CN1192715A - 用来制作毛绒线地毯的方法和装置 - Google Patents
用来制作毛绒线地毯的方法和装置 Download PDFInfo
- Publication number
- CN1192715A CN1192715A CN96196189A CN96196189A CN1192715A CN 1192715 A CN1192715 A CN 1192715A CN 96196189 A CN96196189 A CN 96196189A CN 96196189 A CN96196189 A CN 96196189A CN 1192715 A CN1192715 A CN 1192715A
- Authority
- CN
- China
- Prior art keywords
- yarn
- wool knitting
- knitting yarn
- welded
- base fabric
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B26—HAND CUTTING TOOLS; CUTTING; SEVERING
- B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
- B26D1/00—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor
- B26D1/0006—Cutting members therefor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B26—HAND CUTTING TOOLS; CUTTING; SEVERING
- B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
- B26D1/00—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor
- B26D1/01—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work
- B26D1/12—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work having a cutting member moving about an axis
- B26D1/14—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work having a cutting member moving about an axis with a circular cutting member, e.g. disc cutter
- B26D1/20—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work having a cutting member moving about an axis with a circular cutting member, e.g. disc cutter coacting with a fixed member
- B26D1/205—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work having a cutting member moving about an axis with a circular cutting member, e.g. disc cutter coacting with a fixed member for thin material, e.g. for sheets, strips or the like
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B26—HAND CUTTING TOOLS; CUTTING; SEVERING
- B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
- B26D11/00—Combinations of several similar cutting apparatus
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B26—HAND CUTTING TOOLS; CUTTING; SEVERING
- B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
- B26D3/00—Cutting work characterised by the nature of the cut made; Apparatus therefor
- B26D3/001—Cutting tubes longitudinally
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B26—HAND CUTTING TOOLS; CUTTING; SEVERING
- B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
- B26D7/00—Details of apparatus for cutting, cutting-out, stamping-out, punching, perforating, or severing by means other than cutting
- B26D7/08—Means for treating work or cutting member to facilitate cutting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
- B29C53/80—Component parts, details or accessories; Auxiliary operations
- B29C53/8008—Component parts, details or accessories; Auxiliary operations specially adapted for winding and joining
- B29C53/8016—Storing, feeding or applying winding materials, e.g. reels, thread guides, tensioners
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
- B29C53/80—Component parts, details or accessories; Auxiliary operations
- B29C53/82—Cores or mandrels
- B29C53/821—Mandrels especially adapted for winding and joining
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
- B29C65/083—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations using a rotary sonotrode or a rotary anvil
- B29C65/086—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations using a rotary sonotrode or a rotary anvil using a rotary anvil
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/05—Particular design of joint configurations
- B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
- B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
- B29C66/112—Single lapped joints
- B29C66/1122—Single lap to lap joints, i.e. overlap joints
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
- B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
- B29C66/43—Joining a relatively small portion of the surface of said articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
- B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
- B29C66/45—Joining of substantially the whole surface of the articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/80—General aspects of machine operations or constructions and parts thereof
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/80—General aspects of machine operations or constructions and parts thereof
- B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
- B29C66/812—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
- B29C66/8126—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps characterised by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
- B29C66/81264—Mechanical properties, e.g. hardness
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/80—General aspects of machine operations or constructions and parts thereof
- B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
- B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
- B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
- B29C66/81411—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat
- B29C66/81413—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat being non-symmetrical
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/80—General aspects of machine operations or constructions and parts thereof
- B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
- B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
- B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
- B29C66/81411—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat
- B29C66/81421—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat being convex or concave
- B29C66/81423—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat being convex or concave being concave
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
- B29C66/81433—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined being toothed, i.e. comprising several teeth or pins, or being patterned
- B29C66/81435—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined being toothed, i.e. comprising several teeth or pins, or being patterned comprising several parallel ridges, e.g. for crimping
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
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- B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
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- B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
- B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
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Abstract
用来制作一块地毯的一种方法和装置,该地毯由被焊接到一块底布(50)上的多根毛绒线(42,44,46,48)形成。公开了用来精确地把毛绒线定位,并把多根毛绒线(42,44,46,48)超声焊接到底布(50)上的方法和装置。
Description
本发明的背景
本申请是1994年8月31日提交的申请序列号No.08/298,642的部分继续申请。
本发明涉及用来制作绒毛物品的方法和装置,当使它们与其它的绒毛物品对准,并把它们装接到一块底布基底上制作出一绒毛表面结构时,这些绒毛物品可以用做地毯或壁毯。
传统的毛绒地毯的制作是靠使一块可变形的机织的主底布通过一台有一大排针的机器,这些针迫使地毯的纱线穿过该底布,在把针抽回之前,一大排钩把纱线留在那里。在12英寸的长度内可以有大约1400根针。底布必须能承受针的穿过,而没有损坏。随后,使该底布向前移动一个短距离(对于通常的高质量的毛绒密度,大约为1/10英寸),并把针再次***,通过底布,形成下一系列毛绒。与钩相结合可以采用一大排切割器,把***通过底布的毛绒环切断,产生出一个绒毛切断的地毯。在把针和钩已缩回和使底布移动到下一个蔟绒位置之后,摩擦力把毛绒保留在底布中。在用做地毯的过程中,此摩擦力不足以把毛绒固定住,所以,以足够的数量使用一种粘合剂,把在毛绒底部的所有的纤维粘接到地毯的背侧面上(针进入的那一侧),并把这些纤维装到主底布的背面上。为了帮助稳定,加固,增加强度,并防止毛绒底部磨损,毛绒和主底布的这一结构有一个装到该主底布的背面上的一第二底布,可以用相同的粘合剂层或使用更多的粘合剂把该底布固定住。
已经建议了另外的地毯结构,比如属于Faris的美国专利No.2,475,019,属于Ahier的美国专利No.2,680,469,和属于Runton的美国专利No.2,698,044和2,698,045,建议采用装到底布上的复合绳绒线,而不用机织。这些另外结构的某些改型省去了传统的背面上浆和毛绒粘接。一般,这种结构靠使用大量的粘合剂,这在制作过程中处理起来十分肮脏,并且当尼龙高聚物被用做毛绒时这些粘合剂很难再循环。建议用于这些另外结构的机器是难以安装和操作的,因为这些机器在一个连续的耦合加工过程中采用了一种整体对模块的设计来处理整个地毯的材料宽度。这些机器通常也要求在一个可移动的纱架中的断续的纱线供应,对该加工过程供料,所以为了在间隔进行广泛的纱线的再上料要求停机,或在个别的线轴随机地用完时经常停机来更换这些线轴。
本发明的概述
本发明是用来制作一块地毯的方法和装置,这是靠把合股加捻的纱线的多个向上的毛绒焊接到线绳上,制作出绒毛物品,并把多个绒毛物品并排地焊接到底布上,形成一个地毯结构。
最好在一个多侧面(最好有四个侧面)的芯轴上组装纱线和线绳,这是靠把一根或两根纱线围绕着多根线绳(最好四根线绳)缠绕,用单一的超声焊头一次焊接一根或多根线绳(最好两根线绳),并切断纱线,提供多根(最好四根)细长的绒毛物品,或毛绒线,把这些毛绒线放置成与其它的毛绒线并排地分离开,并把它们焊接到底布上,形成一地毯结构。可以以一个或多个房间尺寸的地毯批量地制作地毯,这是靠在一个滚筒上或在分离开的滚轮之间供应底布,并一次横截着底布螺旋形地缠绕几根毛绒线实现;或可以连续地制作地毯,这是靠提供一个连续的底布供应,并横截着底布的整个宽度在卷绕方向上提供多根毛绒线实现的。在任何情况下都有突出的优点,与传统的毛绒机器相比,只需要在一静止的纱线架中提供较少的纱线端就能完成12英尺宽的地毯。这减小了对于一块地毯所需要的静止纱线架的尺寸,并当改变地毯式样时减少改变纱线架所需要的时间和人力。当采用预先染色的纱线时,这特别地重要,在这种情况下,对于地毯的每次颜色的改变度一定会改变纱线架。
制作地毯结构的优选方法采用超声能量把纱线焊接到线绳上,并把所形成的绒毛物品或毛绒线焊接到底布上。本发明包括用来精确地把毛绒线定位,并用由底布的顶侧面或底侧面操作的单一的超声焊头焊接多根毛绒线,把毛绒线固定到底布上的方法和装置。地毯制作机器在设计上是模件式的,为的是制造,组装,维修和引头时容易。
附图的简要描述
图1A为采用毛绒线和一个大的滚筒来制作地毯的批量生产***的等角投影图;
图1B为被螺旋地缠绕的两组毛绒线的示意图;
图2为由图1A的2-2方向的侧视图,对于单个的芯轴毛绒线形成装置它也是典型的;
图3为一个超声焊接组件的等角投影图;
图4为一个毛绒线形成芯轴的部分剖面图;
图5为沿着图4的5-5线截取的该芯轴的端部的放大了的剖面图;
图6A,6B和6C为与图4的芯轴一起使用的超声焊头的前视图,剖面图和侧视图;
图7A为用来切断芯轴上的纱线的一个切割器的剖面图;
图7B为在图7A的芯轴的角部上的凹槽的一个放大了的细节剖面图;
图7C为图7A所示的刀片的切割边缘的放大图;
图8为切割器与图7的芯轴相接合的放大了的细节剖面图;
图9为由图2取向的一个双切割器装置的剖面图;
图10为用来在一个紧凑的空间中制作八根毛绒线的一个双芯轴组件的等角投影图;
图11为用来在一个紧凑的空间制作72根毛绒线的一个18芯轴组件的前等角投影图;
图12A和12B分别示出了对多根毛绒线进行导向用来从底布的顶侧面进行焊接的一个引导件的正视图和顶视图;
图13A和13B,13C,13D和13E为用来由底布的顶侧面把毛绒线焊接到底布上的一个超声焊头的不同方向的视图;
图14为用来把毛绒线焊接到一细长的连续底布材料带上的一个带组件的侧视图;
图15为用来把毛绒线焊接到一个细长的底布材料卷上的一个卷绕组件的侧视图;
图16A,16B,16C和16D为对多根毛绒线进行导向用来从底布的底侧面进行焊接的一个引导件的不同方向的视图;
图17A,17B和17C为用来由底布的底侧面把毛绒线焊接到底布上的一个超声焊头的不同方向的视图;
图18为用来采用一个卷绕组件制作毛绒线地毯的一个***的示意性平面图;
图19为带有对于采用预先染色的表面纱线的毛绒线地毯进行膨松化的一个最后加工***的示意性平面图;
图20A,20B,20C,20D,20E和20F为毛绒线形成芯轴的不同改型的示意图。
本发明的详细描述
在图1A中示出了选择用于表示的目的的一个用来制作全宽度地毯的实施例,此实施例包括一个毛绒线形成组件38和一个滚筒组件49,它们由纱线架62,64和66与线绳架68和70供料。地毯结构的形成是靠:沿着在毛绒线形成组件38的一个芯轴上的隆脊对多股线绳,比如线绳30,32,34和36,进行导向,并围绕着该芯轴和在线绳上缠绕纱线,比如纱线40,把纱线焊接到线绳上,并把纱线切断,以便制作出多个细长的绒毛物品,或毛绒线。把多根毛绒线,比如毛绒线42,44,46和48并排地设置,并把它们焊接到一块被支承在滚筒组件49上的一底布基底50上。在这一***中,在单一的芯轴上同时形成四根毛绒线,像在下面将解释的那样。最好,横截着滚筒组件49中的一个滚筒52的表面,在九个分离开的位置,比如是位置54,56,58和60,把八根毛绒线(只示出了四根)并排地成组设置。在滚筒旋转同时形成地毯的过程中,在滚筒里面的一个夹子(未画出)夹住底布的端部。
当在滚筒上引导每组八根毛绒线时,使滚筒旋转,并在横向上移动,这样,把毛绒线拉到底布上,并拉到多个超声焊头(未画出)的下面,这些超声焊头把毛绒线熔融焊接到底布上。当底布继续沿箭头51的方向旋转并沿箭头53的方向横向移动时,每组八根毛绒线在滚筒52上形成一排螺旋的毛绒线。在滚筒的一转之后,在一组中刚刚被焊接的毛绒线邻接着第一被焊接的毛绒线,并与它们分离开等于在八根一组中由一根毛绒线到下一根相邻的毛绒线的间隔的一个距离,对于通常的毛绒线密度这一般为0.2英寸。在滚筒的10转之后,第一组八根毛绒线将与第二组八根毛绒线的第一被焊接的端部对准,在针脚连接部位出现毛绒线的邻接。整个横截着滚筒由一组毛绒线到下一组毛绒线存在这种状况,所以,现在在滚筒上出现了一个已经完成的地毯结构。这时停止滚筒的旋转,停止毛绒线的形成,并且,针脚连接部位与一个切断装置对准。一块板在毛绒线和它们各自的焊接装置的下面滑动,并把它们提高,离开滚筒。该切断装置沿着对准的针脚连接部位横过,并把所有毛绒线和底布切断,把地毯由滚筒松开,提供出一个15英尺长的地毯,这相当于滚筒的周长。现在可以把另一块底布装到滚筒上,可以把该滚筒在横向上再次定位到开始点处,可以重新开始毛绒线的形成和把毛绒线焊接到底布上。可以把加工好的地毯的边缘切毛边,以得到一个12英尺×15英尺的方形地毯,同时开始制作下一块地毯。图1B示意性地示出了如何对与另一组相邻的毛绒线61分离开的一组毛绒线59螺旋形地进行缠绕。组59有一起点63,组61有一起点65。对组59进行螺旋形的缠绕,这样,刚刚焊接上的毛绒线,例如在位置67的毛绒线邻接着已经焊接起来的毛绒线,例如在位置69的毛绒线。逐渐地,刚刚焊接起来的毛绒线组59也邻接着相邻的组61的已经焊接起来的毛绒线,比如在位置71和位置73。最后,在位置55的刚刚焊接起来的毛绒线组59端部对端部地遇到对于组61的开始点65,如图所示,形成一个针脚连接部位。随后,过程停止,把完成的地毯结构切断,离开滚筒。
可以只采用72根毛绒线制作一块整个的地毯,这些毛绒线可以只采用18,36或54个端部的纱线。在本文件中,采用36个端部的纱线,这样,一次在四个毛绒线芯轴上缠绕两根纱线,可以用比较合理的缠绕速度比只用一根被缠绕的纱线更快地形成毛绒线。此外,如果采用多个端部,可以沿着一根毛绒线的长度出现纱线端部的有利的杂乱的混纺;这样,沿着一根毛绒线和由一根毛绒线到另一根毛绒线可以把由一根纱线的端部到另一根纱线的端部的颜色的稍微不同混合起来,这可以减少由于颜色不同而造成的色条缺陷。为了如需要的那样有更多的速度的增加或更多的式样可变能力,可以在一个芯轴上缠绕三个或更多的端部;例如,三个端部可以是不同颜色或不同类型的纱线。
在图1A中,示出了用于高生产率的三个纱线架组件62,64和66。一个组件装放用来运行纱线端部的36卷纱线和用于备份端部的36卷纱线,可以以传统的方式采用换筒纱尾把这些备份纱线卷连接到运行纱线卷上,从而可以有不断的纱线供应。示出的另一个纱线架组件是为了提供用于产品改变的纱线。第三个纱线架组件可以用于进一步的产品改变,或用来以更多的端部运行,以便如所提到的那样更快地运行或式样变化。
示出了两个线绳架组件68和70,总共装80个线绳卷。因为可以在大的卷上提供线绳,它的消耗速度比纱线慢得多,所以可以不需要用于连接换筒纱尾的附加的卷。当单根的线绳不被缠绕时,希望不对这些线绳进行捻纱,所以,对于每一卷最好滚动地取出。周期性地,当为了由滚筒把焊接好的地毯移出而停止时,可以同时如所需要的那样补充单个的线绳卷。可以采用更多的线绳架组件,从而使卷的更换变得更容易。通常,对于纱线产品的改变,不改变线绳。
图2示出了毛绒线形成组件38的2-2向的端视图,并示出了采用一个四根毛绒线的芯轴74的一个基本的单一芯轴毛绒线形成装置72的细节。毛绒线形成装置72的主要部件是四侧面的芯轴74,一个框架75,一个纱线缠绕装置76,两个超声焊接组件78和80,一个纱线供料组件84,一个切断装置86,和一个毛绒线驱动组件88。通过一个空转供料滚轮90和受驱动的供料滚轮92把纱线40送进,围绕着枢轴96起作用的液压缸体94把这两个滚轮挤压在一起,把纱线40夹住,对于每个芯轴可以包括一个或多个纱线端部。通过一个空转供料滚轮98和受驱动的供料滚轮100把线绳30,32,34和36送进,围绕着枢轴104起作用的液压缸体102把这两个滚轮挤压在一起。四根线绳被送到芯轴74的进口端106,在那里引导每根线绳通过在芯轴中的一个中心中空件里的一个分开的管,保持这些线绳彼此分开,防止缠结。在芯轴的在切断装置86的下游的一侧上的托架107把该芯轴装接到框架75上,这一结构使得被缠绕的纱线由芯轴脱开,并形成四根分开的绒毛被切断的毛绒线。通过一个空转出口滚轮109和受驱动的出口滚轮111把毛绒线42′,44′,46′和48′送进,围绕着枢轴121起作用的液压缸体119把这两个滚轮挤压在一起,把这些毛绒线夹住。受驱动的滚轮111有凹槽,以便装"U"字形的毛绒线,空转滚轮109有配合进凹槽的肋,使毛绒线在其中。
图4示出了该芯轴的纱线进入的进口端106和纱线出去的出口端108。图5为出口端的一个放大的截面图,该图示出了对于每根纱线的一个返回轮,该轮由在芯轴74的中心的一个中空的通道110引导该纱线。轮112引导纱线30,轮114引导纱线32,轮116引导纱线34,轮117引导纱线36。把这些纱线由通道110引导到在芯轴角部上的凹槽中,如下面将讨论的那样。
缠绕装置76把纱线围绕着芯轴缠绕,并在芯轴的角部上的凹槽中的支承线绳上缠绕,该缠绕装置包括一个中空的梭芯118,它带有一个纱线进口端120和一个纱线出口端122。装设到框架75上的一个支承组件124把该梭芯可旋转地保持住。通过一个皮带轮和皮带装置128起作用的一个马达126使该梭芯旋转。当纱线40围绕着芯轴74缠绕时,线绳30,32,34和36沿着芯轴在轴向上向前进(向下),携带着线绳和纱线离开缠绕装置,并到达超声焊接组件78和80。
图3示出了焊接组件78的等角投影图,此组件与组件80相同,托架,比如托架130和132把两个组件都以在芯轴74的相对的侧面上对准的方式装到框架75上。基本的焊接组件包括一个被装接到一放大器135上的超声焊头134和一个装接到框架138上的超声驱动器136。框架138被装到四杆连动组件140上(示出了两根杆),此连动组件被装接到托架132上。在杆端146上的U形托架144把液压缸体142装设到框架138上,并且液压缸体142被装接到缸体端部上的托架130上。液压缸体杆端部146的运动使得超声驱动器,放大器和焊头组件以向前的方向运动,离开芯轴,同时保持与芯轴74垂直,从而挤压在焊头与芯轴上的线绳之间的纱线;在这种状态下的芯轴用作一个超声砧座。把纱线与线绳挤压在一起,同时把超声能量施加到焊头上,使得纱线和线绳被迅速加热,从而使纱线纤维彼此熔化,并在它们接触的部位对线绳熔化。纱线不会粘到焊头上,线绳也不会粘到芯轴上。液压缸体的压力确定了在芯轴与焊头之间和它们中间的纱线与线绳之间所施加的挤压作用力。这一作用力是确定耦合到纱线和线绳上的超声能量的数量的一个重要因素。另外的因素是焊头的振动的振幅和频率。
图6A-C示出了焊头的形状,该焊头容许一个焊头一次把两根线绳焊接到纱线上。这样,为了焊接沿着一个有四个侧面的芯轴引导的四根线绳只需要两个焊头。焊头134有两个带角度的表面148和150,此二-表面分别对着芯轴74的角部152和154挤压纱线和线绳(二者都没有示出)。这些表面足够地长,从而如果使用一个较大的芯轴74a,相同的焊头134仍然可以对着芯轴74a的角部把纱线和线绳接合起来。对于如所示出的一个正方的芯轴,表面148和150与芯轴的侧面156成45度角,如标号158所示。对于一个焊头在两个相邻的角部上焊接的六角形的芯轴来说,这个角度将是30度。在图6B中以放大的剖面图示出了表面154(和表面156)的形状,它有一个带角度的引入端,此端有一曲率半径160,用来引导在焊头下面的纱线。纱线可以以箭头162的方向前进。在图6C中,焊头134的深度164很小,使得由表面148和150的长度所产生的焊头应力为最小,并且,此深度足够地大,以便清除预期与所想要用的芯轴一起使用的所有纱线。焊头134的宽度166大约为0.5英寸,此宽度与超声的振幅,频率,以及驱动器的功率有关。
参见图5,每个焊头,比如焊头134,被用来把两根支承线绳,比如线绳30和36,焊接到缠绕在其上的纱线40上。最好通过设置焊头134的带角度的表面148和150来完成这一工作,这样,这些表面基本上垂直于通过线绳并平分由在每根线绳的两侧的纱线所确定的包含角的假想平面。这样,当把纱线切断形成绒毛被切断的毛绒线时,在线绳的两侧的毛绒线在毛绒线的基底上形成相同的角度,这些毛绒线被焊接在该基底上。假想平面153通过线绳30,并平分在线绳30上弯曲的纱线40的端部157和159之间的包含角155。表面150基本上垂直于平面153,如以标号161所表示的那样。类似地,假想平面163通过线绳36,并平分在线绳36上弯曲的纱线40的端部167和169之间的包含角165。表面148基本上垂直于平面163,如以标号171所表示的那样。注意,假想平面153和163也在芯轴74的截面的中心或形状中心处相交。
参见图4和5,把纱线40在芯轴74的侧面上的四个隔离体168,170,172和174上缠绕。这些隔离体被保持在芯轴的侧面中的浅的狭缝中。这些隔离体的用途是增加在纱线被焊接之前由纱线看上去的芯轴的周长。这些隔离体在邻近焊头134和134′的位置176处终止。如果纱线是尼龙6-6,已经发现,纱线由于超声加热后的冷却而显著地收缩,所以,当纱线运动离开焊头时,它越过在176处的隔离体,并可以收缩到一个较小的周长,而不会粘接到芯轴上。
在焊接之后,必须把纱线40切断,以便把它由芯轴74脱开。当严格地在线绳之间的中间切断时,被切断的端部可以确定当把毛绒线装配进一地毯中时纱线的最后的毛绒高度。当严格地切断和组装时,在最后的地毯产品中不需要进一步的毛绒剪切,但是,对于某些产品来说,进行剪切可能仍然是优选的。在图2中的切断装置86由四个旋转的圆形刀片构成,每个刀片压靠着固定到芯轴上的一个底刀。在图4中示出了被装在芯轴74的一个狭缝180中的一个这样的底刀178。图7A示出了由图2的7-7向的剖面图。用键把圆形的刀片182可旋转地装到轴184上,该刀片在轴向上可以沿着轴滑动,弹簧186把刀片对着底刀178推。圆形的夹紧装置188和190一个在刀片的一侧,这些夹紧装置把纱线和支承线绳牢固地固定在芯轴的角部上的凹槽中。轴184可旋转地支承着这些夹紧装置,但是这些夹紧装置不受来自轴184的扭转力矩;并且,这些夹紧装置在轴向上可以沿着轴滑动。这些夹紧装置可以自由地旋转,与由线绳的运动驱动的轴无关。弹簧192和194分别把夹紧装置188和190分别压向芯轴74的角部196和198。夹紧装置把线绳(以及焊接到该线绳上的纱线)牢固地固定在芯轴的角部上的凹槽中,同时刀片把一个切割作用力施加到表面纱线上,把它切断。把轴184可旋转地支承在壳体200中,马达202(部分地示出)旋转地驱动该轴。图7B示出了在芯轴74的角部的一个凹槽197的一个放大了的图。该凹槽的深度为199。深度199可以在线绳的厚度的大约25%与75%之间,以便把它牢固地固定住,并且在焊接的过程中仍然不会干扰焊头的表面148和150,并仍然支承着纱线,不受芯轴的限制,用来在焊接之后沿着芯轴进行运送。
当沿着芯轴74推进焊接了的纱线和线绳时,对着旋转的刀片182拉动纱线,当纱线被截在刀片与底刀之间时,刀片把纱线切断。图8示出了刀片182,底刀178,芯轴74和纱线40的示意性剖面图。把纱线以箭头204的方向带进刀片与底刀之间的相交部位206,在这一部位刀片切过纱线。为了有效地切断尼龙6-6纱线,已经发现,在周边涂有无定形金刚石(可以由Tetrabond,Inc.得到,它是在Rockaway,NJ的Multiarc,Inc.的子公司)的C-11级亚微米的碳化钨的刀片材料对着D2高速工具钢的底刀工作得很好。参见图7C,进行涂覆的刀片的部分最好是部分203,205和207。无定形的金刚石涂层有大约6000单位的Vickers硬度。另外的可以工作得很好的涂层是2微米的碳化钛化学蒸气沉积的涂层以及2微米的氮化钛的进一步涂层。这样的涂层可以有大约2600单位的Vickers硬度。为了改善刀片和底刀表面的寿命,已经发现,采用一个涂敷毡垫208把水和一种纱线涂层,比如一种磷酸烷基酯,的冷却润滑剂施加到刀片表面上是有用的,靠采用静脉内点滴***209或类似装置使该毡垫保持湿润。这样的涂层可以是Zelex NK,它可以由在Wilmington,DE的E.I.DuPond Co.得到,它作为一种防静电纱线涂层销售。把它与蒸馏水混合,以在混合物中涂层的体积百分比为0.5-2.0%。相信,使刀片在纱线前进的方向旋转,并以稍高于(大约3-10%)纱线在刀片下通过的速度的一个周边速度旋转,在切断纱线方面刀片最有效,而没有过度的磨损。相信,低速会降低磨损速率,并且,该旋转方向使切断过程中任何纱线张力的增加降到最低。这造成了与锯断作用相比较的剪切作用,在锯断作用中,刀片的周边速度比纱线前进的速度要快得多(大约要大500-1000%)。然而,当刀片以与纱线前进的方向相反的方向旋转和/或以高速度旋转时,可以出现可按受的切断,这样,出现锯断作用。当采用剪切作用时,在刀片上的切割边缘角度210(图7A和7B)最好大约为75度(对于锯断作用为45度),并且,在切割边缘的被涂部分203,205和207上的涂层的均方根值(rms)为大约1-2微英寸。虽然已经描述了一种静止的底刀和装了弹簧的刀片,用来把刀片与底刀压在一起,但是把刀片182固定地安装在轴184上并使底刀178可以在芯轴74上移动和对着刀片18装上弹簧也是可以的。
当切断芯轴上的纱线时,可以用两个刀片(并且在同时)切断芯轴的在相同的纵向位置处的相对侧面上的纱线,因为在相对的侧面上的切割器彼此没有干扰。也可以用沿着芯轴在纵向上分离开的切割器进行切断。这是可能的,因为夹紧装置把线绳和装上的纱线牢固地固定在芯轴的角部上的凹槽中,这是由于在切断的过程中切割器把不大的张力施加到纱线上。夹紧装置对抗这一张力,把线绳拉出凹槽。图9示出了带有刀片212和214的两个切割器,它们可以在芯轴74的相对的侧面上的相同的纵向位置。在这些情况下,当进行切断时,旋转的夹紧装置216和218固定被刀片212切断的纱线,并且,夹紧装置220和222固定用于刀片214的纱线。所示出的夹紧装置与刀片对准,但是如果它们被设置在与刀片分开并位于邻近刀片的上游侧,更靠近纱线被切断的相交部位206(见图8),它们也可以工作。
图15示出了带有切割器的两个芯轴组件215,这些切割器可以分享用来使切割轴旋转的驱动马达。在一种设置中,马达224可以通过一个皮带和皮带轮装置(未示出)驱动对于芯轴232的切割器轴230和对于芯轴228的轴226。在另一种设置中,可以把对于芯轴228的刀片234和对于芯轴232的刀片236装设在相同的轴238上,马达242通过一个皮带和皮带轮装置240驱动此轴。芯轴和被装设到托架107上的切割器的这一设置得到了一种紧凑的低成本的组件,它可以容易地进行维修和保养处理。在这一设置中,首先在每个芯轴上在箭头260的相同的纵向位置进行两次切断,接着在箭头262的位置在每个芯轴上进行一次切断,随后,在箭头264的位置在每个芯轴上进行一次切断。在一个给定的芯轴上,可以改变这一2∶1∶1的切断顺序,而不影响在芯轴上的毛绒线的产生;例如,另外的切断顺序可以是1∶2∶1或1∶1∶2。有更多或更少的切割器马达,皮带驱动装置和切割器轴的其它设置是可能的,而不会影响质量和两个芯轴毛绒线组件215的操作。
参见图10的底部,在双芯轴组件上有多个毛绒线引导皮带轮。对于芯轴228,皮带轮244和246分别引导由芯轴角部248和250出来的毛绒线;皮带轮252和254分别引导由芯轴角部256和258出来的毛绒线。对于芯轴232有一个类似的皮带轮设置。每个皮带轮有一个凹槽,容纳毛绒线,使线绳的那一侧朝向皮带轮的轮毂,并使毛绒朝向皮带轮的周边。每个双芯轴组件制作8根毛绒线。
图11为示于图1的毛绒线形成组件38的细节图。在9个位置示出了图10的双芯轴组件215,比如横截着形成组件38的宽度的位置54,56,58和60,提供72根毛绒线。形成组件38对于所有72根毛绒线有对于线绳的共同的入口挤压滚轮和对于绒毛纱线的共同入口挤压滚轮,并对于72根毛绒线有共同的出口挤压滚轮。参见图2讨论线绳入口挤压滚轮,该入口挤压滚轮被示出为空转送料滚轮90和由马达93旋转的受驱动的送料滚轮92。参见图2讨论纱线入口挤压滚轮,该入口挤压滚轮被示出为空转送料滚轮98和由马达101旋转的受驱动的送料滚轮100。参见图2讨论毛绒线出口挤压滚轮,该出口挤压滚轮被示出为空转出口滚轮109和由马达113旋转的受驱动的出口滚轮111。用来把毛绒线引导到滚筒组件49(见图1A)的一个毛绒线引导滚轮266处在形成组件38的顶部。
也可以有对于芯轴的缠绕装置的组合驱动。例如,一个马达可以驱动对于5个双芯轴组件的5对缠绕装置,并且,一个马达可以驱动对于其余的4个双芯轴组件的4对缠绕装置。这样的设置可以采用一个皮带和皮带轮***,如在图11中在箭头268处部分地示出的那样。框架75把毛绒线组件38的所有部件固定在一起。
在滚筒组件49中,有多个毛绒线引导件,用来精确地把多个毛绒线引导到底布上,并引导到超声焊头的下面,用来进行焊接。图12A示出了用来焊接间隔紧密的多根毛绒线的第一毛绒线焊接焊头270和第二焊头271的放大了的侧视图;以及用来把间隔紧密的多根毛绒线引导成与第一焊头270对准的一个毛绒线焊接引导件272。每个焊头被装进一类似于在图5中所示出的那种组件的一个焊接组件中,用来把纱线焊接到芯轴上的支承线绳上。在径向上对每个焊头施加作用力,比如如图所示地对于焊头270以箭头274,对着底布基底50和对着滚筒52挤压毛绒线。第一焊头被用来把毛绒线轻微地点焊到底布上,同时保持由引导件272所确定的对准,焊头271可以把更多的能量施加到仍然是热的毛绒线上,把它牢固地装接到底布上。两个焊头的加合效应可以把大量的能量快速地加到对毛绒线的焊接中。应该保持焊头270和271之间的距离273较短,以便得到这一效应的利益,但这一距离也提供了一定的时间,用来使来自第一焊头的热量穿透支承线绳。在不需要快速地添加大量能量的低速的情况下,可能只需要第一焊头。当把表面纱线焊接到在毛绒线形成芯轴上的线绳上时,这一双焊头技术也可能是有用的。例如,在图13A-E中更详细地示出了焊头270。在图13A中的焊头有四个叉形件276,278,280和282,把每个设计成装配在单根的毛绒线上的毛绒之间,并在毛绒的底部与支承线绳相接触。叉形件之间的间隔284与在成品地毯上的所希望的毛绒线的间隔相同。对于不同的毛绒线的间隔,可以使用带有相应的叉形件间隔的不同的焊头。叉形件的高度286与成品地毯中所希望的最大毛绒高度的毛绒线上毛绒的最大长度相对应。焊头有图13B中的所示的长度288,此长度与超声的振幅,频率,以及驱动器的功率有关。图13C示出了叉形件282的前端290和尾端292的典型细节,示出了一个不大的半径294,以帮助在焊头的下面平滑地引导毛绒线。图13D示出了叉形件的另一种可能的形状,其中半径294′在叉形件的长度上伸展,这样,当毛绒线在焊头的下面滑动时,逐渐地施加压力。其它的形状也可能是有利的,第一焊头270可以有与第二焊头271不同的形状。图13E示出了叉形件282的顶部296的形状的典型细节,它有一个中凹的表面298,该表面沿着叉形件的长度288引导支承线绳,在焊接过程中保持该线绳不滑到侧面,由叉形件下面滑出。这一中凹的表面在整个半径290和294′上伸展,在焊头的压力和振动施加到毛绒线上之前帮助使毛绒线的线绳的轨迹在焊头的下面。
参见图12B,引导件272有多个狭缝,比如狭缝300,它有一个很窄的宽度302,这迫使毛绒线上的毛绒彼此朝向,并迫使毛绒在支承线绳的上方。对于多根毛绒线的狭缝收缩成等于在最后的地毯组件中所想要的毛绒线的间隔的一个间隔。这些狭缝把适当间隔的毛绒线引导到焊头,此焊头有同样间隔的叉形件,并且此焊头紧靠着引导件272的端部304。毛绒线以对于滚筒的表面大约15度的一个角度趋近该焊头,这样,在焊头中的中凹的表面帮助使毛绒线的轨迹定位。在叉形件上,对于被引导到其上的毛绒线的毛绒分开,从而一排毛绒沿着一个叉形件的一侧通过,另一排毛绒沿着叉形件的另一侧通过,叉形件296的顶部在支承线绳的上方,并对它施加压力。在焊头270的一侧,犁形件263必然把先前焊接的毛绒线推到侧面,从而单个的毛绒不会被截留在被引导的毛绒线的下面,并在焊头下面被焊接。在焊头270的相对的侧面308上,通常没有先前被焊接的毛绒线存在,所以把一个支承指状件310安装到引导件272上,支承在焊头的那一侧面上的外部毛绒。指状件310邻近焊头271伸展,并越过焊头伸展,把毛绒向上固定,直到焊接冷却下来。如果外部的毛绒不被指状件310支承,则发现,在加热的过程中和当被焊接的毛绒线冷却时,外部的毛绒倾向于向下覆盖,从而在最后的地毯组件中这一排毛绒产生一个与相邻的一排不同的可以看得见的"条纹",甚至在毛绒的剪切之后有这样的条纹,这样,地毯有一个被称为条痕的缺陷。
在滚筒52上的焊接完成之后,滚筒继续旋转一个短的距离,可以使装在引导件300下面的一块板265沿箭头267的方向压靠。该板265被压在被引导的但还未被焊接的毛绒线和焊头270,271的下面,这样,可以把引导件,毛绒线和焊头提升起来,用来把毛绒线切断,把成品的地毯移开,以及把一块新的底布穿进到滚筒上。可以把引导件,毛绒线和焊头降下,并把板抽出,从而毛绒线处于对着新的底布的位置,在准备用来进行焊接的焊头的下面,重新开始制作地毯的过程。
图14示出了皮带组件311的一个侧视图,该组件是对于滚筒组件的一个替代,在该组件中,多个滚轮312,314,316和318支承着无端的环形底布基底50,而不是像图1A中所示的一个单一的大滚筒52。这样,可以提供一个大的底布环,用来制作一个长的地毯,而没有一个大直径滚筒的费用。滚轮316能容易重新定位,改变该环的长度,以适应地毯块的尺寸。图14的实施例也横过在滚轮312的长度上的毛绒线组,该滚轮保持静止不动,与图1A的实施例不同,在那里毛绒线保持不动,而滚筒横过毛绒线组之间的距离。滑动架320携带着毛绒线引导组件322和324,第一焊接组件326,第二焊接组件328,以及毛绒线焊接引导件272′。这两个焊接组件与图5中所示的组件类似,但是,带有图13A的焊头。静止不动的杆330和可旋转的带螺纹的杆332支承着滑动架320,杆332由一个被安装的马达(未示出)驱动;该带螺纹的杆与在滑动架320中的一个带螺纹的螺母相接合。马达334通过一皮带和皮带轮***336驱动滚轮312。滚轮314,316和318中的一个或多个可以是中间稍微***的,保证底布基底的轨迹在支承滚轮上的一个固定的位置。对于底布的一个边缘引导件,比如边缘引导件338,也可以帮助轨迹的定位。框架340支承着皮带组件311的所有部件。当图1A的***运行但采用皮带组件311时,可能会希望把皮带组件90取向成与所示出的毛绒线42,44,46和48的方向成90度,从而它们可以与横向移动的滑动架320的行进方向对准,这样,在横向移动的过程中毛绒线的角度可以不改变。
皮带组件311可以与多组毛绒线一起运行,如参考着图1A所描述的那样,或者,它可以只与一组毛绒线一起运行,该毛绒线横截着滚轮312的整个长度在横向上移动,滚轮312用做对于这一组件的超声砧座。这样,只需要制作非常少的毛绒线,并只需要非常少的表面纱线供应卷和支承线绳卷。这形成一种低成本的地毯组装***,但是,该***的生产率比在图1A中所示出的***要低得多。对于某些情况,这可能是优选的。例如,如果希望在销售的地方制作地毯,这种运行方式的低成本和紧凑的优点可能是特别希望的。
图15示出了一个卷绕组件342的侧视图,该组件为所讨论的滚筒组件49和皮带组件311的一种替代。在该卷绕组件342中,地毯的整个宽度所必须的多根毛绒线被引导到一个焊接滚轮344上,在那里它们与一细长卷的底布基底50连接,并被焊接到该卷底布上,制作出一整卷地毯;或者,如果底布可以被拼接起来提供一个没有终端的供应,支承线绳可以被拼接起来提供一个没有终端的供应,并且,可以在飞轮上在横向上把地毯切断;可以进行连续制作地毯的过程。可以把地毯缠绕成卷,或可以把地毯切断成间断的长度,并重叠起来。如果希望制作12英尺的全宽度地毯,图1A中所示的毛绒线组件38的数目必须增加到10倍,提供大约720根毛绒线,并且相应地增加表面纱线架的数目,比如62,和支承线绳架的数目,比如68。另外,可以把附加的双芯轴组件添加到毛绒线形成组件38上,这样可以只需要五个这样改进了的组件38。
在图15中,卷绕组件可以采用讨论过的顶侧焊接技术,在此技术中,把毛绒线引导到叉形焊头的下面,或可以采用底侧面焊接,如将参考着图15和16A-D讨论的那样。卷绕组件342包括一个焊接滚轮344;多个焊接组件,比如346,348,350和352;底布基底支承装置353;毛绒线引导组件354和356;焊接滚轮驱动马达358;地毯驱动滚轮360以及地毯挤压组件362;所有这些都装设到框架364上。
首先在引导组件354中的四个间隔开的高度上引导来自毛绒线组件38的毛绒线,引导组件354把毛绒线分离开,接近它们在地毯结构中所要求的最后间隔。四根相邻的毛绒线中的每一根在不同的高度上,为的是容易处理和防止缠结。引导件354包括带有不同宽度的狭缝的一个不动的滚轮;该滚轮可以周期性地旋转一圈的一部分,以便使磨损均匀。把毛绒线保持在引导组件356中它们被引导的高度上,在该引导组件356中得到在地毯中所想要的毛绒线到毛绒线的最后间隔。图16A示出了在引导组件356中的通道,比如下通道363。每个通道有被切成圆角的入口,比如在通道363中的入口365,把毛绒,比如毛绒对367,369和375,由它们的带角度的取向引导成如图所示的平行的取向。
重要的是使毛绒线的角度向下,以角度371越过被切成圆角的入口365的圆角部分373,这样,当毛绒进入引导件356时毛绒"成扇状散开",并且毛绒不会与毛绒线上的其它毛绒缠结。这一角度应该在大约5-45度之间,最好,大约为20度。重要的是,当毛绒线进入引导件356时,使毛绒线保持彼此分开,并使它们彼此不会缠结。实现这一点是靠进入引导件的多个高度的交错的路径。例如,对于如所示出的毛绒对367和375,每第四根毛绒线处于相同的高度,它们分离开足够远,使得毛绒367不会与毛绒375缠结。相邻的毛绒线367和369在竖直方向上交错分离开一个足够的距离,从而毛绒367不会与毛绒369缠结。多根圆杆,比如杆377和379,被分离开,在引导件356的前面,在不同的高度上对着毛绒轻微地刷(只示出了两根),防止当毛绒线进入引导件356时它们偏离向上的取向;这确保了毛绒线的线绳将在引导件356的通道363中对中。
引导组件356把毛绒线引导进焊接滚轮344上的凹槽中,以毛绒面朝下进入凹槽,并使支承线绳被支承在把凹槽分开的肋的顶部上。图16B示出了引导件356的一个侧截面和焊接滚轮344的一部分。一根毛绒线,比如毛绒线48,首先在成圆角的入口365和成圆角的角部366上作一个带角度的转弯,沿着通道363向下,通过一个犁形件370,以角度372在通道363的底部的端部396的一个成圆角的角部上作另一个带角度的转弯,并被引导到肋374上,使毛绒向下在肋的每一侧的凹槽中,比如在凹槽376中。焊接滚轮344以箭头378的方向旋转。重要的是,毛绒线以角度372作一个突然的转弯,接近肋374,所以毛绒快速地和被强迫地通过一个短的距离由引导件到滚轮,避免了毛绒进入并被保留在凹槽,比如凹槽376,中而出现的问题。角度372应该在大约45度到135度之间,最好大约为90度。为了进一步确保毛绒线牢固地在凹槽中,并确保线绳对着肋374,可以采用一个滚轮380对着滚轮344向毛绒线施加压力。在滚轮344的半径上弯曲的毛绒线中的张力保持毛绒线在滚轮344上的位置,直到底布在其位置为止。围绕着引导滚轮382引导底布50,该引导滚轮与滚轮344上的毛绒线的背面相接触。底布处于张力的作用下,该张力把毛绒线和底布保持在滚轮344上的位置,直到焊头,比如焊头384可以把底布焊接到毛绒线上为止,以滚轮344上的肋做为超声的砧座。
图16C示出了另一幅图,示出如何把毛绒线由引导件356中的通道引导到在焊接滚轮344中的凹槽中。例如,包括支承线绳386和第一排毛绒388以及第二排毛绒390的毛绒线48向下通过通道363,朝向翅片391,该翅片为在犁形件370上的多个翅片之一。为了清楚起见,略去了在相邻通道中的毛绒线。在平行的板392和394之间形成了通道363,这些板向下伸展,越过通道363的底部的端部396,并进入滚轮344上的凹槽。板392伸展进凹槽376,而板392伸展进凹槽376′。肋374在板392和394的端部之间伸展,这些板伸展进凹槽。翅片391与肋374对准,并沿着通道363伸展,在两排毛绒388和390达到肋374之前把它们分开。翅片391有一个尖端398,面对着毛绒线前进的方向,当毛绒排经过时帮助把它们分开。肋374的顶部有一个中凹的表面400,容纳支承线绳,并保持该线绳不会由肋的顶部落下,落进相邻的凹槽中。如果在最后的地毯结构中由一根毛绒线到另一根毛绒线的间隔(节距)被改变,可以改变引导组件356和焊接滚轮344,并用有新的间隔的引导件和滚轮来替代。如果在第一位置提供了对于毛绒线的狭缝的必要数目,可以不需要改变引导件354。
图16D示出了穿过焊接滚轮344的一个剖面,示出了底布50如何在毛绒线,比如毛绒线48和46,上定位,以及超声焊头384如何对着肋374和374′把它们挤压在一起,进行焊接。只采用一个超声驱动器和放大器,焊头384就可以一次焊接多根毛绒线;例如,相信,用单一的焊头/驱动器/放大器可以可靠地一次把八根毛绒线焊接到底布50上。
图17A示出了一个用来从背表面焊接在卷绕组件342上的多根毛绒线的典型的焊头384。焊头384的边缘402和404可以伸展越过焊头体,形成焊接表面406。焊接表面406的长度408(见图17B)与超声的振幅,频率,以及驱动器的功率有关,表面最好有半径410的型线,如在图17C的放大图所看到的那样。半径410帮助引导底布和在焊头下面的毛绒线,同时该焊头挤压它们并把它们焊接在一起。在图15中示出了多个焊接组件,用来完成间隔紧密的可靠的焊接。多个与组件346对准的焊接组件把第一组多根间隔开的毛绒线轻微地点焊到底布上,而不会扰动由引导组件356所得到的在焊接滚轮344的肋上的对准。与组件350对准的多个焊接组件牢固地把第一组多根毛绒线焊接到底布上。多个与组件348对准的焊接组件把第二组多根间隔开的毛绒线(由所有其余的毛绒线组成的)轻微地点焊到底布上,而不会扰动由引导组件356所得到的在焊接滚轮344的肋上的对准。与组件352对准的多个焊接组件牢固地把第二组多根毛绒线焊接到底布上。
在焊接之后,带有被装上的毛绒线的底布,现在是一种地毯结构412,绕过滚轮414,并绕过驱动滚轮360。挤压组件362把空转滚轮416可作枢轴转动地压向驱动滚轮360,用来驱动地毯结构412通过卷绕组件342。随后,地毯结构越过框架364,用来作进一步的加工。
图18示出了一个完整的地毯制作***的布置图,该***包括多个毛绒线形成组件38和一个卷绕组件342。在示出的布置图中,五个毛绒线形成组件38a,38b,38c,38d和38e被设置成每个提供144根毛绒线,对于12英尺宽的地毯产品总共720根毛绒线。这些毛绒线以一平行的排418被送到一卷绕组件342a,该卷绕组件被设计用来横截着该组件的宽度接受720根毛绒线。在420提供了一卷底布基底。12英尺宽的底布基底50在一个90度转弯的滚轮422上通过,并被送进卷绕组件342a,用来焊接到毛绒线排上。每个毛绒线形成组件由一个纱线架供应,比如对于组件38a的线架424,该线架对于一个形成组件中的每个缠绕装置可以固定多至三个纱线端,或者108个运行卷和108个连接卷;并由一个支承线绳架供应,比如对于组件38a的线架426,它有144个运行卷和144个连接卷。在428和430设置了传统的卷材累积器,为的是提供连续的运行。地毯结构412a在结束处432被缠绕成一卷;地毯卷被积累,用来分段运输到在保存区域434的产品加工线。机器控制装置405控制整个过程。操作面板407容许操作者输入。散布的控制器409,411,413,415,417和419控制在毛绒线形成组件和卷绕组件上的超声***。
此毛绒线形成过程特别适合于采用预先染色的纱线(溶液染色的纱线),因为所需要所纱线架可以比用传统的地毯毛绒化操作所需要的明显地小。当为了对于地毯的每次颜色的改变必须改变线架时,一个小的线架是一个优点。当预先染色的纱线被用于毛绒线地毯时,地毯结构必须经过一个分开的膨松化过程,因为在传统的地毯***中提供膨松化的其它步骤,比如地毯染色操作和挂胶干燥操作,是不必要的。图19示出了特殊的最后加工生产线,它包括一个把卷打开的装置435,一个膨松加热炉436,一个冷却室438,一个传统的剪切装置440,一个检查输送装置442,以及一个成卷装置444。在卷绕之后,成品的地毯卷由一捆包机443捆扎起来,并放到台子445上,等待发运。在446,448和450设置了传统的卷材累积器,为的是提供连续的运行。在共同未决的申请RD-7035-P1中描述了膨松化过程和装置,该申请在这里被结合进来作为参考。
图2中的毛绒线形成组件38和图18中的组件38a-e要求某些特殊的控制考虑,可以参见图2最清楚地讨论这些考虑。为了开始和停止超声焊接过程,并生产出可接受的产品,超声焊头的振幅和焊头的压力必须随着毛绒线的速度的上升和下降而上升和下降。在稳定状态的运行中,必须监测和控制在纱线,支承线绳和毛绒线上的张力,并监测超声功率且将其控制为恒定值。例如,散布的超声控制器409(在图2中与毛绒线形成组件38一起示出)被连接到超声驱动器136和136′上,而这些驱动器又连接到焊头134和134′上。机器控制器405被连接到散布的控制器409和用螺旋线段示出的其它部件上,下面将讨论。
除了参考着图2已经讨论的那些部件以外,毛绒线形成组件也包括在切割器装置86上的四个马达;对于焊接组件78和80分别有电压对压力调节器452和454,缸体142和142′和超声驱动器136和136′;对于缸体94,102和119分别有阀门456,458和460;以及为了监测已经完成的毛绒线之一上的张力的张力计462,和为了监测相应的线绳,比如线绳30,上的张力的张力计464。
马达113是用来把线绳沿着芯轴的隆脊拉过芯轴74的,并用来在纱线被焊接到线绳上并被切断之后拉动毛绒线。当开动毛绒线形成组件时,伺服马达113的速度由一个安装的解析装置监测,缸体142和142′所施加的作用力增加,超声驱动器136和136′所施加的焊头振幅增加。作用力和振幅都以马达113的速度的上升速率成线性比例关系增加。考虑到焊头和缸体有响应延迟,也可以有某些不大的滞后,目的是使焊头总把所有的纱线焊接到线绳上,而没有过度的焊接和损坏任何纱线的纤维。机器控制器405控制该作用力,此控制器控制输到每个焊接组件上的每个电压对压力调节器,比如452和454,的单个信号。机器控制器405控制该振幅,此控制器控制输到每个焊接组件上的每个超声驱动器,比如136和136′,的信号。当马达113上升到一稳定状态的速度时,机器控制器由振幅控制改变成功率或能量控制,维持稳定的焊接条件。作用力被保持为常数,而改变振幅,以便对于每个超声驱动器和焊头保持不变的功率。已经发现,超声驱动器的效率随着在连续的操作过程中该单元被加热而改变。维持功率不变的振幅的改变校正了效率的这一变化,从而得到稳定的焊接。焊头本身也已看到会加热升温,可以通过管道455和457对冷却空气进行导向,限制焊头焊接表面所受到的温度上升;也可以把冷却空气导向朝着驱动器。
当停止毛绒线形成时,机器控制器由不变的功率控制开始改变,实现与开动相反的步骤,随着马达113的速度的下降把振幅和作用力降下来。振幅的基础值是刚刚在停止发生之前所采样的振幅,因为振幅随着不变的功率控制的进行而变化。毛绒线速度由大约0-15 YPM上升的典型时间为大约3-5秒。已经发现,在某些情况下,在启动和停止时只需要改变作用力,而振幅保持不变,但是优选的操作是同时改变作用力和振幅。
在直接耦合到滚筒组件49或皮带组件311,或卷绕组件342上的毛绒线形成组件的运行过程中,对这些组件中的每个的驱动也拉动毛绒线,所以,必须用对于每个毛绒线形成组件,比如38,的单一的张力计462监测毛绒线的张力。随后,机器控制器405调节马达113的速度,保持毛绒线的张力不变。这防止了张力过大和过松,这些可能扰乱形成毛绒线过程,并使毛绒线断。类似地,也必须用对于每个毛绒线形成组件38的单一的张力计464监测线绳的张力,机器控制器405调节马达93的速度,保持线绳的张力不变。设置张力计462和458是为了在对纱线进行焊接制作毛绒线之前和之后对同一根线绳的线路进行测量。
纱线送料滚轮马达101和缠绕装置马达126由机器控制器405控制,这样,在被送进芯轴74和被缠绕在芯轴上的纱线40中的张力保持不变。按照来自操作面板407(见图18)的每个操作者的指示,控制器设定缠绕速度,得到所想要的沿着线绳每英寸线绳的数目。马达101的速度被设定成正比于缠绕马达126的速度,以便基于逐次逼近法得到所想要的张力。如果愿意,可以在送料滚轮92与梭芯进口端120之间的纱线上使用一个张力计,帮助形成张力,并控制此张力,但是,已经发现,固定的速度比会工作很好。
已经示出了芯轴74为一种中空的结构,支承线绳(和/或携带线绳)通过表面纱线的缠绕装置内的中心。其它"中空的"芯轴结构可以工作得同样好。图20A示出了带有三个臂的星形芯轴466,支承线绳(或携带线绳,如果所有支承线绳被焊接到缠绕在芯轴上的纱线的外面)通过芯轴的臂,比如470和472,之间的凹陷部,比如468。线绳由中心到隆脊,彼此横截着。围绕着芯轴设置了切割器,比如474,和超声焊头,比如476。图20B示出了一种星形四臂的芯轴478,在此芯轴中,由中心到隆脊的线绳路径最好不与臂的中心对准。在图20C中示出了芯轴的另一种改型,在此芯轴中,芯轴480只制作两根毛绒线,并有对于线绳的引导管482和484。可以把隆脊486和488的表面设置成垂直于线绳路径,如果线绳有平的或椭圆形的侧面,使线绳的加捻最小。图20D示出了带有沿着一个边缘的狭缝492的一种单根毛绒线芯轴490,该狭缝引导支承线绳,并提供切断用的凹槽。图20E示出了图20D的芯轴的侧视图,示出了在芯轴的一个边缘上的倾斜的端部494,帮助把纱线输送到超声焊头上,因为在此边缘没有与纱线接合的支承线绳用来帮助运送该纱线。在刚刚讨论的另一芯轴实施例中,示出的切割刀片不需要底刀来实现纱线的切断。图20F示出了一个实体的芯轴496的侧视图。由关于芯轴498旋转的分开的来源498和500供应纱线。这样,可以如图所示地供应线绳502和504,而不是沿着芯轴,从而该芯轴不需要是带有对于支承线绳或携带线绳的通道的中空的或星形的形状。
虽然已经通过制作被切断的绒毛地毯描述了本发明,但是毛绒线形成组件38可以与适宜于制作环形绒毛毛绒线的芯轴组件相配合。这样的芯轴组件可以以环形绒毛毛绒线装置和加工过程为基础,这些装置和过程已经在1994年10月28日申请的共同未决的申请No.08/331,074中描述了,该申请在这里被结合进来作为参考。在这种情况下,可能需要更多的芯轴,因为一个芯轴只制作一根环形绒毛毛绒线,尽管每根环形绒毛毛绒线有两排环,从而在地毯中可能只需要较少的毛绒线就可以得到与切断的绒毛毛绒线相同的覆盖。可以把环形绒毛毛绒线送给如所描述的地毯形成组件49,311或342中之一,形成一块环形绒毛毛绒线地毯。可以采用类似于对于切断的绒毛毛绒线所描述的引导和焊接技术。对于环形绒毛地毯可以采用一个不同的最后加工生产线,这取决于地毯打算的用途。
Claims (16)
1.一种用于制作地毯的方法,它包括:
靠把纱线焊接到一根支承线绳上形成多根毛绒线;
把毛绒线分成多组,把每组中的毛绒线设置成并排的一排,这些组彼此隔离开;
把每组中的毛绒线焊接到连续的底布基底环上,每组由横截着底布环的宽度与其它组的开始点对准的一个开始点开始;
以螺旋形的排列缠绕每组毛绒线,从而在沿着连续的底布环进行第一螺旋之后,在刚刚焊接的每组毛绒线与在该组中已经焊接的毛绒线并排地会合,并且,在沿着连续的底布环进行最后螺旋的过程中,在刚刚焊接的每组毛绒线与在相邻的组中已经焊接的毛绒线并排地会合,并且,在相邻的组的开始点,在刚刚焊接的每组毛绒线与在相邻的组中已经焊接的毛绒线并排地会合,这些毛绒线首先被焊接;
停止焊接;以及
把毛绒线和底布在开始点横截着底布环的宽度对准的位置切断。
2.按照权利要求1所述的方法,其特征在于,靠在一个加了超声能量的焊头与一个砧座之间把纱线与线绳挤压在一起实现把纱线焊接到线绳上,一个超声焊头同时把多根线绳焊接到纱线上。
3.按照权利要求1所述的方法,其特征在于,靠在一个加了超声能量的焊头与一个砧座之间把毛绒线与底布基底挤压在一起实现把多组毛绒线焊接到底布基底上,一个超声焊头同时把多根毛绒线焊接到底布基底上。
4.按照权利要求1所述的方法,其特征在于,在把多组毛绒线焊接到底布基底上的过程中,沿着每组毛绒线的边缘的外部毛绒在焊接过程中被支承在与毛绒在内部的毛绒线中的位置相同的位置,这些内部的毛绒线中的毛绒被相邻的毛绒支承着。
5.一种把两根支承线绳焊接到缠绕在其上的纱线上的方法,它包括:
把一第一根线绳放在一第一凹槽中,并把一第二根线绳放在一第二凹槽中,所述凹槽在一个芯轴上的相邻隆脊上,该芯轴用作一超声砧座;
在所述第一线绳上缠绕纱线,从而在第一线绳的两侧上的纱线确定了一第一包含角;
在所述第二线绳上缠绕纱线,从而在第二线绳的两侧上的纱线确定了一第二包含角;以及
用被单一的超声驱动器施加能量的超声焊头对着两根线绳向缠绕的纱线施加压力,其中所述焊头有一个与所述纱线接触的第一表面,从而所述第一表面基本上垂直于一第一假想平面,该平面通过所述第一线绳并基本上平分所述第一包含角,并且,所述焊头有一与所述纱线接触的第二表面,从而所述第二表面基本上垂直于一第二假想平面,该平面通过所述第二线绳并基本上平分所述第二包含角。
6.按照权利要求5所述的方法,其包括改变芯轴的周长的步骤,从而改变由一第一位置缠绕的纱线的周长,在该第一位置所述纱线首先在所述线绳上被缠绕到与所述焊头相邻的一第二位置,从而由第一线绳到第二线绳沿着纱线的距离在所述第一位置比在所述第二位置大,以便适应在焊接过程中纱线的收缩。
7.一种把装接到支承线绳上并沿着平行于该线绳纵向轴线的一个芯轴运送的纱线切断的方法:
在沿着一个细长的芯轴的轴线的一个路径中运送该纱线,该纱线的纵向轴线基本上垂直于线绳的纵向轴线;
在该芯轴上,在纱线的路径上设置一个静止不动的底刀,该底刀有一个与纱线接触的第一表面和一个基本上垂直于第一表面的第二表面,所述二表面的相交部位确定了底刀的切割边缘;
把旋转的圆盘形刀片的一个侧表面的一部分与底刀的第二表面压靠在一起,所述部分在其上有一个涂层,该涂层的Vickers硬度至少为2500,刀片有一个相交表面,该表面与所述侧表面成一个锐角,从而形成了一个刀片切割边缘;以及
在把刀片与底刀压靠在一起的部位对着旋转的刀片压靠纱线,从而当沿着所述路径运送纱线时,把纱线切断。
8.按照权利要求7所述的方法,其包括如下步骤:
施加一种不会沾污纱线的流体到刀片与底刀接触的那部分刀片的侧表面上,润滑和冷却刀片。
9.按照权利要求7所述的方法,其包括:
使刀片在有助于沿着所述路径运送所述纱线的一个方向上并以超过纱线沿着所述路径的速度的一个周边速度旋转;以及
把纱线夹紧,防止当纱线沿着所述路径到达刀片时纱线横截着所述路径运动。
10.按照权利要求8所述的方法,其特征在于,所述流体是水。
11.按照权利要求7所述的方法,其特征在于,刀片的涂覆材料是一种无定形的金刚石涂层。
12.一种把毛绒线上的毛绒引导进在平行的肋之间形成的在一个滚轮上的凹槽中的方法,该方法包括:
沿着在平行的板之间形成的一个通道引导毛绒线;
把这些板伸展进凹槽中;
把一个翅片插进毛绒排之间,使翅片在一通道中与肋对准,并邻接于肋;以及
就在毛绒线到达滚轮上的肋时把毛绒线拉过45-135度之间的一个突变角度,从而快速地把毛绒经过滚轮上的一个短的弧形由通道传送到凹槽中。
13.按照权利要求12所述的方法,其包括:
把一块底布基底引导到滚轮上的毛绒线上,其位置邻近把毛绒线引导进凹槽中的部位;以及
施加张力到底布基底上,固定毛绒线和底布,与滚轮的周边相接触。
14.按照权利要求13所述的方法,其包括:
靠把毛绒线以交错的多个高度的排的形式分离开,把毛绒线引导进所述通道中,从而在进入所述通道之前每根毛绒线不会与其它的毛绒线缠结,以及
当每根毛绒线进入所述通道时,使它通过一个半径的一部分。
15.一种用于制作地毯的装置,它包括:
用来靠把纱线焊接到一根支承线绳上形成多根毛绒线的装置;
用来把毛绒线分成多组并把这些组彼此隔离开的装置,把每组中的毛绒线设置成并排的一排;
用来把每组中的毛绒线焊接到连续的底布基底环上的装置,每组由横截着底布环的宽度与其它组的开始点对准的一个开始点开始;
用来以螺旋形的排列缠绕每组毛绒线的装置,从而在沿着连续的底布环进行第一螺旋之后,在刚刚焊接的每组毛绒线与在该组中已经焊接的毛绒线并排地会合,并且,在沿着连续的底布环进行最后螺旋的过程中,在刚刚焊接的每组毛绒线与在相邻的组中已经焊接的毛绒线并排地会合,并且,在相邻的组的开始点,在刚刚焊接的每组毛绒线与在相邻的组中已经焊接的毛绒线并排地会合,这些毛绒线首先被焊接;
用来停止焊接的装置;以及
用来把毛绒线和底布在开始点横截着底布环的宽度对准的位置切断的装置。
16.按照权利要求15所述的装置,其特征在于,用来把多组毛绒线焊接到底布基底上的装置是一个加了超声能量的焊头与一个砧座,其特征还在于,一个超声焊头同时把多根毛绒线焊接到底布基底上。
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US51373495A | 1995-08-10 | 1995-08-10 | |
US08/513,734 | 1995-08-10 |
Publications (1)
Publication Number | Publication Date |
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CN1192715A true CN1192715A (zh) | 1998-09-09 |
Family
ID=24044474
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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CN96196189A Pending CN1192715A (zh) | 1995-08-10 | 1996-08-06 | 用来制作毛绒线地毯的方法和装置 |
Country Status (13)
Country | Link |
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EP (1) | EP0843620A1 (zh) |
JP (1) | JPH10511027A (zh) |
CN (1) | CN1192715A (zh) |
AR (1) | AR003236A1 (zh) |
AU (1) | AU6766396A (zh) |
BR (1) | BR9610066A (zh) |
CA (1) | CA2227552A1 (zh) |
CO (1) | CO4650078A1 (zh) |
MX (1) | MX9800759A (zh) |
PL (1) | PL324994A1 (zh) |
TR (1) | TR199800199T1 (zh) |
WO (1) | WO1997006003A1 (zh) |
ZA (1) | ZA966766B (zh) |
Families Citing this family (4)
Publication number | Priority date | Publication date | Assignee | Title |
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EP1357220A1 (en) * | 1997-12-05 | 2003-10-29 | E.I. Du Pont De Nemours And Company | Velour-like pile articles and pile surface structures and methods of making |
US6720058B1 (en) * | 1997-12-05 | 2004-04-13 | E.I. Du Pont De Nemours And Company | Velour-like pile articles and pile surface structures and methods of making |
US6543083B1 (en) | 1998-06-05 | 2003-04-08 | E. I. Du Pont De Nemours & Co. | Bristles having varying stiffness |
US6638384B1 (en) | 1999-04-23 | 2003-10-28 | E.I. Du Pont De Nemours And Company | Method and apparatus for making bristle subassemblies |
Family Cites Families (6)
Publication number | Priority date | Publication date | Assignee | Title |
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US2475019A (en) * | 1944-06-10 | 1949-07-05 | Prodesco | Process of making pile yarns and fabrics |
JPS5945378B2 (ja) * | 1981-05-08 | 1984-11-06 | 山崎産業株式会社 | 自動モツプ縫製装置 |
US4964932A (en) * | 1987-07-22 | 1990-10-23 | Xmas-Mil Display Products Pty. Ltd. | Method and apparatus for manufacturing decorative garland |
US5472762A (en) * | 1993-02-22 | 1995-12-05 | E. I. Du Pont De Nemours And Company | Method and apparatus for making a pile article and the products thereof |
US5470629A (en) * | 1993-02-22 | 1995-11-28 | E. I. Du Pont De Nemours And Company | Method and apparatus for making a pile article and the products thereof |
AU3493795A (en) * | 1994-08-31 | 1996-03-22 | E.I. Du Pont De Nemours And Company | Moisture stable tuftstring carpet |
-
1996
- 1996-08-06 BR BR9610066A patent/BR9610066A/pt unknown
- 1996-08-06 CA CA 2227552 patent/CA2227552A1/en not_active Abandoned
- 1996-08-06 JP JP50860797A patent/JPH10511027A/ja active Pending
- 1996-08-06 PL PL32499496A patent/PL324994A1/xx unknown
- 1996-08-06 MX MX9800759A patent/MX9800759A/es unknown
- 1996-08-06 AU AU67663/96A patent/AU6766396A/en not_active Abandoned
- 1996-08-06 EP EP19960928065 patent/EP0843620A1/en not_active Withdrawn
- 1996-08-06 CN CN96196189A patent/CN1192715A/zh active Pending
- 1996-08-06 TR TR1998/00199T patent/TR199800199T1/xx unknown
- 1996-08-06 WO PCT/US1996/012785 patent/WO1997006003A1/en not_active Application Discontinuation
- 1996-08-08 ZA ZA9606766A patent/ZA966766B/xx unknown
- 1996-08-09 CO CO96042165A patent/CO4650078A1/es unknown
- 1996-09-08 AR AR10394696A patent/AR003236A1/es unknown
Also Published As
Publication number | Publication date |
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CA2227552A1 (en) | 1997-02-20 |
AR003236A1 (es) | 1998-07-08 |
PL324994A1 (en) | 1998-07-06 |
AU6766396A (en) | 1997-03-05 |
CO4650078A1 (es) | 1998-09-03 |
MX9800759A (es) | 1998-04-30 |
JPH10511027A (ja) | 1998-10-27 |
TR199800199T1 (xx) | 1998-05-21 |
ZA966766B (en) | 1998-02-09 |
EP0843620A1 (en) | 1998-05-27 |
BR9610066A (pt) | 1999-03-02 |
WO1997006003A1 (en) | 1997-02-20 |
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