System and method for formation of woven style tufted cut/loop fabrics
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Solution Overview
Problem
Existing systems for forming tufted carpets with precise and varied patterns are costly and limited in design precision, particularly in creating patterns with intermixed cut and loop pile tufts and woven appearances.
Innovation Solution
A tufting machine system with longitudinally spaced needle bars, controlled yarn feed mechanisms, and shift mechanisms that allow for the formation of cut and loop pile tufts in the same longitudinal rows without requiring expensive pattern attachments, enabling precise and cost-effective creation of complex patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If expensive pattern attachments are used to form precise patterns with intermixed cut and loop pile tufts, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The needle bar is divided into multiple independently controllable sections, each capable of being raised or lowered separately. This segmentation allows different sections to form different pile types (cut or loop) simultaneously, achieving precise pattern formation without complex pattern attachments. The control system independently actuates each section to create the desired pattern design.
Solution Approach 2:
The system employs dynamically adjustable needle bar sections that can change position during the tufting process. By raising or lowering specific sections in real-time based on the pattern requirements, the system adapts to create varied pile types within the same row, replacing static complex pattern attachments with dynamic control.
2Device complexity
If standard yarn feed mechanisms are used, then device complexity is reduced, but manufacturing precision for complex patterns may be limited
Solution Approach 1:
The standard yarn feed mechanism is enhanced with a multi-functional control system that coordinates yarn feeding with the dynamically adjustable needle bar sections. This allows the same yarn feed mechanism to support both cut pile and loop pile formation by synchronizing yarn supply with needle bar position changes, maintaining simplicity while achieving precision.
Solution Approach 2:
The control system incorporates feedback mechanisms that monitor needle bar section positions and adjust yarn feed timing accordingly. This feedback loop ensures precise pattern formation by coordinating yarn delivery with the dynamic positioning of needle bar sections, enabling complex patterns with standard equipment.
3Adaptability or versatility
If multiple needle bars with staggered needles are used, then adaptability for different patterns is improved, but device complexity increases
Solution Approach 1:
Instead of using multiple complete needle bars with staggered needles, the system segments a single needle bar into multiple independently controllable sections. Each section can be actuated separately to create different pile types, providing pattern variety equivalent to multiple needle bars while reducing overall device complexity.
Solution Approach 2:
The system applies partial action by selectively actuating only the necessary needle bar sections for each pattern element. Rather than requiring all sections to be constantly active or using multiple full needle bars, the system activates only the required sections, achieving pattern versatility with reduced complexity.
Data Source
AI summary
A system and method for forming patterned tufted fabrics such as carpets, including the formation of patterns having cut pile and loop pile tufts therein. The system includes a pair of needle bars each carrying a series of needles to which a plurality of yarns are fed. Cut pile hooks are arranged along a cut pile side of a tufting zone, in a position to engage the needles of one of the needle bars, while loop pile loopers are arranged along the opposite loop pile side of the tufting zone, in a position to engage the needles of the other one of the needle bars. A backing material is fed through the tufting zone, and as loop pile tufts of yarns are formed in the backing material, the needles mounted along a needle bar extending along the cut pile side of the tufting zone can be shifted to an off-gauge position, with the yarn feed to these needles further being controlled, to substantially prevent engagement and pick-up of the yarns carried by such needles by the cut pile hooks.