This invention relates to o method of and apparatus for making pile- ^' fabrics.

The invention has been developed primarily In connection with the making of pile carpets but is applicable to pile fabrics generally- One of the most widely practised methods of making a pile carpet wherein the pile is required to present an organised pattern, is that known as the Axminster method. In the Axminster method, tufts which form the pile are introduced into the ground member or backing of the parpet whilst the latter is undergoing weaving, such introduction being effected either by means of grippers which seize individual pile-forming lengths of filamentary material such as yarn, or by means of spools held in spool frames and in which differently coloured, side-by-side, windings of the filamentary material are carried on the spools while the ends protrude through tubular elements of the tube frame.

The mechanisms which it is necessary to provide in looms for weaving such carpets by the Axminster method are relatively complex and slow in operation.

Another widely practised method of making pile carpets utilises needles as the means for introducing pile-forming filamentary material to a pre¬ formed backing or ground member. Machines adapted to operate in accordance with this method are capable of being operated at much higher speeds, but since each needle is threaded with a particular coloured filament from a bulk supply such as a bobbin, production of an organised pile pattern, other than simple stripes, poses problems which have not been satisfactorily solved.

The object of ^' the present invention is to provide a method and apparatus by which patterned pile fabrics, and in particular patterned pile carpets, can be produced at a speed higher than the conventional Axminster method, without serious limiation to the number of colours or complexity of the patterns which can be produced.

According to one aspect, the present invention resides in a method of making a pile fabric comprising the steps of:-

(a) bringing a row of pile-forming lengths of filamentary material arranged side-by-side and collectively into face-to-face relation with a face (herein called the first face) of a pre-formed backing sheet at a tuft-forming station;

(b) pressing each pile-forming length through the backing sheet at positions (herein called insertion positions) inset respectively from opposite ends of the pile-forming length, and spaced apart from each other to cause end portions of the pile-forming length to extend through the backing sheet and to protrude from its opposite face (herein called the second face), while an intermediate portion (herein called the mid-portion) lies against or adjacent to the first face;

(c) advancing the backing material through the tuft-forming station and repeating the operations set forth in sub-clauses (a), (b).

The term "backing sheet" used herein is to be deemed to include any suitable form of backing or ground member whether woven, felted or of homogeneous form and irrespective of the material of which it is made.

The term "filamentary material" used for the pile-forming length is deemed to include any suitable filamentary material for this purpose including yarn as traditionally used, or other filaments whether formed of natural or synthetic material.

The term "face-to-face" used herein is to be deemed to include the case where the pile-forming lengths lie in contact with the first face of the backing sheet and the case where they are adjacent to but spaced from this face.

In cases where it is required that a patterned pile fabric be formed, this method would include the step of selecting each pile-forming length in each row from a plurality of differently coloured filaments. This may be done by utilisation of a colour selector means which may possibly comprise a conventional jacquard mechanism.

The preferred method of conducting the operation of pressing each pile- forming length through the backing sheet is by passing the pile-forming length through aligned eyes of needles penetrating the backing sheet from the second face and protruding from the first face at the insertion positions respectively, and withdrawing the needles through the backing sheet.

OMPI

Selection of the required coloured pile-forming lengths of filamentary material and the bringing of such lengths to the tuft-forming station may be effected by selectively presenting the filamentary material of the required colour at a selector station, seizing said material at the selector station with a gripper movable along a path extending through the aligned eyes of the needles concerned, and drawing a length of said filamentary material through said eyes.

Each of the piie-forming lengths may be severed from a bulk supply of the filamentary material after seizure by the associated gripper, and before completing its passage through the aligned eyes.

From a further aspect, the invention resides in the provision of apparatus for making a pile fabric comprising:-

(a) advancement means for advancing a pre-formed backing sheet stepwise along a feed path through a tuft-forming station;

(b) handling means for bringing a row of pile-forming lengths of filamentary material to the tuft-forming station with the pile- forming lengths in side-by-side relation with each other and collectively in face-to-face relation with a face (herein called the first face) of the backing sheet;

(c) tuft inserting means operative at the tuft-forming station for pressing each of the piie-forming lengths through the backing sheet at positions (herein called insertion positions) inset respectively from opposite ends of the pile-forming length and spaced apart from each other to cause each portion of the pile- forming length to extend through the backing sheet and protrude from its opposite face (herein called the second face) while an intermediate portion (herein called the mid-portion) of the pile- forming length lies against or adjacent to the first face of the backing sheet;

(d) actuating means for actuating the advancement means, handling means, and tuft insertion means in co-ordinated relation.

When a pile fabric presenting an organised pattern is required to be produced, there would be provided, in association with the handling means, a colour selector means for selectively presenting lengths of differently coloured filamentary material at a selector station for bringing to the tuft- forming station by the handling means to enable a patterned pile fabric to be made.

OMFI

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Further, the preferred form of the αppαrαtus:-

(α) the tuft insertion means comprises pairs of tuft inserter needles, with the needles of each pair being spaced apart to define said tuft insertion positions, and the pairs being spaced apart along said row for handling respective pile-forming lengths, threading^' means for drawing the respective pile-forming lengths through aligned eyes of the needles of each pair, when protruding from the first face of the backing sheet; (b) the actuating means provides for penetration of the needles of the backing sheet from its second face, and withdrawal from the backing sheet while threaded with the pile-forming lengths. The threading means may comprise grippers arranged to move along a path extending through the aligned eyes of respective pairs of tuft inserter needles.

The invention will now be described by way of example, with reference to the accompanying drawings, wherein:-

FIGURE I illustrates diagrammatically various stages of one manner of performing the method of the invention;

FIGURE 2 is a diagrammatic view in side elevation and on an enlarged scale showing one embodiment of apparatus in accordance with the invention; and

FIGURE 3 is a view similar to Figure 2 showing the parts of the apparatus In a different position.

Referring firstly to the apparatus illustrated in Figures 2 and 3, the apparatus comprises any suitable structure for supporting a backing sheet, for example a pre-woven sheet of hessϊan, during passage lengthwise through a tuft inserting station 1 1. For convenience, only the portions 10a and I OJD of the backing sheet 10 (Figure l a) respectively approaching and leaving the tuft inserting station 1 1 have been shown. At the tuft inserting station there would be provided, for example, a breast comprising a horizontal plate underlying the path of movement of the backing sheet through the tuft inserting station, and preferably connected at its rearward edge to a step plate 12 ^' descending from the rearward edge of the breast beam. The breast beam would be apertured for upward passage of pairs of tuft inserter needles 13a, 13b, each formed with an elongated eye of which the (leading) upper boundaries are indicated at 1 a, l*.b, and the (trailing) lower boundaries at 15a, 15b.

When aligned as shown In Figure I , these eyes provide a passageway for travel of a handling means in the form of a plurality of grippers, of which one is seen at 16. The dimensions of the needle eyes depthwise, i.e. in the direction of length of the length of the needles, such as to accommodate upper and lower jaws 17 and 18 of each gripper, and allow pivoting about an axis 19 relatively to each other between an open position and a closed position, as seen in Figure 2 when filament ends are required to be siezed which part of the gripper is still within the eyes as hereinafter described.

It will be understood that there are as many grippers as there are pairs of needles and one gripper will be associated with each pair of needles.

The pairs of needles mgy be placed as closely adjacent to each other laterally as possible so as to provide a high lateral pile density which may typically be in the region of 2 to tufts per centimetre width of the backing sheet 10.

Likewise, the two needles of each pair, such as 13a, 13b, although for convenience shown spaced apart by a gap equal to about half the corresponding dimension of each needle may be placed as close together consistent with obtaining reliable anchorage of the pile in the backing sheet, again to obtain a high pile density in the direction of the length of the backing sheet, i.e. the direction in which it is advanced through the tuft inserting station.

The apparatus may comprise any suitable mechanism for advancing the backing sheet stepwise, for example a spiked take-up roller may be provided and disposed at the exit side of the tuft inserting station, round which roller the pile fabric produced is wrapped, while a supply of the backing sheet is provided on a supply roller situated in advance of the tuft inserting station.

In association with the grippers 16 there is provided a pile colour selector means which may comprise a plurality of apertured carrier strips 20 arranged side-by-side and affording pile receiving apertures through which end portions 21 a to 21 b can protrude sufficiently far to the right of the strip 20 to permit of seizure of a selected end by the appropriate one of the grippers 16.

The carrier strips 20 are movable vertically under the control of a selector device such as a jacquard mechanism to bring any one of end portions 21 a to 21 b to a selector station in alignment with the path of movement of the associated gripper 16 in each cycle of operations of the apparatus, thereby control the pattern to be presented by the pile of the fabric.

Knif e means 21 is provided preferably adjacent to the carrier strips 20, and extending across the whole width of the machine. The knife means may comprise a knife element 22 and an anvil element 23 which, as seen in Figures la and 2, can be moved relatively into positions for severing a pile forming length 24 of filamentary material from one of the end portions, suc μ as 21b.

For positional control of the piie-forming lengths, the apparatus may include a comb 25, the dents of which have'their lower edges in contact with the backing sheet and have a height such that their upper edges are more or less coplanar with the upper surface presented by the mid-portions of each inserted pile-forming length These dents lie between adjacent pairs of needles I 3cι, I 3b_ and which are carried by a beam 26. Above the backing sheet a further control comb 28 may be provided having its dents passing between adjacent pairs of needles such as 13(3, I3b_ and supported by a carrier bar 29. This comb in effect acts as a lateral fence for each pile-forming length during the operation of inserting through the backing sheet.

The manner of operation of the apparatus will be described with reference to Figure I , reference being made, as necessary, to the more detailed features illustrated in Figures 2 and 3.

In the stage of Figure la, each carrier strip 20 will have been brought to a predetermined position to present one of the end portions, such as 21 b, of a particular colour at a selector station in the path of movement 16a of the gripper 16 associated with such strip, vertical positioning of the strip by movement in the direction indicated by arrow 30 being effected by an actuating means 31 , controlled by a jacquard cylinder and cards fed through control unit 32 in a conventional manner. For convenience the parts 31 and 32 are omitted from stages shown in Figures 1^ to le.

In the stage of Figure l b, each pair of needles 1 a, I 3t> is moved in the direction of its length to penetrate the backing sheet from its underface (the second face previously referred to) and to protrude above its upper face (the first face previously referred to) with the eyes of the needles in alignment with each other. The upper and lower boundaries of the needles may be symmetrically disposed above and below the path 16a of longitudinal movement of the associated gripper 16, but such symmetrical disposition is not essential.

The gripper 16 is moved by its actuating means to the left, as shown in the stage of Figure l b so that its jaws, which are opened after attainment of the position shown, are disposed above and below the protruding end portion 21b of the filamentary material. The actuating means for the gripper then causes these jaws to close and seize the end portion 21 b preparatory to the--' gripper being retracted to the position illustrated in the stage of Figure lc where typically the nose or leading end of the gripper is level with or just projects a small distance to the left of the needle 13a. The position of the gripper is determined by the length of filamentary material which it is required to cut off to form a tuft for insertion through the backing sheet. It will normally be convenient to effect cut-off before the filament has been drawn through, or fully through, the eyes of the needles but for long pile cut¬ off may be effected at a latter stage of gripper withdrawal. When the gripper 16 has come to rest at the position shown in the stage of Figure l c, knife elements are moved relatively to each other to an operative cutting position to sever the pile-forming length, held only by the jaws of the gripper.

The gripper is then retracted to a further extent to draw the pile- forming length into a position in which it extends through both needle eyes, preferably symmetrically so that the mid-point of the pile-forming length is equidistant from needles 13a, 13b respectively.

The jaws 17, 18 of the gripper 16 are then opened and the pile-forming length then rests freely either on the upwardly presented first face of the backing sheet 10 or possibly on the lower boundaries 15a, I5b of the aligned eyes of the two needles.

The upper boundaries 14a, 14b of the two needles are then utilised as pressure applying means for causing pressure to be applied to the pile- forming length 24 at spaced positions (the insertion positions) each inset from a respective end of the length 24 and spaced apart from each other by virtue of the spacing of the needles of each pair.

Withdrawal of the needles towards the second underface of the backing member, as illustrated in the stage of Figure le, applies pressure to the pile- forming length at the insertion positions, causing these to be drawn through the backing sheet. Such action is facilitated by the holes which will already have been formed by penetration of the needles 13a, 13b themselves. If the backing sheet is a pre-woven member it will of course be understood that the needles may well pass through spaces afforded between the wefts and warps of the backing sheet, but if the latter is of felted or homogeneous form, the

αction of the needles in pre-forming holes in the backing sheet would be of greater Importance.

Although not shown in the stage of Figure l e, the needles are subsequently withdrawn to a further extent to release the end portions of the pile-forming length 24, the mid-portion of which is then firmly in contact with the first or upwardly presented face of the backing sheet.

With the needles totally withdrawn, the backing sheet is then advanced by one step of its travel to bring the newly inserted row of tufts to the right of the step plate 12.

Movement of the backing member may then be reversed to move it to the left to compress the newly inserted tuft between the step plate 12 and tufts inserted in preceding operations and to bring a fresh portion of the backing sheet, (one closely adjacent to the newly inserted row of tufts) into position at the tuft inserting station 1 1 ready for a repeat of the operations illustrated in stages a to e.

It will be appreciated that arrangement of the needles 13a, 13b is such that when they are withdrawn the upper boundaries apply pressure to the pile-forming length 24 at spaced positions to reach the level of the first face of the backing sheet simultaneously and are withdrawn at the same speed, at least after reaching this position, so that there is no tendency for a piie- forming length 24 to be pulled out of threaded relation with one of the needle eyes on the downward movement of the other needle.