US3741254A

US3741254A - Method and apparatus for weaving pile fabrics

Info

Publication number: US3741254A
Application number: US00195171A
Authority: US
Inventors: E Clark; U Clark
Original assignee: Fieldcrest Mills Inc
Current assignee: FIELD CREST CANNON Inc
Priority date: 1971-11-03
Filing date: 1971-11-03
Publication date: 1973-06-26
Anticipated expiration: 1990-06-26
Also published as: DE2226834C3; DE2226834B2; DE2226834A1; CA955503A; BE780732A; GB1378927A

Abstract

In the weaving of pile fabrics on an Axminster loom equipped with an endless conveyor means on which spool carrying tube frames are mounted with pile yarns extending through a row of tubes on each frame, the tube frames cooperate with the loom reed and weft inserting means in an improved manner according to this invention to position each successive row of tubes between the warps incident to the forming of tufts from the respective pile yarns without displacing the conveyor means from its normal path of travel or removing the successive tube frames from the conveyor means, and without displacing the tubes relative to the tube frames.

Description

[111 3,741,254 June 26, 1973 United States Patent [1 1 Clark, deceased METHOD AND APPARATUS FOR WEAVING 382,943 10/1932 Great [39/2 PILE FABRICS [75] Inventor:

sszt'fiis'ass ti ztlzt iiffiilfifii'iiimifi administratrix [73] Assignee: Fieldcrest Mills, Inc., Eden, N.C.

[22] Filed:

ABSTRACT In the weaving of pile fabrics on an A equipped with an endless conve xminster loom yor means on which Nov. 3, 1971 [21] App]. No.: 195,171 spool carrying tube frames are mounted with pile yarns extending through a row of tubes on each frame, the

tube frames cooperate with the loo 2 g i i 'gg g setting means in an improved manner acco U 'g i C 139 4 7 invention to position each successive row e d 0 earc tween the warps incident to h the respective pile yarns without displacing the cone .mm N m h rt r o l e W m fled om t 30 we? 885 eh m a n rn s i hem bl. mun. 0 h fled mm aao e h mC h IUW OS W m v ma B 7 9 3 1 m N" mm M M C m E mTm An e a S D R M H9 NH U3 9 6 M n "D. 3

frames.

FOREIGN PATENTS OR APPLICATIONS 1,051,243 9/1953 France................................ 139/7 A 19 Claims, 17 Drawing Figures PATENTEU JUNZG 973 PATENTEDJUIZS 975 3. 741. 254

PAIENTEDauuas ma 3.741. 1254 saw 0501 10 PATENIEU JUN 26 B73 sum USU 10 PATENT! Jul 26 8975 SEE! 07!! 10 PAIENIEMuazs 1915 3.741. 254 sum user 10 PAIENIEDJms 1915 SEE! 090! 10 METHOD AND APPARATUS FOR W'EAVING PILE FABRICS As is well known, the weaving operation of conventional Axminster looms has necessarily been inherently slow for many years due largely to the time required for advancing the conveyor means one step and then removing each successive tube frame from its conveyor means and imparting translatory motion thereto in ordr to project the pile yarn guide tubes thereof into the warps and then to return the tube frame to the conveyor means. Usually, therefore, three beats of the loom were required to form each weftwise row of pile tufts during each pile tuft forming cycle of the loom. More recently, in order to increase the speed of an Axminster loom, it has been proposed that the portion of the conveyor means above and adjacent the path of the reed be moved downwardly in a translatory manner, to project pile yarns extending from each successive row of pile yarn guide tubes into the warps, whereupon a double weft shot was beaten up and the thus pinched pile yarns were unreeled from the respective spool as the conveyor means was returned to its normal position. Here again, in order to present the pile yarns to the warps, it was necessary to advance the conveyor means one step and then to impart said translatory motion thereto during each pile tuft forming cycle of the loom, notwithstanding the necessity of providing special mechanism for carrying and imparting such translatory motion to the portion of the conveyor means adjacent the reed.

It is therefore an object of this invention to provide an improved method and apparatus facilitating high speed weaving of pile fabrics on a loom of the Axminster type in which each successive row of pile yarn guide tubes is positioned in and withdrawn from the warps by advancing the respective tube frame and the conveyor means about a fixed axis along respective arcuate paths of substantially uniform radii substantially throughout movement of the tubes from the time they start to enter between the warps until they have with drawn from the warps, without removing or otherwise displacing the successive tube frames relative to the conveyor means.

It is a more specific object of this invention to provide, in combination with a loom, rotary support means mounted on a substantially fixed rotational axis adjacent the path of the warps in the loom and guidingly engaging conveyor means having spaced spool carrying tube frames mounted thereon with tubes thereon through which pile yarns extend, and wherein the rotary support means is so located with respect to the warps that the tubes of each successive tube frame advanced by the conveyor means are guided in an arcuate path into operative position into the warps and in the path of the beating means of the loom during stepwise movement of the conveyor means so as to position corresponding pile yarns between the warps without removing the tube frames from the conveyor means.

In the preferred embodiment of the invention, each successive tube frame dwells in the operative position as weft strands are inserted in a shed of the warps respectively in front of and in back of the corresponding row of tubes, and during which the beating means also dwells adjacent and rearwardly of the row of tubes, whereupon the tubes move further along the aforementioned arcuate path and are thus withdrawn from the warps as the beating means beats the weft strands and the pile yarns therebetween up to the fell of the fabric.

Some of the objects and advantages of the invention having been stated, others will appear as the description proceeds, when taken in connection with the accomapnying drawings, in which:

FIG. 1 is a schematic warpwise view of an Axminster loom modified according to the invention and showing the relationship between the read or beating means and the tube frame conveyor means asthey occupy dwell positions for the insertion of weft in the warp shed;

FIG. 2 is a fragmentary perspective view of a portion of tufted pile fabric as woven on the loom of FIG. 1 and showing the free ends of a pair of weft needles as they may appear immediately following their withdrawal from a warp shed;

FIG. 3 is an enlarged fragmentary view similar to the central portion of FIG. 1, showing the reed operating mechanism with the reed occupying full back position, and being taken substantially along line 3-3 in FIG. 6A;

FIG. 4 is an enlarged fragmentary view similar to the upper central portion of FIG. 3, but showing the reed and a corresponding tube frame occupying their respective dwell positions;

FIG. 5 is a view similar to FIG. 4, but showing the reed occupying full beat-up position and showing the pile tuft yarn cutting means in operative position;

FIGS. 6 and 6A are collectively a front elevation of the loom with various parts broken away for purposes of clarity;

FIG. 7 is a fragmentary view of mechanism for imparting stepwise movement to the tube frame conveyor means, and is taken substantially along line 7-7 in FIG. 6;

FIG. 8 is a fragmentary elevation of the cloth take-up mechanism taken substantially along line 8-8 in FIG.

FIG. 9 is a somewhat schematic view of the operating mechanism for the weft catch cord shuttle adjacent the left-hand side of the fabric 20 in FIG. 6;

FIG. 10 is another view looking inwardly adjacent the left-hand side of the fabric 20 in FIG. 6, but showing means cooperating with the catch cord shuttle for shifting the corresponding end portion of the front weft forwardly in advance of the corresponding beat-up of the reed so that the lower ends of the corresponding row of pile yarn guide tubes will pass above and forwardly of the front weft upon subsequent stepwise movement being impartment to the tube frame conveyor means;

FIG. 11 is a fragmentary view of the warp shed forming mechanism taken substantially along line 11-11 is FIG. 6A;

FIG. 12 is a fragmentary view of mechanism aiding in shifting forwardly the end portion of the front weft adjacent the right-hand side of the fabric in FIG. 6A;

FIG. 13 is a fragmentary perspective view showing mechanism for operating a pile shield plate which serves to shield previously formed weftwise rows of pile tufts from the cutting means during the cutting of a succeeding weftwise row of pile tufts;

FIG. 14 is a fragmentary view of operating mechanism for a weft shifting means which cooperates with, and is disposed on the same side of the loom as, the mechanism shown in FIG. 12;

FIG. 15 is a fragmentary view of suitable operating mechanism for warp separator plates which cooperate with the reed and the noseboard for maintaining the warps separated for the insertion of the pile yarns therebetween; and

FIG. 16 is a fragmentary perspective view of mechanism for operating the pile yarn cutting means.

SYNOPSIS OF THE INVENTION Referring more specifically to the drawings, the im proved apparatus is embodied in a loom which may be of the conventional Axminster type in many respects, and which includes warp shed forming means in the form of a pair of

harnesses

10, 11, a reciprocatory beating means or reed l2, and a noseboard 13. Banks of chain or hinder warps 14, are drawn under tension from respective sources or beams 14a, 15a and pass forwardly through the heddles of the respective harnesses l0, 1 1, through openings 12a in the spaced dents or plates 12b of reed 12 (FIGS. 3-5), and through the usual slots defined between the hooks 13a noseboard 13 to the fell of the pile fabric 20, a portion of which is shown in detail in FIG. 2. The pile fabric passes forwardly over a breast beam 21, engages a take-up roll 22, and then is wound on a windup roll 23.

Rolls

22, 23 may be driven by a suitable take-up mechanism shown in the form of a ratchet mechanism generally designated at 22a in FIG. 8 and operated by a cam 22b fixed on the main shaft of the loom. Since the structure and operation of such take-up mechanisms are well known, a further description thereof is deemed unnecessary.

Pile tuft yarns 24 are positioned between certain of the

warps

14, 15 by means of a series of substantially equally spaced tube frames 25 mounted on a conveyor means 26 embodied in a pair of

endless sprocket chains

26a, 26b (FIGS. 6 and 6A) mounted on rotary support means or chain sprockets 27-31 (FIG. 1 Tube frames 25 are attached to links of

chains

26a, 26b so that they will not turn or oscillate relative to conveyor means 26 at any time during operation of the loom. Each tube frame 25 carries a spool 25a from which a respective plurality or row of the pile tuft yarns 24 pass through a weftwise row of pile yarn guide tubes 25b which are spaced apart so as to pass between reed dents 12b and the warps l4, 15 extending through the reed dents. With the important exception that the tube frame 25 remains fixedly secured to the

chains

26a, 26b during operation of the loom, the tube frames 25,

chains

26a, 26b and sprockets 27-31 may be conventional and, therefore, a more detailed description thereof is deemed unnecessary.

It is to be noted however that the lower sprockets 27 are fixed on a pull-over shaft 27a journaled in fixed

side frame members

32, 33 of the loom frame F (FIGS. 6 and 6A). Thus, each successive tube frame 25 moves in an arcuate path of substantially uniform radius about the fixed axis of shaft 27a as the corresponding tube frame is moved into and out of operative position with respect to the warps and the reed. In this regard, it is important to note that shaft 27a is positioned in such close proximity to the path of the warps between

harnesses

10, 11 and noseboard 13 that the pile yarns projecting from each successive row of pile yarn guide tubes 25b move into the plane of the warps and between the same (FIG. 3), with the tubes 25b per se being positioned between at least the then upper bank of warps when the warps occupy fully open shed positions and when the tubes 25b occupy a dwell position at substantially the lowest point in their arcuate path of travel (FIG. 4), this being the operative position of each successive row of tubes 25b. Following the substantially simultaneous insertion of respective front and rear or first and second wefts W-l, W-2 forwardly and rearwardly of tubes 25b, which wefts preferably are double wefts as shown in FIG. 2, reed 12 heats up the wefts, with the pile yarns 24 pinched therebetween, over noseboard 13 as the rear surfaces of noseboard hooks 13a bend the pile yarns upwardly partially around the corresponding rear weft W-2 to form a weftwise row of tufts 24a from the pile yarns 24 (FIG. 5). At the same time, the then lowermost row of tubes 25b moves forwardly substantially in unison with, but ahead of, reed 12 so that the pile yarns will not be excessively withdrawn from between wefts W-l, W-2, and the next succeeding row of tubes 25b starts its arcuate movement toward operative position.

As the wefts and pile yarns are beaten up over the hooks 13a of noseboard 13 (FIG. 5), the pile yarns 24 are clamped tightly between the then rear weft W-2 and the front surfaces of the hooks 13a. Thus, as the corresponding row of pile yarn guide tubes 25b moves forwardly a predetermined distance from the fell of the fabric, additional pile yarns are withdrawn from the corrsponding spool 25a through the tubes 25b and a cutting means 75, to be later described, quickly severs or cuts the pile tuft yarns along a weftwise plane between the pile yarn guide tubes 25b and noseboard 13, and during which reed 12 starts to move rearwardly so as to occupy full back position as shown in FIG. 3 by the timethe pile yarns projecting from the next succeeding row of pile yarn guide tubes 25b start to move into the plane of the

warps

14, 15 and toward operative position.

DRIVE FOR TUBE FRAME CONVEYOR MEANS The mechanism for imparting stepwise movement to conveyor means 26 will now be described. Referring to FIGS. 6 and 7, it will be observed that pull-over shaft 27a has a ratchet mechanism mounted thereon comprising a ratchet wheel 27b whose teeth are in the form of a plurality of circularly spaced rods 27c engaged by a ratchet pawl 27d. Ratchet pawl 27d is pivotally mounted on a substantially U-shaped pawl carrier 27e pivotally mounted on pull-over shaft 27a. A link 27f connects pawl carrier 27e to a follower arm 27g pivotally mounted intermediate its ends on a pivot shaft 27h and having a follower 27] on its lower portion which engages a face cam 27k. Face cam 27k is fixed on a main drive or cam shaft 35 suitably driven to rotate continuously during operation of the loom. In this instance, main shaft 35 rotates one revolution for every two picks or every two tuft forming cycles of the loom and, therefore, cam 27k is of symmetrical form as are others of the cams to be later described which are mounted on main shaft 35. v

In order that the successive tube frames 25 can dwell in an operative position between the planes of a pair of weft inserters, which preferably are in the form of a pair of weft inserting needles 36, 37 (FIGS. 2 and 4), and also to ensure that the arcuate path of the tube frames is such that tubes 25b pass closely above noseboard 13 (FIG. 5), the diameter of sprockets 27 is such that each successive row of tubes 25b must move downwardly a substantial distance rearwardly of the

weft inserting needles

36, 37 and rearwardly of the usual back position of the reed of a conventional Axminster loom.

Therefore, since reed 12 spaces groups of

warps

14, 15 for passage of tubes 25b therebetween, the throw of reed 12 is substantially greater than usual so that it is spaced a substantial distance rearwardly of weft needles 36, 37 when it occupies back position. Conveniently, the back position of reed 12 is such that the free ends of tubes 25b of each successive tube frame 25 will pass between the upper portions of reed dents 12b during an active stroke of pawl 27d (FIG. 7).

Also, since the warp shed must be open during weft insertion, reed 12 is controlled by operating mechanism (FIG. 3) to move forwardly in back of and substantially in unison with each successive row of pile yarn guide tubes 25b to further ensure that the warps are spaced apart to accommodate the tubes and pile yarns 24 therebetween. Thus, reed l2 dwells in an intermediate or dwell position in the course of each beatup stroke thereof (FIG. 4) rearwardly of and adjacent rear weft needle 37 and rearwardly of the row of tubes 25b then dwelling in operative position. Then, immediately following weft insertion, a succeeding stepwise movement is imparted to conveyor means 26 and, as the then active row of pile yarn guide tubes 25b moves forwardly, reed l2 resumes its forward movement and again moves forwardly in back of and substantially in unison with the corresponding row of pile yarn guide tubes 25b and to full beat-up position with its reed dents 12b positioned in the slots between the hooks 13a of noseboard 13 (FIG. 5).

However, since a succeeding row of pile yarn guide tubes 25b is moving toward operative-position at the same time that a preceding row of pile yarn guide tubes 25b is being advanced forwardly of the plane of the

weft inserting needles

36, 37, a full rearward stroke must be imparted to reed 12 within a very short space of time immediately following a full beat-up stroke thereof and about at the same time that the pile yarns are being cut between noseboard l3 and the lower ends of the preceding row of pile yarn guide tubes 25b, so as to ensure that the reed 12 again occupies full back position at about the time'that the pile yarns 24 extending from the succeeding row of pile yarn guide tubes 25b approach the plane of the path of travel of reed l2.

REED OPERATING MEANS In order to control reed 12 in the manner described above, reed 12 is carried by rocker arms 40 fixed on a rocker shaft 41 journaled in the

side frame members

32, 33 of the loom and which has a crank 42 depending therefrom (FIGS. 3 and 6A). The reed operating mechanism includes a link 43 connecting the lower portion of crank 42 to the upper portion of a follower arm or lever 44 pivotally mounted at its lower portion, as at 45, on a fixed part of the loom or asupporting surface therebeneath. A follower 44a on follower arm 44 engages an irregular groove in one face of a face cam 46 fixed on main shaft 35. Since main shaft 35 rotates one revolution every two beat-up strokes of reed 12,'cam 46 is symmetrical and each'half of the cam 46 includes low, intermediate and

high cam surfaces

46a, 46b, 460 which successively move into engagement with follower 44a.

During rotation of cam 46, when either low cam surface 46a is engaging follower 44a, reed l2 dwells forabout 10 of a reed cycle (5 of angular movement of cam 46) in the back position of FIG. 3. Reed 12 then moves forwardly during about 50 of its cycle to its intermediate position of FIG. 4 as the succeeding cam surface 46b moves into engagement withfollower 44a. Reed 12 then dwells for about 176 of its cycle while cam surface 46b is moving in engagement with follower 44a, and during which the conventional weft needle drive mechanism 50 of FIG. 6A imparts a reciprocatory movement to

weft needle

36, 37 to insert wefts W-l, W-2, in the form of respective double wefts, in the then open warp shed. Thereupon, reed 12 moves forwardly during about 58 of its cycle to its full beat-up position of FIG. 5 as the next succeeding cam surface 460 moves into engagement with follower 44a. Immediately there-. after, a full rearward stroke is imparted to reed 12 for about 66 of a reed cycle, to complete a cycle in the operation of the reed as the next succeeding low cam surface 46a of cam 46 moves into engagement with follower 440.

It should be noted that a full rearward stroke is imparted to reed 12 during only about 18 percent of each cycle of the reed, which is about the same as or only slightly greater than the relative amount of time in which reed 12 moves from its intermediate or operative position of FIG. 4 to the full beat-up position of FIG. 5, itbeing noted that the latter movement of reed 12 is effected during about 16 percent of the time of each cycle in the operation of the reed.

WARP SEPARATOR PLATES Warp separator plates 47 (FIGQB), controlled by a rotary cam 47a (FIG. 15 are in substantial alignment with the dents 12b of reed 12 to define guide-aisles for the successive pile yarns 24. Cam 47a is 'so positioned on the main shaft 35, and so shaped, as to cause separaof FIG. 5. Since the warp separator plates 47 may be conventional and theiroperation is similar to that of conventional warp separator plates, a further description thereof is deemed unnecessary.

HARNESS OPERATING MEANS Due to space limitations, the arc of travel of reed 12 about the axis of rocker shaft 41 is of relatively short radius so that the upper portion of reed l2 occupies a relatively low position with respect to

harnesses

10, 11 when reed 12 is in'the back position of FIG. 3. Normally, the open shed position of

harnesses

10, 11 is reversed at about the time at which full beat-up of reed 12 occurs, with such change in the position of the

harnesses

10, 11 being completed at about the time that the reed subsequently reaches full back position. However, since the reed then occupies such relatively low position with respect to the

harnesses

10, 11, as stated above, the upper walls of the openings 12a through the dents 12b of reed 12 would place the top sheet of warps in the shed under undesirably excessive tension. This cannot be remedied by the use of a reed having openings therethrough which are not closed at their upper ends, since the reed then would pass below the upper sheet of warps forming a warp shed when the reed 12 occupied back position. Therefore, in order to avoid placing the top sheet of warps in the warp shed under excessive tension, without interfering with the normal operation of the

harnesses

10, 11 in the formation of open sheds at the proper times during operation of the loom, the operating mechanism for harnesses 10, 11 (FIG. 11) is specially designed to momentarily return each

respective harness

10, 11 upon being fully raised,

to an intermediate or middle shed position as reed 12- approaches back position (FIG. 3), while reed l2 dwells in said back position, and as it starts a forward stroke. Although the lower harness, in each instance, also moves upwardly to a middle shed position each time the then upper harness is lowered to middle shed position, such movement of the lower harness is simply incidental, and is not necessary.

In order to operate

harnesses

10, 11 in the aforementioned manner, they are mounted on respective frames a, 11a (FIG. 11) which extend through suitable stationary guide means 52 and are connected, by respective links 10b, 11b to substantially diametrically opposed arms of a bracket 53 suitably secured on a harness rocker shaft 54 journaled in the

side frame members

32, 33 of the loom.

A link 55 connects a crank 56 fixed on rocker shaft 54 to the lower end portion of a follower lever 57 whose upper end portion is pivotally connected, as at 60, to a fixed part of the loom frame F. A follower 61, on a medial portion of follower lever 57, engages a groove in a harness face cam 62 fixed on main shaft 35. Since a complete shed change must be effected during each pick of the loom and cam 62 rotates one revolution for every two picks of the loom, harness cam 52 is asymmetrical and is provided with a circular series of variant height surfaces a-f. Both of the surfaces a, e are located about the same distance from the axis of shaft 35, but are low surfaces as compared to surfaces b, d which are located the same distance from the axisof shaft 35 relative to each other, but are relatively high surfaces as compared to the low surfaces a, e.

The surfaces a, d of cam 62 are positioned substantially diametrically opposite from each other and each extends through an arc of about 90 so as to cause

harnesses

10, 11 to dwell in fully open shed positions throughout about 180 of each reed cycle; i.e., from the time that reed 12 reaches about to its operative position of FIG. 4 in the course of a forward movement thereof until its dwell and a weft insertion have been completed. Of course, while surface a of cam 62 is engaging follower 61, harness 10 is up and harness 11 is down. Conversely, while surface d of cam 62 is engaging follower 61, harness 10 is down and harness 11' is It will be noted that the surfaces 0, f are disposed in substantially diametrically opposed relation with respect to each other and, while these surfaces are located about the same distance from the axis of shaft 35, surface f projects outwardly to an intermediate height relative to the two adjacent surfaces a, e straddling the same, while surface c is recessed to said intermediate height with respect to the adjacent surfaces 1:, d straddling the same. Thus, as the harness cam 62 rotates in a counterclockwise direction in FIG. 11 from the position shown, and as high surface b moves into engagement with follower 61, which is about the time that the reed 12 reaches a full beat-up position, harnesses 10, 11 quickly reverse their positions while forming an open shed which crosses the upper and lower banks of

warps

14, 15 relative to the last double weft W-2 just positioned over the noseboard hooks 13a and on the supporting surface 13b to firmly bind the corresponding lengths of pile yarn between the two double wefts W-l, W-2 last beat-up by reed 12.

Since reed 12 starts to move rearwardly immediately following each beat-up thereof, the surface b is very nearly pointed so that the next succeeding intermediate cam surface c quickly moves into engagement with follower 61 to return the then upper harness 11 to the middle shed position as shown in FIG. 3 by the time that the reed 12 reaches back position (FIG. 3). However, just prior to the reed subsequently reaching operative position (FIG. 4), the high, dwell, surface d of harness cam 62 moves into engagement with follower 61, thereby returning harness 11 to the fully raised position as harness 10 is returned to the fully lowered position. As heretofore indicated, the arc of surface d is of such length as to maintain the warp shed fully open throughout the dwell period of the reed 12 in the operative position. Thereafter, cam surfaces e, f, a function in substantially the same manner as the respective surfaces b, c, d heretofore described with the exception that engagement of surface e with follower 61 quickly reverses the open shed positions of

harnesses

10, 11 so that harness 10 will occupy up position and harness 11 will occupy down position as shown in FIG. 11. By the time that reed 12 again reaches back position, intermediate surface f will have engaged follower 61 and will have thereby caused the thenupper harness 10 to move to the middle shed position as the lower harness 11 is moved upwardly to the middle shed position. Thereafter, movement of surface a into engagement with follower 61 again returns the harness 10 to the fully raised position and the harness 11 to the fully lowered position to complete a cycle in the operation of the

harnesses

10,11.

TI-IE FABRIC In order that the further structure and operation of the loom may be clearly understood, the portion of the fabric 20 produced on the loom and shown in FIG. 2 will now be described, wherein it will be observed that the double wefts W-l, W-2 form successive groups of wefts with each group of wefts including a plurality of successive pairs of weft strands; i.e., each front double weft W-l forms a first pair of weft strands and each rear double weft W-2 forms a second pair of weft strands. The portion of fabric shown in FIG. 2 includes four successive groups of wefts indicated at G, G-l, G-2 and 0-3. The respective banks of chain or binder warps 14, 15 extend in opposition to each other over and under the successive groups G, (3-1, G-2, G-3 with the

warps

14, 15 thereby extending between the wefts only at the juncture of adjacent weft groups. Thus, the bank of warps 14 is disposed under alternate weft groups G, G-2 and above intervening weft groups G-l, G-3, with the other bank of warpslS being disposed above said alternate weft groups and under said intervening weft groups. From the foregoing description, it is apparent that the pile face of the fabric 20 includes a single weftwise row of pile tufts 24a formed from the corresponding pile yarns 24 for each group of wefts, and the tufts of each weftwise row have their lower bights looped beneath only one of the pairs of weft strands in each group; i.e., the lower bights of the weftwise rows of pile tufts 24a are looped beneath only the second or rear double weft W-2 in each group G, G-I, G-2, G-3.

Any desired number of chain warps may be provided between adjacent pairs of warpwise rows of tufts 24a. As shown in FIG. 2, by way of example, a group of four chain warps; i.e., two chain warps 14 from one bank and two chain warps 15 from the other bank is provided between each adjacent pair of warpwise rows of tufts 24a.

The left-hand selvage of the fabric in FIG. 2 is in the form of a plurality of hairpin-like selvage loops a, 20b alternately arranged warpwise of the fabric and formed integral with and interconnecting the two strands of the respective first and second or front and rear double wefts W-l, W-2, and a common catch cord or selvage yarn 200 is threaded through and interconnects all of the

selvage loops

20a, 20b at the corresponding warpwise side edge of the fabric.

Since the

weft inserting needles

36, 37 move into the common warp shed substantially simultaneously with each other during each pick of the loom, the right-hand selvage of the fabric shown in FIG. 2 is of novel form, and includes loops of the weft strands, comprising a plurality of first weft selvage loops 20d which alternate with respect to a plurality of second weft selvage loops 20s, with each first selvage loop 20d extending pass the weftwise plane of a respective double weft W-2 and each second selvage loop 20:: extending pass the weftwise plane of a respective'double weft W-l. Since the weft strands are continuous, the legs of each first selvage loop 20d are integral with one of the strands in each of two of the first double wefts W-l, and the legs of each second selvage loop are integral with one of the strands in each of two of the second double wefts W-2. The second loops 20e are larger than the first loops 20d to accommodate a right-hand front weft shifting means (FIG. 14) to be later described. In this regard, one of the strands of each of the double wefts W-l, W-2 in the last group G-3 in FIG. 2 is shown extending from the right-hand selvage to each

respective weft needle

36, 37 so that the operation of the right-hand front weft shifting means may be clearly understood. Thus, it is to be understood that, during weaving, when weft needles 36, 37 are aligned with double wefts W-l, W'-2 of the last group G-3 as shown in FIG. 2, the latter double wefts will not have been beaten up to the fell, and the last row of tufts 24a will not have been looped beneath the last double weft W-2, since the last two double wefts are beaten up to the fell at a position forwardly of the weftwise plane of weft needles 36, 37 and the looping of the tufts beneath the rear double weft W-2 is effected by the noseboard as the rear double weft W-2 passes over noseboard hooks 13a. Also, the rear portions of the pile tufts are not cut'until the rear double weft W-Z and the tufts drop forwardly of hooks 13a.

The fabric of FIG. 2 is disclosed and claimed in my copending application, Ser. No. 195,293, filed concurrently herewith now U.S. Pat. No. 3,716,078", and entitled WOVEN PILE FABRICS to which reference is made for a more detailed disclosure of the fabric 20.

FRONT WEFT SHIFTING MEANS Referring again to the structure of the loom, during each weft insertion, weft needles 36, 37 are operated in a conventional manner to draw respective weft strands from respective supply sources, not shown, to

form the double wefts W-l, W-2. The catch cord 200 (FIG. 2) is inserted in the hairpin-

like loops

20a, 20b during operation of the loom by a conventional reciprocating shuttle 65 (FIG. 9) which may be of a type such as is disclosed in U. S. Pat. No. 631,233, dated Aug. 15, 1899, for example. Therefore, a detailed description of the construction and operation of shuttle, 65 is deemed unnecessary, it being deemed sufficient to state that shuttle 65 is mounted on the upper end of a post 65a journaled in the loom frame and having a crank 65b fixed thereon which is reciprocated by suitable linkage 656 provided with a follower 65d which engages a rotary cam 65e fixed on main shaft 35.

As heretofore stated, each front double weft W-l inserted in the warp shed by the front weft inserting needle 36 is moved forwardly relative to the rear double weft W-2 so that the lower ends of each successive row of pile yarn guide tubes 25b will move above the front double weft ahead of the reed 12 during subsequent advancement of tube frame conveyor means 26 and reed 12. Therefore, opposite sides of the loom are provided with respective left-hand and right-hand weft shifting fingers 70, 71 (FIGS. 10 and 14) and cooperating lefthand and right-hand weft separating fingers 72, 73 (FIGS. 10 and 12). Left-hand weft shifting fingers is substantially horizonally disposed and guided for forward and rearward longitudinal movement in a guide member 70a suitably secured to a fixed part of the loom rearwardly of the race 65f (FIG. 9) for shuttle 65. One arm of a bell crank 70b (FIG. 10) is pivotally connected to a rear portion of left-hand weft shifting finger 70, as at 70c, and bell crank 70b is pivotally connected to the loom frame, as at 70d. The forwardly extending arm of hell crank 70b is connected, by means i of a link 70e, to a follower arrn 70f pivotally connected, as at 70g, to the loom frame. A follower 70h on follower arm 70f is urged into engagement with a cam 70i by means of a suitable spring 70j. Cam 70i is fixed on main shaft 35. l

The upper portion of left-hand weft separating finger 72 is positioned in a vertical plane about half-way between the paths of travel of the weft inserting needles 36, 37 (FIG. 4) and loosely penetrates a suitable guide member 72a (FIG. 10) carried by the loom frame. The lower end of left-hand weft separating finger 72 is pivotally connected, as at 72b, to a follower arm 72c which also is pivotally connected at 70g to the loom frame. Follower arm 72c has a follower 72d thereon which is urged into engagement with the peripheral surface of a cam 72e by a suitable spring 72f. Cam 72e is fixed on main shaft 35. i

The

cams

65e, 70i, 72e (FIGS. 9 and 10) are so positioned with respect to each other and are so shaped that the left-hand weft separator finger 72 moves upwardly from the lowered position shown in FIG. 10 and enters between the weft needles 36, 37 (FIG. 4) at about the same that shuttle 65 (FIG. 9) moves rearwardly through the loops of the double wefts W-l, W-2 (FIG. 2) so that the front weft W-l and needle 36 will not be pulled-rearwardly against the back weft needle 37 as the shuttle passes through the front loop 20a of the front weft W-l (FIG. 2). Also, as shuttle 65approaches the end of its rearward stroke through the,

weft loops

20a, 20b, weft needles 36, 37 start to withdraw from shuttle 65 and the left-hand weft shifting finger 70 moves forwardly through the loop20b (FIG. 2) of the rear weft W-2then being penetrated by shuttle 65. Spaced a relatively short distance rearwardly from the pointed free front end of shifting finger 70 is an upwardly projecting shoulder 70k thereon which engages the then upper strand of the front double weft (-1 as the pointed free end of finger 70 enters the front weft loop 20a. Thus, shoulder 70k pushes the front weft W-l forwardly a predetermined distance to a position forwardly of the arcuate plane of travel of the lower ends of the corresponding pile yarn guide tubes 25b upon their next succeeding stepwise motion, but spaced rearwardly of noseboard 13. i

It should be noted that the shoulder 70k (FIG. on left-hand weft shifting finger 70 passes through the back weft loop 20b without pushing the latter loop forwardly because the latter loop is being held open by shuttle 65 passing therethrough as shoulder 70k passes through the rear weft loop 20b. Also, the rear weft W-2 is being restrained from any substantial forward movement by the row of pile yarn guide tubes 25b then occupying operative position (FIG. 4).

After the shuttle 65 has passed through the front loop 20a, left-hand weft separator finger 72 returns to the lowered, inoperative, position shown in FIG. 10, but the left-hand weft shifting finger 70 remains in engagement with the

corresponding weft loops

20a, 20b at least until weft needles 36, 37 have fully withdrawn from the warp shed. Thereafter, the left-hand weft shifting finger 70 moves rearwardly and withdraws from the

corresponding weft loops

20a, 20b.

Referring now-to FIG. 12, it will be observed that the right-hand weft separator finger 73 is carried by and projects upwardly from a lever 73a pivotally connected, as at 73b, to the loom frame. A medial portion of lever 73a has a link 73a connecting the same to a front portion of a follower lever 7 3c whose medial portion is pivotally connected, as at 73d, to a fixed part of the loom frame. A spring 732 urges a follower 73f on follower lever 73c into engagement with a rotary cam 73g fixed on main shaft 35. During full beat-up movement of reed 12 and take-up of the fabric 20, righthand weft separator finger 73 occupies the lowered inoperative position shown in dotted lines in FIG. 12. However, as the weft needles 36, 37 enter the righthand side of the warp shed, spring 73c and cam 73g cause separator finger 73 to move upwardly between the planes of weft needles 36, 37 to the solid-line position shown in FIG. 12 and closely adjacent the righthand selvage of the fabric being woven so as to be positioned between the strands of weft yarn then extending from the weft needles 36, 37 into the warp shed. Thus, as needles 36, 37 enter the warp shed, the weft strand extending through front needle 36 forms a small selvage loop 20d (FIG. 2) against the adjacent selvage warp 15 as the weft strand extending through weft needle 37 is looped partially around separator finger 73 (FIG. 12) to form a corresponding open, larger selvage loop c. Separator finger 73 penetrates the latter selvage loop and thereby maintains the strands of weft yarn separated when needles 36, 37 subsequently withdraw from the warp shed as in FIG. 2 and during operation of the right-hand weft shifting finger 71 (FIG. 14).

In this regard, right-hand weft shifting finger 71 is substantially vertically disposed and is normally positioned below and adjacent the right-hand selvage of the fabric 20 being woven. The lower portion of right-hand weft shifting finger 71 is pivotally connected, as at 710 (FIG. 14), to a follower arm 7112 having a follower 71c thereon. Follower arm 71b is pivotally connected, as at 71d, to the loom frame and is normally urged upwardly at its rear portion by a suitable spring 7 1e, thus normally urging follower 71c into engagement with a rotary cam 71f. Cam 71 f is fixed on an auxiliary cam shaft 71g which, in this instance, is also driven to rotate one revolution for every two picks of the loom by a suitable sprocket and chain transmission 27h (FIGS. 6 and 7) drivingly connecting main shaft 35 to auxiliary cam shaft 71g.

Cam 71f (FIG. 14) is so positioned and so shaped with respect to cam 73g (FIG. 12) that, during withdrawal of weft needles 36, 37 to about the position of FIG. 2, right-hand weft shifting finger 71 moves upwardly from the lowered, inoperative position of FIG. 14 and enters the latter selvage loop 20e then on finger 73 rearwardly of the front strand: of weft yarn then extending from the front weft inserting needle 36 as shown in FIG. 2. Thereupon, a forward movement is imparted to the upper portion of the right-hand weft shifting finger 71 (FIG. 14) to push the corresponding portion of the last inserted front double weft W-l forwardly a predetermined distance clear of the subsequent path of travel of the lower ends of the tubes 25b (FIG. 4) of the corresponding tube frame 25. Thereupon, finger 71 returns rearwardly and then downwardly to its original position shown in FIG. 14, and finger 73 returns to the dotted-line position of FIG. 12.

In order to impart the forward and rearward movement to right-hand weft shifting finger 71, the upper portion of finger 71 is connected to a follower lever 71 by means of a link 7lj (FIG. 14). A medial portion of lever 71i is pivotally connected, as at 71k, to a fixed part of the loom frame. A follower 71m on the lower end of follower lever 71: is normally urged into engagement with the peripheral surface of a cam 71:: by means of a spring 71p. Cam 71!: is fixed on auxilary cam shaft 71g. If desired, additional weft separators and weft shifting fingers similar to the right-hand weft separator 73 (FIG. 12) and the right-hand weft shifting finger 71 (FIG. 14) may be spaced along the width of the loorn to further aid in advancing the front double weft W-l forwardly following the insertion thereof and preceding the subsequent stepwise movement of tube frame conveyor 26.

PILE YARN CUTTING MEANS As heretofore stated, the pile yarns 24 are cut as each respective row of pile yarn guide tubes passes over and forwardly of the hooks 13a of noseboard 13 (FIG. 5) to complete the and of each respective weftwise row of pile tufts 24a (FIGS. 2, 4 and 5). Although ratchet pawl 27d (FIG. 7) moves through a complete active strokewithout interruption following each weft insertion, it is to be understood that cam 27k may be so shaped as to permit pawl 27d to dwell momentarily during the course of each active stroke thereof, if desired, so that each successive tube frame 25 may dwell in substantially the position shown-in FIG. 5 to further facilitate the cutting of the pile yarns.

In either event, the successive sets of pile yarns 24 may be cut by a cutting means broadly designated at 75 and which may be of the general type disclosed and indicated at 37 in U. S. Pat. No. 3,521,676, granted to John T. Maclsaac et al., July 28, 1970, to which reference is made for a more detailed disclosure of a cutting means. As shown in FIG. 16, cutting means 75 comprises relatively

movable members

75a, 75b which move forwardly and rearwardly unitarily during each tuft forming cycle. While

members

75a, 75b occupy the rearward or active position shown in FIG. 5, movable member 7512 moves weftwise relative to fixed member 75a to cut the pile yarns 24 then extending between a corresponding row of pile yarn guide tubes 25b and the hooks 13a of noseboard 13. The fixed member 75a of cutting means 75 may be in the form of an elongate plate whose rear edge is serrated so as to receive the corresponding pile yarns 24 between the teeth thereof as the

members

75 a, 75b move rearwardly to active position. Movable member 75b is then moved weftwise relative to fixed member 75a to move the cutting blades of the movable member 75b relative to the fixed member 750 for severing all of the pile yarns in the corresponding row. Fixed member 75a is suitably secured to an elongate carriage bar 750 having a plurality of upwardly extending posts 75d thereon mounted for forward and rearward sliding movement on substantially horizontaly extending guide rods 75e carried by the loom frame. Movable member 75b is guided for weftwise sliding movement between the rear portion of carriage bar 75c and fixed member 75a, and means 75b connects the left-hand portion of movable member 75b to the plunger of a solenoid 75f whose coil is suitably secured upon an enlarged outer portion of carriage bar 75c (FIG. 16).

The front ends of a plurality of links 75g are pivotally connected to the rear portion of carriage bar 750. The rear ends of links 75g are each pivotally connected to a corresponding crank 75h whose lower ends are fixed on a rocker shaft 75i suitably journaled in the loom frame. The cranks 75h, and thus the carriage bar 750, are urged forwardly by suitable springs 75j.

A crank 75k, fixed on rocker shaft 75i, has the upper end of a link 75m connected thereto, whose lower end is pivotally connected to a follower arm 75n. The rear end of follower arm 7511 is pivotally connected, as at- 75p, to a fixed part of the loom frame. Follower arm 75n has a follower 75g thereon which engages a rotary cam 75r fixed on main cam shaft 35. The coil of solenoid 75f is interposed in an electrical circuit in series with a normally open switch 75s positioned so as to be engaged and closed by projections 75t on a rotary cam 75a fixed on main shaft 35.

The cams 75r, 7514 are so positioned and so shaped that carriage bar 75c and, thus, the cutting

members

75a, 75b move forwardly during each stepwise movement of tube frame conveyor 26 and thus move into engagement with the pile yarns 24 substantially as the corresponding row of pile yarn guide tubes 25b reaches the position shown in FIG. in the course of a forward movementthereof. At about the time that the corresponding pile yarns 24 are received against the serrated rear edge of fixed member.75a, one of the projections 75: (FIG. 16) on cam 75a moves into engagement with and momentarily closes switch 75s so as to impart an active stroke to movable member 75b thereby cutting the corresponding pile yarns. Thereupon, the corresponding projection 75! on cam 75u moves out of engagement with switch 75s and a spring 75w (FIG; 16) then returns movable member 75b to its original or inactive position. Also, cam 75r then permits springs 75 j to move carriage bar 750 forwardly to return the cutting means 75 to its original or inactive position shown in FIG. 4. It should be noted that, before the movable member b is actuated in the manner heretofore described, the corresponding tube frame 25 will have moved forwardly sufficiently to withdraw a predetermined length of pile yarns 24 from the corresponding spool 25a.

TUFT SHIELDING MEANS In order to avoide accidental mutilation of previously formed tufts by the cutting means 75 and to also prevent the previously formed tufts from interfering with the operation of cutting means 75, movable shielding means is provided for overlying and shielding preceding rows of tufts formed in the fabric from the cutting means 75 during operation thereof.

Such shielding means comprises a movable shield plate which is best shown in FIGS. 3, 4, 5 and 13. Shield plate 80 is positioned beneath cutting means 75 and overlies noseboard l3 and breast beam 21. The free rearmost portion of shield plate 80 is provided with a downwardly projecting hook-like shoulder or rib 80a thereon which functions somewhat in the manner of a rake to the extent that shield plate moves rearwardly and upwardly from the position of FIG. 5 at an angle relative to the fabric supporting surface 13b of noseboard 13 and passes over the hooks 13a. When rib 800 has moved over and past the last-formed row of tufts 24a, as in FIG. 4, shield plate 8 0 then moves downwardly and forwardly and comes to rest with its rib 80a spaced forwardly of hooks 13a and positioned closely adjacent and above the fabric supporting surface 13b. There then is sufficient space between the front surfaces of hooks 13a and the rear edge of shield plate 80 for receiving the next pair of double wefts W-l, W-2 (FIG. 2) and the corresponding row of tufts 24a therebetween with the subsequent full beat-up of reed 12 while the rib 80a presses the last-formed row of tufts and some of the other previously formed rows of tufts downwardly toward the base of the fabric 20 without clamping the same so firmly as to interfere with normal take-up of the fabric. The cutting means 75 then moves into operative position and closely above the rear edge of shield plate 80 to cut the pile yarns in the manner heretofore described.

In. order to impart the raking motion to shield plate 80 in the manner heretofore described, the front portion of shield plate 80 is suitably secured to an upper rocker shaft 80c (FIGS. 6, 6A and 13) rotatably mounted in a pair of spaced crank arms 80d which extend downwardly and are fixedly secured to a lower rocker shaft 80e journaled in a pair of bearing blocks 80f suitably secured to the loom frame. The right-hand end of lower rocker shaft 80e in FIGS. 6A and 13 has a downwardly extending crank 80g fixed thereon whose lower portion has an adjustable abutment or set screw 80h therethrough adapted to engage a fixed frame member 81 serving as a first limiting member and projecting outwardly from the main frame F of the loom. An L-shaped second limiting member 80: is carried by fixed frame member 81 and, at times, the front portion of second limiting member 80: is engaged by crank arm 80g to limit the extent of forward movement thereof. At other times, set screw 80h engages frame member 81 to limit rearward movement of crank arm 80g, as will be later described.

The left-hand end of the upper shaft 80c (FIGS. 6 and 13) has a follower arm 80j fixed thereon and extending downwardly therefrom. The lower portion of follower arm 80j has a follower 80k thereon which engages the periphery of a rotary cam 82 fixed on auxilary cam shaft 71g. Follower 80k is urged against cam 82 by means of a suitable spring 80m. Since cam 82 rotates one revolution during every two picks of loom, it is of symmetricl form and is provided with a series of cam surfaces 82a-82d. The surfaces 82a, 82c are diametrically opposed with respect to each other and the relatively lower surfaces 82b, 82d are diametrically opposed with respect to each other.

In operation of the shield plate 80, with the parts occupying the position shown in FIG. 13, shield plate 80 occupies the operative position shown in FIG. 5. The

succeeding relatively low cam surface 82b of cam 82 moves into engagement with follower 80k at about the time that the weft needles 36, 37 start to withdraw with respect to the warp shed. Thus, spring 80m pulls the upper shaft 80c in FIG. 13 rearwardly while also causing shaft 80c to rotate clockwise to some extent until further rearward movement of plate 80, shaft 800 and crank arms 80d is limited by engagement of crank arm 80g with abutment 80i, preventing further counterclockwise rotation of lower rocker shaft 80e. The depth and curvature of the lower cam surface 82b is such relative to the high surface 82a of cam 82 that spring 80m then imparts further clockwise movement to upper shaft 80c to ensure that shield plate 80 ultimately moves to the rearward raised position shown in FIG. 4. Thus, the rib 80a of shield plate 80 is then positioned forwardly of the free ends of the tufts in the last-formed weftwise row thereof.

As the weft needles 36, 37 complete their withdrawal from the warp shed, the succeeding high surface 820 of cam 82 (FIG. 13) is approaching follower 80k, thus surface 82b moves follower arm 80j outwardly in opposition to spring 80m. In so doing, shaft 800 is rotated counterclockwise in FIG. 13 until further forward movement of plate 80, shaft 80c and crank arms 80d is limited by engagement of set screw 80h with frame member 81, preventing further clockwise rotation of lower rocker shaft 80e. Thereupon, cam surface 82b imparts further counterclockwise movement to upper shaft 80c until the succeeding high surface 82c moves into engagement with follower 80k, thus causing the lower surface of shield plate 80 and its rib 80a to bend the last-formed few rows of pile tufts downwardly and forwardly while pressing them toward the supporting surface 131: of noseboard 13 before the next rearward movement of cutting means 75 is effected. Thus, plate 80 shields the previously formed weftwise rows of tufts from the operation of the cutting means 75 in severing the pile yarns 24 in the formation of succeeding weftwise row of pile tufts 24a. 7

From the foregoing, it can be seen that the tube frames 25, shed forming harnesses 10, ll, reed 12, cutting means 75 and associated mechanisms cooperate in a novel manner so that the tubes 25b of each successive tub'e frame 25 are moved successively into and out of operative position in an arcuate path of substantially pile yarns between one row of tubes 25b and the fell of the fabric being woven while a succeeding row of tubes 25b is being advanced toward operative position. It can be seen further that two double wefts W-l, W-2 are inserted in each successive warp shed forwardly and rearwardly of each respective weftwise row of pile yarns so that the pile yarns are pinched between the two double wefts as theyare looped beneath theback double weft W-2 by. the noseboard 13 during beat-up, with the front double weft being shifted forwardly out of the path of the corresponding row of tubes 25b as they move forwardly in the aforementioned arcuate path and withdraw from between the

warps

14, 15. It is also seen that the cutting means moves into operative positon and cuts the corresponding row of pile yarns 24 to complete formation of a weftwise row of tufts 24a as previously formed rows of tufts are shielded from the cutting means by shield plate 80.

In the drawings and specification, there has been set forth a preferred embodiment of the invention and, although specific terms are employed, they are used in a generic and desciptive sense only and not for purposes of limitation.

That which is claimed is:

1. A method of weaving pile fabrics from warps, wefts and pile yarns in a loom, said method comprising the successive steps of inserting pile yarns between the warps, then inserting first and second wefts in a common shed of the warps forwardly and rearwardly, respectively, of the thus inserted pile yanrs, and beating up both wefts with the pile yarns against the fell while looping the pile yarns partially around one of the wefts.

2. A method according to claim 1, wherein the inserting of pile yarns between the wefts includes advancing in timed relation with the loom a tube frame conveyor means on which is mounted successive tube frames through which pile yarns extend, while moving the tubes of a corresponding tube frame between the warps by advancing the conveyor means and the correspondpile yarns between the warps, inserting simultaneously two pairs of weft strands in the shed forwardly and rearwardly, respectively, of said row of pile yarns, and beating up against the fell of the fabric the pairs of weft strands with the'pile yarns therebetween while looping the pile yarns beneath the rearward pair of weft strands to form a weftwise row of tufts from the pile yarns.

4. A method according to claim 3, including the further steps of reversing the shed so that said one bank of warps is down and the other bank is up, inserting another weftwise row of pile yarns between the warps, inserting simultaneously two additional pairs of weft strands in the reversed shed forwardly andrearwardly, respectively, of said other row of pile yarns, beating up against the fell said two additional pairs of weft strands with said other row of pile yarns therebetween while looping said other row of pile yarns beneath the corresponding rearward pair of weft strands to form another weftwise row of tufts from said other row of pile yarns, and repeating the steps as prescribed.

5. A method of weaving pile fabrics on a loom in which successive conveyor supported tube frames are advanced stepwise to position pile yarns extending through the tubes thereof between warps preparatory to the beating up of a shot of weft against the thus positioned pile yarns and, in turn, against the fell of the fabric being woven; characterized in that the step of advancing the tube frames includes directing the conveyor with the tube frames connected thereto about a fixed axis along an arcuate path of substantially constant radius so as to move the tubes of each successive tube frame into and out of the warps as the respective tubes are being advanced about the fixed axis for positioning the pile yarns in the warps.

6. A method of weaving pile fabric on a loom which comprises advancing in timed relation with the weaving operation of the loom a tube frame conveyor means on which is mounted successive tube frames through which pile yarns extend, while moving the tubes of each successive tube frame between warps of the loom to position the pile yarns between the warps by advancing the conveyor means with the respective tube frame thereon in an arcuate path of substantially uniform radius generated about a fixed axis as the respective tubes are positioned between the warps inserting at least one weft in a shed of the warps and adjacent the thus positioned pile yarns, looping the pile yarns about the respective weft while further advancing the conveyor means and the respective tube frame thereon along said arcuate path, and cutting the thus looped pile yarns to form a weftwise row of the U-shaped tufts therefrom.

7. A method according to claim 6, wherein said one weft is inserted in the warps rearwardly of the thus positioned pile yarns, and further comprising inserting at least one additional weft in the shed forwardly of the thus positioned pile yarns prior to the step of looping the pile yarns about the first-named weft.

8. A method of weaving pile fabric on a loom having a series of tube frames provided with tubes through which pile yarns extend, and conveyor means supporting the tube frames, said loom also having warps, and a noseboard provided with hooks, said method comprising advancing the conveyor means with its tube frames in a stepwise manner to position the pile yarns of each successive tube frame between the warps by moving the tube frame downwardly and forwardly to move its tubes into the warps in an arcuate path of substantially constant radius about a fixed axis while maintaining the tube frame in attached relation to the conveyor means, causing the conveyor means and the tube frame to dwell with its tubes in the warps while inserting first and second double wefts in a shed of the warps forwardly of and rearwardly of the pile yarns, respectively, beating up the first and second wefts and the pile yarns therebetween to push the wefts and pile yarns over the hooks of the noseboard while advancing the tube frame further along said arcuate path and over the noseboard to loop the pile yarns around the second double weft, and cutting the pile yarns between the noseboard and the tubes of the tube frame to form U- shaped tufts from the pile yarns.

9. The improvement in a loom for weaving pile fabrics from warps, wefts and pile yarns, said loom having a conveyor means movable stepwise in timed relation with the weaving operation of the loom, a plurality of successive tube frames carried by said conveyor means and provided with respective rows of tubes through which pile yarns extend, shed forming means for the warps, a reciprocating beating means through which the warps extend from the shed forming means to the fell of the fabric being woven, and weft inserting means for inserting wefts in successive warp sheds formed by said shed forming means; the improvement comprising rotary support means mounted on a fixed axis adjacent the path of the warps between said shed forming means and said fell of the fabric and guidingly engaging said conveyor means and the proximity of said rotary support means to the path of the warps being such that the tubes of each successive tube frame are guided thereby in an arcuate path into operative position into the warps and in the path of the beating means during stepwise movements of said conveyor means to position corresponding pile yarns between the warps without removing the tube frames from said conveyor means.

10. Apparatus according to claim 9, wherein said weft inserting means includes means operable in timed relation to said conveyor means for inserting a first double weft and a second double weft in the warp shed respectively forwardly and rearwardly of the tubes of each successive tube frame moved into operative position.

11. Apparatus according to claim 9, wherein said weft inserting means includes means operable in timed relation with said conveyor means for inserting at least one first weft strand and at least one second weft strand in the warp shed respectively in front of and in back of the tubes of each successive tube frame moved into operative position.

12. Apparatus according to claim 11, further comprising means for intermittently driving said conveyor means and permitting each successive tube frame to dwell in said operative position during insertion of said first and second weft strands in the warp shed.

13. Apparatus according to claim 12, including a noseboard having a plurality of hooks toward which said beating means moves the weft strands and the pile yarns, and wherein the arcuate path of each successive row of tubes about said fixed axis is such that the tubes of a respective tube frame withdraw from the warps and pass above said noseboard during movement of said conveyor means following each operation of said weft inserting means, said beating means including means spacing certain of the warps extending therethrough for passage of the successive rows of tubes therebetween, means for reciprocating said beating means between a back position substantially coinciding with the point at which each successive row of tubes initially enters between the warps and a beat-up point adjacent said noseboard, and said reciprocating means including means causing said beating means to move forwardly substantially in unison with each successive row of tubes and to dwell rearwardly of the corresponding row of tubes while the tubes occupy said operative position and then to cause said beating means to complete its corresponding forward movement to push the corresponding weft strands and pile yarns over the hooks of said noseboard as the corresponding row of tubes passes over said noseboard, whereby said beating means aids in maintaining said certain warps in spaced relation for accommodating each successive row of tubes throughout its passage into and out of the warps.

14. Apparatus according to claim 13, including cutting means normally spaced forwardly of said hooks on said noseboard, and means for moving said cutting means rearwardly and then forwardly as each successive tube frame advances a predetermined distance

Claims

2. A method according to claim 1, wherein the inserting of pile yarns between the wefts includes advancing in timed relation with the loom a tube frame conveyor means on which is mounted successive tube frames through which pile yarns extend, while moving the tubes of a corresponding tube frame between the warps by advancing the conveyor means and the corresponding tube frame about a fixed axis in an arcuate path of substantially uniform radius.

3. A method of making a woven pile fabric from weft strands and a pair of banks of warps which comprises forming a shed of the banks of warps with one bank up and the other bank down, inserting a weftwise row of pile yarns between the warps, inserting simultaneously two pairs of weft strands in the shed forwardly and rearwardly, respectively, of said row of pile yarns, and beating up against the fell of the fabric the pairs of weft strands with the pile yarns therebetween while looping the pile yarns beneath the rearward pair of weft strands to form a weftwise row of tufts from the pile yarns.

4. A method according to claim 3, including the further steps of reversing the shed so that said one bank of warps is down and the other bank is up, inserting another weftwise row of pile yarns between the warps, inserting simultaneously two additional pairs of weft strands in the reversed shed forwardly and rearwardly, respectively, of said other row of pile yarns, beating up against the fell said two additional pairs of weft strands with said other row of pile yarns therebetween while looping said other row of pile yarns beneath the corresponding rearward pair of weft strands to form another weftwise row of tufts from said other row of pile yarns, and repeating the steps as prescribed.

6. A method of weaving pile fabric on a loom which comprises advancing in timed relation with the weaving operation of the loom a tube frame conveyor means on which is mounted successive tube frames through which pile yarns extend, while moving the tubes of each successive tube frame between warps of the loom to position the pile yarns between the warps by advancing the conveyor means with the respective tube frame thereon in an arcuate path of substantially uniform radius generated about a fixed axis as the respective tubes are positioned between the warps , insertinG at least one weft in a shed of the warps and adjacent the thus positioned pile yarns, looping the pile yarns about the respective weft while further advancing the conveyor means and the respective tube frame thereon along said arcuate path, and cutting the thus looped pile yarns to form a weftwise row of the U-shaped tufts therefrom.

8. A method of weaving pile fabric on a loom having a series of tube frames provided with tubes through which pile yarns extend, and conveyor means supporting the tube frames, said loom also having warps, and a noseboard provided with hooks, said method comprising advancing the conveyor means with its tube frames in a stepwise manner to position the pile yarns of each successive tube frame between the warps by moving the tube frame downwardly and forwardly to move its tubes into the warps in an arcuate path of substantially constant radius about a fixed axis while maintaining the tube frame in attached relation to the conveyor means, causing the conveyor means and the tube frame to dwell with its tubes in the warps while inserting first and second double wefts in a shed of the warps forwardly of and rearwardly of the pile yarns, respectively, beating up the first and second wefts and the pile yarns therebetween to push the wefts and pile yarns over the hooks of the noseboard while advancing the tube frame further along said arcuate path and over the noseboard to loop the pile yarns around the second double weft, and cutting the pile yarns between the noseboard and the tubes of the tube frame to form U-shaped tufts from the pile yarns.

14. Apparatus according to claim 13, including cutting means normally spaced forwardly of said hooks on said noseboard, and means for moving said cutting means rearwardly and then forwardly as each successive tube frame advances a predetermined distance above the level of said noseboard for cutting the pile yarns between said noseboard and the corresponding row of tubes.

15. Apparatus according to claim 9, including a noseboard having a plurality of hooks toward which said beating means moves the pile yarns and wefts in timed relation to movement of the successive rows of tubes into operative position, the arcuate path of each successive row of tubes about said fixed axis being such that the tubes thereof pass forwardly over said noseboard hooks during the corresponding beat-up of said beating means, a supporting surface for the fabric adjacent and forwardly of said noseboard hooks, means for cutting the pile yarns between the hooks and the corresponding row of tubes thereabove, and movable shield means for overlying and shielding the preceding row of tufts thus formed in the fabric from said cutting means during operation thereof.

16. The improvement in a loom for weaving pile fabrics from warps, wefts and pile yarns, wherein the loom includes a reciprocating beating means, a noseboard having a plurality of hooks thereon toward which the beating means moves during beat-up, a tube frame conveyor means having a series of tube frames attached thereto and provided with respective rows of tubes through which pile yarns extend, shed forming means for the warps, and weft inserting means; the improvement including means for imparting stepwise movement to said conveyor means and presenting each successive tube frame to the warps in a dwell position in which the tubes thereof extend between the warps forwardly of the beating means while an open shed of the warps is present without removing the tube frame from said conveyor means, said weft inserting means including means for substantially simultaneously inserting at least two wefts in said open shed while each successive tube frame occupies said dwell position with one weft in front of and the other weft in back of the corresponding row of tubes, means for operating said beating means to beat up said two wefts with the corresponding pile yarns therebetween during the next succeeding stepwise movement of said conveyor means to push the latter wefts and pile yarns over the noseboard hooks and thereby loop the pile yarns beneath said Other weft, and means for cutting the pile yarns between said noseboard and the respective row of tubes to form U-shaped tufts from the pile yarns.

17. Apparatus according to claim 16, including weft shifting means operable in timed relation to said weft inserting means for advancing the front weft forwardly a predetermined distance out of the path of the respective row of tubes and in front of said beating means but short of the noseboard so that the tubes will not engage the front weft during said succeeding stepwise movement of said conveyor means.

18. Apparatus according to claim 16, wherein said beating means comprises a reed having a plurality of spaced dents provided with holes therethrough through which the warps extend from said shed forming means to the fell of the fabirc being woven, said shed forming means being operable to form said warps into first and second banks of warps during each cycle in the operation of said beating means, said shed forming means including means for moving said banks of warps to open shed positions following each beat-up of said reed and including means for momentarily moving at least the then upper bank of warps to substantially a middle shed position as said reed moves rearwardly of its center position and for then returning the upper bank of warps to full open shed position during subsequent forward movement of said reed substantially to its center position and before the next succeeding operation of said weft inserting means.

19. Apparatus according to claim 16, wherein said means for operating said beating means includes means for stopping said beating means in a dwell position closely adjacent and rearwardly of each successive row of tubes as the latter occupies the first-mentioned dwell position, and said operating means being operable to subsequently advance said beating means to full beat-up position during said next succeeding stepwise movement of said tube frame conveyor means.