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US 2003/0164130 A1Published application
Servo motor driven scroll pattern attachments for tufting machine with computerized design system and methods of tufting
AssigneeTuftco Corporation
InventorsMichael R. Morgante, Mike Bishop, Randall E. Stanfield, Eric J. Vaughen, Richard Prichard
Life of this patent
Estimating the term…
Abstract
The present invention provides alternative scroll-type yarn feed attachments for tufting machines characterized by independent servo-motor control of sets of yarn feed rolls, and a software design system to facilitate use of the attachment to produce novel patterns and photo images.
Claims20
A method of creating and tufting a carpet pattern comprising the steps of:
- selecting pattern parameters of width, length, a relatively high pile height and a relatively low pile length, for stitches on a computer display;
- creating a border pattern for at least one border to surround a central image;
- scanning an image to create a digital image;
- processing the digital image by a computer to calculate corresponding yarn heights and yarn feed increments for a plurality of colors of yarns in a carpet pattern to create pattern information;
- inputting the pattern information into a master controller of a multi-needle tufting machine;
- threading yarn ends of said plurality of colors of yarns from a yarn supply through a yarn drive array to a plurality of laterally spaced needles;
- reciprocating the plurality of laterally spaced needles threaded with said plurality of yarns through a backing fabric fed longitudinally from front to back through the tufting machine;
- sending information relative to the position of the plurality of needles to the master controller;
- the main controller sending information relative to the amount of yarn to be fed for the next stitch to the yarn drive array;
- operating a looper mechanism in synchronized cooperation with the plurality of needles to seize loops of yarn tufted through the backing fabric;
- thereby forming a tufted carpet having:
- a top surface on the backing fabric, a bottom surface and an outer perimeter encompassing a center portion;
- a first border surrounding the center portion comprising a first plurality of bights on the outer perimeter of the top surface of the backing fabric;
- wherein the plurality of bights comprising said first border is formed by feeding stitches of yarn in at least three distinct increments of length.
11 more elements
A tufted carpet comprising:
- (a) a generally planar backing fabric having a top surface, a bottom surface and an outer perimeter encompassing a center portion;
- (b) a first border surrounding the center portion comprising a first plurality of bights on the outer perimeter of the top surface of the backing fabric;
- (c) a second border surrounding the center portion visually distinct from and located interior of said first border, and comprising a second plurality of bights on the outer perimeter of the top surface of the backing fabric;
- (d) wherein the plurality of bights comprising at least one of said first and second borders is formed by feeding stitches of yarn in more than three distinct increments of length.
1 more element
Dependencies are inferred from the claim text.