Method and apparatus for making pile fabrics from a block of pile yarns

Claim 3

A method according to claim 1, which includes following the depositing of the pile yarns, the step of pressing the successive deposited pile yarns and the backing together to aid in connecting the deposited pile yarns to the backing.

Claim 4

A method according to claim 1, including the steps of drying and curing the adhesive on the adhesive-coated backing while pressing the deposited pile yarns and the backing together to aid in connecting the deposited pile yarns and the backing together.

Claim 5

A method according to claim 1, which includes moving the block of pile yarns over the backing and over a stationarily mounted severing means in the same general direction as that in which the backing is being advanced during the severing of the pile yarns and the depositing of the severed pile yarns onto the backing.

Claim 6

A method according to claim 4, in which the advancing of the backing comprises advancing the same at a faster rate than that at which the block of pile yarns is being moved to obtain a desired density of the severed pile yarns on the backing.

Claim 7

A method according to claim 4, in which the advancing of the backing comprises imparting stepwise forward movements thereto with the length of each step substantially corresponding to that length of pile fabric to be formed by the severing of one slice from the pile yarns, and moving the block of pile yarns rearwardly of the severed pile yarns last deposited onto the backing following the severing of each successive slice from the pile yarns and during respective intervals between successive stepwise forward movements of the backing.

Claim 8

A method according to claim 6, which includes continuously feeding the backing forwardly from a source located rearwardly of the severing means while accumulating a length of the fed backing at a location rearwardly of the severing means but forwardly of the source, and wherein the step of imparting stepwise forward movements to the backing comprises drawing the backing from the accumulated length during each stepwise movement of the backing.

Claim 9

A method according to claim 6, which includes continuously feeding the backing from a source rearwardly of and toward the severing means while forming a catenary loop of the backing at a location upstream of the severing means, and the step of imparting stepwise forward movements to the backing including drawing the backing from the catenary loop past the severing means during each of said stepwise movements.

Claim 10

A method according to claim 6, in which the advancing of the backing further comprises accumulating a length of the pile fabric formed of the backing during advancement thereof at a location downstream of the severing means, and said method further comprising contiNuously taking up the pile fabric downstream of the accumulated length of the pile fabric by withdrawing the pile fabric from the accumulated length at a rate substantially in accord with the average rate of the stepwise forward movements of the backing past the severing means.

Claim 11

A method according to claim 6, wherein the advancing of the backing further comprises forming a catenary loop of the pile fabric during advancement thereof at a location downstream of the severing means, and said method further comprising continuously taking up the pile fabric downstream of the catenary loop by withdrawing the pile fabric from the loop at a rate substantially in accord with the average rate of the stepwise forward movements of the backing past the severing means.

Claim 12

A method according to claim 1, which includes applying an adhesive material to the end of the block of yarns before each severing of the pile yarns transversely of their axes to aid in the subsequent connecting of the respective severed pile yarns to the adhesive-coated backing.

Claim 13

A method according to claim 1, which includes moving the block of pile yarns over the backing and in the same general direction as that at which the backing is being advanced during the severing of the pile yarns and the depositing of the severed pile yarns on the backing, and wherein the severing of the pile yarns is effected at a predetermined substantially fixed point in the path of travel of the pile yarn block, and the advancing of the backing relative to the block of pile yarns including moving the backing in a path converging toward and into close proximity to the path of the block of pile yarns at said fixed point to aid in the depositing of the severed pile yarns onto the backing.

Claim 16

A method according to claim 13, wherein the support is a backing and including the step of fusibly securing the slice being formed to the upper surface of the backing.

Claim 19

A method according to claim 15, which also includes advancing the backing forwardly upstream of the tuft forming zone by moving the backing in substantially spaced relation below the horizontal plane of the path of the container in the course of movement of the backing into the tuft forming zone, and said method further including the step of subjecting the lower ends of the pile yarns in the block to a treatment which renders the lower ends of the pile yarns adhesive during that portion of the forward movement of the container and the block of pile yarns upstream of the tuft forming zone.

Claim 20

A method according to claim 15, wherein the severing of tufts from the pile yarns in the block includes moving the yarn block past and in engagement with a laterally moving cutting blade occupying a predetermined substantially horizontal position in said tuft forming zone, and said method further comprising maintaining the container on a higher level during rearward movement thereof over the cutting blade than the level occupied by the container during its forward movement past the cutting blade so that the lower surface of the yarn block is spaced above and out of contact with the cutting blade during rearward movement of the yarn block.

Claim 23

A method according to claim 18, which includes moving the block of pile yarns over the adhesive-coated backing and over a stationarily mounted severing means in the same general direction as that in which the backing is being advanced during the severing of the pile yarns and the depositing of the tufts onto the backing.

Claim 24

A method according to claim 18, which includes following the depositing of the tufts, the step of pressing the successive deposited tufts and the backing together to aid in connecting the deposited tufts to the backing.

Claim 25

A method according to claim 18, which includes moving the block of pile yarns over the adhesive-coated backing and over a stationarily mounted severing means in the same general direction as that in which the backing is being advanced during the severing of the pile yarns and the depositing of the tufts onto the backing, and wherein the advancing of the backing comprises advancing the same at a faster rate than that at which the block of pile yarns is being moved to obtain a desired density of the tufts on the backing.

Claim 26

A method according to claim 21, in which the advancing of the backing further comprises imparting stepwise forward movements thereto with the length of each forward step substantially corresponding to that length of pile fabric to be formed by the severing of one slice from the pile yarns, and said method also including the step of moving the block of pile yarns rearwardly of the severed pile yarns last deposited onto the backing following the severing of each successive slice from the pile yarns and during respective intervals between successive stepwise forward movements of the backing.

Claim 27

A method according to claim 22, which includes successively drying and curing the adhesive coating on the backing by moving the pile fabric formed of the backing and tufts forwardly through a heated zone downstream of the severing means during the stepwise forward movements of the pile fabric, and cooling the pile fabric by advancing the same through a cooling zone forwardly of the heated zone during the stepwise forward movements of the pile fabric, the advancing of the backing further comprising accumulating a length of the pile fabric during the stepwise forward movements thereof at a location forwardly of the cooling zone, and said method further comprising continuously taking up the pile fabric forwardly of the accumulated length of the pile fabric by withdrawing the pile fabric from the accumulated length at a rate substantially in accord with the average rate of the stepwise forward movements of the backing past the severing means.

Claim 28

Apparatus for making pile fabrics such as carpets and the like from pile yarns and a backing and comprising an open-ended container for accommodating therein a block of substantially parallel pile yarns, means supporting said container with the pile yarn axes extending substantially vertical therein, means for incrementally feeding the pile yarns downwardly parallel to their axes from said container in successive increments of an amount equal to a desired pile length, means cooperating with said feeding means for progressively severing the pile yarns transversely of their axes to form cut tufts thereof following each incremental feeding of the pile yarns from said container, means for applying a coating of adhesive material to the backing, and means for advancing the backing forwardly relative to and closely beneath the yarn block and said severing means during the severing of the pile yarns so that the tufts being formed of the pile yarns are progressively deposited onto the adhesive-coated backing and thereby joined to the backing during the progressive severing of the pile yarns.

Claim 29

Apparatus for making pile fabrics such as carpets and the like from pile yarns and a backing and comprising an open-ended container for accommodating therein a block of substantially parallel pile yarns, means supporting said container with the pile yarn axes extending substantially vertical therein, means for incrementally feeding the pile yarns downwardly parallel to their axes from said container in successive increments of an amount equal to a desired pile length, means cooperating with said feeding means for progressively severing the pile yarns transversely of their axes to form cut tufts thereof following each incremental feeding of the pile yarns from said container, means for applying a coating of adhesive material to the backing, and means for advancing the backing forwardly relative to and closely beneath the yarn block and said severing means during the severing of the pile yarns so that the tufts being formed of the pile yarns are progressively deposited onto the adhesive-coated backing and thereby joined to the backing during the progressive severing of the pile yarns.

Claim 30

Apparatus according to claim 24, including means stationarily mounting said severing means, and drive means operatively connected to said container for imparting forward movement thereto past said severing means and at a slower rate than that of the backing.

Claim 31

Apparatus according to claim 25, including means connecting said drive means to said backing advancing means, and means interposed between said drive means and said backing advancing means for relatively varying the rate of forward movement of said backing and said container to vary the density of the tufts joined to the backing.

Claim 32

Apparatus for making pile fabrics, such as carpets, rugs and the like, from pile yarns and a backing, said apparatus comprising an open-ended container for containing therein a compact block of substantially parallel, juxtaposed, pile yarns, means operatively associated with said container for incrementally feeding the pile yarns parallel to their axes from one open end of said container in increments of an amount equal to the desired length of pile, means for moving said container forwardly in a predetermined path transversely of the pile yarn axes, severing means in the forwArd path of travel of each successive increment of pile yarns fed from said container and arranged to progressively sever the ends of the pile yarns during forward movement of said container past said severing means to form tufts of the pile yarns, means for applying an adhesive coating to the backing, and means for advancing the adhesive-coated backing forwardly past and adjacent said severing means and adjacent said pile yarn block during the severing of the pile yarns so that the tufts being formed are progressively deposited onto the backing and joined thereto during the severing of the pile yarns.

Claim 33

Apparatus for making pile fabrics, such as carpets, rugs and the like, from pile yarns and a backing, said apparatus comprising an open-ended container for containing therein a compact block of substantially parallel, juxtaposed, pile yarns, means operatively associated with said container for incrementally feeding the pile yarns parallel to their axes from one open end of said container in increments of an amount equal to the desired length of pile, means for moving said container forwardly in a predetermined path transversely of the pile yarn axes, severing means in the forwArd path of travel of each successive increment of pile yarns fed from said container and arranged to progressively sever the ends of the pile yarns during forward movement of said container past said severing means to form tufts of the pile yarns, means for applying an adhesive coating to the backing, and means for advancing the adhesive-coated backing forwardly past and adjacent said severing means and adjacent said pile yarn block during the severing of the pile yarns so that the tufts being formed are progressively deposited onto the backing and joined thereto during the severing of the pile yarns.

Claim 34

Apparatus according to claim 27, including driving connections between said container moving means and said backing advancing means, and means interposed in said driving connections for varying the rate of advancement of said backing relative to the rate of forward movement of said container to vary the density of the tufts deposited onto the backing.

Claim 35

Apparatus according to claim 27, including means associated with said backing advancing means for adjustably supporting said backing for movement in predetermined spaced relation below said severing means, and means for varying the extent of each increment of feed of said means for incrementally feeding the pile yarns from said container whereby the length of tufts deposited onto the backing may be varied.

Claim 36

Apparatus according to claim 27, including guide means for guiding the backing in a path converging forwardly toward and into close proximity to said severing means and said path of said container, and said guide means also including means for guiding the backing in a forwardly diverging path away from said severing means and away from said forward path of said container, and means positioned forwardly of said severing means and between said path of said container and said diverging path of said backing for pressing the tufts and the backing together to aid in securing the tufts to the backing.

Claim 37

Apparatus according to claim 27, wherein said severing means comprises an elongate cutting blade extending transversely across the path of said container, and said container including a transverse shield member having an elongate forwardly facing recess therein and disposed at the trailing edge of said compact block of pile yarns, the recess in said shield member being so positioned as to receive said cutting blade therein during the forward movements of said container past said severing means so that said shield member will aid in supporting each successive increment of the pile yarns at the rear end of the pile yarn block during the severing thereof in the course of each forward movement of said container.

Claim 38

Apparatus according to claim 27, including means forwardly of said severing means for heating the pile fabric formed from the tufts and the backing for drying and curing the adhesive on the adhesive-coated backing.

Claim 39

Apparatus according to claim 32, including means downstream of said heating means for cooling the previously heated pile fabric during the advancement of the pile fabric.

Claim 40

Apparatus for making pile fabric such as carpets, rugs and the like, from pile yarns and a backing, said apparatus comprising a container having an open lower end and containing therein a compact block of substantially parallel pile yarns, container guide means for guiding said container in a substantially horizontal path with the axes of the pile yarns substantially vertically disposed and projecting from the open lower end of said container, means for moving said container forwardly and rearwardly along said path in alternation, severing means positioned closely adjacent and below the path of said container and arranged to sever the lower ends of the pile yarns projecting from the open lower end of said container to form tufts thereof during each forward movement of said container past said severing means, backing guide means for guiding the backing in an abruptly changing path converging forwardly and upwardly toward and into close proximity to said severing means and said path of said container, adhesive applying means disposed rearwardly of said severing means for applying an adhesive coating to the upper surface of the backing in its course to said severing means, means operatively associated with said container for incrementally feeding the pile yarns downwardly from the open lower end of said container in increments of an amount equal to the desired length of pile while the container occupies a position rearwardly of said severing means, and means operable periodically and in timed relation with the forward movements of said container for advancing the adhesive-coated backing forwardly along said abruptly changing path past and adjacent said severing means at a faster rate than the rate of each respective forward movement of said container during the severing of tufts from the lower ends of the pile yarns in the block so that the tufts being formed are progressively deposited onto the backing and joined thereto to form the pile fabric during the severing of the pile yarns.

Claim 41

Apparatus for making pile fabric such as carpets, rugs and the like, from pile yarns and a backing, said apparatus comprising a container having an open lower end and containing therein a compact block of substantially parallel pile yarns, container guide means for guiding said container in a substantially horizontal path with the axes of the pile yarns substantially vertically disposed and projecting from the open lower end of said container, means for moving said container forwardly and rearwardly along said path in alternation, severing means positioned closely adjacent and below the path of said container and arranged to sever the lower ends of the pile yarns projecting from the open lower end of said container to form tufts thereof during each forward movement of said container past said severing means, backing guide means for guiding the backing in an abruptly changing path converging forwardly and upwardly toward and into close proximity to said severing means and said path of said container, adhesive applying means disposed rearwardly of said severing means for applying an adhesive coating to the upper surface of the backing in its course to said severing means, means operatively associated with said container for incrementally feeding the pile yarns downwardly from the open lower end of said container in increments of an amount equal to the desired length of pile while the container occupies a position rearwardly of said severing means, and means operable periodically and in timed relation with the forward movements of said container for advancing the adhesive-coated backing forwardly along said abruptly changing path past and adjacent said severing means at a faster rate than the rate of each respective forward movement of said container during the severing of tufts from the lower ends of the pile yarns in the block so that the tufts being formed are progressively deposited onto the backing and joined thereto to form the pile fabric during the severing of the pile yarns.

Claim 42

Apparatus according to claim 34, including a variable speed mechanism operatively connected to said backing advancing means for varying the rate of advancement of said backing relative to the rate of forward movement of said container to thereby vary the density of the tufts deposited onto the backing.

Claim 43

Apparatus according to claim 35, including an additional adhesive applying means disposed rearwardly of said backing guide means, and said additional adhesive applying means being disposed adjacent the path of the pile yarn block projecting from the open lower end of said container for applying adhesive to the lower ends of said pile yarns in the course of each forward movement thereof into operative relation to said severing means.

Claim 44

Apparatus according to claim 34, wherein said backing guide means comprises a first endless conveyor having an upper reach on which the backing is supported and advanced past said severing means, and means including an additional endless conveyor positioned closely above and extending in substantially parallel relation to the upper surface of said first endless conveyor and forwardly of said severing means but below the path of travel of said container for pressing the tufts and the adhesive-coated backing together.

Claim 45

Apparatus according to claim 34, wherein said feeding means operatively associated with said container comprises a substantially horizontal pusher plate positioned for substantially vertical movement in and relative to said container for pushing downwardly against the upper ends of the pile yarns in the yarn block, and means operatively connected to said pusher plate for imparting incremental downward movements thereto to push corresponding increments of the pile yarns out of the open lower end of said container.

Claim 46

Apparatus according to claim 34, including means responsive to forward movement of said container into a position closely adjacent said severing means for initiating operation of said backing advancing means, and means responsive to forward movement of said container relative to said severing means for stopping operation of said backing advancing means following the severing and depositing of each successive slice of tufts onto the backing.

Claim 47

Apparatus according to claim 39, including means automatically operable during each rearward movement of said container for elevating said container and maintaining the same in an elevated position so that the lower ends of the pile yarns in said block will clear and be positioned out of engagement with said severing means in the course of each rearward movement thereof.

Claim 48

Apparatus according to claim 34, including means upstream of said backing guide means for feeding said backing in a substantially continuous manner from a source toward said backing guide means, and said backing feeding means including a supporting roll for the backing and spaced rearwardLy of said backing guide means for cooperating therewith so that a length of the backing may be accumulated between said supporting roll and said backing guide means to facilitate the periodic advancement of the backing past said severing means as the backing is being fed continuously by said backing feeding means.

Claim 49

Apparatus according to claim 34, wherein said backing guide means includes a fabric supporting roll at its front end, fabric take-up means downstream of said backing guide means, means for driving said take-up means in a substantially continuous manner, an additional fabric supporting roll spaced forwardly of said first-named fabric supporting roll and supporting the pile fabric in its course to said take-up means, and said supporting rolls being arranged so that a length of the pile fabric may accumulate therebetween to facilitate continuous take-up of the pile fabric during the periodic advancement of the backing past said severing means.