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WO1997006003A9 - Procede et equipement de fabrication d'un tapis en fils d'arcade tuftes - Google Patents

Procede et equipement de fabrication d'un tapis en fils d'arcade tuftes

Info

Publication number
WO1997006003A9
WO1997006003A9 PCT/US1996/012785 US9612785W WO9706003A9 WO 1997006003 A9 WO1997006003 A9 WO 1997006003A9 US 9612785 W US9612785 W US 9612785W WO 9706003 A9 WO9706003 A9 WO 9706003A9
Authority
WO
WIPO (PCT)
Prior art keywords
tuftstrings
yarn
strand
tuftstring
mandrel
Prior art date
Application number
PCT/US1996/012785
Other languages
English (en)
Other versions
WO1997006003A1 (fr
Filing date
Publication date
Application filed filed Critical
Priority to CA 2227552 priority Critical patent/CA2227552A1/fr
Priority to EP19960928065 priority patent/EP0843620A1/fr
Priority to PL32499496A priority patent/PL324994A1/xx
Priority to MX9800759A priority patent/MX9800759A/es
Priority to BR9610066A priority patent/BR9610066A/pt
Priority to JP50860797A priority patent/JPH10511027A/ja
Priority to AU67663/96A priority patent/AU6766396A/en
Publication of WO1997006003A1 publication Critical patent/WO1997006003A1/fr
Publication of WO1997006003A9 publication Critical patent/WO1997006003A9/fr

Links

Definitions

  • the present invention relates a method and apparatus for making pile articles that are useful as floor and wall covering when aligned with other pile articles and attached to a backing substrate to make a pile surface structure.
  • Conventional tufted carpets are made by passing a flexible woven primary backing through a machine having a large array of needles that force the carpet yarn through the backing where the yarn is restrained by a large array of hooks before the needle is retracted. There may be about 1400 needles across a 12' width. The backing must accommodate needle penetration without damage.
  • FIG. 3 is an isometric view of an ultrasonic bonding module.
  • Fig. 4 is a view partially in section of a tuftstring forming mandrel.
  • Fig. 5 is an enlarged section view of the end of the mandrel taken along line 5-5 of Fig. 4.
  • Figs. 6A, 6B, and 6C are front, section, and side views of an ultrasonic horn useful with the mandrel of Fig. 4.
  • Fig. 7A is a section view of a cutter for cutting yarn on the mandrel.
  • Fig. 7B is an enlarged detail section view of the groove in the corners of the mandrel of Fig. 7A.
  • Fig. 7C is an enlarged view of the cutting edge of the blade of Fig. 7A.
  • Fig. 8 is an enlarged detail section view of the cutter engagement with the mandrel of Fig. 7.
  • Fig. 9 is a section view taken from Fig. 2 of a dual cutter arrangement.
  • Fig. 10 is an isometric view of a dual mandrel module for making eight tuftstrings in a compact space.
  • Fig. 11 is a front isometric view of an eighteen mandrel module for making 72 tuftstrings in a compact space.
  • Figs . 12A and 12B show an elevation and a plan view, respectively, of a guide to direct multiple tuftstrings for bonding from the top side of the backing.
  • Figs. 13A, 13B, 13C, 13D, and 13E are different views of an ultrasonic horn useful for bonding tuftstrings to a backing from the top side of the backing.
  • Fig. 14 is a side view of a belt module for bonding tuftstrings to an elongated endless belt of backing material. tuftstrings and bonded to a backing to make a carpet structure.
  • the carpets can be made in batches of one or several room sized carpets by supplying the backing on a drum or between spaced rolls and spirally wrapping several tuftstrings at a time across the backing; or the carpets can be made continuously by providing an endless supply of backing and a plurality of tuftstrings in the warp direction across the entire width of the backing.
  • the preferred method of making a carpet structure uses ultrasonic energy to bond the yarn to the strand and to bond the pile article or tuftstring thus formed to the backing.
  • the invention includes methods and apparatii for accurately positioning the tuftstring and ultrasonically bonding multiple tuftstrings with a single ultrasonic horn operating from the top side or bottom side of the backing to secure the tuftstrings to the backing.
  • the carpet making machines are modular in design for ease in fabrication, assembly, maintenance, and threadup.
  • Fig. IA is an isometric view of a batch system for making carpet using tuftstrings and a large drum.
  • Fig. IB is a schematic diagram of two groups of tuftstrings being spirally wound.
  • Fig. 2 is a side view 2-2 from Fig. IA that is also typical for a single mandrel tuftstring former.
  • a clamp (not shown) inside the drum retains the ends of the backing during drum rotation while forming the carpet .
  • the drum is rotated and moved laterally so the tuftstrings are pulled onto the backing and under a plurality of ultrasonic horns (not shown) which fusion bond the tuftstrings to the backing.
  • each group of eight tuftstrings forms a spiral array of tuftstrings on the drum 52.
  • the just bonded tuftstrings in a group are adjacent the first bonded tuftstrings and are spaced from them at a distance equal to the space from one tuftstring to the next adjacent tuftstring in the group of eight, which is commonly 0.2 inches for a popular density of tufts.
  • the first group of eight tuftstrings will be aligned with the first bonded end of the second group of eight tuftstrings and an abutment of tuftstrings occurs at a butt joint. This condition exists from one group of tuftstrings to the next all across the drum so a completed carpet structure now exists on the drum.
  • Fig. 15 is a side view of a warp module for bonding tuftstrings to an elongated roll of backing material .
  • Figs. 16A, 16B, 16C, and 16D are different views of a guide to direct multiple tuftstrings for bonding from the bottom side of the backing.
  • Figs. 17A, 17B, and 17C are different views of an ultrasonic horn useful for bonding tuftstrings to a backing from the bottom side of the backing.
  • Fig. 18 is a schematic plan view of a system for making a tuftstring carpet using a warp module.
  • Fig. 19 is a schematic plan view of a finishing system with bulking for a tuftstring carpet using pre-dyed face yarn.
  • Figs. 20A, 20B, 20C, 20D, 20E, and 20F are schematic views of different versions of tuftstring forming mandrels.
  • FIG. IA An embodiment chosen for purposes of illustration for making a full width carpet is shown in Fig. IA and includes a tuftstring forming module 38 and a drum module 49 fed by yarn creels 62, 64, and 66, and strand creels 68 and 70.
  • the carpet structure is formed by directing a plurality of strands, such as strands 30, 32, 34, and 36, along ridges on a mandrel in a tuftstring forming module 38 and winding yarn, such as yarn 40, around the mandrel and over the strands, bonding the yarn to the strands and cutting the yarn to make a plurality of elongated pile articles, or tuftstrings.
  • a plurality of tuftstrings such as tuftstrings 42, 44, 46, and 48 are arranged side-by-side and bonded to a backing substrate 50 supported on drum module 49.
  • four tuftstrings are formed on a single mandrel at once, as will be explained below.
  • eight tuftstrings are grouped side-by-side at nine spaced locations, such as locations 54, 56, 58, and 60.
  • Another creel module is shown for setup of yarn for a product change.
  • the third creel module is available for further product change setups or for running with more ends for faster operation or styling variations as mentioned.
  • FIG. 2 shows end view 2-2 of the tuftstring forming module 38 and illustrates details of a basic single mandrel tuftstring former 72 using a four tuftstring mandrel 74.
  • Major elements of the tuftstring former 72 are the four-sided mandrel 74, a frame 75, a yarn wrapper 76, two ultrasonic bonding modules 78 and 80, a yarn feed module 82, a strand feed module 84, a cutter arrangement 86, and a tuftstring drive module 88.
  • Yarn 40 is fed in through an idler feed roll 90 and driven feed roll 92 that are nipped together by fluid cylinder 94 acting around pivot 96 to grip the yarn 40 that may comprise one or several yarn ends for each mandrel.
  • Strands 30, 32, 34, and 36 are fed in through an idler feed roll 98 and driven feed roll 100 that are nipped together by fluid cylinder 102 acting around pivot 104 to grip the strands .
  • Four strands are fed to the entrance end 106 of mandrel 74 where each strand is guided through a separate tube within a central hollow in the mandrel to keep the carpet 12'X15' while the next carpet is being made.
  • Fig. IB illustrates schematically how one group of tuftstrings 59 are spirally wrapped spaced from another adjacent group of tuftstrings 61.
  • Group 59 has a starting point 63 and group 61 a starting point 65.
  • Group 59 is spirally wrapped so the just bonded tuftstrings, for instance, at position 67, are adjacent the already bonded tuftstrings, for instance, at position 69. Eventually, the just bonded tuftstrings of group 59 are also adjacent the already bonded tuftstrings of the adjacent group 61, such as at position 71 and position 73. Finally, the just bonded tuftstrings of group 59 at position 55 meet end-to-end with the starting point 65 for group 61, as shown, to form a butt joint. The process is then stopped, and the completed carpet structure is cut off the drum.
  • An entire carpet can be made this way using only 72 tuftstrings that may utilize only 18, 36, or 54 ends of yarn.
  • 36 ends are used so two yarns are wrapped on a four tuftstring mandrel at one time, and the tuftstrings can be formed faster with more reasonable wrapping speeds than with only one yarn being wrapped.
  • there is a beneficial random blending of yarn ends along the length of a tuftstring if multiple ends are used; in this way slight dye differences from one yarn end to another are blended along a tuftstring and from tuftstring to tuftstring which may reduce streaking defects due to dye differences.
  • Three or more ends can be wrapped on a mandrel for further speed increases or styling flexibility as needed; the three ends can be different colors or types of yarn, for instance.
  • Fig. IA three creel modules 62, 64, and 66 are shown for high productivity.
  • One module holds 36 packages of yarn for running yarn ends and 36 packages for back-up ends that are tied in to the running packages using transfer tails in a conventional manner so an endless supply of yarn is available.
  • the basic bonding module comprises an ultrasonic horn 134 attached to a booster 135 and an ultrasonic driver 136 attached to frame 138.
  • Frame 138 is attached to four-bar linkage assembly 140 (two bars shown) which is attached to bracket 132.
  • Fluid cylinder 142 is attached to frame 138 by clevis bracket 144 on the rod end 146 and to bracket 130 on the cylinder end. Motion of the fluid cylinder rod end 146 causes the ultrasonic driver, booster, and horn assembly to move in a direction toward and away from the mandrel 74 while staying perpendicular to mandrel 74 to thereby squeeze the yarn between the horn and strand on the mandrel; the mandrel in this position acts as an ultrasonic anvil. Squeezing together of the yarn and strand while ultrasonic energy is applied to the horn causes the yarn and strand to rapidly heat, thereby causing the yarn filaments to fuse to each other and to the strand where they are in contact .
  • the yarn does not stick to the horn nor does the strand stick to the mandrel.
  • the fluid cylinder pressure determines the squeezing force exerted between the mandrel and horn and the yarn and strand therebetween. This force is an important factor determining the amount of ultrasonic energy coupled to the yarn and strand. Other factors are the horn vibrational amplitude and frequency.
  • Figs. 6A-C shows the shape of the horn that permits one horn to bond two strands to the yarn at one time. In this way, only two horns are needed to bond the four strands guided along one four-sided mandrel.
  • the horn 134 has two angled surfaces 148 and 150 that squeeze the yarn and strand (neither shown) against the corners 152 and 154, respectively, of the mandrel 74. The surfaces are long enough so that if a larger mandrel 74a is used, the same horn 134 can still engage the yarn and strand against the corners of the mandrel 74a. For a square mandrel as shown, the surfaces 148 and 150 are at 45 degrees to the side 156 of the
  • the mandrel is attached to frame 75 by bracket 107 on one side of the mandrel downstream from the cutter arrangement 86 that frees the wrapped yarn from the mandrel and forms four separate cut-pile tuftstrings.
  • the tuftstrings 42', 44', 46', and 48' are fed through an idler exit roll 109 and driven exit roll 111 that are nipped together by fluid cylinder 119 acting around pivot 121 to grip the tuftstrings.
  • Driven roll 111 has grooves to hold the "U"-shaped tuftstrings and idler roll 109 has ribs fitting into the grooves with the tuftstring therebetween.
  • Fig. 4 shows entrance end 106 of the mandrel where the strands enter and exit end 108 where the strands exit.
  • Fig. 5 is an enlarged section view of the exit end that shows a turning pulley for each strand that guides the strand from a hollow passage 110 in the center of the mandrel 74.
  • Pulley 112 guides strand 30, pulley 114 guides strand 32, pulley 116 guides strand 34, and pulley 117 guides strand 36.
  • the strands are guided from the passage 110 to grooves on the corners of the mandrel as discussed below.
  • the yarn is wrapped around the mandrel, and over the support strands in the grooves on the corners of the mandrel, by wrapper 76 that comprises a hollow spindle 118 with a yarn entrance end 120 and a yarn exit end 122.
  • the spindle is rotationally held by a bearing assembly 124 attached to frame 75.
  • the spindle is rotated by a motor 126 acting through a pulley and belt arrangement 128.
  • FIG 3 shows an isometric view of the bonding module 78 which i ⁇ the same as module 80, both of which are attached to frame 75 in an aligned relationship on opposite sides of the mandrel 74 by brackets such as sides of the mandrel 74.
  • the spacers are held in shallow slots in the sides of the mandrel. The purpose of the spacers is to increase the circumference of the mandrel seen by the yarn before the yarn is bonded.
  • the spacers terminate at position 176 adjacent the horns 134 and 134' .
  • the yarn contracts significantly upon cooling from the ultrasonic heating, so as the yarn moves away from the horns, it passes beyond the spacers at 176 and can contract to a smaller circumference without binding on the mandrel.
  • the cutter arrangement 86 in Fig. 2 consists of four rotating circular blades each bearing against a bed knife fixed to the mandrel. One such bed knife 178 is shown mounted in a slot 180 in mandrel 74 in Fig. 4.
  • Fig. 7A shows section view 7-7 from Fig. 2.
  • Circular blade 182 is rotationally keyed to shaft 184, is axially slideable along the shaft, and is urged by spring 186 against bed knife 178.
  • Circular clamps 188 and 190 one on each side of the blade, hold the yarn and support strand securely in the grooves in the corner of the mandrel.
  • the clamps are rotationally supported by, but are free of torque from shaft 184; and are axially slideable along the shaft.
  • the clamps are free to rotate independently of the shaft driven by movement of the strand.
  • Springs 192 and 194 urge clamps 188 and 190, respectively, toward corners 196 and 198, respectively, of the mandrel 74. The clamps securely hold the strand in the groove on the corners of the mandrel (and the yarn bonded to the strand) while the
  • each horn such as horn
  • tufts on the sides of the strand form the same angle at the base of the tufts where they are bonded on.
  • Imaginary plane 153 passes through strand 30 and bisects included angle 155 between the ends 157 and 159 of yarn 40 bent over strand 30.
  • Surface 150 is essentially perpendicular to plane 153 a ⁇ indicated at 161.
  • imaginary plane 163 passes through strand 36 and bisects included angle 165 between the ends 167 and 169 of yarn 40 bent over strand 36.
  • Surface 148 is essentially perpendicular to plane 163 as indicated at 171. Notice that the imaginary planes 153 and 163 also intersect at the center or centroid of the cross-section of mandrel 74.
  • the yarn 40 is wrapped over four spacers 168, 170, 172, and 174 on the Zelex NK available from the E. I. DuPont Co. of Wilmington, DE and sold as an anti-static yarn finish. It is mixed with distilled water in a 0.5-2.0% volume ratio of finish in the mixture.
  • the blade is believed to be most effective in cutting the yarn without undue wear by rotating the blade in the direction of yarn advance and at a peripheral speed slightly above (about 3-10%) the speed of the yarn passing under the blade. It is believed the low speed reduces the wear rate and the direction of rotation minimizes any yarn tension increase during cutting.
  • the cutting edge angle 210 (Figs. 7A and 7C) on the blade is preferably about 75 degrees (45 degrees for sawing) , and the finish on the coated portions 203, 205, and 207 of the cutting edge is about 1-2 microinches rms.
  • Fig. 7B shows an enlarged view of a groove 197 in the corner of mandrel 74.
  • the groove has a depth
  • Fig. 13E shows a typical detail of the profile of the tip 296 of fork 282 that has a concave surface 298 that guides the support strand along the length 288 of the fork to keep it from sliding to the side out from under the fork during bonding.
  • This concave surface extends throughout the radius 290 and 294' to aid in tracking the tuftstring strand under the horn before the pressure and vibration of the horn acts on the tuftstring.
  • guide 272 has a plurality of slots, such as slot 300 that has a narrow width 302 that forces the tufts on the tuftstring in toward one another and over the support strand.
  • the first horn is used to lightly tack the tuftstring to the backing while maintaining the alignment determined by guide 272, and horn 271 can apply more energy to the still heated tuftstring to securely attach it to the backing.
  • a large amount of energy can be rapidly put into bonding the tuftstring by the additive effect of two horns.
  • the distance 273 between horns 270 and 271 should be kept short to take advantage of this effect but this distance also provides some time for the heat from the first horn to penetrate the support strand. At low speeds where a lot of energy does not need to be added rapidly, only the first horn may be needed. This two- horn technique may also be useful when bonding the face yarn to the strand on the tuftstring forming mandrel.
  • the horn 270 for instance, is shown in more detail in Figs. 13A-E.
  • the horn in Fig. 13A has four forks 276, 278, 280, and 282, each designed to fit between the tufts on a single tuftstring and contact the support strand at the base of the tufts.
  • the spacing 284 between forks is the same as the desired tuftstring spacing on the finished carpet. For different tuftstring spacings, different horns would be used with corresponding fork spacings.
  • the height 286 of the forks corresponds to the maximum length of the tufts on the tuftstrings for the desired maximum tuft height in the finished carpet.
  • the horn has a length 288 in Fig. Fig.
  • Carriage 320 carries tuftstring guide assemblies 322 and 324, first bonder module 326, second bonder module 328, and tuftstring bonding guide 272' .
  • the bonder modules are similar to those shown in Fig. 5, but with the horn of Fig. 13A.
  • Carriage 320 is supported by stationary rod 330 and rotatable threaded rod 332 that is driven by an attached motor (not shown) ; the threaded rod engages a threaded nut in the carriage 320.
  • a support finger 310 is attached to guide 272 to support the outer tuft on that side of the horn. Finger 310 extends adjacent horn 271 and beyond to hold the tufts up until the bond cools.
  • the drum After bonding is stopped on drum 52, the drum continues rotating a short distance and there is a plate 265 mounted under guide 300 that can be urged in the direction of arrow 267.
  • the plate 265 is urged under the guided, but unbonded, tuftstrings and horns 270 and 271 so the guide, tuftstrings and horns can be lifted for tuftstring cutting, removal of the finished carpet, and threading of a fresh piece of backing onto the drum.
  • the guide, tuftstrings, and horn can be lowered and the plate withdrawn so the tuftstrings are in place against the fresh backing and under the horn ready for bonding and restarting of the carpet making process .
  • Fig. 14 shows a side elevation view of a belt module 311 which is an alternate to the drum module where the endless loop of backing substrate 50 is supported by a plurality of rolls 312, 314, 316, and 318 instead of a single large drum 52 as in Fig. IA.
  • Roll 316 can be repositioned easily to change the length of the loop to suit the size of the carpet piece. The embodiment of to their final spacing desired in the carpet structure. Four adjacent tuftstrings are each at a different elevation for ease of handling and to prevent entanglement.
  • the guide 354 comprises a stationary roll with different depth slots; the roll can be periodically rotated a partial turn to distribute wear.
  • tuftstrings are maintained at their guided elevations in guide module 356 where the final tuftstring-to-tuftstring spacing desired in the carpet is achieved.
  • Fig. 16A shows channels, such as lower channel 363, in guide module 356. Each channel has a radiused entrance, such as entrance 365 in channel 363 to guide the tufts, such as tufts pairs 367, 369, and 375, from their angled orientation to a parallel orientation as shown.
  • the tuftstring is angled down at angle 371 over part of the radius 373 of radiused entrance 365 so the tufts "fan out” as they enter guide 356 and are free of entanglement with other tufts on the tuftstring.
  • This angle should be between about 5-45 degrees, and preferably, about 20 degrees.
  • the tuftstrings are kept separated from and free of entanglement with one another as they enter guide 356. This is accomplished by the multi- level staggered approach to the guide. For instance, for the tuft pairs 367 and 375 as shown, every fourth tuftstring is at the same level which spaces them apart far enough that the tufts 367 are free of entanglement with tufts 375.
  • Adjacent tuftstrings 367 and 369 are staggered apart vertically by a sufficient distance so tufts 367 are free of entanglement with tufts 369.
  • a plurality of round rods, such as rod 377 and 379, are placed ahead of guide 356 to gently brush against the tufts at the different levels (only two shown) to prevent the tuftstrings from twisting from an upright orientation as they approach guide 356; this insures the tuftstring strand will be centered in the channels 363 of guide 356.
  • Fig. 15 shows a side elevation of a warp module 342 which is an alternative to the drum module 49 and belt module 311 discussed.
  • a plurality of tuftstrings necessary for an entire width of carpet are guided to a bonding roll 344 where they are joined with and bonded to an elongated roll of backing substrate 50 to make an entire roll of carpet; or if the backing can be spliced to provide an endless supply, the support strand can be spliced to provide an endless supply, and the carpet can be transversely cut on the fly; the process can run making carpet continuously.
  • the carpet can be wound into rolls or cut to discrete lengths and stacked.
  • the number of tuftstring modules 38 shown in Fig. IA must be increased to ten to provide about 720 tuftstrings and the number of face yarn creels, such as 62, and support strand creels, such as 68, must be increased accordingly.
  • additional two-mandrel modules can be added to the tuftstring forming module 38 so only five of these modified modules 38 would be required.
  • the warp module 342 comprises a bonding roll 344; a plurality of bonder modules, such as 346, 348, 350, and 352; backing substrate support 353; tuftstring guide modules 354 and 356; bonder roll drive motor 358; carpet drive roll 360 and carpet nip assembly 362; all mounted to frame 364.
  • Fin 391 is aligned with rib 374 and extends along channel 363 to separate the rows of tufts 388 and 390 before they reach rib 374. Fin 391 has a pointed end 398 facing opposite the direction of travel of the tuftstrings to help separate the rows of tufts as they pass by.
  • the top of rib 374 has a concave surface 400 to receive the support strand and keep the strand from falling off the top of the rib and into one of the adjacent grooves. If the spacing from one tuftstring to another (pitch or gage) is to be changed in the final carpet structure, the guide module 356 and bonding roll 344 would be changed and replaced with a guide and roll having the new spacing.
  • Fig. 16D shows a section through the bonding roll 344 showing how the backing 50 is positioned over the tuftstrings, such as tuftstring 48 and 46, and the ultrasonic horn 384 squeezes them together against ribs 374 and 374' to effect bonding.
  • Horn 384 may bond a plurality of tuftstrings at once using only one ultrasonic driver and booster; for instance, it is believed that eight tuftstrings may be reliably bonded at one time to backing 50 by a single horn/driver/ booster.
  • Fig. 17A shows a typical horn 384 for back ⁇ side bonding a plurality of tuftstrings on the warp module 342. The edges 402 and 404 of horn 384 may extend beyond the body of the horn to form the bonding
  • the backing 50 is guided around guide roll 382 that contacts the back of the tuftstrings on roll 344.
  • the backing is under tension which holds the tuftstrings and backing in place on roll 344 until bonding horns, such as horn 384 can bond the backing to the tuftstring with the ribs on roll 344 acting as ultrasonic anvils.
  • Fig. 16C shows another view of how the tuftstrings are guided from the channels in guide 356 to the grooves in bonding roll 344.
  • tuftstring 48 comprised of support strand 386 and first row of tufts 388 and second row of tufts 390
  • the tuftstrings are fed in a parallel array 418 to a warp module 342a designed to accept the 720 tuftstrings across the width of the module.
  • a roll of backing substrate is provided at 420.
  • the twelve-foot wide backing substrate 50 passes over a 90-degree turning roll 422 and is fed into the warp module 342a for bonding to the tuftstring array.
  • Fig. 18 shows a layout view of a complete carpet-making system including a plurality of tuftstring forming modules 38 and a warp module 342.
  • five tuftstring forming modules 38a, 38b, 38c, 38d, and 38e are arranged to each provide 144 tuftstrings, for a total of 720 tuftstrings, for a twelve-foot wide carpet product. ridges, and pulling the tuftstring after the yarn is bonded on the strand and cut.
  • the amplitude is controlled by machine controller 405 controlling the signal to each ultrasonic driver, such as 136 and 136', on each bonding module.
  • each ultrasonic driver such as 136 and 136'
  • the machine controller changes from amplitude control to power, or energy, control to maintain stable bonding conditions.
  • the force is held constant, and the amplitude is varied to maintain constant power to each ultrasonic driver and horn. It has been discovered that the ultrasonic driver efficiency changes as the unit heats up during continuous operation. Changing the amplitude to maintain constant power corrects for this changing efficiency so stable bonds are produced. The horn itself has also been observed to heat up.
  • the baseline for the amplitude is that amplitude sampled just before stopping is executed, since the amplitude is changing as the constant power control is operated.
  • Typical times to ramp the tuftstring speed from about 0 - 15 YPM is about 3-5 seconds. It has been found in some cases, only the force needs to be ramped at start and stop and the amplitude held constant, but the preferred operation is to ramp both force and amplitude.
  • the drive for each of these modules also pulls the tuftstring so the tension of the tuftstring must be monitored by a single tensiometer 462 for each tuftstring forming module, such as 38.
  • the speed of motor 113 is then adjusted by machine controller 405 to keep the tuftstring tension constant. This prevents overtension and slack that may upset the process and break the tuftstring.
  • the strand tension must also be monitored by a single tensiometer 464 for each tuftstring forming module 38, and the speed of motor 93 is adjusted by machine controller 405 to keep the strand tension constant.
  • the tensiometers 462 and 458 are set up to measure the same strand line before and after the yarn is bonded to make a tuftstring.
  • the yarn feed roll motor 101 and wrapper motor 126 are controlled by machine controller 405 so the tension is maintained constant in yarn 40 being fed in and wrapped on mandrel 74.
  • the controller sets the wrap speed to achieve the number of strands per inch desired along the strand per operator instructions from the operator panel 407 (Fig. 18) .
  • the speed of motor 101 is set proportional to the speed of wrapper motor 126 to achieve the desired tension based on trial and error.
  • a tensiometer could be used on the yarn line between feed roll 92 and spindle entrance end 120, if What is Claimed is:
  • a method for making a carpet comprising: forming a plurality of tuftstrings by bonding yarn to a support strand; grouping the tuftstrings in a plurality of groups, the tuftstrings in each group being arranged in a side-by-side array the groups being spaced one from another; bonding the tuftstrings in each group to an endless loop of backing substrate starting each group at a starting point aligned with the starting point of the other groups across the width of the backing loop; wrapping each group of tuftstrings in a spiral array whereby the tuftstrings in each group just bonded meet side-by-side with the already bonded tuftstrings in that group after the first spiral along the endless backing loop, and the tuftstrings in each group just bonded meet side-by-side with the already bonded tuftstrings in the adjacent group during the last spiral along the endless backing loop, and the tuftstrings in each group just bonded meet end-to-end with the already bonded tuftstrings in the adjacent group, that were first bonded, at
  • the mandrel does not need to be hollow or star-shaped with passages for support strands or carrier strands.
  • the tuftstring forming module 38 can be fitted with mandrels modules suitable for making loop pile tuftstrings .
  • mandrels modules would be based on the loop pile tuftstring apparatus and process described in copending application Serial No. 08/331,074 filed October 28,
  • loop pile tuftstring would be forwarded to one of the carpet forming modules 49, 311, or 342 as desired to form a loop pile tuftstring carpet . Guiding and bonding techniques similar to those described for cut pile tuftstring would be used. A different finishing line would be used for the loop pile carpet depending on the use intended for the carpet .

Abstract

La présente invention concerne un procédé et un équipement de fabrication d'un tapis constitué par plusieurs fils d'arcade tuftés (42, 44, 46, 48), liés à un envers (50). L'invention concerne aussi des procédés et des dispositifs permettant de positionner avec précision le fil d'arcade tufté et de relier par ultrasons plusieurs fils d'arcade tuftés (42, 44, 46, 48) à l'envers (50).
PCT/US1996/012785 1995-08-10 1996-08-06 Procede et equipement de fabrication d'un tapis en fils d'arcade tuftes WO1997006003A1 (fr)

Priority Applications (7)

Application Number Priority Date Filing Date Title
CA 2227552 CA2227552A1 (fr) 1995-08-10 1996-08-06 Procede et equipement de fabrication d'un tapis en fils d'arcade tuftes
EP19960928065 EP0843620A1 (fr) 1995-08-10 1996-08-06 Procede et equipement de fabrication d'un tapis en fils d'arcade tuftes
PL32499496A PL324994A1 (en) 1995-08-10 1996-08-06 Method of and apparatus for making carpets of covered cords
MX9800759A MX9800759A (es) 1995-08-10 1996-08-06 Metodo y aparato para elaborar una alfombra de cordones afelpados.
BR9610066A BR9610066A (pt) 1995-08-10 1996-08-06 Método para fabricar carpete método de fixar dois cordões de suporte ao fio neles enrolado método de cortar o fio fixado a um cordão de suporte método de guiar as fileiras de tufos na tira de tufos para sulcos em um cilindro e dispositivo para fabricar carpete
JP50860797A JPH10511027A (ja) 1995-08-10 1996-08-06 タフトストリングカーペットの製作方法と装置
AU67663/96A AU6766396A (en) 1995-08-10 1996-08-06 Method and apparatus for making a tuftstring carpet

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US51373495A 1995-08-10 1995-08-10
US08/513,734 1995-08-10

Publications (2)

Publication Number Publication Date
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JP (1) JPH10511027A (fr)
CN (1) CN1192715A (fr)
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CA (1) CA2227552A1 (fr)
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US6720058B1 (en) * 1997-12-05 2004-04-13 E.I. Du Pont De Nemours And Company Velour-like pile articles and pile surface structures and methods of making
EP1357220A1 (fr) * 1997-12-05 2003-10-29 E.I. Du Pont De Nemours And Company Articles textiles a poils de type velour, structures de surfaces textiles a poils et procédés de fabrication
US6543083B1 (en) 1998-06-05 2003-04-08 E. I. Du Pont De Nemours & Co. Bristles having varying stiffness
US6638384B1 (en) 1999-04-23 2003-10-28 E.I. Du Pont De Nemours And Company Method and apparatus for making bristle subassemblies

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US2475019A (en) * 1944-06-10 1949-07-05 Prodesco Process of making pile yarns and fabrics
JPS5945378B2 (ja) * 1981-05-08 1984-11-06 山崎産業株式会社 自動モツプ縫製装置
US4964932A (en) * 1987-07-22 1990-10-23 Xmas-Mil Display Products Pty. Ltd. Method and apparatus for manufacturing decorative garland
US5470629A (en) * 1993-02-22 1995-11-28 E. I. Du Pont De Nemours And Company Method and apparatus for making a pile article and the products thereof
US5472762A (en) * 1993-02-22 1995-12-05 E. I. Du Pont De Nemours And Company Method and apparatus for making a pile article and the products thereof
WO1996006685A2 (fr) * 1994-08-31 1996-03-07 E.I. Du Pont De Nemours And Company Tapis a fils de velours stable a l'humidite

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