Backing Shifter for Variable Gauge Tufting
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Solution Overview
Problem
Conventional tufting machines face limitations in efficiently shifting the backing fabric relative to the needles, particularly with synthetic backings, which restrict the ability to create variable gauge and patterned fabrics due to interference from needle plate fingers and uneven movement.
Innovation Solution
A tufting machine with a reciprocating needle plate and backing shifter that allows for precise lateral shifting of the backing fabric, enabling variable gauge and pattern creation by moving the backing fabric independently of the needle plate fingers, using a servo motor drive and tension rolls for controlled movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the needle plate fingers are used to support the backing fabric during penetration, then the backing fabric can be supported during tufting, but the fingers interfere with lateral shifting of the backing and prevent precise gauge control
Solution Approach 1:
The backing support function is segmented from the needle plate fingers. Instead of using the fingers for both support and allowing shifting, the patent introduces separate support mechanisms (support bars or support needles) that provide backing support without interfering with the lateral shifting capability of the backing fabric through the gauge.
Solution Approach 2:
The support function is extracted from the needle plate finger system and assigned to dedicated support elements. This allows the needle plate fingers to focus on their primary function of guiding needles while the extracted support function is performed by elements that do not obstruct backing shifts.
2Adaptability or versatility
If conventional backing shifting methods are used with synthetic backings, then some shifting capability is achieved, but the movement is uneven and unreliable
Solution Approach 1:
The patent introduces an intermediary mechanism (the combination of support bars/needles and gauge interaction) that mediates between the backing fabric and the shifting action. This intermediary system ensures that synthetic backings are shifted uniformly and reliably by providing controlled support points that guide the movement through the gauge.
Solution Approach 2:
The patent changes the parameters of backing support by using adjustable support bars or support needles that can be positioned at optimal locations. This allows the support force distribution to be optimized for different backing materials, ensuring uniform shifting of synthetic backings that previously responded unevenly to conventional methods.
3Quantity of substance
If the needle bar is shifted laterally to increase stitch density, then density can be increased, but the machine gauge is limited and cannot simulate finer gauge machines
Solution Approach 1:
The patent moves the shifting action from the needle bar (one-dimensional lateral shift) to the backing fabric itself (two-dimensional control through lateral shift combined with gauge interaction). By shifting the backing through the gauge rather than shifting the entire needle bar, the system achieves effective gauge simulation without being constrained by the physical gauge of the needle bar.
Solution Approach 2:
Instead of shifting the needles relative to the backing (conventional approach), the patent inverts the approach by shifting the backing relative to the stationary needles and gauge. This inversion allows the backing to be fed through the gauge at controlled angles, effectively simulating finer gauge configurations without requiring physically finer needles.
4Ease of manufacture
If the backing is shifted laterally to create patterns and break up streaks, then aesthetic appearance is improved, but the shifting mechanism becomes complex
Solution Approach 1:
The patent makes the backing shifter a universal component that serves multiple functions: it provides backing support during penetration, enables lateral shifting for pattern creation, and facilitates uniform movement of synthetic backings. This multi-functionality reduces the need for separate specialized mechanisms for each function.
Solution Approach 2:
The patent merges the backing support function and the backing shifting function into a unified system. The support bars or support needles work in conjunction with the gauge and needle plate to provide both support and controlled lateral movement, eliminating the need for separate support and shifting mechanisms.
Data Source
Figure 1
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Figure 3A~5B
AI summary
A shiftable backing feed is utilized with a tufting machine having reciprocating needles and gauge parts for seizing yarns wherein needle plate fingers reciprocate in synchronization with the cycles of the needle bar to support the backing during penetration of the backing fabric yet allow backing shifts between stitches.