifold bar defining a plurality of openings configured to receive a respective yarn. Each opening extends along an axis that meets a vertical axis at an angle of at least 14 degrees.
Also disclosed herein, in one aspect, is method including applying, using a pressure foot injector, a pressure less than 10 psi (e.g., from 1 psi to 10 psi). Optionally, the pressure foot injector does not apply pressure.
Also disclosed herein, in one aspect, is method including applying a first pressure of above 90 psig for feeding or tufting a yarn; applying a second pressure for holding the yarn, wherein the second pressure is lower than the first pressure, wherein the second pressure is above 70 psig; and applying a third pressure to a needle injector of above 90 psig.
Additional advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.
These and other features of the preferred embodiments of the invention will become more apparent in the detailed description in which reference is made to the appended drawings wherein:
The present disclosure can be understood more readily by reference to the following detailed description, examples, drawings, and claims, and their previous and following description. However, before the present devices, systems, and/or methods are disclosed and described, it is to be understood that this disclosure is not limited to the specific devices, systems, and/or methods disclosed unless otherwise specified, as such can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.
The following description is provided as an enabling teaching of the disclosed articles, systems, and methods in their best, currently known embodiments. To this end, those skilled in the relevant art will recognize and appreciate that many changes can be made to the various aspects of the articles, systems, and methods described herein, while still obtaining the beneficial results of the disclosure. It will also be apparent that some of the desired benefits of the present disclosure can be obtained by selecting some of the features of the present disclosure without utilizing other features. Accordingly, those who work in the art will recognize that many modifications and adaptations to the present disclosure are possible and can even be desirable in certain circumstances and are a part of the present disclosure. Thus, the following description is provided as illustrative of the principles of the present disclosure and not in limitation thereof.
As used throughout, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, unless the context dictates otherwise, reference to “a needle” provides disclosure of embodiments in which only a single such needle is provided, as well as embodiments in which a plurality of such needles are provided.
Ranges can be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint. Optionally, in some aspects, when values are approximated by use of the antecedents “about,” “substantially,” or “generally,” it is contemplated that values within up to 15%, up to 10%, up to 5%, or up to 1% (above or below) of the particularly stated value can be included within the scope of those aspects. In other aspects, when angular values are approximated by use of the antecedents “about,” “substantially,” or “generally,” it is contemplated that angular values within up to 15 degrees, up to 10 degrees, up to 5 degrees, or up to one degree (above or below) of the particularly stated angular value can be included within the scope of those aspects.
As used herein, the terms “optional” or “optionally” mean that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.
The term “tuft,” as used herein, encompasses both cut yarn stitches and loop yarn stitches, and the term “tufting” encompasses both the act of forming a cut yarn stitch and the act of forming a loop yarn stitch.
The terms “fiber” and “yarn” as used herein refer to a continuous strand or bundle of filaments. The filaments can include, for example, ribbons (e.g., slit films). Thus, such fibers and yarns can include, for example and without limitation, tape ribbons, monofilament yarns, cut yarns, looped yarns, fibrillated yarns, multifilament yarns, twisted yarns (e.g., twisted staple yarns), wrapped yarns, staple yarns, and the like. Optionally, consistent with the use of the terms “fiber” and “yarn”, the continuous strand or bundles of fibers can be cut to form cut fibers or cut yarns. Optionally, fibers/yarns can be textured using conventional methods. “Fibers” and “yarns” as disclosed herein are capable of being independently delivered to a backing structure (for example, via tufting). A yarn or a fiber can be a single end fiber (single ply yarn) or a multiple end fiber (e.g., a plied yarn) that includes a plurality of single end fibers that are entangled or otherwise commingled with one another (for example, by air entanglement, twisting, wrapping, and the like) such that the single end yarns are no longer individually or independently moveable. For example, a plurality of single end yarns can be twisted together to form a plied yarn (e.g., a two-ply yarn can include two single end yarns that are twisted together). Each single end yarn/fiber can be formed from at least one filament (optionally, a plurality of filaments). Thus, within a multiple end yarn, each single end yarn that makes up the multiple end yarn can include a respective filament or plurality of filaments.
As used herein, the term “denier” refers to the weight in grams of 9,000 meters of yarn. “Denier per filament” refers to the denier (weight in grams of 9,000 meters) of a single filament of a yarn. When the yarn consists of a single end yarn, the “total denier” of the yarn can refer to the combined denier (i.e., the sum of the respective deniers) of all filaments of the single end yarn. When the yarn includes a plurality of yarn ends (a plurality of single end yarns) that are entangled or otherwise commingled with one another such that the yarn ends are no longer individually or independently moveable, then the “total denier” of the yarn can refer to the combined denier (i.e., the sum of the respective deniers) of the plurality of yarn ends (the plurality of single end yarns that define the multiple end yarn).
The total denier, denier per filament (dpf), and ply information can be used to determine the number of filaments within a given yarn. As a first example, a single-ply yarn can be identified as a 6000 total denier, 4 dpf yarn. This indicates that the single-ply yarn has a total denier of 6000, and that each filament of the single-ply yarn has a denier (per filament) of 4. The total number of filaments can be determined by dividing the total denier (6000) by the dpf (4), producing a result of 1500 filaments within the yarn. Rather than identifying the yarn as a 6000 total denier, 4 dpf yarn, it is contemplated that the yarn can instead be identified as a 6000/1500 filament yarn (with the dpf (4) being determined by dividing the total denier (6000) by the number of filaments (1500)).
As another example, consider a two-ply yarn that has the same total denier (6000) but is formed by twisting or otherwise commingling two of the same single-end yarns. Such a yarn can be identified as a 3000×2 yarn, which indicates that the yarn is a two-ply yarn, with each ply corresponding to a single-end yarn having a total denier of 3000. If the dpf of each of the single-end yarns is 15, then the number of filaments of each of the single-end yarns can be calculated by dividing the total denier (3000) by the dpf (15), producing a result of 200 filaments within each of the single-end yarns. Therefore, the total number of filaments within the two-ply yarn can be determined to be 600 (the sum of the number of filaments within the two single-end yarns that make up the two-ply yarn).
In yet another example, consider a yarn formed by twisting or otherwise commingling two different single-end yarns to form a yarn bundle. The yarn bundle can include a first single-end yarn that is a 3000 total denier, 15 dpf yarn and a second single-end yarn that is a 3000 total denier, 4 dpf yarn. This indicates that the first single-end yarn has a total denier of 3000, with each filament of the yarn having a denier (per filament) of 15. The second single-end yarn has a total denier of 3000, with each filament of the yarn having a denier (per filament) of 4. Thus, the first single-end yarn has 200 filaments (with each filament having a denier of 15 to provide a total denier of 3000), while the second single-end yarn has 750 filaments (with each filament having a denier of 4 to provide a total denier of 3000).
Referring now to the drawings, in which like reference characters indicate like parts throughout the several views, disclosed herein are hollow needle tufting machines that are, or can be, configured to form tufted articles from yarns including, but not limited to, turf yarns, staple fiber, wool, large yarns (e.g., greater than 5000 denier), and yarns that do not include or maintain a yarn twist. Also disclosed herein are methods of forming tufted articles using hollow needle tufting machines and articles formed using hollow needle tufting machines.
An exemplary tufting apparatus 10 is shown in
An exemplary frame 12 of the tufting apparatus 10 is shown in
The backing transport system 14 can transport the backing 16 through the tufting apparatus 10 while the reciprocating hollow needles 18 implant tufts of yarn in the backing at the yarn applying region 21. The backing can be in the form of a continuous running web. The backing 16 can move in the direction of the arrow in
As shown in
A second pair of pin rollers 90 and 91, which have smaller diameters than the entry and exit pin rollers 70 and 71, can be located closely adjacent to reciprocating needles 18 on the opposite sides of the backing 16. These additional pin rollers 90 and 91 can provide better control of the backing 16 in the area adjacent to where the yarn tufts are implanted. The smaller pin rollers 90 and 91 can be carried on respective brackets 92 and 93.
The backing transport system 14 can further comprise at least one bedplate (e.g., a pair of bed plates 94 and 96) for supporting the backing 16 as the backing moves through the tufting apparatus 10. One of the bed plates 94 can be positioned below the backing 16 and upstream of the reciprocating needles 18 between the reciprocating needles and the entry pin roller 70. The other of the bed plates 96 can be positioned above the backing 16 and downstream of the reciprocating needles 18 between the reciprocating needles and the exit pin roller 71. The at least one bed plate (e.g., bed plates 94 and 96) can be transversely shiftable relative to the backing advance direction.
Each of the bed plates 94 and 96 can be carried on a pair of transversely extending rods 100 and 102 affixed to the frame 12. The bed plates 94 and 96 can be connected at each end by respective connecting members 104 and 105. Optionally, the entry and exit pin rollers 70 and 71 can be carried by the shiftable bed plates 94 and 96, respectively. The connecting members 104 and 105 can be connected to at least one electric motor (not shown) with at least one commercially available ball screw drive. The ball screw drive can be capable of producing very small and precisely controlled transverse movements when rotated by the motor. Specifically, this precision mechanism can enable precisely controlled incremental movements of the order of a half inch to one-tenth of an inch or less. The motor and the ball screw drive can shift the bed plates 94 and 96, as well as the pin rollers 70 and 71, transversely toward the longitudinal direction of advancement of the backing which produces a corresponding transverse shifting movement of the backing 16 so that each needle 18 may insert yarn into the backing at a number of transverse locations. The guide rollers 78 and 79 can also be shifted transversely in substantial correspondence with the pin rollers 70 and 71 by a second, less precise shifting mechanism.
The needle actuation assembly 20 can reciprocate the needles 18 by adjustable cam assemblies 110 which are coupled to the needles by respective link assemblies 112. The adjustable cam assemblies 110 are shown in
As best shown in
Many turf yarns have the tendency to twist together while tufting, moving, or being fed, with adjacent yarns in this area positioned between the creel header and yarn feed mechanisms. In some aspects, the tufting machine can comprise tubing that guides respective yarns to the yarn exchanger. For example, the tufting machine can comprise a header, and the tubing can extend from the header to the yarn exchanger. In some aspects, tubing can extend beyond all conventional yarn guides and pneumatic componentry (e.g., to a lowest point possible, just before the yarn feed mechanisms), to eliminate the possibility of the yarns mixing or entanglements between the existing creel header and yarn feed mechanisms, while tufting (which requires a machine stoppage to fix). That is, the tubing can inhibit undesired twisting or other interactions between yarns.
The needle mounting bar 130 can be rectangular in cross-section, and for each needle 18, can have a central passage (not shown) extending from an inlet at the top of the mounting bar to a funnel (e.g., provided in a funnel block 19 (
In various aspects, the funnel block can comprise channeling therein to segregate (or otherwise provide spacing between) yarns within the block. The channeling can inhibit yarns within the funnel block from mixing or becoming entangled.
The needles 18 can each have a hollow passage extending from an inlet to an outlet 132 at a tip 134, which can optionally be an angled pointed tip. An exemplary structure of the needles is disclosed in more detail in U.S. Pat. No. 4,991,523, which is incorporated by reference herein in its entirety. Each needle 18 can be disposed such that the inlet of the needle is in communication with the outlet of the respective funnel.
The needle actuation assembly 20 can be driven by electric motors (not shown) operatively connected to opposite ends of the main drive shaft 118 and mounted to opposite ends of the main drive housing 64 for rotating the main drive shaft. For high product throughput, the main drive motors can rotate the main drive shaft 118 at speeds up to about 1000 rpm.
Each rotation of the main drive shaft 118 can cause the needles 18 to penetrate and then withdraw from the backing 16. In other words, each rotation of the main drive shaft 118 can cause one needle reciprocation cycle, also referred to as a tufting cycle, which includes a downstroke and an upstroke of the needles 18.
During each tufting cycle, the hollow needles 18 of the yard applicator 20 can reciprocate between a top position and a bottom position. The backing can be is positioned between the top position and the bottom position of the tufting cycle. In one cycle, the tip 134 of each hollow needle 18 can travel from the top position to the bottom position and back to the top position. Between the top position and the bottom position, the hollow needle 18 can penetrate the backing 16 and implant a yard tuft therein. The movement of the hollow needle 18 between the top position and the bottom position is the downstroke of the cycle, and the movement of the needles from the bottom position to the top position is the upstroke of the cycle.
As shown in
The reciprocation mechanism 140 for each blade 138 can comprise an air cylinder 142 for driving a shaft 143 in a vertical reciprocating motion and an air solenoid 144 for activating the air cylinder. A pressurized air supply pipe 145 can supply air to the air cylinder 142 as shown in
The knife blades 138, blade holders 139, and reciprocating mechanisms 140 can be mounted to the cutting system frame 141 along a transverse C-bar 147. As will be explained in more detail below, each of the knife blades 138 can be individually controlled and can be individually reciprocated independent of the other so that on any penetration by any needle 18, the respective knife blade 138 can be positioned to form a cut tuft or form a loop tuft.
The reciprocating mechanisms 140 can move the knife blades 138 and blade holders 139 up and down synchronous with the reciprocating movements of the hollow needles 18. The knife blades 138 can reciprocate between a bottom position and a top position. Each stroke of the knife blades 138 can include an upstroke from the bottom position to the top position and a downstroke from the top position to the bottom position. In the top position, the knife blades 138 can engage respective hollow needles 18 and cut the yarn. The structure of an exemplary yarn cutting assembly 22 is disclosed in more detail in U.S. Pat. No. 5,588,383, which is incorporated by reference herein in its entirety.
An alternative yarn cutting assembly is generally described in U.S. Pat. No. 7,831,331, which is incorporated herein by reference in its entirety. Referring now to
As shown in
While
Referring now to
Optionally, to prevent the needles 18 from raising the backing 16 when the needles are removed from the backing during the upstroke of the yarn applicator 20, a plurality of presser feet 24 can be disposed adjacent the needles transversely across the tufting apparatus 10 and slightly above the backing. The presser feet 24 can be connected to an elongated rail member 150, shown in
Each of the presser feet 24 can extend below the needles 18 and have a plurality of bores corresponding to each needle and through which the respective needles may reciprocate freely.
Air conduits 248 can communicate with each of the needle bores. Pressurized air of pressure foot injectors can be blown through the conduits 248 by corresponding tubes 155 connected to a pressurized air pipe 156. Pressurized air can be directed through the conduits 248 and into the needle bores as the needles 18 are withdrawn from the backing 16. This air can force the severed limb of yarn, which is the limb forming the last backstitch and which is no longer connected to the needle, down into the opening in the backing before the needle makes a subsequent opening. This can eliminate the excess yarn on the rear of the backing and preclude the yarn from forming a backstitch raised above the surface of the backing material. Optionally, each air conduit 248 can be disposed at an angle of about 45° relative to the axis of the respective needle 18. Exemplary presser feet 154 are disclosed in U.S. Pat. No. 5,158,027, the disclosure of which is incorporated by reference herein in its entirety.
With conventional use of hollow needle tufting machines, the presser feet usually require from 60 psi to 80 psi of pressurized air blown through the conduits 248. An absolute minimum pressure is about 20 psi to about 30 psi. Unlike conventional use of hollow needle tufting machines, in some aspects, it can be advantageous to limit, minimize, or eliminate air pressure applied at the presser feet. For example, in some aspects, the pressure foot injectors of the tufting machine can apply less than 20 psi to the yarn. In further aspects, the pressure foot injectors can apply less than 15 psi to the yarn (e.g., from about 1 psi to about 15 psi), or less than 10 psi to the yarn (e.g., from about 1 psi to about 10 psi), or less than 5 psi to the yarn (e.g., from about 1 psi to about 5 psi). In further exemplary aspects, the pressure foot injectors can apply less than 1 psi (e.g., above zero but less than 1 psi) or zero pressure to the yarn.
In further aspects, the air foot injector can be omitted. For example, yarn pullers can be used to drive yarns into the air manifold blocks and yarn conduits.
The tufting apparatus 10 can supply at least one yarn (e.g., a plurality of different yarns) to each needle 18 of the tufting apparatus. The yarns can be of different colors so that the tufting apparatus 10 can be used to make multicolor patterned tufted goods such as carpet or turf. Optionally, as further disclosed herein, it is contemplated that the tufting apparatus can have only a single hollow needle 18. In other aspects, it is contemplated that the tufting apparatus 10 can have a plurality of needles spaced apart. The particular number of needles depends on the product to be produced and the level of throughput desired. The tufting apparatus 10 is capable of selecting, for any given needle 18, on any given needle reciprocation cycle, one yarn of a plurality of different yarns and delivering the desired length of that yarn to the respective needle. In addition, the tufting apparatus is capable of simultaneously withdrawing one yarn from a needle 18 and inserting another yarn into that needle in the same needle reciprocation cycle. Thus, in use, it is contemplated that the disclosed tufting apparatus 10 can permit different yarns to be delivered to the same needle during sequential needle reciprocation cycles (i.e., with a first yarn being delivered to a particular needle during a first reciprocation cycle and a second yarn being delivered to the same needle during a second reciprocation cycle that immediately follows the first reciprocation cycle).
Yarn can be supplied to the tufting apparatus 10 through overhead tubes from a creel (not shown). The creel generally comprises a frame for holding a plurality of yarn spools. The structure and function of such creels is well known to those skilled in the art and is not discussed herein in detail.
At least one yarn feed assembly 26 can be disposed adjacent the push rod 124 of the yarn cutting system 22 and extend between the vertical end frames 40 of the tufting frame 12 along the inlet and exit sides 59 and 61 of the tufting apparatus. The yarn feed assemblies 26 on each side of the tufting apparatus 10 can identical to each other, but in reverse image. Each yarn feed assembly 26 can comprise a driven roller 162 extending between end panel 62 of the vertical end frames 40. In addition, each yarn feed assembly 26 can include a yarn feeder 164 which is driven by the driven roller 162, and an actuator 166 pivotally connected to the yarn feeder for pivoting the yarn feeder. Accordingly, there can be several yarn feeders 164 and actuators 166 associated with each tufting needle 18. In exemplary aspects, the yarn feed assembly 26 can comprise a yarn cylinder 168 as further disclosed herein.
Each driven roller 162 can be concentrically mounted about a drive shaft which extends the length of the tufting apparatus 10. Each drive shaft can be independently driven by respective electric motors (not shown). Therefore, each driven roller can be rotated at different speeds allowing for different yarn feed rates. As is known in the art, this can allow for tufts of different pile height in the same tufted good.
Each yarn feeder actuator 166 can move the respective yarn feeder 164 into and out of peripheral engagement with the respective driven roller 162. Suitable actuators can include a pneumatic cylinder and other reciprocating devices such as an electric solenoid or a hydraulic actuator.
Optionally, a manifold bar 224 (also referred to as a manifold block) can extend between the vertical end frames 40 of the tufting frame 12 and receive the yarn 160 from each of the yarn feeders 164 along the length of tufting apparatus. In some aspects, the manifold bar 224 can be stationary. In other aspects, the manifold bar 224 can be configured to reciprocate. The manifold bar 224 can have a plurality of passageways 225 (
Conventionally, with reference to
Referring to
Conventional hollow needle tufting machines require air pressures throughout the yarn exchange process that are high enough to drive the yarns for the tufting process but low enough so that the yarns are not blown back out of the yarn exchanger due to air back pressure. The air pressures for holding and feeding the yarns for tufting are typically different, with a Low Air Pressure (LP) used for holding the yarn in a position and a High Air Pressure (HP) used for tufting or facilitating feeding of the yarns. There is also an air injector in the yarn exchanger positioned just above the top/opening of the hollow needle, referred to as the needle injector. The needle injector receives air (needle pressure) to act on and drive all yarns inside the needle through it for the tufting process. Conventional hollow needle tufting machines can include air reliefs built into the funnel block to aid in overcoming some of the back pressure issues that can arise disrupting yarn flow, but the amount of relief is limited due to other phenomena. For example, the air relief or air escape vents cannot be too large, or yarns will tend to escape the funnel block with the relief air too, diverting the yarn flow from tufting to outside the tufting and into the surrounding atmosphere. Such complications can create a machine stop and runnability issues. The running air pressures on conventional hollow needle tufting machines are typically as high as HP=80, LP=60 and needle pressure=80 PSIG, but often are run at lower pressures (e.g., HP=60, LP=40). Air pressures higher than these maximum values can cause runnability issues due to yarns blowing out of the manifold bar/yarn exchanger due to back pressures, and/or yarns drooping between a jerker (described further herein) and the manifold bar 224 during the yarn selections and insertion into the funnel block/hollow needle due to limited yarn flow velocity.
These conventional air pressures are unsuitable when tufting turf yarns. For example, in some aspects, in order to tuft turf yarns using a hollow needle tufting apparatus as disclosed herein, the HP can be set above 80 psig (for example, about 85 psig, or at least 85 psig, or at least 90 psig (e.g., from 85 psig to 120 psig or from 90 psig to 120 psig) or about 100 psig or more than 100 psig (e.g., from 100 psig to 120 psig), or above 120 psig (e.g., from 120 psig to 140 psig)). The LP can be at least 70 psig (for example, at least 75 psig (e.g., from 75 psig to 100 psig), about 80 psig, or above 80 psig (e.g., from 80 psig to 100 psig)). The needle pressure can be set above 80 psig. For example, the needle pressure can be set at at least 85 psig, or at least 90 psig (e.g., above 90 psig, from 85 psig to 120 psig, from 90 psig to 120 psig, at least 95 psig, from 95 psig to 120 psig, or about 100 psig, or more than 100 psig, or from 100 psig to 120 psig, or above 120 psig). Accordingly, consistent with the present disclosure, it has been discovered that pressures substantially higher than conventional pressures can achieve improved results when used with the yarns included in turf products. This is contrary to conventional wisdom, as high pressures are expected to cause runnability issues for tufted articles. Further, the increased pressures can enable production efficiency far exceeding conventional turf tufting machine efficiency levels.
In some optional aspects, it is contemplated that the needle pressure can be constant or substantially constant during operation.
In some optional aspects, the HP value can be equal or substantially equal to the needle pressure value.
It is further contemplated that the step of reducing the pressure from the HP setting to a LP setting (the air pressure for maintaining stationary yarn positions) can be omitted so that the air pressure provided to the yarns flowing through the hollow needles from the exchanger remains at the same HP value throughout the yarn exchange process. In other words, the pressure can remain the same for all yarns entering the yarn exchanger, and the pressure need not be modulated to a lower pressure (e.g., for maintaining stationary yarn positions).
Optionally, as further disclosed herein, the at least one yarn feed assembly 26 can comprise at least one servo motor (optionally, a plurality of servo motors), with each servo motor being configured to control delivery of a respective yarn in accordance with processor control based on an automated process, pattern file, or through instructions received from a user/operator (e.g., through a human-machine interface (HMI)).
Referring to
The jerker 500 can further comprise at least one guide 520 relative to which the clevis moves and along which the yarn travels. For example, the jerker can comprise a pair of guides 520 on opposite sides of the clevis 502. The yarn can move across the guides 520 and through the clevis 520. The clevis 502 can move relative to the pair of guides 520, and the guides can be positioned relative to the clevis 502 to amplify or increase (e.g., double) the movement of yarn in response to movement of the clevis.
A conventional jerker is shown schematically in
Conventionally, each yarn travels through a respective hole 521 in each guide 520 (
In some aspects, and with reference to
Referring to
As another example, with reference to
The control system 30 of the tufting apparatus 10 can receive instructions from an operator and/or a pattern file input (separate from the operator instructions) for making a particular product such as a patterned carpet. In use, as further described herein, the control system can control the various subsystems of the tufting apparatus, including the backing transport system 14, the needle actuation assembly 20, the yarn cutting assembly 22, and the yarn feed assembly 26, in accordance with the operator's instructions to make the desired product. As shown in the schematic diagram of
The motion controller 250 can control and coordinate the motors mounted on the tufting apparatus 10 for driving the backing transport system 16, the needle actuation assembly 20 via the main drive shaft 118, and the yarn feed assembly 26 via the driven rollers 162, The motion controller 250 can communicate with the yarn controller 252 and generate data representing the position and speed of movement of the main drive shaft 118. The motion controller can include a processor, which can be provided as a component of a computing device, such as a personal computer, a laptop computer, a tablet, a smartphone, a programmable logic controller, and the like. An exemplary motion controller is a GALIL model 1040 motion controller manufactured by GALIL Motion Control, Inc., of Sunnyville, Calif.
The yarn controller 252 can comprise at least one computing device (such as a personal computer, a laptop computer, a tablet, a smartphone, a programmable logic controller, a programmable automation controller, at least one servo drive, at least one hardware interfacing device, and the like) that is programmed with operator utility software and run time software and generally stores yarn color pattern information and controls operation of the yarn feed assembly 26 in accordance with the selected multi-colored pattern. The operator utilities software can include functions such as selecting pattern files from a pattern input 258 such as a stored pattern file, decompressing or compressing pattern files, changing pattern colors, setting up the yarn creel, and performing diagnostic functions with the yarn control input/output. Optionally, patterns such as multi-colored patterns for carpet can be scanned using a conventional multicolor pattern scanning device, translated into a pattern file, and downloaded onto a disk, flash drive, or the hard drive of the yarn controller 252. The operator can input instructions through the operator control interface 256 for the timing of the tufting operation.
The run time software can control the yarn colors and pattern generation during operation of the tufting apparatus 10. The run time software can allocate the pattern information from the pattern file to the correct needles 18 at the correct time relative to the position of the main driveshaft 118. In the event the yarn feed comprises at least one servo motor for controlling delivery of an individual yarn, the run time software can provide pattern information to each servo motor to ensure that the yarn is delivered in the correct amount and at the correct rate.
The cutting system controller 254 can comprise at least one computing device (such as a personal computer, a laptop computer, a tablet, a smartphone, a programmable logic controller, a programmable automation controller, at least one hardware interfacing device, and the like) that controls the yarn cutting assembly 22 in accordance with a cut/loop pattern so as to selectively cut the yarn and plant it in the backing to form a cut tuft or alternatively form a loop tuft, so that the tufted good has both cut tufts and looped tufts. Like the yarn controller 252, the cutter controller 254 can include operator utility software and run time software. The cutting system controller 254, however, can receive and store cut/loop pattern information from a cut/loop pattern input 260 such as a stored pattern file.
The run time software of the cutting system controller 254 can allocate the pattern information to the appropriate knife blades 113 at the correct time relative to the main shaft 118 position, and send a signal to the appropriate knife blade reciprocating mechanism 140 to selectively cut yarn or not cut yarn to form the desired cut/loop pattern. Although the yarn controller 252 and the cutting system controller 254 are synchronized, they can operate independently of one another so that yarn color patterns and cut/loop patterns can be implemented independently for each tufted good. Therefore, any yarn color pattern can be combined with any cut/loop pattern to produce a wider variety of tufted goods.
After the tufting apparatus 10 is properly set up, the tufting apparatus can produce, in one pass, tufted patterned articles, such as carpet, carpet tiles, turf products, and the like. Optionally, the tufting apparatus 10 can be configured to produce multi-colored articles. For example, the tufting apparatus 10 can be set up to deliver six different yarns to each needle, but also could be set up to produce carpet or turf having a pattern with more or less than six colors. In addition, the tufting apparatus 10 can produce a patterned carpet or patterned turf having some cut tufts and some loop tufts. The cut and loop tufts can be arranged to form a pattern themselves independent from the yarn color pattern. Furthermore, the tufting apparatus can be set up to produce a patterned article having tufts of different pile heights in the same carpet or turf article and can be set up to produce patterned carpet or patterned turf having various tuft constructions (i.e., various gauges and stitch rates). These methods are explained in more detail below.
To set up the tufting apparatus 10, the control system 30 can first be programmed with the appropriate pattern and the timing data, and the air pressures for the pneumatic systems and the presser foot can be set via the operator control interface touch screen 256 to levels appropriate for the types of yarns being used. The yarn color pattern can be fed to the yarn controller 252 through the yarn color pattern input 258, and the cut/loop pattern can be fed to the cutting system controller 254 through the cut/loop pattern input 260. The speeds of the driven rollers 162, 71, 75 and bed plates 94, 96 in the needle actuation assembly 20 can be set to achieve the desired pile height, stitch gauge, or stitch rate for the tufts. Next, the backing 16 can be fed into the backing transport system 14, and the yarns can be mounted on the creel and fed through overhead tubes, the yarn supply mechanisms 26, and the yarn delivery tubes 228 to the yarn applicator 20.
The motion controller 250 can also be programmed with the stitch gauge of the pattern being used so that the backing advance motors, the backing shifting motors and the main drive motors cooperate to reproduce the desired pattern in the tufted product. The tufting operation can be initiated by the operator by sending a start signal to the control system 30. The backing transport system 14, the yarn applicator system 20, the yarn cutting system 22, and the yarn feed mechanism 26 can then begin simultaneous operation to produce carpet or turf having the pattern being implemented by the control system 30. Each full rotation of the main drive shaft 118 is a cycle of the tufting apparatus 10. Through the adjustable cam assemblies 110 and the link assemblies 112, the needles 18 can be reciprocated by the rotation of the main drive shaft 118. For every rotation of the main drive shaft 118, the needles 18 can reciprocate through a full cycle which includes a downstroke and upstroke. During each reciprocation cycle of the yarn applicator 20, the needles 18 can implant a yarn tuft into the backing 16. As the backing advance motors advance the backing 16 and the backing shifting motors move the backing transversely to the direction of advancement of the backing, the reciprocating needles 18 can penetrate the backing and implant yarn in the backing successively along transverse rows.
During each cycle of the tufting apparatus 10, yarns can be fed to the needles 18 by the yarn feeders 164. The yarn feeders can feed a yarn to each needle 18 during each stroke so that a yarn is tufted by each needle at each penetration of the backing 16 by the needles. In accordance with data sent by the yarn controller 252 to tufting apparatus 10, the yarn feed mechanisms 26 can feed yarn, selectively retract or not retract yarn, or hold yarn in accordance with the pattern being implemented by the yarn controller. Optionally, the yarn feed mechanisms 26 can be configured to provide unidirectional yarn flow such that they do not retract yarn.
In some aspects, a method can comprise using a hollow needle tufting machine as disclosed herein to form a tufted article. In some aspects, the tufted article can be artificial turf. In these aspects, the hollow needle tufting machine can tuft turf yarn. In additional aspects, the tufting machine can tuft a yarn (or a plurality of yarns) having a denier of at least 4000, or at least 5000, or at least 6000, or at least 7000 (e.g., ranging from 4,000 to 25,000 or from 5,000 to 20,000). In further aspects, the tufting machine can tuft a staple fiber yarn(s) (as opposed to a bulk continuous fiber (BCF)) to form a tufted article. Optionally, in these aspects, the tufting machine can tuft one or more wool yarns to form a tufted article. In other aspects, the tufting machine can tuft BCF. In some aspects, the yarn does not comprise polyethylene terephthalate (PET). For example, the yarn can comprise polystyrene. However, in other aspects, it is contemplated that yarn comprising PET can be tufted using the disclosed methods. In various aspects, the tufting machine can tuft yarn comprising polyethylene or polypropylene. More generally, it is contemplated that any material suitable for use as an artificial turf face fiber can be used in the disclosed systems and methods. For example, in some optional aspects, it is contemplated that yarns comprising nylon and yarns comprising a combination of polymer materials can be used. In various aspects, the yarns can comprise one or more of a conventional nylon, polyester, polypropylene (PP), polyethylene (PE), polyurethane (PU), thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyethylene terephthalate (PET), polypropylene terephthalate (PPT), polybutylene terephthalate (PBT), polytrimethylene terephthalate (PTT), ethylene vinyl acetate (EVA), latex, styrene butadiene rubber, or any combination thereof. It is contemplated that the conventional nylon of the yarns can be, for example and without limitation, nylon 6/6, nylon 6, nylon 10, nylon 10/10, nylon 10/11, nylon 11, and the like. Additionally, the yarns can comprise natural fibers, such as cotton, wool, or jute. In exemplary aspects, the yarns can comprise one or more biodegradable materials, including, for example and without limitation, polylactic acid (PLA).
As disclosed herein, the yarns can be turf yarns. That is, the yarns can be configured to simulate synthetic grass in feel (e.g., performance). In further optional aspects, the turf yarns can be configured to simulate the look (e.g., color and texture) of synthetic grass. Optionally, the disclosed turf yarns can have a denier per filament (dpf) ranging from 61 to 3600 dpf or from 100 to 3600 dpf or from 200 to 3600 dpf or from 500 to 3600 dpf. However, it is contemplated that other dpf values can be used depending on the particular application and desired performance properties.
For example, in some aspects, the turf yarn can be or comprise monofilament yarn. The monofilament yarn can be produced by extruding molten polymer through a spinneret. The monofilament can be drawn to provide a desired strength and elasticity. The shape of the cross-section of the yarn can be dictated by a spinneret hole and can be, for example and without limitation, a diamond shape, a serrated diamond shape, a half-moon shape, or an oval or round shape. The monofilament yarns can comprise multiple filaments, such as, for example, from about 2 to about 20 filaments, or from about 6 to about 12 filaments, or 6, 8, or 12 filaments. In some optional aspects, each filament can simulate a blade of grass. The filaments can be provided in various deniers and colors. In exemplary aspects, the monofilament yarn can comprise, for example, 7200 denier to 10800 denier. For example, the yarn can be from 7200 denier/4 filament (1,800 denier per filament/blade)−10800 denier/6 filament (1,800 denier per filament/blade).
In some aspects, the turf yarn can be or comprise thatch/texturized yarn. Thatch/texturized can be a specialized type of monofilament yarn. Thatch/texturized yarn is available in various deniers, texture levels, and colors. These yarns can be used below the face yarn in artificial turf to enhance the turf's ability to recover. In exemplary aspects, the thatch/texturized yarn can have a denier from 4500-5000 (e.g., 4500 denier/8 filament (562 denier per filament/blade)−5000 denier/8 filament (625 denier per filament/blade)).
In some aspects, the turf yarn can be or comprise tape/fibrillated yarn. Tape/fibrillated yarns can be formed by extruding a thin film that is subsequently cut into small strips and fibrillated, resulting in a honeycomb-like structure. The process creates a soft, natural-looking surface. They are available in various deniers and colors. For example, an exemplary denier range for tape/fibrillated yarn can be from 5000 denier to 9000 denier.
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In some aspects, the primary backing, through which tufts 640 are tufted, can be a single ply primary backing. Optionally, the weight can be about double the weight of a conventional primary backing. Additionally, the thickness can be about double the thickness of a conventional primary backing. For example, conventional primary backings usually have a weight within a range of 3 oz/yd2 to 4 oz/yd2. In some aspects, the backing of the disclosed article can have a weight from 5 oz/yd2 to 8 oz/yd2, or from 6 oz/yd2 to 7 oz/yd2 (e.g., between 6.2 and 6.4 oz/yd2). In exemplary aspects, the primary backing can be woven. For example, the primary backing can have 13 picks (weft threads) per inch by 22 warp rows per inch.
In some aspects, the article can comprise at least 2 different types of yarn, at least 3 different types of yarn, at least 4 different types of yarn, at least 5 different types of yarn, or at least 6 different types of yarn. For example, the article can comprise at least 2 different colors of yarn, at least 3 different colors of yarn, 4 different colors of yarn, at least 5 different colors of yarn, or at least 6 different colors of yarn. In some aspects, one or more rows of tufts (e.g., rows extending the along the axis the backing moves relative to the tufting machine) can comprise at least 2 different types of yarn, at least 3 different types of yarn, 4 different types of yarn, at least 5 different types of yarn, or at least 6 different types of yarn. The different types (e.g., different color, yarn type, or yarn size) of yarn can be provided in different regions to form a particular pattern. The particular pattern can be, for example, a logo, symbol, graphics, text, aesthetic appearance, or combinations thereof. In further aspects, the different regions can have different pile heights. Thus, for example, a first region within a pattern can have a first pile height, and a second region within the same pattern (optionally, adjacent to the first region) can have a second pile height that is greater than or less than the first pile height. Optionally, in this example, the first region can include at least one yarn (optionally, a plurality of yarns) that is of a different color than any yarn within the second region. In further optional aspects, the yarn(s) within the first region can all be identical or substantially identical, and the yarn(s) within the second region can all be identical or substantially identical.
Optionally, in exemplary aspects, the tufted articles can comprise artificial turf articles (e.g., artificial turf panels). In further optional aspects, and as further disclosed herein, it is contemplated that the surface covering can be at least a portion of a sports field, such as a baseball field, a football field, a tennis court, a golf course, a cricket field, a soccer field, a pickleball court and the like. In exemplary aspects, it is contemplated that complementary patterned regions of adjacent tufted articles can cooperate to form particular sections of a sports field, such as, for example and without limitation, a tee box, fairway, rough, approach, collar, and/or green of a golf course, a grass, skin, and/or track area of a baseball field, a grass and/or pitch area of cricket grounds, white line sections for a tennis court, and the like. The particular pattern formed by the different types (e.g., colors) of yarns in different regions can cooperate to form markings that allow for usage of the field without the need for using separate processes (e.g., cutting, patching, and the like). Such markings include, for example and without limitation, boundaries, hash marks, yard marks, and other markings that are required for play.
Optionally, a plurality of such articles can be provided to form a surface covering, or a portion thereof. For example, the articles can form some of or an entirety of an athletic field, such as, for example and without limitation, a baseball field, a football field, a tennis court, a golf course, a cricket field, a lacrosse field, a field hockey field, a soccer field, or a pickleball court.
In some aspects, the articles can have a length of at least 80 feet, or at least 90 feet, or at least 150 feet. For example, the articles can be configured to extend an entirety of, or substantially an entire dimension of a playing area of a sports field (e.g., a football field, a soccer field, a tennis court, or a pickleball court.) Additional exemplary patterns consistent with articles and surface coverings disclosed herein are described in U.S. patent application Ser. No. 17/476,870, filed Sep. 16, 2021, the entirety of which is incorporated by reference herein for all purposes.
In still further aspects, it is contemplated that the disclosed articles can be used in landscaping, commercial, residential, or industrial applications. For example, it is contemplated that the articles disclosed herein can be used to form surface coverings that are positioned in various open spaces, such as for example, and without limitation, a park, an airport runway, a landfill cover, a home or office lawn or greenspace, an indoor or outdoor gathering space, or the like. Optionally, in these applications, it is contemplated that the tufted articles can be provided with wayfinding markings, logos, graphics, text, or combinations thereof.
Optionally, the tufted article 10 can comprise infill 6500 (e.g., sand). The infill can optionally be provided at a weight ranging from about 1 lb/sq. yard to about 9 lb/sq. yard. In these aspects, it is contemplated that the infill can comprise a single component or any combination of a plurality of components. When the infill comprises a plurality of components, it is contemplated that the infill material can optionally comprise a plurality of layers, with each layer corresponding to a different infill component or combination of components. Alternatively, it is contemplated that the plurality of components can be provided as a mixture, which can be either homogenous or non-homogenous. In exemplary aspects, it is contemplated that the infill can comprise clay, TPE, EPDM, coconut husks, walnut shells, crushed brick, sand, or combinations thereof. More generally, it is contemplated that the infill can comprise any material that is capable of imparting desired characteristics to a surface covering (e.g., a floor or ground covering) as disclosed herein. In further aspects, the tufted article 10 does not comprise infill (and is not filled during use).
With conventional hollow needle tufting machines, certain yarns, such as larger (e.g., turf) yarns, will not typically flow well through the jerker and associated guides or enter air manifold block openings to the yarn conduits leading to the funnel block and needle. Due to physical restraints and friction, certain yarns will not flow well through the air manifold block conduits and into the hollow needle. Staple yarns have similar inherent issues as the larger yarns, as short staples protruding from the yarns restrict yarn flow, particularly into and through the air manifold block conduits, and many times interact with other yarns flowing into and out of the funnel block and hollow zones during the yarn exchange process (yarns that are passing in these shared areas). The unfavorable staple yarn interaction results in yarns mixing or entangling together in the funnel block and/or needle, resulting in the yarn flow stopping, machine stops, and service required to clear the resultant air entanglements before tufting can continue. Notwithstanding these issues, many staple yarns and/or untwisted yarns have inherent and undesirable yarn interactions before the yarn feed mechanisms and after the yarn feed mechanisms, before the jerker. Adjacent yarns tend to mix and entangle together as they twist or rotate during tufting machine feeding or any yarn movement (e.g., as the yarns exit the creel tubing or header that is conventionally fixed above the tufting machine), thereby entangling the yarns together, inhibiting yarn flow during and for the tufting process and forcing a machine stop to service the yarn coming into the jerkers. These phenomena can prevent the conventional yarn tufting machines from running at acceptable run-efficiency levels and/or can cause tufting machine down time or articles of deficient quality.
The disclosed tufting machine can address one or more of these deficiencies. For example, the disclosed manifold bar can reduce friction of yarn passing therethrough. Further, the disclosed jerker can prevent pinching yarns between the clevis and the guides. The increased air pressures provided in the yarn exchange process can permit turf-tufting efficiency exceeding historical speeds. Additionally, the reduced foot injector pressures can improve operation and tufted article (e.g., tufted artificial turf) quality.
In view of the described products, systems, and methods and variations thereof, herein below are described certain more particularly described aspects of the invention. These particularly recited aspects should not however be interpreted to have any limiting effect on any different claims containing different or more general teachings described herein, or that the “particular” aspects are somehow limited in some way other than the inherent meanings of the language literally used therein.
Although several embodiments of the invention have been disclosed in the foregoing specification, it is understood by those skilled in the art that many modifications and other embodiments of the invention will come to mind to which the invention pertains, having the benefit of the teaching presented in the foregoing description and associated drawings. It is thus understood that the invention is not limited to the specific embodiments disclosed hereinabove, and that many modifications and other embodiments are intended to be included within the scope of the appended claims. Moreover, although specific terms are employed herein, as well as in the claims which follow, they are used only in a generic and descriptive sense, and not for the purposes of limiting the described invention, nor the claims which follow.
This application claims priority to and the benefit of the filing date of U.S. Provisional Patent Application No. 63/598,369, filed Nov. 13, 2023, the entirety of which is incorporated by reference herein.
| Number | Date | Country | |
|---|---|---|---|
| 63598369 | Nov 2023 | US |
