JP4847982B2 - Tufting machine and adjustment shaft for tufting machine - Google Patents

Description

  The present invention relates to a tufting machine for producing pile fabric by planting pile yarn on a base fabric, and an adjustment shaft used in the tufting machine.

A pile fabric such as a tuft carpet is obtained by planting pile yarn on a base fabric. Such pile fabric is produced using a tufting machine having a plurality of rows of needles.
Conventionally, tufting machines that can be planted on a base fabric while changing the height of pile yarn are known. A pile fabric produced by such a tufting machine has a pattern on the pile surface based on the height difference of the pile yarn.

Conventionally, as the tufting machine, those disclosed in Patent Documents 1 and 2 are known.
In Patent Document 1, in the pile yarn path from the feed roller to the needle, the pile yarn path is lengthened when a loop is formed by the needle piercing motion by causing the pile yarn to follow the eccentric cam mechanism. Alternatively, a tufting machine that adjusts the supply length of pile yarn by shortening it is disclosed.
The tufting machine of Patent Document 1 can produce a loop pile fabric in which a pattern based on the height difference (unevenness change) of the pile yarn appears by adjusting the supply length of the pile yarn by a cam mechanism.

Patent Document 2 includes a guide bar that changes the length of the pile yarn traveling path, the guide bar drive motor, and an electric input device that sends an instruction signal to the motor. A tufting machine is disclosed in which a guide bar drive motor is rotated at a cycle of a ratio synchronized with an operation cycle of a needle.
The tufting machine of Patent Document 2 can form a low loop pile and a high loop pile according to the standard, and can produce a loop pile fabric in which a pattern based on the height difference of the pile appears.
Japanese Examined Patent Publication No. 53-44853 Japanese Patent Laid-Open No. 62-257454

However, the tufting machine of Patent Document 1 changes the pile yarn supply length in synchronization with the rotation trajectory of the cam mechanism. Therefore, the difference in the height of the pile yarn implanted in the base fabric is caused by the rotation of the cam mechanism. It becomes the same as the trajectory. For this reason, only pile fabric with a regular pattern can be produced.
On the other hand, since the tufting machine of Patent Document 2 rotates the guide bar drive motor in synchronism with the operation cycle of the needle by the electric input device, complicated electric control is required, and the tufting machine becomes expensive.

A first object of the present invention is to provide a tufting machine that can easily produce a pile fabric in which an irregular pattern due to a difference in height of a pile yarn appears.
A second object of the present invention is to provide an adjustment shaft for a tufting machine that can irregularly change the length of a pile yarn traveling path.

  The tufting machine of the present invention is provided in a traveling path of a plurality of rows of needles that are provided along the gauge direction of the base fabric and in which pile yarns are implanted in the base fabric, and the pile yarn that is sent to each needle. And an adjustment shaft that changes the length of the travel path of the pile yarn in contact with the pile yarn, and the adjustment shaft has a spiral portion having a spiral continuous surface on the outer peripheral contour surface. And

In a preferred tufting machine according to the present invention, the axial direction of the adjustment shaft is disposed substantially parallel to the gauge direction of the base fabric.
In another preferable tufting machine according to the present invention, the plurality of rows of pile yarns are in contact with the spiral portion along the axial direction of the adjustment shaft.
In another preferred tufting machine according to the present invention, the adjustment shaft can rotate forward and backward about its axis.
In another preferred tufting machine according to the present invention, the adjustment shaft can rotate around the axis, and the rotation speed can be changed.

According to another aspect of the present invention, an adjustment shaft for a tufting machine is provided. The adjustment shaft for the tufting machine is an adjustment shaft that is provided in the travel path of the pile yarn sent to the needle and changes the length of the travel path of the pile yarn in contact with the pile yarn. It is comprised from the strip | belt-shaped flat plate twisted so that it may have a helical continuous surface.
The preferable adjustment shaft of the present invention is formed in an arc shape in which the outer peripheral contour surface bulges outward.

Since the tufting machine according to the present invention includes the adjustment shaft having the first spiral portion, the pile yarn can be implanted in the base fabric with an irregular height difference. By using such a tufting machine, a pile fabric having an irregular pattern can be easily produced.
Further, the adjustment shaft for the tufting machine according to the present invention can irregularly change the length of the travel path of the pile yarn. For this reason, by using the adjustment shaft in a tufting machine, a pile fabric having an irregular pattern can be easily produced.

Embodiments of the present invention will be described with reference to the drawings.
<Configuration of tufting machine>
1 and 2, reference numeral 1 denotes a machine body 2, a needle part 31 provided on the lower side of the machine body 2, a yarn guide 51 for guiding the pile yarn 4, and a pile on the needle part 31 through the yarn guide 51. A roller 61 for feeding the yarn 4 and an adjusting shaft which is provided in the running path of the plurality of rows of pile yarns 4 sent to the needle portion 31 and changes the length of the running path of the pile yarn 4 in contact with the pile yarn 4 71 shows a tufting machine having 71 and a drive device (not shown) for rotationally driving the adjustment shaft 71.

  In the tufting machine 1, a base fabric 9 is disposed on the lower side of the machine body 2, and the base fabric 9 is sequentially transferred to the downstream side in the stitching direction while planting pile yarn 4 on the base fabric 9 (base fabric 9 The transfer direction is indicated by the arrow in FIG. Therefore, a transfer mechanism (not shown) for sequentially transferring the base fabric 9 is provided on the lower side of the machine body 2.

The needle portion 31 has a plurality of rows of needles 311 provided side by side in the gauge direction G (width direction of the machine body 2) of the base fabric 9.
The adjustment shaft 71 has a spiral portion 711 having a spiral continuous surface on the outer peripheral contour surface 71a. The adjustment shaft 71 is disposed so that the axial direction thereof is substantially parallel to the gauge direction G of the base fabric 9, and the adjustment shaft 71 is rotatable about the axis O.

Hereinafter, each component of the tufting machine 1 of this embodiment is demonstrated concretely.
In the present specification, the upstream side in the stitch direction of the base fabric is referred to as “front side”, and the opposite side is referred to as “rear side”. Further, the side away from the machine body in the direction parallel to the stitch direction of the base fabric is called “outside”, and the opposite side is called “inside”.

The tufting machine 1 of the present embodiment is provided with a pile planting mechanism on each of the front side and the rear side of the machine body 2 so that the pile yarn 4 can be planted on the base fabric 9 before and after the machine body 2. ing.
Hereinafter, when a component of the pile planting mechanism provided on the front side of the fuselage 2 is particularly meant, the prefix “first” is attached, and a component of the pile planting mechanism provided on the rear side of the aircraft is particularly designated. The meaning is prefixed with “second”.

A first needle 311 that moves up and down is provided on the front lower side of the body 2. A plurality of the first needles 311 are arranged at predetermined intervals along the gauge direction G of the base fabric 9 (the width direction of the machine body 2). The first needle portion 31 is composed of a plurality of rows of first needles 311 arranged in the gauge direction G. The pile yarn 4 is sent to each of the first needles 311.
A second needle 321 that moves up and down is provided below the machine body 2. Similarly, a plurality of second needles 321 are arranged at predetermined intervals along the gauge direction G of the base fabric 9, and the second needle portion 32 is configured. The pile yarn 4 is sent to each of the second needles 321.

The first needle 311 and the second needle 321 are provided alternately in the gauge direction G of the base fabric 9. That is, when viewed from the front side of the machine body 2, the first needles 311 and the second needles 321 are arranged so that the second needles 321 are positioned between the rows of the first needles 311.
By arranging the first needle 311 and the second needle 321 in this way, the pile yarn is planted by the second needle 321 between the pile yarn planted by the first needle 311. For this reason, various patterns can be made by changing the type of the pile yarn 4 planted by the first needle 311 and the second needle 321, planting conditions, and the like. In addition, since the first needle 311 and the second needle 321 both plant the pile yarn 4, the density of the pile yarn 4 can be increased.

The number of rows of the first needle 311 and the second needle 321 in a plurality of rows can be set as appropriate. As will be described later, when the number of rows of the first needles 31 and the second needles (the number of needles per unit length in the gauge direction G) is increased, a pile fabric with dense wave patterns can be produced. The number of needle rows is not particularly limited, but is preferably 2 to 16 rows per inch (about 2.54 cm), more preferably 8 to 12 rows per inch. Further, in the width direction of the machine body 2 of the tufting machine 1 (the width of the machine body 2 is about 4 m, for example), the first needle 311 and the second needle 321 preferably have 300 rows to 2,500 rows, preferably 1,200 rows to More preferably, there are 2,000 rows.
Moreover, it can set suitably also about the space | interval (front-back space | interval) of the 1st needle part 31 and the 2nd needle part 32. FIG.

A first yarn guide 51 is provided above the first needle portion 31. A pair of upper and lower first yarn guides 51 are provided at predetermined intervals in the upper and lower directions.
For example, the first yarn guide 51 is composed of a plate-like body having a plurality of openings (holes or grooves) corresponding to the number of rows of the first needles 311 (that is, the number of pile yarns 4). As the plate-like body, for example, a metal plate such as stainless steel or iron in which openings are formed at predetermined intervals can be used. By inserting the pile yarn into each opening of the first yarn guide 51, the pile yarn is guided so as not to be displaced in the gauge direction G. Accordingly, the plurality of rows of pile yarns 4 inserted through the first yarn guide 51 are arranged in the gauge direction G of the base fabric 9 and supplied to the first needle 311 as shown in FIG. Both ends of the upper and lower first yarn guides 51 are attached to the airframe 2 (attachment structure is not shown).

  A pair of upper and lower second yarn guides 52 is also provided above the second needle portion 32. Similar to the first yarn guide 51, the second yarn guide 52 is constituted by a plate-like body having a plurality of openings corresponding to the number of rows of the second needles 321, for example.

  In addition, although the 1st yarn guide 51 and the 2nd yarn guide 52 are comprised from the plate-shaped body which has the said opening part, it can replace with this and can also be changed as follows. For example, the first yarn guide 51 and the second yarn guide 52 may be composed of a pair of front and rear rods extending substantially parallel to the gauge direction G of the base fabric 9. The pile yarn 4 can be guided to the first needle 311 and the second needle 321 by inserting the pile yarn 4 between the pair of front and rear rods.

A first roller 61 is provided above the first yarn guide 51. The first roller 61 is formed of a rotatable cylindrical body that extends substantially parallel to the gauge direction G of the base fabric 9. In the example shown in the figure, three first rollers 61 are provided at intervals in the vertical direction, but the number of the first rollers 61 is not limited to this.
A second roller 62 is also provided above the second yarn guide 52 with the same configuration as the first roller 61.

The pile yarn 4 pulled out from the bobbin reaches the first needle portion 31 from the first roller 61 through the upper and lower first yarn guides 51.
Similarly, the pile yarn 4 pulled out from the bobbin reaches the second needle portion 32 from the second roller 62 through the upper and lower second yarn guides 52.
The path from the roller to the needle is the travel path of the pile yarn 4.

The adjusting shaft of the present invention is provided so as to contact the pile yarn 4 in the middle of the traveling route.
The first adjustment shaft 71 is provided between a pair of first yarn guides 51, 51 that are spaced apart from each other by a predetermined distance.
The second adjustment shaft 72 is provided between a pair of second yarn guides 52 and 52 that are vertically spaced apart from each other.

  As shown in FIG. 3, the first adjustment shaft 71 is provided with a first spiral portion 711 having a spiral continuous surface on the outer peripheral contour surface 71 a and axial positions of both end portions of the first spiral portion 711. Column-shaped first shaft portions 712 and 712.

For example, as shown in FIG. 4 (a), the first spiral portion 711 is centered on the central portion (axis N) in the width direction of a strip-shaped plate steel 7a (for example, made of stainless steel) having a rectangular shape in plan view. It can be formed by twisting the steel 7a in the direction of the arrow.
The spiral direction of the first spiral portion 711 is not particularly limited, and may be clockwise or counterclockwise around the axis O. By twisting the strip-shaped steel plate clockwise, the first spiral portion 711 whose spiral direction is clockwise can be formed, and by twisting the strip-shaped plate steel counterclockwise, the first spiral portion 711 whose spiral direction is counter-clockwise. Can be formed.
The thickness of the strip steel plate is not particularly limited, but is 5 mm to 15 mm, preferably 7 mm to 12 mm in view of strength and twist workability.

  The first shaft portion 712 can be provided in the first spiral portion 711 by fixing columnar members to both ends of the first spiral portion 711.

The first adjustment shaft 71 is rotatably attached to the front side of the machine body 2 so that the axial direction thereof is substantially parallel to the gauge direction G (width direction of the machine body 2) of the base fabric 9. For example, the first adjustment shaft 71 is attached by rotatably supporting the first shaft portion 712 on the bearing portion 21 provided in the machine body 2.
Further, as shown in FIG. 1, the first adjustment shaft 71 is arranged such that its axis O is on the imaginary line connecting the upper and lower first yarn guides 51 or outside the imaginary line.

Accordingly, the first spiral portion 711 of the first adjustment shaft 71 is located in the travel path of the pile yarn 4 between the upper and lower first yarn guides 51, 51. The pile yarn 4 that is traveling is in contact with the outside of the first spiral portion 711 arranged in the traveling path in this way. That is, all or some of the plurality of rows of pile yarns 4 arranged along the first yarn guide 51 are arranged in the axial direction of the first spiral part 711 and contact the first spiral part 711 to apply an outward tension. Has been.
The pile yarn 4 may run inside the first spiral portion 711. That is, in consideration of operability and a pattern to be formed, the pile yarn 4 may run outside the first spiral portion 711 or may run inside. In FIG. 1, the case where the pile yarn 4 is run inside the first spiral portion 711 is indicated by a two-dot chain line.

  The first adjustment shaft 71 is rotated by a driving device 8 (a motor and its control device) provided in the machine body 2. The direction of rotation can be either clockwise or counterclockwise. A first rotation speed control device 81 is provided so that the rotation speed of the first adjustment shaft 71 can be changed. The first rotation speed control device 81 is interposed between the drive device 8 and the first adjustment shaft 71 and adjusts the rotation speed (the number of rotations) of the first adjustment shaft 71.

  The second adjustment shaft 72 includes a second spiral portion 721 having a spiral continuous surface on the outer peripheral contour surface 72a, and a cylindrical second shaft projecting at the axial position of both end portions of the second spiral portion 721. Part 722.

Similarly to the first spiral portion 711, for example, the second spiral portion 721 is formed by twisting the strip-shaped plate steel around the center (axis) in the width direction of a strip-shaped plate steel (for example, made of stainless steel) having a rectangular shape in plan view. Can be formed.
The spiral direction of the second spiral portion 721 is not particularly limited, and may be clockwise or counterclockwise around the axis O. By twisting the strip-shaped plate steel clockwise, the second spiral portion 721 whose spiral direction is clockwise can be formed, and by twisting the strip-shaped plate steel counterclockwise, the second spiral portion 721 whose spiral direction is counterclockwise can be formed. Can be formed.
The thickness of the strip-shaped flat steel is not particularly limited, but is 5 mm to 15 mm, preferably 7 mm to 12 mm in consideration of strength and twist workability.

  The second shaft portion 722 can be provided in the second spiral portion 721 by fixing columnar members to both ends of the second spiral portion 721.

The second adjustment shaft 72 is rotatably supported on the rear side of the machine body 2 so that the axial direction thereof is substantially parallel to the gauge direction G of the base fabric 9.
Further, as shown in FIG. 1, the second adjustment shaft 72 is arranged such that its axis O is on the imaginary line connecting the upper and lower second yarn guides 52 or outside the imaginary line.

Accordingly, the second spiral portion 721 of the second adjustment shaft 72 is located in the travel path of the pile yarn 4 between the upper and lower second yarn guides 52 and 52. The pile yarn 4 that is traveling is in contact with the outside of the second spiral portion 721 that is arranged in the traveling path in this way. That is, all or a part of the plurality of rows of pile yarns 4 aligned along the second yarn guide 52 are aligned in the axial direction of the second spiral portion 721 and are in contact with the second spiral portion 721 to apply an outward tension. Has been.
Note that the pile yarn 4 may run inside the second spiral portion 721. That is, in consideration of operability and a pattern to be formed, the pile yarn 4 may run outside the second spiral portion 721 or may run inside. In FIG. 1, the case where the pile yarn 4 is caused to travel inside the second spiral portion 721 is indicated by a two-dot chain line.

  The second adjusting shaft 72 is rotated by a driving device 8 (a motor and its control device) provided in the machine body 2. The direction of rotation can be either clockwise or counterclockwise. A second rotation speed control device 82 is provided so that the rotation speed of the second adjustment shaft 72 can be changed. The second rotation speed control device 82 is interposed between the drive device 8 and the second adjustment shaft 72 and adjusts the rotation speed (the number of rotations) of the second adjustment shaft 72.

  The diameter D of the first spiral portion 711 and the second spiral portion 721 is not particularly limited (see FIG. 3), but if this is too small, the fluctuation range of the length of the travel path of the pile yarn 4 becomes small, and the base fabric 9 The height difference of the pile yarns 4 to be planted is relatively small. Considering this point, the lower limit of the diameter D is preferably 30 mm, more preferably 50 mm, and more preferably 75 mm. On the other hand, the upper limit of the diameter D is not particularly limited, but if it is too large, the fluctuation range of the length of the travel path of the pile yarn 4 becomes too large, and an excessive load is applied to the pile yarn 4 and it becomes easy to break. The pile yarn 4 that has been planted may fall off the base fabric 9 due to a load. For this reason, the upper limit of the diameter D is 200 mm normally, Preferably it is 180 mm, More preferably, it is 150 mm.

  The first spiral part 711 and the second spiral part 721 are not limited to those having a constant diameter in the axial direction. The diameters of the first spiral portion 711 and the second spiral portion 721 may change in the axial direction. For example, the first spiral portion 711 and the second spiral portion 721 are (1) those having the largest diameter in the central portion in the axial direction, (2) those having the smallest diameter in the central portion in the axial direction, and (3) diameters in a portion. Examples include large or small ones, and (4) one having alternately large-diameter portions and small-diameter portions.

(1) As shown in FIG. 4 (b), the spiral portion having the largest diameter in the central portion in the axial direction is centered on the central portion (axis N) in the width direction of the strip-shaped flat steel plate 7b having a substantially spindle shape in plan view. It can be formed by twisting the strip steel plate 7b in the direction of the arrow.
(2) As shown in FIG. 4 (c), the spiral portion having the smallest diameter in the central portion in the axial direction is centered on the central portion (axis N) in the width direction of the strip-shaped steel plate 7c having a substantially hourglass shape in plan view. It can be formed by twisting the strip steel plate 7c in the direction of the arrow.
(3) As shown in FIG. 4 (d), the spiral portion whose diameter is large or small in part is formed in a band shape centering on the center portion (axis N) in the width direction of the strip-shaped flat plate steel 7d partially protruding in plan view. It can be formed by twisting the flat steel 7d in the direction of the arrow.
(4) As shown in FIG. 4 (e), the spiral portion alternately having large diameter portions and small diameter portions is centered in the width direction center portion (axis N) of the rectangular plate-like strip steel plate 7e. Thus, the strip-shaped flat steel 7e can be formed by twisting in the direction of the arrow.

The spiral period length W of the first spiral portion 711 and the second spiral portion 721 is not particularly limited, but if it is too short or long, the pile yarn 4 slides along the outer peripheral contour surfaces 71a and 72a of the spiral portions 711 and 721. It may be difficult to lean on. Further, if the helical cycle length W is too long, the wave interval of the wave pattern due to the height difference of the pile becomes too large, and if the helical cycle length W is too short, the wave interval may become too small. Considering this point, the lower limit of the helical cycle length W is preferably 50 mm, more preferably 60 mm, and more preferably 100 mm. On the other hand, the upper limit of the helical cycle length W is preferably 4,000 mm, more preferably 2,000 mm, and more preferably 500 mm. For example, as shown in FIG. 11, a very long spiral portion 711, 712 having a spiral cycle length W of 4,000 mm has a spiral cycle length W close to the length L of the spiral portions 711, 712 (in this case, The spiral portions 711 and 712 have a length L of 4,000 mm or more, preferably 4,000 mm or more and 5,000 mm or less), and serve as an adjustment shaft with a slow helical twist.
Further, a tile carpet or the like can be obtained by preparing a pile fabric, forming a backing layer on the back surface thereof, and then cutting it into a predetermined size (generally, a 500 mm square size). When producing such a pile fabric cut into a 500 mm square size, the upper limit of the helical cycle length W is preferably 500 mm, more preferably 250 mm, and more preferably 150 mm.

  In order for the pile yarn 4 to easily move toward one side in the axial direction or the other side in the axial direction while sliding along the outer peripheral contour surfaces 71a and 72a of the spiral portions 711 and 721, the helical cycle length W is set to The diameter D is preferably 0.25 times to 130 times, more preferably 0.5 times to 80 times, and particularly preferably 1.5 times to 40 times. More preferred.

The lengths L of the first spiral part 711 and the second spiral part 721 are appropriately set according to the width of the machine body 2.
Although the length L of the first spiral part 711 and the second spiral part 721 varies depending on the size of the airframe 2, it is usually 800 mm to 5,000 mm, preferably 1200 mm to 4,000 mm.

  In addition, the 1st adjustment shaft 71 and the 2nd adjustment shaft 72 are not restricted to what was formed by twisting strip | belt-shaped flat steel as mentioned above, You may be formed with a synthetic resin, woody material, etc. For example, the first adjustment shaft 71 and the second adjustment shaft 72 may be a synthetic resin molded product formed so as to have a spiral continuous surface on the outer peripheral contour surface. However, in consideration of ease of processing, mechanical strength, and the like, the first adjustment shaft 71 and the second adjustment shaft 72 are preferably made of a twisted strip-shaped steel plate.

In addition, the first spiral portion 711 described above has corner portions whose both end edges of the outer peripheral contour surface 71a are sharpened at a substantially right angle. But the 1st spiral part 711 is not limited to this, For example, as shown in FIG. 5, the both-ends edge of the outer periphery outline 71a may be rounded off. Since the first spiral portion 711 is formed in an arc shape with the outer peripheral contour surface 71a bulging outward, it is possible to prevent the pile yarn 4 in contact with the first spiral portion 711 from being worn.
The second spiral portion 721 may also be formed in an arc shape in which the outer peripheral contour surface 72a bulges outward as in the other embodiments of the first spiral portion 711.

<Operation of tufting machine>
Next, the operation of the tufting machine 1 and the method for producing the pile fabric will be described.
Note that the pile planting mechanism provided on the rear side of the machine body 2 operates in the same manner as the pile planting mechanism provided on the front side. For this reason, the operation of the pile planting mechanism provided on the front side will be mainly described below, and the description of the operation of the pile planting mechanism on the rear side will be omitted.

The plurality of rows of pile yarns 4 are inserted from the first roll 61 into the needle holes of the first needle 311 via the first yarn guide 51. The pile yarn 4 to which tension is applied between the paths is in a taut state. Then, when the first needle 311 implants the pile yarn 4 on the base fabric 9, the pile yarn 4 is pulled out from the bobbin, and the pile yarn 4 travels along the path.
By the operation of the first needle 311, the pile yarns 4 in each row are implanted in the stitch direction S of the base fabric 9.

In the travel path of the pile yarn 4, the plurality of rows of pile yarns 4 are passed outside the first spiral portion 711 of the first adjustment shaft 71. Therefore, the plurality of pile yarns 4 arranged in the gauge direction G are in contact with the outer peripheral contour surface 71 a of the first spiral portion 711. For this reason, the pile yarn 4 protrudes outside the imaginary line connecting the upper and lower first yarn guides 51, and tension is applied to the pile yarn 4.
The plurality of rows of pile yarns 4 are preferably all passed through the outside of the first spiral portion 711, but the present invention is not limited to this, and some of the pile yarns 4 of the plurality of rows of pile yarns 4 are not limited thereto. However, it may be passed inside the first spiral portion 711. In this way, when a part of the pile yarn 4 is passed through the inside of the first spiral portion 711, the change in the length of the travel path of the part of the pile yarn 4 is the travel when it is passed through the outside. Small compared to the change in path length. Alternatively, when the first adjustment shaft 71 is disposed far outside the imaginary line connecting the upper and lower first yarn guides 51, a part of the pile yarn 4 that is passed inside the first spiral portion 711. The length of the travel route does not substantially change.

  In this way, by moving a part of the plurality of pile yarns 4 to the outside of the first spiral part 711 and running a part of the pile yarn 4 to the inside of the first spiral part 711, the height of the pile is partially increased. Pile fabric with a reversed pattern can be produced. This is because, when the pile yarn 4 traveling inside the first spiral portion 711 forms a high pile, the pile yarn 4 traveling outside forms a low pile, and on the contrary, the pile yarn traveling inside This is because, when 4 forms a low pile, the pile yarn 4 traveling outside forms a high pile.

  Since the first spiral portion 711 has a spiral shape, as shown in FIG. 2, the first spiral portion 711 has an outer peripheral contour surface 71a on the inside and outside at the position corresponding to the pile yarn 4A in the A-th row. The outer peripheral contour surface 71a is inclined with respect to the airframe 2 at a position corresponding to the pile yarn 4B in the B-th row (this direction is referred to as an inclined direction). At the position corresponding to the pile position 4C in the C-th row, the outer peripheral contour surface 71a faces upward and downward (this direction is referred to as “vertical direction”).

As shown in FIG. 6 (a), the pile yarn 4A in the A-th row contacting the first spiral portion 711 with the outer peripheral contour surface 71a facing inward and outward protrudes outward, and the travel route thereof is It is the longest.
As shown in FIG. 6C, the pile yarn 4C in the C-th row contacting the first spiral portion 711 with the outer peripheral contour surface 71a facing up and down travels on the innermost side, as shown in FIG. 6C. Is the shortest.
As shown in FIG. 6 (b), the pile yarn 4B in the B-th row contacting the first spiral portion 711 with the outer peripheral contour surface 71a in an inclined direction has a traveling path length of the pile yarn 4A and the pile yarn. It is in the middle of the length of the traveling path of the yarn 4C.

When the pile yarn 4 having the longest travel path is planted on the base fabric 9, a pile having the lowest pile height is formed.
On the other hand, when the pile yarn 4 having the shortest travel path is planted on the base fabric 9, a pile having the highest pile height is formed.

When the first spiral portion 711 rotates, for example, at the corresponding position of the pile yarn 4A in the A-th row, the outer peripheral contour surface 71a of the first spiral portion 711 is directed inwardly, outwardly, inclinedly, and vertically. And change sequentially. Accordingly, when the first spiral portion 711 rotates, the length of the travel path of the pile yarn 4A in the A-th row sequentially changes. Similarly, with respect to the pile yarns 4 in the other rows, the lengths of the travel paths of the pile yarns 4 in each row change sequentially as the first spiral portion 711 rotates.
For this reason, the pile yarn 4 can be planted with a height difference in the stitch direction S of the base fabric 9, and a pile fabric in which a wave pattern resulting from the height difference of the pile appears as a whole can be produced.

  Furthermore, since the outer peripheral contour surface 71a of the first spiral portion 711 is a spiral continuous surface (since it is a gentle curved surface having an arc around the axis), a plurality of rows of pile yarns 4 in contact with the outer peripheral contour surface 71a. A part of the pile yarn 4 slides on the outer peripheral contour surface 71a and approaches one side in the axial direction or the other side in the axial direction. That is, the pile yarn 4 normally travels on a straight line parallel to the imaginary line connecting the upper and lower first yarn guides 51, but some pile yarns 4 are on one side in the axial direction or on the axis line on the outer peripheral contour surface 71a. The other side of the direction is bent (in FIG. 2, a part of the pile yarn that has approached is indicated by reference numeral 4D).

The pile yarn 4 in contact with the portion where the outer peripheral contour surface 71a is inclined and the pile yarn 4 in contact with the portion where the outer peripheral contour surface 71a is inward and outward are close to one side in the axial direction or the other side in the axial direction. In particular, the pile yarn 4 that is in contact with the inward and outward portions has a large degree of deviation (the bending angle of the pile yarn 4 is large).
However, all of the pile yarns 4 that contact the portion where the outer peripheral contour surface 71a is inclined and all of the pile yarns 4 that contact the portion where the outer peripheral contour surface 71a faces inward or outward are one side in the axial direction or the axial direction. The pile yarn 4 may not partly move toward the other side. That is, the deviation of the pile yarn 4 toward one side in the axial direction or the other side in the axial direction occurs irregularly.

The length of the travel path of the pile yarn 4 that is close to one side in the axial direction or the other side in the axial direction is slightly shorter than that in the case where it travels linearly.
The deviation of the pile yarn 4 can occur irregularly as described above. For this reason, according to the tufting machine 1 of the present invention, since the length of the travel path of the pile yarn 4 supplied to the first needle 31 changes irregularly, the pile fabric having irregularly changed pile heights can be obtained. Can be made.
Such a pile fabric has an irregular wave pattern on its surface due to an irregular height difference of the pile.
The pile of the obtained pile fabric may be in the form of a trap (loop pile), or may be cut into a tuft (cut pile).

In addition, although the tufting machine 1 of the said embodiment is provided with the pile planting mechanism in the front side and back side of the body 2, the tufting machine 1 of this invention is not limited to this.
For example, a tufting machine according to another embodiment of the present invention may be provided with a pile planting mechanism only on either the front side or the rear side of the body 2.

<Control of rotation of adjustment shaft>
In the pile fabric manufacturing method using the tufting machine, the rotation speed of the adjustment shafts (the first adjustment shaft and the second adjustment shaft) may be constant or may be changed as appropriate.
The tufting machine according to the present invention can produce a pile fabric having a more varied pattern by changing the rotation speed of the adjusting shaft.
For example, the pile yarn may be planted on the base fabric by rotating the adjustment shaft at a low speed or by rotating the adjustment shaft at a high speed. Further, the pile yarn may be planted on the base fabric while alternately rotating and stopping the adjusting shaft.

Further, the rotation direction of the adjustment shaft may be changed.
The tufting machine of the present invention can produce a pile fabric with a pattern that is more varied by combining forward and reverse (clockwise and counterclockwise) rotation directions of the adjustment shaft.
For example, the pile yarn may be planted while rotating the adjustment shaft clockwise, and then the pile yarn may be planted while rotating the adjustment shaft counterclockwise.
Furthermore, a pile fabric having a more varied pattern can be produced by appropriately combining the change in the rotation speed of the adjustment shaft and the change in the rotation direction.

Example 1
In Example 1, a pile fabric was produced by changing the rotation speed of the adjusting shaft and the number of stitches.
FIG. 7 is a photograph of the surface of each pile fabric obtained in Example 1.
The tufting machine used in Example 1 was provided with a pile planting mechanism only on the front side of the machine body.
The adjustment shafts used in this pile planting mechanism are: the diameter of the spiral portion: 75 mm, the same spiral period length: 135 mm, and the same spiral direction: clockwise. In addition, the photograph of the real thing of the adjustment axis | shaft used in Example 1 (and Example 2-4 mentioned later) is shown in FIG. The rotation speed of the adjustment shaft (the rotation direction of the adjustment shaft is clockwise) was performed at three types of 5 rpm, 8 rpm, and 15 rpm. The number of stitches per inch (ST) in the stitch direction was 10 stitches, 13 stitches, and 17 stitches.

FIG. 7 (1 a) shows a pile fabric produced with a rotation speed of the adjusting shaft of 5 rpm and a stitch count of 10 stitches / inch.
FIG. 7 (2 a) shows a pile fabric produced with a rotation speed of the adjusting shaft of 5 rpm and a stitch count of 13 stitches / inch.
FIG. 7 (3 a) shows a pile fabric produced with a rotation speed of the adjusting shaft of 5 rpm and a stitch count of 17 stitches / inch.

FIG. 7 (1 b) shows a pile fabric produced with a rotation speed of the adjusting shaft of 8 rpm and a stitch count of 10 stitches / inch.
FIG. 7 (2 b) shows a pile fabric produced with a rotation speed of the adjusting shaft of 8 rpm and a stitch count of 13 stitches / inch.
FIG. 7 (3 b) shows a pile fabric produced with a rotation speed of the adjusting shaft of 8 rpm and a stitch count of 17 stitches / inch.

FIG. 7 (1 c) shows a pile fabric produced with a rotating speed of the adjusting shaft of 15 rpm and a stitch count of 10 stitches / inch.
FIG. 7 (2 c) shows a pile fabric produced with a rotation speed of the adjusting shaft of 15 rpm and a stitch count of 13 stitches / inch.
FIG. 7 (3 c) shows a pile fabric produced with a rotation speed of the adjusting shaft of 15 rpm and a stitch count of 17 stitches / inch.

  The faster the rotation of the adjusting shaft is, the more the pattern pattern pile fabric can be made with the interval between the wave patterns being closer and the wave pattern being more inclined. Further, as the number of stitches per unit length is increased, a pile fabric having a pattern pattern in which the interval between the wave patterns becomes closer and the inclination of the wave pattern becomes gentler can be produced. In this manner, a pile fabric having a wave pattern with a desired interval and an inclination can be produced by appropriately adjusting the rotation speed of the adjusting shaft and the number of stitches per unit length. In addition, the wave pattern obtained is a pattern peculiar to the present invention that has irregular undulations and has a texture that could not be achieved conventionally.

(Example 2)
In Example 2, a pile fabric was produced by combining high-speed rotation and low-speed rotation as the rotation speed of the adjusting shaft.
FIG. 8A is a photograph of the surface of the pile fabric obtained in Example 2. FIG.

The tufting machine used in Example 2 was provided with a pile planting mechanism only on the front side of the machine body.
The adjustment shafts used in this pile planting mechanism are: the diameter of the spiral portion: 75 mm, the same spiral period length: 135 mm, and the same spiral direction: clockwise.
The number of stitches per inch in the stitch direction was set to 13 stitches.
The rotation speed of the adjustment shaft (the rotation direction of the adjustment shaft is clockwise) was set as shown in the graph of FIG. In the graph of FIG. 9A, the vertical axis represents the rotation speed of the adjustment shaft, and the horizontal axis represents the elapsed time from the start of rotation. In addition, about the rotation speed after 20 seconds, since it is the same period, it is abbreviate | omitting.

  As in the second embodiment, by changing the rotation speed of the adjusting shaft from high speed to low speed, the pile pattern in which the wave pattern due to the high pile is dark and the wave pattern due to the low pile appear irregularly appears. A dough can be produced (see FIG. 8A).

(Example 3)
In Example 3, a pile fabric was produced by combining rotation and stop of the adjusting shaft.
FIG. 8B is a photograph of the surface of the pile fabric obtained in Example 3.

The tufting machine used in Example 3 was provided with a pile planting mechanism only on the front side of the machine body.
The adjusting shaft and the number of stitches used in this pile planting mechanism are the same as those in the second embodiment.
The rotation speed of the adjustment shaft (the rotation direction of the adjustment shaft is clockwise) was set as shown in the graph of FIG. 9B. In the graph of FIG. 9B, the vertical axis represents the rotation speed of the adjustment shaft, and the horizontal axis represents the elapsed time from the start of rotation. In addition, about the rotation speed after 20 seconds, since it is the same period, it is abbreviate | omitting.

  As in Example 3, a pile fabric in which intermittent wave patterns appear irregularly can be produced by repeatedly rotating and stopping the adjusting shaft (see FIG. 8B).

Example 4
In Example 4, a pile fabric was produced by combining forward rotation and reverse rotation of the adjustment shaft.
FIG. 8C is a photograph of the surface of the pile fabric obtained in Example 4.

The tufting machine used in Example 4 was provided with a pile planting mechanism only on the front side of the machine body.
The adjusting shaft and the number of stitches used in this pile planting mechanism are the same as those in the second embodiment.
Further, the rotation speed of the adjustment shaft (the rotation direction of the adjustment shaft is clockwise) was set as shown in the graph of FIG. In the graph of FIG. 9C, the vertical axis represents the rotation speed of the adjustment shaft, and the horizontal axis represents the elapsed time from the start of rotation. A range in which the rotation speed is a positive value indicates that the adjustment shaft is rotated clockwise, and a range in which the rotation speed is a negative value indicates that the adjustment shaft is rotated counterclockwise. In addition, about the rotation speed after 20 seconds, since it is the same period, it is abbreviate | omitting.

  By repeating forward and reverse rotation of the adjustment shaft as in Example 4, a pile fabric in which a wave pattern continuous in an S shape appears irregularly (see FIG. 8C).

The partial omission reference side view showing the tuft machine concerning one embodiment of the present invention. A partially omitted reference front view of a portion provided with the first adjustment shaft of the tuft machine as viewed from the front side. The partial omission front view of the adjustment axis | shaft which concerns on one embodiment. (A) is a top view of the strip steel plate for forming the adjustment axis | shaft which concerns on one embodiment, (b)-(e) is a strip | belt-shaped steel plate for forming the adjustment shaft which concerns on other embodiment. FIG. The side view which looked at the adjusting shaft which concerns on other embodiment from the axial direction. 2A is an end view taken along line VIa-VIa in FIG. 2, FIG. 2B is an end view taken along line VIb-VIb in FIG. 2, and FIG. 3C is an end view taken along line VIc-VIc in FIG. The photograph figure of the surface of the pile cloth of Example 1. The photograph figure of the surface of the pile cloth of Examples 2-4. The graph showing the change of the rotational speed of the adjustment axis | shaft of Example 2-Example 4. FIG. (A) is a photograph of the adjusting shaft used in Examples 1 to 4, and (b) is a partially enlarged photograph of the same. The front view of the adjusting shaft which concerns on other embodiment.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 ... Tufting machine, 2 ... Airframe, 31 ... 1st needle part, 32 ... 2nd needle part, 311 ... 1st needle, 321 ... 2nd needle, 4 ... Pile thread, 51 ... 1st yarn guide, 52 ... Second yarn guide, 61 ... first roller, 62 ... second roller, 71 ... first adjustment shaft, 71a ... outer peripheral contour surface of first adjustment shaft, 711 ... first spiral portion, 72 ... second adjustment shaft, 72a ... outer peripheral contour surface of second adjustment shaft, 721 ... second spiral portion, 9 ... base fabric, O ... axis of adjustment shaft, G ... gauge direction of base fabric (width direction of machine body), S ... stitch direction of base fabric

Claims (6)

A plurality of needles that are provided along the gauge direction of the base fabric and in which pile yarns are implanted in the base fabric, and are provided in a travel path of the pile yarns that are sent to the needles. An adjustment shaft that contacts and changes the length of the pile yarn travel path,
The tufting machine, wherein the adjustment shaft has a spiral portion having a spiral continuous surface on an outer peripheral contour surface.   The tufting machine according to claim 1, wherein an axial direction of the adjustment shaft is arranged substantially parallel to a gauge direction of the base fabric.   The tufting machine according to claim 1, wherein the adjustment shaft is rotatable forward and backward about the axis.   The tufting machine according to any one of claims 1 to 3, wherein the adjustment shaft is rotatable about an axis thereof and the rotation speed thereof can be changed. An adjustment shaft for a tufting machine provided in a travel path of a pile yarn sent to the needle and changing the length of the travel path of the pile yarn in contact with the pile yarn,
An adjustment shaft for a tufting machine, wherein the adjustment shaft is formed of a twisted belt-like flat plate having a spiral continuous surface on an outer peripheral contour surface.   The adjusting shaft for a tufting machine according to claim 5, wherein the outer peripheral contour surface is formed in an arc shape bulging outward.