Tufting Machine With Retraction And Method Of Use

Abstract

Improved retraction control for use with tufting machines provides a number of possible outcomes and design capabilities. Specifically, retractor controls allow for at least two different amounts of retractions other than no retraction. This can result in smooth or curved transitions instead of only waffle patterns as has been done in the prior art. Combining with relative movement of the backing relative to the needles allows one to pattern in directions other than parallel and perpendicular to the direction of tuft. For some embodiments yarn may contact more than one retractor which could be operated together, independently, or not at all depending on the directives of the retractor controller.

The invention claimed is: 
     
         1 . A tufting machine comprising:
 a base fabric moving longitudinally through said machine in a direction of feed;   a first row of needles spaced transversely of the feeding direction configured to penetrate the base fabric;   a yarn feeder at least selectively providing yarn to needles in in the first row of needles;   and at least one retractor between the yarn feeder and the first row of needles coupled to a retractor controller, said retractor controller selectively directing retraction of yarn at least one of at least two specified retraction amounts other than no retraction after yarn has been fed to at least a needle of the first row of needles.   
     
     
         2 . The tufting machine of  claim 1  wherein the at least one retractor further comprises first and second retractors both contacting the yarn, and the retractor controller provides selective operation neither first or second retractor for no retraction, operation of either the first or the second retractor for a first specified amount of the at least two specified amounts, and operation of both the first and second retractors for a second specified amount of the at least two specified amounts, said second specified amount greater than the first specified amount. 
     
     
         3 . The tufting machine of  claim 2  wherein the machine has at least three retractors and the yarn contacts at least two of the at least three retractors. 
     
     
         4 . The tufting machine of  claim 1  wherein the at least two specified retraction amounts are provided in relative amounts. 
     
     
         5 . The tufting machine of  claim 1  wherein the at least two specified retraction amounts are provided in degrees of rotation of at least one of the at least one retractor. 
     
     
         6 . The tufting machine of  claim 1  wherein the at least two specified retraction amounts are based on yarn type. 
     
     
         7 . The tufting machine of  claim 1  wherein the retractor controller provides a progression of increasing or decreasing amounts of retraction to provide a smooth or curved face of tufts. 
     
     
         8 . The tufting machine of  claim 1  wherein the retractor controller is a portion of a pattern controller for the tufting machine. 
     
     
         9 . The tufting machine of  claim 1  further comprising a variable gage system comprising at least one of a variable stitch rate and a variable backing feed system. 
     
     
         10 . The tufting machine of  claim 1  wherein the yarn feed system is a variable yarn feed system. 
     
     
         11 . The tufting machine of  claim 1  in combination with relative lateral shifting of the needles relative to backing through at least one of needle bar shifting and backing shifting thereby providing patterning due to retraction in directions other than parallel and perpendicular to the direction of tuft. 
     
     
         12 . The tufting machine of  claim 11  wherein the retractor controller provides a progression of increasing or decreasing amounts of retraction to provide a smooth or curved face of tufts. 
     
     
         13 . The tufting machine of  claim 11  wherein the retractor controller provides directions providing curved side edges of tufted carpet patterns internal to the pattern due to retraction. 
     
     
         14 . The tufting machine of  claim 11  wherein the patterning due to retraction is one of chevron and curved design portions. 
     
     
         15 . The tufting machine of  claim 11  further comprising a variable gage system comprising at least one of a variable stitch rate and a variable backing feed system. 
     
     
         16 . The tufting machine of  claim 1  in combination with the yarn feeder providing at least one transition stitch thereby assisting in providing a sheer face at the retraction location. 
     
     
         17 . The tufting machine of  claim 1  wherein the retraction controls are independent of the yarn pattern. 
     
     
         18 . The tufting machine of  claim 1  wherein the retraction controls are independent of the yarn feeder. 
     
     
         19 . The tufting machine of  claim 1  wherein the retraction controls are independent of any relative movement of the first needle bar relative to the backing.