EP 1 985 731 A1 (19) » (43) Date of publication: 29.10.2008. Bulletin 2008/44 (12) (21) Application number: 081549446 (22) Date of fing: 22.04.2008 ty EP 1 985 731 A1 EUROPEAN PATENT APPLICATION (61) Int. oso sswze —posD sa/ast=«o (84) Designated Contracting States: AT BE BG CH CY CZ DE DK EE ES FIFR GB GR HR HUIEISIT LILT LU LV MC MT NL NO PL PT ROSESISKTR Designated Extension States: AL BAMK RS (80) Priory: 28.04.2007 GB 0707800 (71) Applicant: BRINTONS LIMITED Kidderminister Worcestershire DY10 1AG (GB) (72) Inventors * Burton, Michael Winspear Stourbridge, Worcestershire DY9 OLB (GB) + Hodges, Bruce Peter Kidderminster, Worcestershire DY10 4RT (GB) (74) Representative: Finnie, Peter John Gill Jennings & Every LLP Broadgate House 7 Eldon Street London EC2M 7LH (GB) (64) Yarn tuft holder (57) Ayam tuft holder (11) for holding yarn tuts re ceived from one or more yam tuft inserting devices (2) prior to removal by grippers (13) ofa carpet manufactur ing machine, comprising a resiliently deformable comb portion (17) for recelving and holding yarn tuts and @ Tigid comb portion (16) disposed adjacent the resifently deformable como portion and for guiding grippers con- figured to remove yarn tufts held by the resiliently de- {ormable comb portion. Also, loom for making carpet, comprising one or more of the yarn tuft holders, and @ ‘method for making carpet using the loom,1 EP 1.985731 A1 2 Description Field of the Invention [0001] The invention relates to a yarn tuft holder. The Invention relate, n particular, to a yarn uftholderforan ‘Axminster loom for making Axminster carpet. [0002] On a gripper Jacquard Axminster loom each weaving point includes a yarn cartier which is normally fed by eight, or sometimes sixteen, yams usually of dt ferent colour and the Jacquard mechanism moves the carrier to bring a selected yarn to the yarn selection po- sition. A gripper moves towards the cartier, grips the yam at the yarn selection position then relative movernent ‘apart ofthe gripper and the carrier pulls predetermined length of yam from the carrer. [0003] The yarn is then cut o form a tuft and moved by the gripper to the weaving point. The tut carried by the gripper is ofthe appropriate colour forthe tft to be ‘supplied to the next row of carpet to be woven. [0004] In spool Axminster looms a separate spool is provided for each row of the pattern repeat and each spool hasa separate yarn windingfor each weaving point along each row. Background to the Invention [0005] In both the Jacquard and spool Axminster looms a row of tufts for a complete row of the carpet is created simultaneously and transferred to the weaving point at which they are wven into a backing to produce the carpet [0006] A different approach to yarn tuft formation is described in WO 95131894, Tufts of yar to form a row cof the carpet are produced by first loading yarn tufts into ‘a yarn tuft holder by traversing the tut holder stepwise through a seq uence of loading postions so as to tem: poraily present predefined ttt retention sites ofthe tft holderto each of apluraltyof stationary tuftforming units, ‘Ateach loading positon one ormore tuts are loadedinto the sites by the tut forming units until the tuft holder is loaded with tufts for a complete row of the carpet. The tufts are then transferred from the tut holder the weav- ing points simuttaneously by means of grippers. Since the grippers do not perform the tuft formation, tuft forma tion can take place at the same time as the Weaving op- tration and thus tut formation can take place substan tially continuously throughout the operation of the loom, This isto be contrasted with the conventional spool or ‘ripper type looms where tuft formation takes place over only about half of each weaving cycle. [0007] A yet further approach to yarn tuft formation is deseribed in WO 02/0978. The loom includes one or ‘more tut forming units each of which includes a yam selector wheel which typically holds 12 or 24 yams of different colour. A motor dives the yam selector wheel Into one of a number of angulary discrete positions to select yam of predetermined colour. As the or each tuft ‘forming unit traverses the loom relative to a stationary ‘yarn tut holder, tufts of predetermined colour are placed intuftretenton sites ofthe tuftholder. When the tut hold- er is loaded with tuts for @ complete row of the carpet, the ut aretransferredtromthe tuttholdertothe weaving points simutaneously by means of grippers. [0008] The yarn tuft holders ofthe prior art may take many diferent forms for securely holding each tuft. The tuftholdermaybe rigid andthe profile ofeach slot defining ‘atutretenton site may be shaped such thatthe inherent elasticity ofthe turt holds the tut tthe botom ofthe slat ‘when pressed therein. Atematively, one or both oppos- ingsides of each siotmaybe formed ofaresiient material capable of gripping a tut presented into the slot. Yetfur- ther, the sides of each slot may be rigid and a resilient clip may be provided to hold the tut in place. [0009] A problem associated with the yarn tuft holders ofthe prior artis that the position ofthe yarn tufts inthe holder, and transfer of the tuts theretrom ay the grippers, cannot always be accurately controlled. Uniess all of the tufts are positioned correctly in the loaded tut holder and all of the grippers can securely transport all ofthe tufts {rom the tut holder to the weaving points, the grippers may transfer some of the tufts to the weaving points in- correctly or fal to transfer them at al. This can lead to @ requirement for longer tufts so that these can be more readily arippedby the grippers resuttingin increased yam wastage. Any transfer fellures can lead to downtime of the loom, and/or necessitate post production rectification of any flaws inthe carpet. [0010] There is therefore a need in the at for an im proved yarn tuftholder which alleviates the above prob lems, ‘Summary of the Invention [0011] According toast aspectof the invention there is provided a yam tut holder for holding yarn tuts re- ceived trom one or more yarn tuft inserting devices prior to removal by grippers of a carpet manufacturing ma- chine, the holder comprising a resiliently deformable comb portion for receiving and holding yarn tufts, and a rigid comb portion disposed adjacent the resiiently de- {ormable comb portion and for guiding grippers contig- Ured to remove yarn tuts held by the resiliently deforn- ‘able comb portion, The invention provides improvedcon- ‘rol over the yarn tuts and the grippers leading to more reliable transfer ofthe yarn tufts to their weaving posi- tions. [0012] According to a second aspect ofthe invention there is provided a carpet manufacturing machine, com prising one or more yarn tuft holders in accordance with the fist aspect. The carpet manufacturing machine may be similar to that described in WO 95/3194 or WO 02100978, or any other suitable carpet manufacturing machine, [0013] Accordingto.thirdaspectoftheinventionthere is provided a method for making carpet using a carpet8 EP 1.985731 A1 4 ‘manufacturing machine in accordance with the second ‘aspect, comprising the steps of inserting yarn tufts into the resiliently deformable com portion of one ofthe yam tuft holders, quiding grippers using the rigid comb portion cof sald yar tuft holder during removal of said yam tufts by sald grippers from said yarn tuft holder, and securing the removed yam tufts nto a backing. [0014] In apreterred exemplary embodiment the resi: ‘ently deformable comb portion is of plastics material and formed having an array of teeth separated by slots. The teeth are shaped so as to define a stem portion and a head portion wider than the stom potion. The length and form of the stem defines the degree of flexibilty of each tooth; a shorter, fatter stem producing a stiffer tooth. The head portion has a cut out for forming @ cavity with an ‘adjacent tooth, the cavity being adapted for receivingand holding yamtuftata yarn tuftretention site, Adimension ofthe cavity s sutable for firmly holding the yam tuftand yet enabling removal ofthe yarn tut by the grippers eas- lly. A fp extends from the top ofthe cavity towards the ‘adjacent tooth to help keep the tut in position. The head portion is tapered towards the top 60 thatthe tooth does rot undergo a large deflection asthe yarn tuts loaded ‘and as the inserting device is retracted. Ths feature is particulary beneficial where the yam tuft holder of the invention is implemented in a loom where the yarn tuft Inserting device(s) continuously traverse across the length ofthe stationary yarntuttholderloaingtutts there- [0015] In atterative exemplary embociments, the ge- ‘metry ofthe tooth form can be altered allow the plas tios comb to accommodate & number of operational var lables such as speed of loading of the tuts, speed of traverse ofthe inserting device(s), form of the yarn tft Inserting device(s), and yarn tut thickness. Thicker yarn tufts may be accommodated by increasing the cavity i ‘mension it may also be of beneft to include a platform ‘extending from the bottom of the cavity towards an ad: Jacent tooth. The platform may extend to beneath the head portion of the adjacent tooth, A serrated edge on atleast one side wallofthe cavity couldbe usedto provide ‘additional rip onthe yarn uf. A channel may be formed ‘extending longitudinally across the resiliently deformable ‘comb portion to define two laterally spaced comios that ‘can retain each of the yam tufts attwo spaced postions along the length of each tut [0016] In the preferred or aternative exemplary em: bodiment, slots formed in the rigid comb portion align With the slots formed in the resilient deformable comb portion. Aplualty of the resiliently deformable comb por tions are removably connected tothe rigid comb portion, Manufacturing the resiienty deformable comb portions ‘as shorter sections than the rigid comb portion provides the benefits of reduced tooling costs, small pitch varia tions due to material shrinkage in the case thatthe sec: tions are moulded, and also makes replacement of the sections easier as they become worn or damaged. Each cof the pluralty of resiliently deformable comb portions is aligned with the rigid comb portion by means of mating projections and recesses oaidpitch control. The number of yam tufts held in each resiliently deformable comb portion can be 20, butany suitable number may be used, from about § to 500, fer example 25 of 20, Brief Description of the Drawings [0017] Examples ofthe present invention wil now be desctived in detall with reference to the accompanying drawings, In whic: Figure 1 is @ partly sectioned side elevation ofthe loom: Figure 2's a schematic side elevation ofthe weaving section ofthe loom: Figure 3 is a partly exploded isometric view of the yam tut holder, Figure 4 is an isometric view of one ofthe resiliently deformable comb portions according to a first pre- ferred embodiment; Figure § is @ schematic view of the teeth of the re- silently deformable comb portion; Figure 6is an isometric view of one ofthe reslienty deformable comb portions according to a second ‘embodiment: and Figure 7is an isometric view of one ofthe resillenty deformable com portions according to a third em- bodiment. Detalled Description [0018] The carpet weaving loom shown in Figures 1 ‘and 2 includes one or more tuft fomming units 1 each of which supplies yam tufts to one ormore different weaving points and each of which includes a yam inserting device 2, a movable cree! 3 for holding supplies of yam, and {uides 4 to guide yarn from a supply 5 on the creel Sto the or each tuft fomming unit 1. The creel 3is located in the front of the loom and behind the weavers postion 7. This is on the opposite side of the loom from the warp beam (not shown) from which the warp threads 8 are provided. Alternatively the creel 3 maybe located above ' remainder ofthe loom 6, The completed carpet is col lected on a roll, [0019] The loom includes a yam tuft transfer system 10 including ve yarn tuft holders 11 mounted on a belt 12, Thebett12isarangedtormovementaroundaciosed loop to sequentially present each of the yan tuft holders 11 to the yam tuft inserting devices 2. A set of grippers 1Sareconfiguredtounloadthe lowermost yamtuftholder 11 that i filled with tuts and transfer these to thei r= spective weaving point 16. [0020] In the preferred embociment shown with refer- fence to Figures 1 and 2, as the tuft forming units 1 traverse across the loom, tufts are placed by inserting devices 2 in tuft retention sites 14 (shown in figure 5) formed along the top edge of the yam tuft holder 115 EP 1.985731 A1 6 When all ofthe tut retention sites 14 have been loaded, the yarntuftholder 11 rotates clockwise (as seen nfigure 2) 10 move the loaded tft holder 11 towards the lower- ‘most position and to move an empty yarn tuft holder 11 towards the uppermost postion. The inserting devices 2 (ofthe tuft forming units 1 then load tufts into the upper: ‘most yam tuft holder as they traverse back across the loom inthe opposite direction [0021] The grippers 13 move upwards, counter-clock- Wise @s seen in Figure 2, with their beaks open and then close to grip all ofthe tfts held by the lowermost yam tuftholder 11. The grippers 13 then rotate inthe opposte direction to move the tuts to the weaving point 15 where the tufts are woven into the carpet and the grippers 13 ‘open to release the tufts. The beet up reeds and weft Insertion mechanism have been omited from Figure 2 for clarity but are entirely conventional and similar to those used on the conventional gripper Axminster camet looms. [0022] The yam tuftholder 11 is shown in detain Fig: re 8 and comprises a rigid comb portion 16 and a plu ralty of resiently deformable comb portions 17. Inthe preferred embodiment the rigid comb portion 16 is made ‘ofmetal and the resiliently deformable comb portions 17 ‘are made of plastics material. The resiienty deformable ‘comb portions 17 receive the yam tufts and hold them securely until the grippers 18 remove them. The rigid ‘comb portion acts as a guide forthe grippers 13 to centre them before they remove the yarn tufts. The rigid comb portion also provides a degree of control ofthe yarn tft fends held in he resiliently deformable comb portions 17. ‘Accurate pitch control of the yasn tufts held in the yam tuftholder 1 isattainedbyusingtheplurlityofreslienty deformable comb portions 17, shorterthan the rigdcomb portion 16, This is also attained by the alignment of pro: Jections 18 extending trom the resiliently deformable ‘comb portions 17 lacated In recesses 19 formed in the rigid comb portion 16. One or more screws, or the ike, are employed for fixing the resiliently deformable comb potions 17 to the igld comb portion 16 at postion 20, This allows for easy removal and replacement ofthe ro: silently deformable comb portions 17 fromthe rigidcomb portion 16 [0023] The number of tut retention sites 14 in each resillently deformable comb portion is preferably 20, but could easily be adapted to 25, 30 or any other sutable ‘number. Manufacturing the resiliently deformable comb portionin small sections provides the benefits of reduced tooling costs, smaller pitch variations due to material shrinkage ifthe partis moulded, and easy replacement when the partis wom or damaged. The form of the teeth 21 ofthe resiliently deformable comb portions 17 willnow bbe desoribed with reference to figure 5. Each tocth of the resiliently deformable comb portions 17 has a flexible stem 22 and a head 23 wider than the stem 22. The de- gree of flexibility ofthe comb is definedby the length and form of the stem 22; a shorter, fatter stem 22 producing astifertooth 21, Each head portion 23 has a cut out 24 ‘forming a cavity with an adjacent tooth 21, the cavity de- fining the tut retention site 14. A dimension of the cavity is suitable for frmly holding the yam tuft and yet enabling removal ofthe yarn tuft by the grippers 18 easly. A lip 25 extends fromthe top ofthe cavity towards the adjacent tooth 21 tohelp keep the tuitin position. Theheadporton 28 is tapered towards the top so thatthe tooth 21 does ot undergo a large deflection as the yarn tufts loaded ‘andthe inserting device 2isretracted. Thisteatureallows the yarn tut insertion to be completed continuously as the yarn tuft inserting device 2 moves across the length ofthe yarn tut holder 11 loading tufts therein [0024] Whilst the preferred embodiment ofthe inven- tion has been described with reference to a gripper ‘Axmrinsterloom similarto that described inWO02/00378, It will be appreciated thatthe yarn tuft holder of the in- vention is equally suitable forthe loom deserbed in WO 95/3189, where the yarn tuft holder moves relative to stationary tuft inserting devices. The design of the yam tuft holder in accordance wit the invention allows con- tinuous movement between the tuft inserting device 2 ‘and the yarn tft holder 11 although this movement may be intermittent. ltematively the yarn tuftholder 11 may- be stationary and hold yam tufts inserted by the yarn ttt Inserting devices, priorto remavalby grippers for aweav: ing operation. [0025] A second, altemative exemplary embodiment ofthe arn tuft holder wilnowbe described ith reference +o Figure 6. The yatn turt holder 11 of the second em: bodiment citfers only from the frst, preferred embodi- ‘ment in festures ofthe teeth 21 ofthe resiliently deform ‘able comb portions 17. In the second embodiment, the resilently deformable comb portion 17a includes a plat- {orm 26 extending from the bottom of the cavity towards the adjacent tooth 21 a, Platform 26 may extend to be- neath the head portion 28a of the adjacent tooth 21 a. A serrated edge 27 is formed on at least one side wall of the cavity to provide adaitional grip on the yarn tut when held in the yarn tuft retention sites 14, It willbe apprect- fated by those sklled In the art thatthe features of the second embodiment may be employed together or sep: arately in te frst, preferred embodiment. [0026] third embodiment ofthe invention will naw be descrived with reference to Figure 7 which shows the further altemative resiliently deformable comb portion 17, In the third embodiment, a channel 28 le formed extending longitudinally across resiliently deformable comb portion 17b to define two laterally spaced combs 29, 80 thatcan retain each ofthe yarn tufts at wo spaced positions along the length of each tuft. Alternatively, a plurality of such channels could be employed so increas- ing the number of retaining positions for each tut. Claims 1. Ayarn tuftholder for holding yarn tuts received trom fone of more yarn tuft inserting devices prior to re-10. 1" 2 7 EP 1.985731 A1 8 moval by grippers of a carpet manufacturing ma- chine comprising: a resiliently deformable comb portion for recelv ing and holding yarn tufts; and 2 righd comb portion disposed adjacent the re silently deformable comb portion and for gui ing grippers configuredto remove yar tuftsheld by the resiienty deformable comb portion. ‘A yarn tuft holder according to claim 1, wherein slots ofthe resllanty deformable combpartion define yam tuft retention site. ‘Ayarn ttt older according to claim 2, wherein teeth ‘between the slots formed Inthe resiliently deforma- ‘ble comb portion are shaped so as to define a stem pportion and a head portion wider than the stem por tion. ‘Ayan tuft holder according to claim 3, wherein the head portion has @ cut out for forming a cavity with ‘an adjacent tooth the cavity being adapted for re: Ccsving an holding a yam tut. ‘Ayam tuftholder according to claim 4, wherein a ip ‘extends from the top ofthe cavity towards the adie cent tooth, ‘A,yam tut holder according to claim 4 or 5, wherein ‘platform extends from the bottom of the cavity to: wards the adjacent tooth ‘yarn tuft holder according to claim 5, wherein the platform extends to beneath the head portion of the adjacent toth ‘Ayyarn tuft holder according to claim any of claims 4 to 7, wherein atleast one side of the cavity has @ serrated wall ‘Ayam tuft holder according to any of claims 3 to 8, \herein the head portion is tapered towards the top. ‘Aya tuft holder according o any of claims 2 to 8, Wherein slots formed in the rigid comb portion align With the slots formed in the recilantly deformable ‘comb portion ‘Ayan tuft holder according to any ofthe preceding claims, wherein a channel extends longitudinally ‘across the resiliently deformable comb portion tode- fine two laterally spaced combs. ‘Ayyarm tuft holder according to any ofthe preceding claims, wherein a plurality of the resilienty deform- ‘able comb portions are removably connected tothe ‘ight comb portion 18. A yam tuft holder according to claim 12, wherein teach of the plurality of the resiliently deformable ‘comb portions has between & and 500 teeth, prefer- ably 20, 26 oF 30 teeth, 14, Ayam tuftholder according claim 120r 13, where: in each of the plurality ofthe resilenty deformable ‘comb portions has one or mare locating projections for aligning with recesses formed inthe rigid comb portion. 18. A carpet manuf acturing machine, comprising one ‘ormore yarn tuftholders in accordance with any one ofthe preceding claims. 16. A loom according to claim 18, wherein the or each yarn tuft holder is adapted to move relative to one or ‘more yam tut inserting devices, 17, A method for making carpet using a carpet manu- facturing machine in accordance with claim 150 16, comprising the steps of: inserting yamtufsintotheresiienty deformable ‘comb portion of one of the yarn tuft holders; ‘uiding grippers using the rigid comb portion of seid yarn tufthoder during removel of said yarn tufts by sald grippers from said yam tuft holder, and ‘securing the removed yam tufts into a backingEP 1.985731 A1 Fig. 1EP 1.985731 A1 Fig. 2EP 1.985731 A1EP 1.985731 A1 Fig. 5EP 1.985731 A1 21a 26 26 21a 23a V 23a 27 26—} (© —~'ta Fig. 6 Fig. 7EP 1.985731 A1 ») Ewopean Patent EUROPEAN SEARCH REPORT & 5 DOCUMENTS CONSIDERED TO BE RELEVANT. Apptcabon tamer EP 08 15 4944 ‘The preset sore repvthas been dawn up fr alla case] _ ln! gene wnat we ever Enan | guapanearouge D,A Wo 95/31594 A (ULSTER CARPET MILLS aa | inv. HOLDINGS L, [68]; STEWART RICHARD DONALD 003039/02 [68]; GRIF) 23 llovenber 1995 (1995-11-23) 003039/08 * page 5, lines 7-23; figure 3 * US 1 872 623 A (CLINTON ALVORD CHARLES) 1-17 16 August 1932, (1932-08-16) * figures 3-5 * 6B 2 227 499 A (CARPETS OF WORTH LIMITED |1-17 {68])" 1 August 1980 (1990-08-01) * figure 1 * GB 1 597 134 A (BOND WORTH LTD) 117 3 Septenber 1981 (1981-09-03) * Figure 2* GB 417 136 A (JOHN EDWARD ROBINSON) 1-17 28 September 1934 (1934-09-28) * Figures 1,2 * GB 389 736 A (ERNEST JOSEPH PERRY) 1-17 —— 23 March 1933 (1933-03-23) 0030 * Figures 1-5 * 05¢ The Hague 7 August 2008 Pussemier, Bart Eppa reer tte ane Seren se Teagan econ tetsu comes 1"EP 1.985731 A1 ANNEX TO THE EUROPEAN SEARCH REPORT ‘ON EUROPEAN PATENT APPLICATION NO. EP 08 15 4944 ‘Toi ann ints he ptt aiy mane relating tthe pant oeumentsotadin the shove menbone Europran reach eso “The Euepeon Paton a ein ne way lable or hee pares When ae maaly givn forthe pupeos of internation 07-08-2008 Patent document Pbleston Patetioniy Puan cain seek pot ‘ee meter) ‘te WO 9531594 A 23-11-1995 AU 681968 82 11-09-1997 AU 2450995 4 05-12-1995 CN 1143396 4 19-02-1997 DE 69508936 D1 12-05-1999 DE 69508936 T2 5-08-1999 0K 759101 13 18-10-1999 0759101 Al 26-02-1997 ES 2132664 73 16-08-1999 ob 3197992 2 13-08-2001 JP 10503246 T 24-03-1998 US 5743306 A 28-04-1998 Us 1872023 A «16-08-1932 NONE GB 2227499 =A 1-88-1990 NONE GB 1597134 —A_~—03-09-1981 NONE 6B 417136 A 28-09-1934 NONE 6B 389736 A 23-03-1933 NONE For or dele abot his nex 400 Otol Jura oft Euopean Pater Oi, No 282 2EP 1.985731 A1 REFERENCES CITED IN THE DESCRIPTION This list of references cited by the applicant i forthe reader's convenience only. It does nat form part of the European patent document. Even though great care has been taken in compiling the references, errors or omissions cannot be ‘excluded and the EPO disclaims all abit in this regard, Patent documents cited in the description + Wo 9831894 A (0006) [0012] (0024) + Wo 0200978 A [0007] 0012} [0024] a