Patent Description:
In tufting, a textile is produced by a textile process in which a thread is inserted on a primary base. Specialized machinery can be used to produce a tufted textile. Such machinery typically can make use of tufting tools to insert the thread to the primary base and to apply the thread in a described manner. In some applications, the tufting tools are provided in a tufting tool module to facilitate reconfiguration of the machinery for different applications. In a tufting tool module, a plurality of tools are embedded within a common cast body member in a side-by-side configuration. To ensure a good function of the loop forming and a good quality of the tufted fabric, it is essential that the different tufting tools are aligned with each other with very high precision. Typically, a tufting machine can hold <NUM> needles, hooks and knifes, and they typically match each other with a precision of tenths of a millimeter, or sometimes even hundreds of a millimeter.

Known tufting tool modules are described in for example <CIT> and <CIT>. For example, in <CIT> a tufting tool module is described having a hole in the securing portion of hooks in order to receive metal for securing the hooks in the base member of the tufting tool module. Also, <CIT> and <CIT> describe similar known tufting tool modules.

There is a constant desire to improve textile machines including tufting machines and parts used within such machinery. Hence, there is a need for an improved tufting tool module that can be used in a tufting machine.

It is an object of the present invention to improve tufting machines and in particular to provide an improved tufting tool module.

This object and/or others are obtained by the tufting tool module as set out in the appended claims.

As has been realized, during the casting process of a tufting tool module, the plurality of tufting tools cast to the base of the tufting tool module tends to be laterally displaced in relation to each other. The result is that the tufting tool module in some cases does not meet the requirements with regard to tolerances. Subsequent re-alignment of the tufting tools can then become necessary which is undesired and increases production costs and production time.

This problem is solved by a tufting tool module as set out in the appended claims.

In accordance with the invention a tufting tool module for a tufting machine is provided. The tufting tool module comprises a plurality of tufting tools. The tufting tools have a head portion and a securing portion. The securing portion of each tufting tool is casted in a base block. The securing portions of each tufting tool are provided with at least two cut outs located inside the base block. By providing such cut outs it is possible to reduce the lateral pressure differences between the different tufting tools of the tufting tool module during casting of the base block. This is because the cast material, such as zinc, is allowed to move more freely within the cast during casting of the base block. Furthermore, the cut outs will during the cooling phase of the metal, e.g. zinc, control and stabilize the shrinkage so the tufting tools will not be dislocated. In other words, dislocation of the tufting tools during the casting process can hereby be reduced or eliminated. The result is a tufting tool module with improved tolerances.

In accordance with some embodiments, the tufting tools are formed such that an upper side of the head portion is displaced in relation to an upper side of the securing portion.

In accordance with some embodiments, at least one of said at least two cut outs have a cross-section in the range of <NUM> - <NUM>, typically, in the range of <NUM> - <NUM>. In particular at least one of the at least two cut outs have a cross-section of <NUM>. Hereby dislocation can be minimized.

In accordance with the invention, wo through holes are formed in the securing portion located inside the base block. Some or all of the cut outs can be circular to provide better performance with regard to reducing the dislocation of the tufting tools during the casting process.

The provision of cut outs in tufting tools is beneficial for all types of tufting tools modules including, but not limited to tufting tool modules having a base block made of zinc. The tufting tools can be any tufting tool casted in a base block including but not limited to, hooks, loopers, reeds, knives, and Level Cut Looper (LCL) tools.

The present invention will now be described in more detail by way of non-limiting examples and with reference to the accompanying drawings, in which:.

In the following, exemplary tufting tool modules will be described. In the Figures, the same reference numerals designate identical or corresponding elements throughout the several figures. It will be appreciated that these figures are for illustration only and are not in any way restricting the scope of the invention. Also, it is possible to combine features from different described embodiments to meet specific implementation needs.

In <FIG>, an exemplary tufting tool module <NUM> in accordance with a first embodiment is depicted in a bottom view. The tufting tool module <NUM> comprises a plurality of tufting tools <NUM> cast in a base block <NUM>. The tufting tool <NUM> is in the embodiment of <FIG> a hook tool but can in accordance with other embodiments be other types of tufting tools as will be exemplified in conjunction with the description of other embodiments. The base block <NUM> can typically be a zinc block in which a securing portion of the tufting tools <NUM> is cast.

When in use in a tufting machine, the base blocks are typically fixed side by side to a bar on the tufting machine. It is essential that the tufting tools in the base block are fixed so that they have exactly the right position in relation to each other and to the other types of tufting tools. For example, the needles must meet with its hook and the knife must meet its hook with a very high precision. In some cases, the base block have locator pins that corresponds to holes in the bar of the tufting machine and in other cases the base blocks are assembled side by side. It is therefore a requirement that the precision between the crucial parts of the tufting tools and the locator pins or base block sides is very high. It has been discovered that the tufting tools tend to be dislocated during the casting process. The dislocation comes from the flow of the molted zinc inserted to the mold and also from uncontrolled shrinkage when the metal, for example zinc, is cooling down.

In <FIG>, the tufting tool module <NUM> in accordance with the first embodiment is depicted in a side view. The hooks <NUM> can be provided with an insert. The insert is typically formed by a material being harder than the rest of the tufting tool <NUM>. The insert can typically be provided to protect the hooks <NUM> from wear from e.g. a knife co-operating with the hooks during operation of a tufting machine in which the tufting tool module <NUM> can be mounted. A beveling <NUM> to ensure a clearance for a cutting knife is shown in <FIG>.

In <FIG>, the tufting tool module <NUM> in accordance with the first embodiment is depicted in a cross-sectional side view. The hooks <NUM> are formed by a securing portion <NUM> configured to mount the hooks to the base block <NUM> and a head portion <NUM> protruding from the securing portion <NUM>. The head portion <NUM> is provided with an upper edge <NUM>. The securing portion <NUM> also has an upper edge <NUM>. The upper edge <NUM> of the securing portion <NUM> can in accordance with some embodiments be displaced in relation to the upper edge <NUM> of the head portion <NUM>. In particular the upper edge <NUM> of the securing portion <NUM> can be lower in relation to the upper edge <NUM> of the head portion <NUM>. Further, the securing portion <NUM> is provided with cut outs <NUM>, <NUM>. The cut outs <NUM>, <NUM> are two, circular, through holes.

It can be advantageous to locate one through hole at a location corresponding to the forward rim of the base block <NUM>, i.e. the rim facing the head portion <NUM>. This would be through hole <NUM> in the embodiment shown in <FIG>. Also, it can be advantageous to locate the through holes at a location where the distance is equal to or close to equal to the upper and lower edge, respectively, of the securing portion <NUM>.

The cut outs <NUM>, <NUM> are provided to reduce or eliminate dislocation of the tufting tools <NUM> during casting of the base block <NUM> of the tufting tool module <NUM>. Thus, when the base block <NUM> is cast in zinc, or some other material, the casting procedure itself can result in that pressure is applied to the securing portion <NUM> of the tufting tools <NUM> whereby when the casting procedure is ended the tufting tools <NUM> can become displaced in relation to the position in which the tufting tools where aligned before the casting. The provision of the cut outs <NUM>, <NUM> can reduce the lateral pressure differences between the different tufting tools <NUM> of the tufting tool module <NUM>. This is because the cast material, such as zinc, is allowed to move more freely within the cast during casting of the base block <NUM>. Furthermore, the cut outs will during the cooling phase of the metal, e.g. zinc, control and stabilize the shrinkage so the tufting tools will not be dislocated. In other words, dislocation during the casting process can hereby be reduced or eliminated.

In <FIG>, the tufting tool <NUM>, a hook, in accordance with the first embodiment is depicted in a side view. The hook <NUM> is shown with cut outs <NUM>, <NUM> in the securing portion <NUM> as described in conjunction with <FIG>. The cut outs <NUM>, <NUM> are formed as circular holes located at some distance from each other. The cross section of the cut outs <NUM>, <NUM> can advantageously be in the range of <NUM> - <NUM>. It is preferred to use a cross-section of <NUM> - <NUM> and <NUM> is used in the embodiment of <FIG> to maximize the benefit of the cut outs <NUM>, <NUM>. The cut outs can advantageously be provided simultaneously with forming the tufting tool <NUM>. In accordance with some embodiments the cut outs <NUM>, <NUM> are formed by electrical discharge machining.

In <FIG>, an exemplary tufting tool module <NUM> in accordance with a second embodiment is depicted in a rear view. The tufting tool module <NUM> comprises a plurality of tufting tools <NUM> cast in a base block <NUM>. The tufting tool <NUM> is in the embodiment of <FIG> a looper. The base block <NUM> can typically be a zinc block in which a securing portion of the loopers <NUM> are cast.

In <FIG>, the tufting tool module <NUM> in accordance with the second embodiment is depicted in a side view. In <FIG>, the tufting tool module <NUM> in accordance with the second embodiment is depicted in a cross-sectional side view. The loopers <NUM> comprise a securing portion <NUM> configured to mount the loopers <NUM> to the base block <NUM>. The securing portion <NUM> is provided with cut outs <NUM>, <NUM>, <NUM>, which are not according to the invention. The cut outs <NUM>, <NUM>, <NUM> comprise in the embodiment of <FIG> one, circular, through hole and two semi-circular cut outs at the rim of the securing portion. However, the cut outs <NUM>, <NUM>, and <NUM> can be formed in other configurations as well. The cut outs <NUM>, <NUM> and <NUM> are provided to reduce or eliminate dislocation of the tufting tools <NUM> during casting of the base block <NUM> of the tufting tool module <NUM>. Thus, when the base block <NUM> is cast in zinc, or some other material, the casting procedure itself can result in that pressure is applied to the securing portion <NUM> of the tufting tools <NUM> whereby when the casting procedure is ended the tufting tools <NUM> can become displaced in relation to the position in which the tufting tools were aligned before the casting. Thus, for the second embodiment, the provision of the cut outs <NUM>, <NUM>, and <NUM> can reduce the lateral pressure differences between the different tufting tools <NUM> of the tufting tool module <NUM>. This is because the cast material, such as zinc, is allowed to move more freely within the cast during casting of the base block <NUM>. The cut outs <NUM>, <NUM>, and <NUM> will during the cooling phase of the metal, e.g. zinc, control and stabilize the shrinkage so the tufting tools will not be dislocated. In other words, dislocation during the casting process can hereby be reduced or eliminated.

In <FIG>, the tufting tool <NUM>, a looper, in accordance with the second embodiment is depicted in a side view. The looper <NUM> is shown with cut outs <NUM>, <NUM> and <NUM>, not according to the invention, in the securing portion <NUM> as described in conjunction with <FIG>. At least two cut outs <NUM>, <NUM> and <NUM> are formed as circular holes while others can be formed as semi-circular holes, the holes being respectively located at some distance from each other. The cross section of the cut outs <NUM>, <NUM> and <NUM> can advantageously be in the range of <NUM> - <NUM>. It is preferred to use a cross-section of <NUM> - <NUM> and <NUM> in the embodiment of <FIG> to maximize the benefit of the cut outs <NUM>, <NUM> and <NUM>. The cut outs <NUM>, <NUM>, and <NUM> can, as for the first embodiment, advantageously be provided simultaneously with forming the tufting tool <NUM>. In accordance with some embodiments the cut outs <NUM>, <NUM> and <NUM> are formed by electrical discharge machining.

In <FIG>, an exemplary tufting tool module <NUM> in accordance with a third embodiment is depicted in a bottom view. The tufting tool module <NUM> comprises a plurality of tufting tools <NUM> cast in a base block <NUM>. The tufting tool <NUM> is in the embodiment of <FIG> a Level Cut Looper tool (LCL). The LCL <NUM> comprises a moving part called slider <NUM>, see <FIG>, running at the back side of the tufting tool <NUM> casted in the base block <NUM>. In an LCL tool <NUM> the moving part <NUM> decides if a loop shall be cut or not. This moving part <NUM> is placed in the center of the LCL tool <NUM>, preventing the possibility to make a cut out in the center. The base block <NUM> can typically be a zinc block in which a securing portion of the LCLs <NUM> is cast.

In <FIG>, the tufting tool module <NUM> in accordance with the third embodiment is depicted in a side view. In <FIG>, the tufting tool module <NUM> in accordance with the third embodiment is depicted in a cross-sectional side view. The LCLs <NUM> comprises a securing portion <NUM> configured to mount the LCLs <NUM> to the base block <NUM>. The securing portion <NUM> is provided with cut outs <NUM>, <NUM>, <NUM>, <NUM>, and <NUM>. The cut outs <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> comprise in the embodiment of <FIG> one, circular, through hole <NUM> , a forward rectangular cut out <NUM>, two rear rectangular cut outs <NUM>,<NUM> at the rim of the securing portion, and a triangular cut out <NUM>. This is not according to the invention. Embodiments of the invention comprise at least two through holes, further the cut outs can be formed in other configurations and in other numbers as well. The cut outs <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> are provided to reduce or eliminate dislocation of the tufting tools <NUM> during casting of the base block <NUM> of the tufting tool module <NUM>. Thus, when the base block <NUM> is cast in zinc, or some other material, the casting procedure itself can result in that pressure is applied to the securing portion <NUM> of the tufting tools <NUM> whereby when the casting procedure is ended the tufting tools <NUM> can become displaced in relation to the position in which the tufting tools where aligned before the casting. Thus, for the third embodiment, the provision of the cut outs <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> can reduce the lateral pressure differences between the different tufting tools <NUM> of the tufting tool module <NUM>. This is because the cast material, such as zinc, is allowed to move more freely within the cast during casting of the base block <NUM>. The cut outs <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> will during the cooling phase of the metal, e.g. zinc, control and stabilize the shrinkage so the tufting tools will not be dislocated. In other words, dislocation during the casting process can hereby be reduced or eliminated.

In <FIG>, the tufting tool <NUM>, an LCL, in accordance with the third embodiment is depicted in a side view. The LCL <NUM> is shown with cut outs <NUM>, <NUM>, <NUM>, <NUM>, and <NUM>, not according to the invention, in the securing portion <NUM> as described in conjunction with <FIG>. The cross section of the cut outs <NUM>, <NUM>, <NUM>, <NUM> and <NUM> can advantageously be in the range of <NUM> - <NUM>. It is preferred to use a cross-section of <NUM> - <NUM> and <NUM> is used in the embodiment of <FIG> to maximize the benefit of the cut outs <NUM>, <NUM>, <NUM>, <NUM>, and <NUM>. The cut outs <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> can, as for the first and second embodiment, advantageously be provided simultaneously with forming the tufting tool <NUM>. In accordance with some embodiments the cut outs <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> are formed by electrical discharge machining.

Claim 1:
A tufting tool module (<NUM>) for a tufting machine, the tufting tool module (<NUM>) comprising a plurality of tufting tools (<NUM>, <NUM>, <NUM>), the tufting tools comprising a head portion (<NUM>, <NUM>,<NUM>) and a securing portion (<NUM>,<NUM>,<NUM>), wherein the securing portion of each tufting tool is casted in a base block (<NUM>) characterized in that the securing portions of each tufting tool is provided with at least two cut outs (<NUM>,<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) located inside the base block, said at least two cut outs comprising two through holes (<NUM>, <NUM>) formed in the securing portion located inside the base block.