US3847692A

US3847692A - Method and apparatus for making pile fabrics from a block of pile yarns

Info

Publication number: US3847692A
Application number: US00363832A
Authority: US
Inventors: E Bondi
Original assignee: Fieldcrest Mills Inc
Current assignee: FIELD CREST CANNON Inc
Priority date: 1969-07-24
Filing date: 1973-05-25
Publication date: 1974-11-12
Anticipated expiration: 1991-11-12
Also published as: DE2035967A1; DE2035967C3; NL157954B; BE753765A; FR2053124B1; CH560787A; US3957555A; JPS5020631B1; DE2035967B2; CH1117970A4; FR2053124A1; CA932257A; NL7010912A; GB1306837A

Abstract

A method and apparatus for making pile fabrics, such as carpets, rugs and the like, ultizing a block of substantially parallel pile yarns in an open-ended container, wherein the pile yarns are incrementally fed from the container parallel to their axes in successive increments of an amount equal to the desired length of pile. Following each successive incremental feeding of the pile yarns from the container, they are progressively severed transversely of their axes while being progressively deposited onto an adhesive-coated backing to connect the severed pile yarns to the backing and while the backing is being advanced relative to the block of pile yarns.

Description

United States Patent 1191 Bondi 1 Nov. 12, 1974 METHOD AND APPARATUS FOR MAKING 3.325.324 6/1967 Schmidt 61 61 156 72 p FABRICS FROM A BLOCK 01: L 2,788,835 4/1957 Brookes YARNS 2,516,559 7/1950 Fuhrhop et a1. 156/72 2,491,258 12/1949 Fuhrhop et a1. 156/72 [75] Inventor: Emanuele Bondi, Milan, Italy 3,085,922 4/1963 Koller 156/435 [73] Assignee: Fleldcrest Mills, Inc., Eden, N.C. FOREIGN PATENTS OR APPLICATIONS 1,040,286 8/1966 Great Britain 156/72 [22] May 1973 1,047,382 11/1966 Great Britain 156/72 [21] Appl. NO; 363,832 790,498 2/1958 Great Britain......, 156/72 496,165 10/1950 Belgium 156 72 Related pp Data 140,288 5/1953 Sweden 156 72 [63] Continuation-impart of Ser. Nos. 54,751, July 14, 332,070 8/1903 France 1 156/254 1970, abandoned, and Ser. No. 316,740, Dec, 20, 1972. Primary Examiner-Daniel J. Fritsch Attorney, Agent, or FirmParrott, Bell, Seltzer, Park [30] Foreign Application Priority Data & Gibson July 24, 1969 Italy 20109/39 Dec. 12, 1969 Italy 25 /4459 57 ABSTRACT 1521 US. (:1 156/72, 156/148, 156/204, A and i fi i ll E f 56/226 56/227 156/251 56/435 as carpets, rugs an t e 1e, u1z1nga 0c 0 su 56/459 56/474 56/516 stantially parallel p1le yarns in an open-ended con- 1 Int Cl B32) 5/00 B32b3l/l2 B32b 31/18 tainer, whereir the pile yarns are incrementally fed Fie'ld 1 56/72 1 177 204 from the container parallel to their axes 1n successive increments of an amount equal to the desired length 156/226, 251, 297, 435, 459, 474, 516, 227; f F n h t 28/72 R 0 pi e. o owmg eac successive incremen a ee mg of the p1le yarns from the contamer, they are progressivel severed transversely of their axes while bein [56] References Cited progiessively deposited onto an adhesive-coated back UNITED STATES PATENTS ing to connect the severed pile yarns to the backing 3,673,048 6/1972 Gidge 156/510 and while the backing is being advanced relative to 3,580,761 5/1971 Boultinghouse 156/72 the block of pile yarns. 3,390,034 6/1968 Hull 156/72 3,359,147 12/1967 Miller 156/72 42 Claims, 14 Drawing Figures PATENTEDNUV 121914 SHE u of 8 3847.692

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METHOD AND APPARATUS FOR MAKING PILE FABRICS FROM A BLOCK OF PILE YARNS This application is a continuation-in-part of my copending application Ser. No. 54,751, filed July 14, 1970, now abandoned and entitled A METHOD AND EQUIPMENT FOR PRODUCING CARPETS WITH WELDED OR GLUED PILE, AND CARPETS TI-IEREBY PRODUCED, and this application also is a continuation-in-part of my copending application Ser. No. 316,740, filed Dec. 20, 1972, and entitled METHOD OF PRODUCING PATTERNED BLOCKS OF PILE YARNS IN MAKING PATTERNED PILE FABRICS.

Various methods and apparatuses have been proposed heretofore for producing patterned blocks of pile yarns and utilizing such blocks for making pile fabrics by anchoring the ends of the pile yarns together, either by means of an adhesive or by melting of the ends of the pile yarns, or by adhesively or fusibly securing the ends of the pile yarns to a suitable backing or substrate and then severing a slice of the pile yarns from the yarn block. Various such methods and apparatuses are disclosed in British Pat. No. 662,531, published Dec. 5, 1951, British Pat. No. 732,980, published July 6, 1955, British Pat. No. 1,040,286, published Aug. 24, 1966, and US. Pat. Nos. 2,438,156; 2,491,258; 3,359,147 and 3,673,048, for example. The methods and apparatuses proposed in these prior art patents, as well as any other methods and apparatuses proposed heretofore within applicants knowledge, have presented many problems and difficulties which could not be effectively overcome to such extent as to permit feasible, economical and practical production-line techniques in the manufacture of pile fabrics, especially pile fabrics having highly intricate pattern designs in the pile surface thereof. Also, such prior art methods and apparatuses have not permitted readily obtaining variations in density of the pile in the various pile fabrics produced in accordance with the teachings of the known prior art.

It is therefore the primary object of this invention to provide an improved method and apparatus for making pile fabrics in which the principle of severing pile tufts from a block of pile yarns is adopted, but which improved method and apparatus is more efficient and more economical than any prior art methods or apparatuses of which I am aware.

It is a more specific object of this invention to provide an improved method and apparatus for making pile fabrics, such as carpets, rugs and the like, from a block of substantially parallel pile yarns in an openended container, and wherein the pile yarns are fed parallel to their axes from the container in successive increments of an amount equal to the desired length of pile and are progressively severed transversely of their axes following each successive incremental feeding of the pile yarns from the container, and also wherein the severed pile yarns are progressively deposited onto an adhesive-coated backing to connect the severed pile yarns to the backing while the backing is being advanced relative to the block of pile yarns.

According to the preferred specific embodiment of the invention, a patterned block of pile yarns is formed by weaving a plurality of weftwise pile yarns of different colors in a predetermined patterned order and then forming a compact stack of layers of the woven fabric by moving the same back and forth and folding the same along identifying weft yarns previously woven into the fabric. The compact stack of folded fabric is then enclosed in an open-ended container to form a confined block of pile yarns with the ends of the pile yarns exposed and forming a composite pattern at an open end of the container. The container then is positioned on a suitable carriage equipped with means for incrementally feeding the block of pile yarns from the open end of the container in successive increments of an amount in accordance with the desired length of pile and also mounted so as to move the container forwardly in a predetermined path transversely of the pile yarn axes while moving the container into cooperating relation with a severing means. The severing means is arranged to progressively sever the ends of the pile yarns during forward movement of the container so as to form tufts of the pile yarns. The apparatus also is provided with means for advancing an adhesive-coated backing forwardly past and adjacent the severing means and the pile yarn block during the severing of the pile yarns so that the tufts being formed are progressively deposited onto the backing and joined thereto during the severing of the pile yarns.

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 accompanying drawings, in which FIG. 1 is a block diagram briefly setting forth steps according to the method of the present invention;

FIG. 2 is a schematic perpsective view of a loom for weaving a fabric of selected weftwise pile yarns used for forming the patterned yarn block of which the improved pile fabric is formed;

FIG. 3 is a schematic perspective view, with portions broken away, showing a preferred form of fabric layering apparatus for forming a cake or stack of superposed fabric layers constituting the patterned block of pile yarns employed in forming the pile fabric;

FIG. 4 is a schematic perspective view of a completed patterned block of pile yarns produced according to the present invention and wherein the layered stack of weftwise pile yarns is positioned in an open-ended container with corresponding ends of the pile yarns exposed so that they may be severed from the pile yarn block to form pile tufts therefrom;

FIG. 5 is a schematic partially exploded view of an upper portion of the stack of superposed fabric layers shown in FIG. 3, for the purpose of illustrating various bands of contrasting or different colors or kinds of weftwise pile yarns in the fabric and also illustrating how the fabric layers may be impaled on restraining pins to ensure proper alignment of the successive layers in the stack being formed;

FIG. 6 is a greatly enlarged fragmentary view of the area 6 of FIG. 5, showing a portion of one of the layers of fabric adjacent one side edge thereof;

FIG. 7 is a vertical sectional view substantially through the central longitudinal plane of the apparatus shown in FIG. 3, but showing the position of a supporting work-table when starting the formation of a stack of superposed pile yarn fabric layers thereupon;

FIG. 8 is a fragmentary perspective view illustrating suitable mechanism for imparting reciprocatory motion to the roll of pile yarn fabric in the upper portion of FIG. 7;

FIG. 9 is a schematic perspective view of the apparatus for progressively severing the pile yarns in the pile yarn block transversely of their axes while progressively depositing the severed pile yarns or tufts onto an advancing adhesive-coated backing to connect the severed pile yarns thereto;

FIGS. 10 and 10A are, collectively, a somewhat schematic longitudinal vertical sectional view through the apparatus shown in FIG. 9, but illustrating additional elements not shown in FIG. 9;

FIG. 11. is an enlarged schematic fragmentary elevation similar to the right-hand portion of FIG. 10, but showing the pile yarn block container in a different position from that shown in FIG. 10 to illustrate how the exposed lower ends of the pile yarns in the container are severed from the pile yarn block and deposited as cut pile tufts on the backing to form a pile fabric;

FIG. 12 is an enlarged fragmentary vertical sectional view similar to the central portion of FIG. 1 1, but showing more in detail how the pile tufts are progressively severed from the block of pile yarns and deposited on the backing to form the pile fabric thereform;

FIG. 13 is a schematic diagram of a suitable electrical circuit for controlling the operation of the pile fabric manufacturing apparatus shown in FIGS. 912;

FIG. 14 is a detail of some of the drive mechanism for imparting a stepwise forward movement to the backing in the course of each forward movement of the container;

FIG. 15 is a schematic view of a modified form of pile fabric manufacturing apparatus and is similar to FIG. 11, but shows means for heat-fusing the lower ends of the pile yarns during forward movement of the container and before the container reaches the severing means; and

FIGS. 16 and 17 are fragmentary views of typical pile fabrics which may be produced with the apparatus arranged as in FIG. 15.

Referring more specifically to the drawings, as illus' trated in the block diagram of FIG. 1, the essential steps involved in making pile fabrics in accordance with the present invention comprise weaving a fabric of selected weftwise pile yarns, and then layering the woven fabric in layers of substantially equal warpwise length to form a compact stack of fabric layers with the ends of the weft yarns therein forming a preliminary pile pattern. As further indicated in the block diagram of FIG. 1, the thus formed stack of layered fabric then is enclosed in an open-ended container to form a confined block of pile yarn with the ends of the pile yarns exposed. According to the preferred embodiment of the invention the block of pile yarns then is positioned with the exposed pile yarn ends facing downwardly above an adhesive-coated substrate or backing and the pile yarn block is fed from the container in a stepwise manner in successive increments of an amount equal to the desired length of the pile. If desired, and as is preferred, adhesive material also may be applied to the pile yarn ends extending fron the container.

As further indicated in FIG. l, a length of pile yarns is severed from the pile yarn block following each incremental feeding of the pile yarns from the container and the severed lengths of pile yarns or tufts are progressively deposited onto a substrate or backing during the severing operation.

The preferred embodiment of the methods and apparatus for forming the compact block of pile yarns is illustrated in FIGS. 1-8, many details of which will not be described herein, since the structure there shown is fully described in said copending application Ser. No. 316,740, filed Dec. 20, 1972, the disclosure of which is incorporated herein by reference.

FILE FABRIC WITH WEFTS OF PILE YARN Referring now to FIG. 2, it will be observed that the pile yarn fabric, generally designated at 20, is woven on a suitable loom which may be of any desired conventional or other type and is preferably in the form of a shuttleless loom equipped with conventional or other suitable means for controlling the harnesses or heddles 21 thereof and also equipped with a suitable weft selector means 23. Weft selector means 23 is pattern controlled, as by a pattern device or pattern control means 24, for selectively introducing predetermined pile yarns 25, one at a time, to a weft inserting means 26 to be inserted in the warp shed prior to each beat-up of a reed 27.

The weft selector means 23 may be of the type disclosed in said last-mentioned copending application, wherein the weft selector means 23 is equipped with suitable selector fingers, not shown, which are moved into an active position, one at a time, for guiding respective weft yarns to the weft inserting means 26. In this instance, the weft selector means 23 not only selects the main weft yarns 25, but is also selects a separate identifying weft yarn 25a to be later described. It should be noted, however, that the pattern control means 24 controls the weft selector means 23 so as to select pile yarns 25 of relatively different color or other appearances and to present them to the weft inserting means 26 which thus arranges the pile yarns in parallel juxtaposition according to a predetermined pattern during weaving of the fabric 20.

The warps of which the warp sheds are formed are largely composed of sparsely spaced binder warp yarns 30 (FIG. 6) which are quite small or fine relative to pile yarns 25. Preferably, binder warp yarns 30 are formed from a material which is barely visible, such as continuous monofilament nylon strands of about 15 to 20 de nier, with the harnesses 21 being so controlled as to effect a shed change following each beat-up of reed 27.

In its preferred embodiment, the pile yarn fabric 20 may be woven any convenient width, e.g., about 8 feet to 12 feet wide, in accordance with the number of lenths of pile fabric to be produced from the subsequently layered fabric 20. It is preferred that, in such a fabric, the relatively fine binder warp yarns 30 are spaced approximately 4 inch to /2 inch apart from each other across the width of the fabric to aid in maintaining the patterned relationship of the weftwise pile yarns 25 during formation of the patterned block of pile yarns. It is preferred that the binder warp yarns 30 are removed from the final pile fabric F (FIG. 9) in making a high quality pile fabric. However, in some instances, as for example in making pile fabrics of lower quality and for purposes of economy, the binder warp yarns 30 might not be removed from the final pile fabric F, it being noted that the binder warp yarns are practically invisible when formed of small monofilaments, which monofilaments are severed or mutilated into short length segments when pile tufts are severed from the patterned block of pile yarns.

At least one visually distinct side edge identifying warp yarn 30a, which is of contrasting appearance,

such as size, color or the like, relative to the weftwise pile yarns 25 and binder warp yarns 30, is interwoven with the weft yarns adjacent each longitudinal side edge of the fabric 20. Additionally, similar intermediate identifying warp yarns 30b are spaced weftwise of the fabric throughout the width thereof at locations about 5 to 6 inches apart for purposes to be later described.

It is important to note that, in order that the identifying

warp yarns

30a, 30b are clearly visible to an operator during the subsequent layering of the fabric, the identifying

warp yarns

30a, and 30b are formed largely as floats (FIGS. 5 and 6) and thereby form a float weave throughout the length of the fabric 20. All of the identifying

warp yarns

30a, 30b pass through the fabric from one side to the other, and vice versa, at a common respective weftwise pile yarn or 25a in each instance. The floats formed of the identifying warp yarns a, 30b may be of any desired length which is readily visible to operators during the forming of the fabric into layers as will be later explained. For example, each identifying

warp yarn

30a, 30b may be floated over 7 or 8 weftwise pile yarns 25 and then may be floated beneath 7 or 8 pile yarns 25, this procedure being repeated throughout the length of the fabric as illustrated, for example, in FIG. 6.

For the purposes of this disclosure, it may be assumed that all of the pile yarns 25 shown in FIG. 2 are .of different colors relative to each other. The identifying weft yarn 25a also may be a pile yarn similar to pile yarns 25, but should be of a different color than pile yarns 25, or it should be otherwise visually distinct from pile yarns 25.

Since it is desirable, according to the invention, that all of the layers L (FIGS. 3 and 5) of the woven pile yarn fabric 20 employed in forming a given block of patterned pile yarns are in predetermined alignment with each other so as to provide a clear definition of the design areas in the pile pattern to be formed, it is preferred that all of the fabric layers are of substantially the same warpwise length. Accordingly, during the weaving of fabric 20 on the loom shown in FIG. 2, the fabric is formed into successive warpwise interconnected sections of substantially uniform length by inserting at each of a plurality of substantially uniformly spaced locations in the fabric 20 at least one, or a group of, the identifying weft yarns 25a.

It will be observed in FIGS. 5 and 6 that the fabric 20 has weftwise indentifying yarns 25a at spaced locations along its length with the identifying weft yarns 25a being arranged in groups of three in this instance. The center of each group of three identifying weft yarns 25a is positioned a substantially uniform distance from the center of the next adjacent group of identifying weft yarns 25a, and they define therebetween a corresponding fabric section which constitutes a layer L of the fabric when it is folded into a compact cake or stack 20b (FIGS. 3, 4 and 5) of successive superposed layers in a manner to be later described.

It willbe observed in FIG. 5 that the fabric 20'is each such layer. Each band a, c, e and g may be formed from brown colored pile yarns, with each band b, d, f being formed from red colored pile yarns as indicated by comparing the exemplary composite pattern shown in FIG. 4 with the portions of the pattern shown in FIG. 5.

It is apparent that, if individual design portions of the composite pattern formed of multiple layers L of the fabric are of varying shape, size or disposition relative to a given transverse plane through all of the fabric layers L in the stack 20b, then the warpwise dimensions of certain weftwise bands, such as bands a-g, will vary from layer to layer L, the number of such bands will vary in different layers and/or some or all of the bands may be omitted in certain layers; i.e., all of the weftwise pile yarns 25 in certain layers may be of the same appearance with the exception of the weftwise fold-line identifying yarns 25a.

From the foregoing description, it is apparent that the groups of identifying weft yarns 25a define foldlines extending parallel with the weftwise pile yarns along which the fabric 20 is folded as it is moved back and forth to form the stack 20b of superposed layers L of the respective sections of the fabric and with the ends of the pile yarns in the layers L collectively forming a composite pattern of pile yarns 25 of relatively different colors or other appearances.

APPARATUS FOR MAKING PILE YARN BLOCKS The folding of the pile yarn fabric 20 may be effected, and alignment of the successivelayers L may be effectively obtained, utilizing a layering apparatus substantially of the type illustrated in FIGS. 3, 4, 7 and 8. Such apparatus is especially useful in instances where the fabric layers L are quite large. In this regard, the fabric 12 may be woven about 3 to 12 feet wide and each warpwise layer L thereof may be 9 to 12 feet long. The latter warpwise dimension determines the width of the carpet or other pile fabric to be formed from the stack 20b.

It will be observed in FIGS. 3 and 7 that the layering apparatus generally comprises an operators elevated platform having an opening 41 therethrough to accommodate a vertically movable, preferably substantially rectangular, worktable 50. Worktable 50 should be of such size as to properly support thereupon a supporting panel 42 which is preferably of about the same width as the weft of each fabric layer, but which should be of slightly greater length than the warpwise length of each fabric layer L, since panel ,42 later serves as one side wall of a container broadly designated at 60 in FIGS. 4, 9, 10, 11 and 12.

Worktable 40'is supported on a plurality of vertically adjustable posts which may be in the form of upright screws 43 (FIGS. 3 and 7). Screws 43 may be adjusted by suitable connections with a hand-crank 45 conveniently mounted on one of the guard rail posts of platform 40 so as to be within easy reach of a workman standing on platform 40. Thus, the level of worktable may be'varied relative to platform 40 by suitable manipulation of hand-crank 45 so that the table 50 and any layers of fabric thereon may be positioned on a level convenient to workmen on platform 40 and may be adjusted from time to time during the layering of the fabric.

To facilitate moving the woven fabric 20 back and forth on panel 42 to foldthe fabric 20 and form the stack 20b (FIG. 3), the fabric 20 may be wound onto an arbor or roll 65 as it is taken up on the loom of FIG. 2 to form a roll 20c of the woven fabric 20. Roll 20c is removed from the loom and mounted on a suitable reciprocable overhead carriage 70 (FIGS. 3, 7 and 8) movable along a pair of laterally spaced tracks 71 by suitable connections with an electrically operable drive means embodied in an electric motor 72 in FIGS. 3 and 7. Tracks 71 extend substantially horizontally and are spaced a substantial distance above the platform 40 and may be supported, as shown, upon the same framework which supports platform 40.

Carriage 70 includes opposite end plates 73 having rollers 74 on their upper portions on which the arbor 65 is supported. The lower portions of end plates 73 have opposite ends of a pair of parallel guide rolls or nip rolls 75 journaled thereon which are suitably driven so that the left-hand guide roll 75 in FIGS. 7 and 8 will be driven in a clockwise direction whenever carriage 70 moves from left to right while the right-hand guide roll 75 idles for drawing fabric 20 from the roll 200 between the guide rolls 75. Conversely, the right-hand guide roll 75 is driven in a counterclockwise direction for feeding fabric 20 to the worktable 50 as the lefthand guide roll 75 idles during movement of carriage 70 from right to left in FIG. 7. In order to effect the reciprocatory movement of carriage 70, electric motor 72 may be controlled by a suitable manually operable reversing switch 76-(FIG. 7) interposed in an electrical circuit to motor 72 and positioned within convenient reach of a workman on platform 40.

To aid in properly aligning the successive layers L of fabric 20 so that the pile yarns will reflect the desired composite pattern as shown, by way of example, in FIGS. 3, 4 and 5, four substantially horizontal rows of perimetrical or outer substantially upright retaining rods or pins 80-83 are associated with worktable 50. The longitudinal or warpwise rows of pins 80, 81 are spaced from each other a distance slightly less than the width of the woven fabric 20 and a distance about equal to the distance between the side edge identifying warp yarns 30a in FIGS. and 6.

The transverse or weftwise rows of retaining

rods

82, 83 extend between the opposite ends of the rows 80, 81 and may be spaced from each other a distance slightly less than that between the identifying weft yarns 25a. One or more intermediate transverse or weftwise rows of substantially upright retaining rods or pins are provided which extend parallel to the outer end rows of

pins

82, 83 and are disposed between the outer longitudinal rows 80, 81. By wap of example, two intermediate rows of retaining rods 84, 85 are shown in FIG. 5 to aid in maintaining corresponding intermediate weftwise pile yarns 25 of each fabric layer in a substantially straight condition during the layering operations. This aids in preventing the occurrence of skew or bow in the woven fabric layers.

The lower ends of pins 8085 are suitably secured in a supporting frame 86 positioned on the workroom floor. For the convenience of the workmen, it is preferred that pins 80-85 are of substantially the same height and project upwardly about 25 to 35 inches above the level of the elevated platform 40 so that a workman standing on platform 40 may reach well over the upper ends of the pins for manually impaling the fabric layers thereon.

Since it may be desirable to form the compact stack 6 to 12 feet high to accommodate a single pattern repeat, it follows that the retaining pins 80-85 should be of a comparable height. Also, the pins should be of relatively small diameter; e.g., about 5 1 to inch in diameter. Therefore, it is preferred that a suitable guide means is provided for stabilizing the medial portions of the upright retaining rods 8085. To this end a suitable rectangular stabilizing frame 87 (FIG. 7) is suspended, as by pliable members 90, from worktable 50 and is provided with suitable holes therethrough which are spaced according to the spacing of the pins 8085 and are loosely penetrated by the pins 8085.

From the foregoing description, it can be seen that a workman may cause the carriage to move in one direction or in the opposite direction, as the case may be, to deposit each successive layer L of the fabric 20 on the supporting panel 42 then resting on table 50. Following each pass of carriage 70 over worktable 50, the operator insures that the fold is formed at the corresponding group of identifying weft yarns 25a (FIG. 5) and then the layer of fabric is impaled on the rows of retaining pins 85. The retaining pins in each row may be spaced any desired distance apart, although it is preferred that they are spaced about 6 to 12 inches apart from each other and is desirable that the pins in the transverse rows 82-85 are spaced from each other a distance about equal to the distance between the several identifying warp yarns 30a, 3011.

Thus, the operator then may use the identifying

warp yarns

30a, 30b as a visual reference in determining the point at which the pins in rows 80-85 are to penetrate each successive layer of the fabric 20. Additionally, the two intermediate transverse rows of pins 84, should be spaced such distance from the endmost transverse rows of

pins

82, 83 that the successive layers L of the fabric 20 will be in proper alignment with each other when the pins in rows 84, 85 penetrate the fabric layers along weftwise pile yarns adjacent the point at which identifying

warp yarns

30a, 30b penetrate the fabric between adjacent weftwise pile yarns 25.

It is apparent that the corresponding weftwise pile yarns 25 then will be properly aligned with the intermediate transverse rows of pins 84, 85 to thereby ensure that the pile yarns 25 are not skewed or bowed with respect to warpwise and weftwise planes of the fabric layers. From time to time during the building of the stack 20b of superposed layers of fabric 20, it is desirable to apply a compressive force to the accumulated layers of fabric 20 in order that the stack being formed will be of substantially uniform density throughout its height as viewed in FIGS. 3, 4 and 5.

Accordingly, it will be observed in FIGS. 3 and 7 that a pressure platen 100, suitably perforated at a to accommodate the several rows of retaining rods 8085, is suitably suspended from a carriage 101 provided with suitable rollers 102 thereon for engaging and riding along tracks 71. As shown in FIGS. 3 and 7 platen 100 may be suspended from the lower end of a piston rod 103 having a piston l04on its upper end mounted for vertical movement in a double-acting cylinder 105 carried by carriage 101. Opposite ends of cylinder 105 are connected, by suitable conduits 106 and manually operable valve means 107, to a suitable driven fluid pressure pump means 110 mounted on carriage 101.

Whenever the operator wishes to compress the layer L of fabric on the panel 42 then resting upon table 50, the operator may control motor 72 so as to move carriage 70 to the right, out of the way of carriage 101 in FIG. 7. Thereafter, carriage 101 may be moved manually or by any other suitable means, not shown, to position the same above and in vertical alignment with worktable 50. The valve means 107 then is operated to move the platen 100 successively into and out of compressing engagement with the uppermost layer of fabric in the stack 20b without disturbing the alignment between the successive fabric layers. Platen 100 then is moved out of the way of carriage 70 so that additional layers of fabric 20 may be positioned upon the layers previously deposited on panel 42 then resting upon worktable 50. Upon the desired number of layers of fabric 20 being accumulated and compacted in the manner heretofore described, the last layer of fabric may be severed from roll 20c, whereupon the completed compact stack or pile yarn block 201) is positioned in container 60.

CONTAINER FOR PILE YARN BLOCK Accordingly, it will be observed in the illustrated embodiment (FIG. 4), that supporting panel 42 serves as the bottom wall of the container 60. Before removing stack 20b from worktable 50,

opposite end panels

61, 62 are positioned against opposing sides of stack 20b at the sides thereof defined by the fold-lines or boundaries of the successive layers of fabric 20. Thereafter, a top wall or panel 63, provided withv rows of perforations 63a-63f therethrough corresponding to the rows of pins 80-85, is positioned upon the uppermost layer of the fabric 20 forming the completed stack 20b. Upper panel 63 is preferably about the same size and shape as lower panel 42 and the

panels

42, 63 are secured against the lower and upper surfaces of the stack 20b by suitable fastening means shown in the form of turnbuckles 64, which firmly secure the lower and

upper panels

42, 63 to the

opposing end panels

61, 62 of container 60 to complete the formation of the confined patterned block of pile yarns.

It should be noted, however, that the inner surfaces of the panel or

walls

42, 61, 62, and 63 preferably are provided with a smooth polished finish so that the entire stack 20b of pile yarns may be incrementally forced outwardly from one open end of container 60. Container is open-ended so that at least corresponding ends of the weftwise pile yarns in the stack 20b are exposed and so' that pile yarn tufts may be severed from stack 20b following each incremental movement thereof outwardly from container 60, as will be presently described. As heretofore indicated, the layering apparatus described with particular reference to FIGS. 3, 4, 5,

, 7 and 8 is described more in detail in said copending application Ser. No. 316,740 and, therefore, a further more detailed description of the layering apparatus is deemed unnecessary.

PREFERRED PILE FABRIC MANUFACTURING APPARATUS After the patterned block of pile yarns 20b has been formed and the container 60 has been assembled around the pile yarn block 20b, any suitable hoisting means, not shown, may-be used for lifting the container 60 off of worktable 50 and out of engagement with the retaining pins 80-85, and then positioning the container in the pile fabric manufacturing equipment boradly designated at and shown in FIGS. 9-14.

Although it is preferred that the pile yarns forming the yarn block 20b in container 60 are in the form of carpet yarns, it is to be understood that the term pile yarns may, in certain instances, include continuous filaments or tows thereof and may also include rovings, slivers or any other material suitable for use as the pile of a pile fabric.

CONTAINER CARRIAGE As shown in FIGS. 9, 10, 11 and 12, container 60 has been turned on its side so that corresponding ends of the pile yarns of the compact block 20b therein have the composite pattern thereon facing downwardly. While such arrangement is not absolutely essential to the carrying out of the method of this invention, it facilitates the slicing or severing of the pile yarns into cut pile tufts and the depositing of the same on a substrate or backing.

Accordingly, it will be observed in FIGS. 9-12 that container 60 is positioned in a composite carriage broadly designated at and which comprises a main or lower substantially rectangular carriage frame 120a and an upper or auxiliary substantially rectangular carriage frame 12% which normally rests upon the lower rectangular carriage frame 1200. The carriage frames 120a, 120b loosely surround a medial portion of container 60 with the upper carriage frame 120b being suitably removably secured to the

walls

42, 61, 62 and 63 of container 60, but with the container 60 being free to move vertically relative to the surrounding lower carriage frame 120a. Thus, container 60 and upper carriage frame 1201: may be raised and lowered relative to lower carriage frame 120a for purposes to be later described.

Opposite sides of lower carriage frame 120a are provided with respective pairs of rollers 121 thereon which ride along suitable substantially horizontally disposed elongate tracks 122, only one of which is shown in FIGS. 9, 10 and 11, and which are preferably in the form of channel bars. Opposite ends of tracks 122 are suitably supported on the upper ends of standards or

posts

124, 125. Carriage 120 and container 60 with the yarn block 20b therein may be reciprocated forwardly and rearwardly along tracks 122 by a driven sprocket chain 126 whose upper reach in FIGS. 10 and 12 is suitably connected to the lower carriage frame 120a. Sprocket chain 126 is mounted on sprocket wheels 126a, 126b carried by the

standards

124, 125, and a carriage drive motive means or reversible electric motor 127 transmits rotation to sprocket wheel l26b through suitable sprocket and chain connections generally designated at 130. Thus, motor 127, sprocket chain 126 and the driving connections between motor 127 and sprocket chain 126 serve as means for moving container 60 forwardly and rearwardly along a substantially horizontal path in alternation.

SEVERING MEANS FOR PILE YARN BLOCK A severing means, embodied in a stationarily mounted endless band type of cutter blade 135, is positioned closely adjacent and below the path of container 60'and is arranged to sever the lower ends of the pile yarns in block 20b projecting from the open lower end of container 60 to form pile tufts T thereof during each forward movement of container 60 past the severing means or blade 135. Thus, the area adjacent cutting blade 135 also may be termed as a tuft forming zone.

With the exception of the blade 135 having a smooth or straight cutting edge, which faces rearwardly with respect to the direction in which the container 60 is moving during the severing operation, the severing apparatus may be in the form of a conventional band saw assembly, with the endless blade 135 being mounted on a pair of pulleys 135a, 135b (FIG. 9) carried by a suitable frame 135c and one of which may be driven by an electric motor 135d (FIGS. 10 and 11). It is apparent INCREMENTAL FEEDING OF YARN BLOCK FROM CONTAINER According to the invention, means are operatively associated with the container 60 for incrementally feeding the pile yarns outwardly from the lower open end thereof in increments of an amount equal to the desired length of pile while the container occupies a position rearwardly of the severing means or. cutting blade 135. In its preferred embodiment, the pile yarn feeding means pushes downwardly-on the entire pile yarn block b so that the block is pushed downwardly in sliding emgagement with the smooth walls of container 60 during each incremental feeding of the pile yarns in the block 20b. In this regard, it should be noted (FIG. 12) that the opposing

panels

42, 63 of container 60 are shown provided with smooth plastic sheets 66 on the proximal faces thereof and, of course, it is apparent that similar plastic sheets may be provided on the proximal surfaces of the opposing end panels or

walls

61, 62 of container 60.

In order to incrementally feed the pile yarns from the open lower end of container 60, it will be observed in FIGS. 9, l0 and 11 that the upper endof pile yarn block 20b is engaged by a substantially horizontally disposed pusher plate 140 having a planar lower surface which engages the upper surface of the pile yarn block 20b and is positioned for substantially vertical movement in and relative to container 60. Any suitable means may be provided for imparting incremental downward movements to pusher plate 140 in response to each rearward movement of container 60 and its carriage 120 a predetermined distance rearwardly of severing means 135. To this end, a fluid operated ram 141, preferably a hydraulically operated ram, has the lower end of its piston rod 141a attached to the upper surface or pusher plate 140. Piston rod 141a extends into a cylinder 141b and has a piston 141c thereon. The upper endof cylinder 141b is connected to the uppermost portion-of a suitable archc of substantially inverted U-shaped form and whose legs are suitably secured, at their lower ends, to-opposite side portions of the substantially rectangular upper carriage frame 120b.

As best shown in FIG. 12, following the feeding of each successive increment of the pile yarns from the open lower end of container 60, it is passed over cutting blade to progressively sever tufts T from the fed increment of pile yarn block 20b. As the tufts T are being formed, they are progressively deposited on a forwardly moving adhesive-coated substrate or backing 142, advancing relative to yarn block 20b, to form the patterned pile fabric F. The backing 142 may be in any desired pliable web form such as nonwoven, woven or knitted materials of natural or man-made fibers or combinations thereof. The backing also may be in the form of a web of paper or synthetic plastic material, either solid or foraminate.

In forming the pile fabric F utilizing an adhesivecoated backing, the pile yarns in block 20b may be of any desired material; e.g., natural, artificial and/or man-made fibers or yarns of any desired cross-sectional shape and size.

BACKING GUIDING AND ADVANCING MEANS Referring now to FIGS. 9-12, it will be observed that a backing guide means is provided for guiding the pliable backing or substrate 142 in an abruptly changing path converging forwardly and upwardly toward and into close proximity to the severing means or blade 135 and the path of the container 60. To this end, a main or lower endless conveyor 143 is provided whose upper reach or run is supported on rollers 143a, 143b, 1430, and whose lower reach or run is supported on

rollers

143d, 143e, 143f. It will be noted that roller l43b is disposed on a substantially higher level than rollers 143a, 143C so that the upper run of conveyor 143 moves in an abruptly changing path converging forwardly and upwardly toward and into close proximity to cutting blade 135 and to the path of the container. Additionally, the upper run of conveyor 143 diverges downwardly and forwardly away from the severing means or cutting blade 135 and away from the substantially horizontal path of travel of container 60. For purposes of clarity, conveyor 143 is omitted in FIG. 9, although rollers 143a, 143b and 143C are shown in FIG. 9.

In order to ensure that the apex of the path of travel of the conveyor 143 and the backing 142 thereover is very nearly the same as the path of travel of the lower surface of the yarn block 20b in the course of forward movement thereof, and to thereby facilitate the progressive depositing of the tufts T (FIGS. 9, 12 and 14) being severed from the yarn block 20b onto the backing 142, opposite ends of the uppermost main conveyor supporting roller 143b are journaled in bearing blocks 144 mounted on suitable vertically adjustable members or screws 145. Screws 145 may be manually rotated relative to the bearing blocks 144.

Only one of the screws 145 is shown in FIG. 11, wherein it will be observed that the lower portion thereof is threadedly mounted in a corresponding standard 146 carried by a frame 147 suitably secured to the floor upon which the main frame of the apparatus is supported. It is apparent'that roller 1 43b also may be vertically adjusted to accommodate desired variations in the length of the tu-fts T to be formed during the severing of the lower ends of the pile yarns projecting from the container 60.

DRYING AND CURING ADHESIVE ON BACKING A substantial length of the portion of the upper reach of main conveyor 143 (FIGS. and 11) immediately downstream of the adjustable roller 143b passes over and in close proximity to or in engagement with a heated hollow platen, plenum or table 150 which may be heated by a suitable circulating hot oil or other hot fluid, for example up to 220 centrigrade or higher for curing the adhesive on the backing. Immediately downstream of heated platen 150 is a cooling platen or table 151 which may engage the lower surface of the upper run of conveyor 143 and is maintained at a relatively low temperature by a suitable circulating cold fluid, such as water. If water is used, for example, it may be circulated at slightly above freezing temperature. Since heating and cooling platens are generally well known in the textile finishing industry, a detailed illustration and description of the heating and

cooling platens

150, 151 of FIGS. 10, 11 and 12 is deemed unnecessary.

The heated platen forms a drying and curing zone thereabove through which the pile fabric F is advanced from the severing means 135 for drying and curing the adhesive coating previously applied to the upper surface of backing 142. It follows, therefore, that heated platen must be of such length and must be heated to such a temperature as to dry the adhesive coating and cure the same so that the tufts T will be firmly anchored to the backing 142. The cooling platen forms a cooling zone thereabove through which the pile fabric F passes for cooling the same to facilitate subsequent take-up and handling of the pile fabric.

In order that the ambient air above

platens

150, 151 is maintained at the desired temperatures to ensure transfer of heat and cold to the respective portions of pile fabric being advanced over the

respective platens

150, 151, it is preferred that backing advancing conveyor 143 is made of a metallic wire netting or mesh material. Conveyor 143 also may be made of a porous or foraminate pliable web material.

PRESSING TUFTS AND BACKING TOGETHER According to the invention, the tufts T and backing 142 are pressed together as they are being advanced forwardly from severing means 135 and while they are advancing through the drying and curing zone above heated platen 150. To this end, an upper endless con-' veyor 152, cooperating with blade guide bar 135e (FIG. 12) serves as suitable means for pressing the cut pile tufts T against the upper surface of the backing 142 following the depositing of the tufts on the backing.

Thus, upper conveyor 152 is positioned above the upper run ofmain conveyor 143 and extends between the path of travel of container 60 and the upper surface DRIVE FOR CONVEYORS An automatically operable electromagnetic clutch means 160 is interposed between the drive mechanism for the container-carriage and the

conveyors

143, 152 for automatically imparting a step in forward movement to

conveyors

143, 152 relative to container 60 at substantially the moment that the leading edge of the exposed lower end of the yarn block 20b engages the cutting blade 135. The clutch means also is operated automatically to cut off the forward movement of the

conveyors

143, 152, preferably at the moment that the trailing edge of the exposed portion of the yarn block 20b moves forwardly of the cutting edge of the blade 135.

The clutch means 160 is shown interposed between an output shaft 161 extending from motor 127 and an input shaft means 162 connected by suitable gearing 163, to the drive roller 153 of upper conveyor 152 (FIG. 11). The shaft means 162 also is connected by suitable gearing 164, to one end of a shaft 166. Shaft 166 extends downwardly substantially parallel with the upper reach of conveyor 143 and is drivingly connected to a pile fabric supporting roll 170 (FIGS. 10A and 14) having its periphery roughened, provided with spikes or covered with wire card clothing material or other suitable material to prevent roll 170 from slipping relative to pile fabric F. A transmission mechanism 171, in turn, drivingly connects shaft 166 to the front end conveyor roller 1436 so that

conveyors

143, 152 and roll 170 are driven whenever clutch means 160 is energized or activated. Clutch means 160 may be provided with a suitable brake means, not shown, for stopping movement of

conveyors

143, 152 and roll 170 immediately upon inactivation of clutch means 160.

BACKING FEED AND PILE FABRIC TAKE-UP Means are provided for permitting intermittent or periodic stepwise advancement of the backing 142 past cutting blade 135 and adjacent the path of yarn block 20b and container 60 without placing the backing 142 under undue or excessive strain and without the need for operating the pile fabric manufacturing apparatus 115 at an undesirably relatively slow speed. Accordingly, the backing 142 is continuously fed forwardly from a source of supply 142a (FIG. 10) while a substantial length of the backing 142 is being accumulated at a location forwardly of the source 142a, but rearwardly of the backing advancing conveyor 143. Thus, during each stepwise forward advancement of the backing 142 by conveyor 143, the backing is withdrawn forwardly from the accumulated length thereof instead of being withdrawn directly from the source 142a.

Additionally, a length of the pile fabric F being formed on the backing advancing conveyor 143 is accumulated during advancement thereof at a location downstream of the cutting blade 135, and the fabric is continuously taken up downstream of the accumulated length of the pile fabric by withdrawing the pile fabric from the accumulated length thereof at a rate substantially in accord with the average length of the stepwise forward movements of the backing past the cutting blade 135.

More specifically, in order to permit the intermittent or stepwise movement of backing 142 in the manner heretofore described, the aforementioned pile fabric supporting roll 170 (FIG. 10A) is positioned adjacent a pit 172 in which a compensating catenary loop of the pile fabric is formed. From the pit 172, the pile fabric extends upwardly over another supporting roll 170a, past a pair of rotary edge-trimming or slitting blades 173 and thence to a take-up mechanism including a pair of rolls 174, 175 on which a roll 176 of the pile fabric F may be wound. The slitting blades 173, of which only one is shown in FIG. 10A, may be driven by an electric motor 173a for removing any surplus or rough edge portions from the backing of the pile fabric F.

The take-up roll 175 may be driven by an electric motor 175a. As indicated in the electrical diagram of FIG. 13, the output speed of motor 175a may be varied by a suitable, manually operable, variable speed control 175b, such as a rheostat or potentiometer. Of course, the variable speed control 175b (FIG. 13) may be in the form of a separate, manually operable, speed variator or any well-known type interposed in driving connections between motor 175a and driven take-up roll 175 (FIG. 10A).

In its course to the main conveyor 143, it will be observed in FIG. 10 that the source 142a of supply for the backing 142 is embodied in a let-off roll equipped with suitable tensioning or braking means, not shown. From let-off roll 142a, the backing 142 successively passes over a plurality of rolls 142b-l42h, the roll 1420 serving as a support beneath a doctor-blade type of liquid adhesive applicator generally designated at 177. The adhesive applicator 177 may be of any well-known type which will apply a thin coating of liquid adhesive of the desired thickness upon the upper surface of the backing 142 in its course from the supply source 142a to the 'main conveyor 143.

The adhesive may be of any suitable type which will firmly bond the tufts T and backing 142 together. The thickness of the liquid adhesive coating may be in the range of about O.l to 1.0 mm or more depending upon the types of backing and pile yarns used in forming the pile fabric F. Acrylic and polyvinyl acetate-acrylic copolymers, polyvinyl chloride, polyurethane, urea resin, melaminic resin, latex and the like are non-limiting examples of adhesive materials which may be used for bonding the tufts T to the backing.

The front supporting roll l42h for the backing being fed should have a spiked, knurled or clothing-covered peripheral surface similar to roll 170. Roll 142h is positioned above a pit 180 in which a compensating catenary loop of thebacking 142 is formed as a length of the backing accumulates between the supporting roll l42h and the conveyor 143. As shown, backing 142 passes from pit 180 upwardly over the rearmost of the supporting rollers 143a which supports the rear portion of the upper reach of main conveyor 143. Supporting roll 142h normally is driven continuously by an electric motor 181 whose speed may be varied by a manually operable variable speed control 181a similar to the variable speed control 17512 (FIG. 13).

Thus, it can be seen that the supporting let-off roll 142h may be driven con-tinously, and the take-up roll 176 also may be driven'continuously at a rate in accord with the average rate of the stepwise forward movements of the backing 142 past cutting blade 135. It should be noted that the catenary loops formed of the backing 142 and the completed fabric F in the

respective pits

180, 172 permit the forward stepwise movements of the

conveyors

143, 152 and the portions of the backing and pile fabric engaged thereby. By providing the continuous let-off of the backing 142 and the catenary loop thereof in the pit 180, each time the

conveyors

143, 152 initiate forwardv movement, they will not exert undue strain upon the backing 142. This is particularly desirable in the event of the backing being made from a relatively flimsy or loosely woven material.

VARYING DENSITY OF TUFTS ON BACKING According to the invention, means are provided facilitating the forming of pile fabrics of varying pile densities. Accordingly, a suitable variable speed mechanism or speed variator 190 is operatively connected to the backing advancing means for varying the rate of advancement of backing 142 relative to the rate of forward movement of container 60 to thereby vary the density of the tufts as they are deposited onto the backing. More particularly, it will be observed in FIGS. 10 and 11 that a speed variator 190 is interposed in the shaft means 162 between clutch and the gearing 163 for the upper conveyor 152. It is apparent that the speed variator 190 may be manually adjusted, or any suitable pattern controlled means, not shown, may be provided for adjusting the speed variator, in order to vary the forward speed of the

conveyor

143, 152 and roll whenever the clutch 160 is activated so as to thereby vary the density of the tufts as they are being deposited onto the backing 142.

During each forward movement of container 60 in the preferred embodiment shown in FIGS. 9 and 10, for example, it is preferred that a liquid adhesive is applied to the lower end of the pile yarn block 20b projecting from container 60 to thereby further aid in insuring that the tufts to be formed subsequently are firmly secured to the adhesive-coated upper surface of backing 142. Accordingly, it will be observed in FIGS. 9 and 10 that a suitable roller type of adhesive applicator 200 is suitably supported so that the upper surface of the roller thereof will wipe against the lower surfaces of the pile yarns projecting from the container 60 in the course of each forward movement of container 60. The roller type of adhesive applicator 200 may be positioned in contact with a suitable supply 201 of liquid adhesive. Since such adhesive applicators are well known in the art, a more detailed description thereof is deemed unnecessary.

From the foregoing description of the apparatus shown in FIGS. 9-12 it is apparent that the operations of incrementally feeding the pile yarn block from container 60 and advancing the backing relative to the pile yarn block are effected in timed relation to the reciprocation of the container 60 along tracks 122. Addition ally, each time the trailing edge of the pile yarn block 20b moves forwardly beyond the cutting blade 135, it is desirable to elevate the yarn block slightly so that it will not rub against the blade 135 in the course of the succeeding rearward stroke of container 60 since, otherwise, the rubbing of the lower ends of the pile yarns against the cutting blade 135 may produce undesirable lint and dust which might become deposited upon the previously adhesive-coated surface of the backing 142, and such dust may inhibit a satisfactory bond between the backing and the succeeding pile tufts T to be formed in the course of the next forward movement of container 60.

Accordingly, the method of operation will now be described in conjunction with a description of the electrical circuit of FIG. 13 not only to explain the operation of the apparatus 115 of FIGS. 9-12, but also to include a description of the means for elevating the container 60 and the pile yarn block b therein relative to cutting blade 135.

METHOD OF OPERATION For the purpose of this description, it may be assumed that a master switch 8-1 in FIG. 13 and manual switches 8-2, 8-3, S-4, 8-5 to the

respective motors

135d, 173a, 175a, 181 have been closed so that the stationarily mounted band type blade 135 is moving around the pulleys 135a, 135b, (FIG. 9), with slitting blades 173 rotating, with the pile fabric roll 176 being rotated by the supporting take-up rolls 174, 175 to take-up the previously formed pile fabric, and with the let-off roll 142h being rotated to withdraw the backing 142 from the supply roll 142a and feed the same into the pit 180 to form the catenary loop in the backing while the

conveyors

143, 152 are at rest. Also, it is to be assumed that the reverse winding of reversible motor 127 is energized with the container 60 moving from right to left in FIG. 10 and closely approaching the end of a rearward stroke thereof. Thus, as container 60 reaches the end of its rearward stroke, the container carriage 120 engages and changes the state of a rear limit switch 210 to open a normally closed contact set 210a and to close a normally open contact set 210b. In so doing, the flow of current to the coil of a previously energized motor reversing relay 211 is interrupted so that the state of the contact sets thereof is as illustrated in FIG. 13 and the forward winding of reversible motor 127 thus is energized.

At the time that the forward winding of motor 127 is energized, the closing of the normally open contact set 21012, by carriage 120 contacting the limit switch 210 causes a pulse of current to flow through a suitable manually adjustable timing device 212 which may include electromagnetic means for changing the state of two contact sets 212a, 212b. This interrupts the flow of current to a solenoid 213 while establishing a flow of current through a solenoid 214. Solenoids 213, 214 are operatively associated with a solenoid valve 215 and may be arranged so that, when solenoid 214 is energized, a regulated amount of hydraulic fluid will flow from a suitable pressurized source 216 through valve 215 and through a manually operable valve 217, to the upper end of cylinder 141b of ram 141.

Conversely, when solenoid 213 is energized and solenoid 214 is deenergized, valve 215 is closed quickly to interrupt the flow of fluid from source 216 to the upper end of cylinder 141b. The timing device 212 is adapted to be manually adjusted so that precisely the desired amount of fluid will flow from the source 216 to the upper end of cylinder 141b to cause the pusher plate 140 to feed the pile yarns in the container parallel to their axes from the container in an increment of an amount equal to the desired length of pile. Thus, it can be seen that the length of successive tufts T may be varied by utilizing the timing device 212 to adjust the extent of the successive increments of feeding of the pile yarns from container 60 and also by adjusting the supporting roll 143b for main conveyor 143 so that the current blade 135 will sever the pile yarns the desired distance above the lowermost ends thereof and the low- ,ermost ends of the pile yarns will'be properly received upon the adhesivecoated-surface of the backing 142.

As heretofore indicated, the movement of switch 210 by container carriage 120 at the end of the left-hand or rearward stroke thereof in FIG. 10 interrupted the flow of current to relay 211. With the consequent upward movement of the lower contact set 211a of relay 211 the flow of current to a container elevating relay 220 also is interrupted, resulting in the contact sets 220a, 2201; thereof being opened and the current to a solenoid valve 221 being interrupted.

Upon interruption of the current flowing to solenoid valve 221, valve 221 is closed to interrupt the flow of fluid pressure from a source 222 to a plurality of fluidoperated lifting devices shown in the form of rams 223. One of each of the rams 223 is disposed adjacent each of the four corners of container carriage 120, with the cylinders of the rams 223 being secured to the lower carriage frame 120a. The plungers or piston rods of the rams 223 project upwardly and engage the lower surfaces of respective projections 224 extending outwardly from the four corners of the upper carriage frame 120b.

It is apparent that, when valve 221 is open, rams 223 are subjected to fluid pressure from source 222 and thus raise the upper carriage frame 120b, the container and yarn block 20b relative to lower carriage frame a. This facilitates the rearward movement of container 60 following the severing of a set or slice of tufts from the pile yarn block 20b so that the lower surface of the pile yarn block will not rub against the blade in the course of the rearward movement thereof. It follows that, when the circuit to relay 220 was interrupted by the operation of switch 210 by container carriage 120, the consequent exhaust of fluid pressure from rams 223 permits the upper carriage frame 12012 to return to its lowest position resting upon lower carriage frame 120a so that container 60 then occupies its normal operating level.

It is thus seen that switch 210 provides means responsive to predetermined rearward movement of container 60 rearwardly of cutting blade 135 for (a) reversing the direction of movement of container 60, (b) feeding a predetermined increment of the pile yarn block 20b downwardly from the open lower end of container 60, and (c) lowering the container 60 and the yarn block 20b from an abnormal raised position to a normal lowered position.

In the course of forward movement of container carriage 120, a coating of liquid adhesive from the source 201 is applied to the lower ends of the pile yarns in the block 20b by the applicator roll 200 as the yarn block passes thereover. As the leading edge of the previously fed increment of the pile yarn block 20b approaches the cutting edge of the blade 135, a switch actuating abutment 120d (FIGS. 9 and 10) projecting outwardly from upper carriage frame 120b engages and momentarily closes a conveyor starter switch 225. As shown in FIG. 10, starter switch 225 may be mounted on one of the tracks 122 so as to be engaged by abutment 120d during the forward movement of carriage 120. However, it is to be noted that abutment 120d will pass above the feeler of switch 225 during the course of the subsequent rearward movement of carriage 120 because'the upper rectangular carriage frame 120b is elevated relative to lower carriage frame 120 duringirearward movement thereof.

Referring now to FIG. 13, it will be observed that the closing-of starter switch 225 energizes the coil of a clutch relay 226, thus changing the state of the contact sets thereof to complete a circuit through the electromagnetic clutch 160. Thus, clutch 160 is activated to start driving the

conveyors

143, 152 at the moment of, or immediately prior to, the leading edge of the pile yarn block 20b engaging the cutting edge of blade 135.

It is apparent that a coating of liquid adhesive is applied to the upper surface of the backing 142 by the applicator 177 upstream of the severing means 135 and

conveyors

143, 152. Thus, upon initiation of forward movement of the proximal runs of

conveyors

143, 152, cutting blade 135 progressively severs the pile yarns transversely of their axes while the tufts T thus being formed are progressively deposited onto the adhesivecoated backing 142 to connect the severed pile yarns to the backing while the backing is being advanced relative to the block of pile yarns 20b. As heretofore indicated, the upper reach of cutting blade 135 is maintained in a predetermined position relative to the forward path of travel of container 60 by engagement of the blade 135 with the rigid guide plate 135a (FIG. 12). Additionally, it will be noted that plate 135s extends downwardly and forwardly in substantially parallel relation to the upper surface of the forward portion of main conveyor 143, thus aiding in properly positioning the successive tufts T on the adhesive-coated surface of the backing 142 as they approach the secondary or upper conveyor 152.

Conveyor 152 also aids in maintaining the previously cut tufts T in substantially upright positions as they are held against the upper surface of the backing 142 during the heating, curing and cooling of the adhesive material thereon by the heating and

cooling platens

150, 151 beneath the upper reach of main conveyor 143.

In order to ensure that the pile yarns at the trailing or rear portion of the pile yarn block 20b are smoothly and cleanly severed by cutting blade 135 during the course of forward movement of yarn block 20b and container 60, it will be observed in FIG. 12 that the trailing wall 42 of container 60 has a suitable elongate recessed back-up bar or shield member 227 suitably secured to the lower edge thereof whose recess 227a is open at the forward edge of bar 227 and is aligned with cuttingblade 135. Thus, recess 227a receives the rear edge portion of cutting blade 135 therein as container 60 reaches the end of its forward stroke to ensure that the ends of the trailing pile yarns in block 20b are cleanly severed by blade 135 as the tufts formed thereof are deposited upon the adhesive-coated backing 142.

The reversible motor 127 may be equipped'with conventional braking means, not shown, so'that it will respond quickly to changes in the flow of current therethrough. Thus, at about the instant that the trailing or rearmost edge off-the corresponding increment of pile .tufts is severed from the lower end of pile yarn block 20b, a right-hand or forward limit switch 230 (FIGS.

10, 11 and 13) is actuated by engagement of the container carriage 120 therewith to change the state of its

contact sets

230a, 230b, 2300 (FIG. 13). It is apparent that actuation of limit switch 230 and the consequent closing of contact set 23% energizes the coil of reversing relay 211 to, in turn, energize the rearward or reverse winding of electric motor 127.

At the same time, the opening of contact set 230c of switch 230 breaks the flow of-current to the coil of relay 226, thus interrupting the flow of current to clutch 160 and stopping further forward movement of the

conveyors

143, 152 and roll 170 (FIGS. 10 and 10A). The momentary closing of contact set 2300, as effected by engagement of switch 230 by the carriage 120, closes a circuit to a suitable time delay mechanism 233 (FIG. 13) which is of a well-known type including a condenser C and a resistor R which function in a well known manner to energize the coil of relay 220 upon the circuit to relay 233 being subsequently broken by the release of limit switch 230.

It is apparent that limit switch 230 is released as motor 127 causes carriage to start to move from right to left or rearwardly in FIGS. 9, 10 and 11. Thus, by delaying the operation of relay 220 in the manner last described, the back-up bar 227 moves rearwardly of the rear edge of cutting blade 135. Thereupon, the energization of the solenoid valve 221 is effected to, in turn, elevate the container 60 and yarn block 20b in the manner heretofore described. It follows that, as the carriage 120 moves rearwardly, the lower surface of the yarn block 20b then will not rub against the cutting blade 135, thus insuring that cutting blade will not cause lint, dust and the like to be dislodged from the pile yarns in the block 20b and thus deposited on the adhesive-coated backing 142. It is apparent that container 60, yarn block 201) and carriage 120 then return to the rearmost position in the path of travel thereof to complete a cycle in the operation of the apparatus of FIGS. 9-14 and to initiate a succeeding cycle in the op eration thereof.

It is also apparent that the operation of the pile fabric manufacturing apparatus 115 may be repeated as many times as desired for obtaining any desired continuous length of pile fabric. Also, if desired, the size of the pile yarn block 20b, when measured parallel to the direction of forward and rearward movements thereof, may be equal to the desired length of a carpet or rug. In such instance, the extent of carpet formed by one movement of the yarn block 20b past the cutting blade 135 may be spaced from a succeeding length of carpet formed by a succeeding movement of the yarn block past the cutting blade simply by providing a suitable manually adjustable relay mechanism or any other suitable means for extending the intervals of operation of the

conveyors

143, 152 after the yarn block 20b has moved ahead of the cutting blade 135.

Because of the relatively high density of the compacted yarn block and the fact that such high density is maintained by the surrounding walls of container 60, it has been found that practically the entire length of the weft yarns forming the pile yarns may be severed from the yarn block before it becomes necessary to replace the yarn block with another obtained from the apparatus of FIG. 3, for example.

In any event, in order to replace the yarn block 2012 and container 60 with another yarn block of similar structure, manually operable valve 217 in the upper portion of FIG. 13 may be operated to return the pusher plate to a raised position relative to container 60. At the same time, the timing device 212 may be manually adjusted to permit a continuous flow of fluid from the source 2.16 through

valves

215, 217 to the lower end of cylinder 14lb to elevate the pusher plate 140 in the manner described. Thereafter, valve 217 may be closed, the conduits extending therefrom to cylinder 141b may be removed from cylinder 141b and a suitable hoisting mechanism then may be employed for lifting the container 60, with the upper carriage frame 120b, upwardly away from lower carriage frame 120a. The arch 120e, ram 141, pusher plate 140 and upper carriage frame 120b then may be removed from the corresponding container 60 and mounted on a fresh filled container 60 so that the fresh container 60 may be positioned in the lower carriage frame 120a preparatory to the manufacture of pile fabric from the pile yarn block therein in the manner heretofore described.

It is to be noted that, while the application of liquid adhesive to the lower surface of the pile yarn block 20b prior to the severing of the tufts therefrom by severing means 135 aids in obtaining a firm bond between the piletufts T and the backing or substrate 142, it has been found that satisfactory results are obtained when the liquid adhesive is applied only to the upper surface of the backing 142. It is to be understood, therefore, that it is not essential in accordance with the invention to treat the lower ends 'of the pile yarns in the yarn block 20b to render them adhesive if the backing is provided with a suitable coating of adhesive thereon prior to the depositing of the severed pile yarn tufts onto the backing 142.

It has been determined however, that by utilizing thermoplastic pile yarns in the block 20b, high density pile fabrics may be manufactured by heat-fusing the lower ends of the pile yarns together or to a substrate of thermoplastic material. To this end, a modified form of pile fabric manufacturing apparatus 115' is shown in FIG. wherein, instead of utilizing an adhesive applicator such as that indicated at 200 in FIG. 10, a suitable heating device 250 is employed which is positioned closely adjacent and upstream of the cutting blade or severing means and immediately below the forward path of travel of the pile yarn block. In all other respects, the apparatus 115 shown in FIG. 15 may be identical to that shown in FIGS. 9-14 and, therefore, the parts shown in FIG. 15 will bear the same reference characters as those applied to like parts shown in FIGS. 9-14, where applicable.

Accordingly, it will be observed in FIG. 15 that the heating device 250 may be in the form of an infrared ray heat-radiating medium or heater having infrared lamps 251 therein which are spaced closely beneath the forward path of travel of the pile yarn block b, an increment of which had been previously discharged from the open lower end of container 60 in the manner heretofore described. Thus, the lower surface of the yarn block 20b is melted to cause the lower ends of adjacent pile yarns therein to adhere to one another, whereupon cutting blade 135 severs the pile tufts from the lower end of the block 20b'and deposits the same onto the upper surface of the backing 142.

In this instance, the backing 142 need not have been coated with a liquid adhesive. In fact, if backing 142 is partially or entirely of a thermoplastic material, the.

ously melted anchoring layer 252a of the thermoplastic v material of which the pile yarn tufts T are formed. In

fact, assuming that the backing 142 in FIG. 16 is of a thermoplastic material, it is also apparent that the thermoplastic material 252a forming the anchoring layer may be formed, in part, from the backing 142.

Referring to FIG. 17, there is shown a portion of a pile fabric 253 which may be identical to the pile fabric 252 with the exception that, instead of the lower ends of the pile tufts T" thereof being fused or otherwise secured to a substrate or backing, such backing is omitted and the lower ends of pile tufts T" are simply fused together by the supporting anchoring layer 253a of previously melted thermoplastic material.

It is apparent that, in forming the pile fabric 253 of FIG. 17, the backing 142 would be omitted in FIG. 15 and the successive slices of pile tufts severed from the lower end of pile yarn block 20b would simply be fused together when subjected to the heat from the infrared lamps 251 and thus deposited somewhat in the form of tiles upon the conveyor 143. Of course, in forming the pile fabrics 252, 253 of FIGS. 16 and 17, it is apparent that the

conveyors

143, 152 then may be operated at a surface speed corresponding to that of the forward movement of the carriage 120.

In all other respects, the apparatus shown in FIG. 15 may be constructed and operated in the same manner as that described for the pile fabric manufacturing apparatus 115 shown in FIGS. 9-14. Therefore, a further description of the apparatus 115' shown in FIG. 15 is deemed unnecessary.

In the drawings and specification there have been set forth preferred embodiments of the invention, and although specific terms are employed, they are used in a generic and descriptive sense only and notfor purposes of limitation.

That which is claimed is:

l. A method of making pile fabrics such as carpets, rugs and the like from a block of substantially parallel pile yarns in an open-ended container, which comprises incrementally feeding the pile yarns parallel to their axes from the container in successive increments of an amount equal to the desired length of pile, progressively severing the pile yarns transversely of their axes following each successive incremental feeding of the pile yarns from the container while progressively depositing the severed pile yarns onto an adhesive-coated backing to connect the severed pile yarns to the backing, and while advancing the backing relative to the block of pile yarns.

2. A method according to claim 1, which includes following the depositing of the pile yarns, the step of pressing the successive deposited pile yarns and the backing together to aid in connecting the depositedpile yarns to the backing.

3. A method according to claim 1, including the steps of drying and curing the adhesive on the adhesivecoated backing while pressing the deposited pile yarns and the backing together to aid in connecting the deposited pile yarns and the backing together.

4. A method according to claim 1,'which includes moving the block of pile yarns over the backing and over a stationarily mounted severing means in the same general direction as that in which the backing is being advanced during the severing of the pile yarns and the depositing of the severed pile yarns onto the backing.

5. A method according to claim 4, in which the advancing of the backing comprises advancing the same

Claims

1. A method of making pile fabrics such as carpets, rugs and the like from a block of substantially parallel pile yarns in an open-ended container, which comprises incrementally feeding the pile yarns parallel to their axes from the container in successive increments of an amount equal to the desired length of pile, progressively severing the pile yarns transversely of their axes following each successive incremental feeding of the pile yarns from the container while progressively depositing the severed pile yarns onto an adhesive-coated backing to connect the severed pile yarns to the backing, and while advancing the backing relative to the block of pile yarns.

2. A method according to claim 1, which includes following the depositing of the pile yarns, the step of pressing the successive deposited pile yarns and the backing together to aid in connecting the deposited pile yarns to the backing.

3. A method according to claim 1, including the steps of drying and curing the adhesive on the adhesive-coated backing while pressing the deposited pile yarns and the backing together to aid in connecting the deposited pile yarns and the backing together.

4. A method according to claim 1, which includes moving the block of pile yarns over the backing and over a stationarily mounted severing means in the same general direction as that in which the backing is being advanced during the severing of the pile yarns and the depositing of the severed pile yarns onto the backing.

5. A method according to claim 4, in which the advancing of the backing comprises advancing the same at a faster rate than that at which the block of pile yarns is being moved to obtain a desired density of the severed pile yarns on the backing.

6. A method according to claim 4, in which the advancing of the backing comprises imparting stepwise forward movements thereto with the length of each step substantially corresponding to that length of pile fabric to be formed by the severing of one slice from the pile yarns, and moving the block of pile yarns rearwardly of the severed pile yarns last deposited onto the backing following the severing of each successive slice from the pile yarns and during respective intervals between successive stepwise forward movements of the backing.

7. A method according to claim 6, which includes continuously feeding the backing forwardly from a source located rearwardly of the severing means while accumulating a length of the fed backing at a location rearwardly of the severing means but forwardly of the source, and wherein the step of imparting stepwise forward movements to the backing comprises drawing the backing from the accumulated length during each stepwise movement of the backing.

8. A method according to claim 6, which includes continuously feeding the backing from a source rearwardly of and toward the severing means while forming a catenary loop of the backing at a location upstream of the severing means, and the step of imparting stepwise forward movements to the backing including drawing the backing from the catenary loop past the severing means during each of said stepwise movements.

9. A method according to claim 6, in which the advancing of the backing further comprises accumulating a length of the pile fabric formed of the backing during advancement thereof at a location downstream of the severing means, and said method further comprising contiNuously taking up the pile fabric downstream of the accumulated length of the pile fabric by withdrawing the pile fabric from the accumulated length at a rate substantially in accord with the average rate of the stepwise forward movements of the backing past the severing means.

10. A method according to claim 6, wherein the advancing of the backing further comprises forming a catenary loop of the pile fabric during advancement thereof at a location downstream of the severing means, and said method further comprising continuously taking up the pile fabric downstream of the catenary loop by withdrawing the pile fabric from the loop at a rate substantially in accord with the average rate of the stepwise forward movements of the backing past the severing means.

11. A method according to claim 1, which includes applying an adhesive material to the end of the block of yarns before each severing of the pile yarns transversely of their axes to aid in the subsequent connecting of the respective severed pile yarns to the adhesive-coated backing.

12. A method according to claim 1, which includes moving the block of pile yarns over the backing and in the same general direction as that at which the backing is being advanced during the severing of the pile yarns and the depositing of the severed pile yarns on the backing, and wherein the severing of the pile yarns is effected at a predetermined substantially fixed point in the path of travel of the pile yarn block, and the advancing of the backing relative to the block of pile yarns including moving the backing in a path converging toward and into close proximity to the path of the block of pile yarns at said fixed point to aid in the depositing of the severed pile yarns onto the backing.

13. A method of making pile fabrics, such as carpets, rugs and the like, which comprises incrementally feeding downwardly a compact block of substantially parallel and substantially vertically extending thermoplastic pile yarns from an open-ended container and in increments of an amount equal to the desired length of pile, fusing the lower ends of the pile yarns together following each incremental feeding of the pile yarn block from the container by moving the pile yarn block in a substantially horizontal path over a heat-radiating medium which melts and thereby fusibly interconnects the lower ends of the adjacent pile yarns, and then severing the fed increment of the pile yarn block transversely of the axes of the pile yarns to form a tuft slice therefrom while continuing the movement of the pile yarn block in said substantially horizontal path and while moving the tuft slice being formed onto a support.

14. A method according to claim 13, wherein the support is a backing and including the step of fusibly securing the slice being formed to the upper surface of the backing.

15. A method of making pile fabrics such as carpets, rugs and the like which comprises moving an open-bottomed container, with a compact block of substantially vertically arranged pile yarns therein, forwardly a predetermined distance in a substantially horizontal path extending over and generally parallel with an adhesive-coated backing, advancing the backing forwardly through a tuft forming zone in a path closely adjacent the lower surface of the pile yarn block and at a faster speed than that of the yarn block and the container, while progressively severing tufts from the lower ends of the pile yarns in the block in their course through the tuft forming zone and progressively depositing the tufts being formed onto the adhesive-coated backing to connect the tufts to the backing, stopping the forward movement of both the container and the backing each time the backing is advanced a distance corresponding to the length of pile fabric to be formed from a single slice of the pile tufts thus severed from the pile yarns, and then moving the container with the block of pile yarns therein rearwardly to a position upstream of said tuft forming zone while positioning The front end of the block of pile yarns rearwardly of the tufts last deposited onto the backing to complete a cycle in making the pile fabric.

16. A method according to claim 15, which also includes advancing the backing forwardly upstream of the tuft forming zone by moving the backing in substantially spaced relation below the horizontal plane of the path of the container in the course of movement of the backing into the tuft forming zone, and said method further including the step of subjecting the lower ends of the pile yarns in the block to a treatment which renders the lower ends of the pile yarns adhesive during that portion of the forward movement of the container and the block of pile yarns upstream of the tuft forming zone.

17. A method according to claim 15, wherein the severing of tufts from the pile yarns in the block includes moving the yarn block past and in engagement with a laterally moving cutting blade occupying a predetermined substantially horizontal position in said tuft forming zone, and said method further comprising maintaining the container on a higher level during rearward movement thereof over the cutting blade than the level occupied by the container during its forward movement past the cutting blade so that the lower surface of the yarn block is spaced above and out of contact with the cutting blade during rearward movement of the yarn block.

18. A method of making patterned pile fabrics, such as carpets, rugs and the like, comprising forming a patterned block of pile yarns by the steps of forming successive interconnected sections of woven fabric utilizing pile yarns for the wefts thereof by selectively interweaving with a plurality of binder warp yarns a plurality of weftwise pile yarns of different colors in a predetermined patterned order, and by inserting visually distinct identifying weft yarns at substantially uniformly spaced locations in the fabric to define the junctures of adjacent fabric sections, forming a compact stack of layers of the woven fabric by moving the fabric back and forth while folding the same along the identifying weft yarns to form the successive fabric sections into a stack of superposed fabric layers while aligning the successive layers with each other so that the ends of the pile yarns therein collectively form a composite pattern, enclosing the compact stack of folded fabric in an open-ended container to form a confined block of the pile yarns with the ends of the pile yarns exposed and forming the composite pattern at an open end of the container, incrementally feeding the block of pile yarns from the open end of the container in successive increments of an amount in accord with the desired length of pile, applying a liquid adhesive coating to a backing, progressively severing the end of the pile yarn block following each successive incremental feeding of the pile yarns from the container to form tufts therefrom while progressively depositing the tufts being formed onto the adhesive-coated backing to connect the tufts to the backing, and while advancing the backing relative to the block of pile yarns.

19. A method according to claim 18, which includes moving the block of pile yarns over the adhesive-coated backing and over a stationarily mounted severing means in the same general direction as that in which the backing is being advanced during the severing of the pile yarns and the depositing of the tufts onto the backing.

20. A method according to claim 18, which includes following the depositing of the tufts, the step of pressing the successive deposited tufts and the backing together to aid in connecting the deposited tufts to the backing.

21. A method according to claim 18, which includes moving the block of pile yarns over the adhesive-coated backing and over a stationarily mounted severing means in the same general direction as that in which the backing is being advanced during the severing of the pile yarns and the depositing of the tufts onto the backing, and wherein the advancing of the backing comprises advancing the same at a faster rate than that at which the block of pile yarns is being moved to obtain a desired density of the tufts on the backing.

22. A method according to claim 21, in which the advancing of the backing further comprises imparting stepwise forward movements thereto with the length of each forward step substantially corresponding to that length of pile fabric to be formed by the severing of one slice from the pile yarns, and said method also including the step of moving the block of pile yarns rearwardly of the severed pile yarns last deposited onto the backing following the severing of each successive slice from the pile yarns and during respective intervals between successive stepwise forward movements of the backing.

23. A method according to claim 22, which includes successively drying and curing the adhesive coating on the backing by moving the pile fabric formed of the backing and tufts forwardly through a heated zone downstream of the severing means during the stepwise forward movements of the pile fabric, and cooling the pile fabric by advancing the same through a cooling zone forwardly of the heated zone during the stepwise forward movements of the pile fabric, the advancing of the backing further comprising accumulating a length of the pile fabric during the stepwise forward movements thereof at a location forwardly of the cooling zone, and said method further comprising continuously taking up the pile fabric forwardly of the accumulated length of the pile fabric by withdrawing the pile fabric from the accumulated length at a rate substantially in accord with the average rate of the stepwise forward movements of the backing past the severing means.

24. Apparatus for making pile fabrics such as carpets and the like from pile yarns and a backing and comprising an open-ended container for accommodating therein a block of substantially parallel pile yarns, means supporting said container with the pile yarn axes extending substantially vertical therein, means for incrementally feeding the pile yarns downwardly parallel to their axes from said container in successive increments of an amount equal to a desired pile length, means cooperating with said feeding means for progressively severing the pile yarns transversely of their axes to form cut tufts thereof following each incremental feeding of the pile yarns from said container, means for applying a coating of adhesive material to the backing, and means for advancing the backing forwardly relative to and closely beneath the yarn block and said severing means during the severing of the pile yarns so that the tufts being formed of the pile yarns are progressively deposited onto the adhesive-coated backing and thereby joined to the backing during the progressive severing of the pile yarns.

25. Apparatus according to claim 24, including means stationarily mounting said severing means, and drive means operatively connected to said container for imparting forward movement thereto past said severing means and at a slower rate than that of the backing.

26. Apparatus according to claim 25, including means connecting said drive means to said backing advancing means, and means interposed between said drive means and said backing advancing means for relatively varying the rate of forward movement of said backing and said container to vary the density of the tufts joined to the backing.

27. Apparatus for making pile fabrics, such as carpets, rugs and the like, from pile yarns and a backing, said apparatus comprising an open-ended container for containing therein a compact block of substantially parallel, juxtaposed, pile yarns, means operatively associated with said container for incrementally feeding the pile yarns parallel to their axes from one open end of said container in increments of an amount equal to the desired length of pile, means for moving said container forwardly in a predetermined path transversely of the pile yarn axes, severing means in the forwArd path of travel of each successive increment of pile yarns fed from said container and arranged to progressively sever the ends of the pile yarns during forward movement of said container past said severing means to form tufts of the pile yarns, means for applying an adhesive coating to the backing, and means for advancing the adhesive-coated backing forwardly past and adjacent said severing means and adjacent said pile yarn block during the severing of the pile yarns so that the tufts being formed are progressively deposited onto the backing and joined thereto during the severing of the pile yarns.

28. Apparatus according to claim 27, including driving connections between said container moving means and said backing advancing means, and means interposed in said driving connections for varying the rate of advancement of said backing relative to the rate of forward movement of said container to vary the density of the tufts deposited onto the backing.

29. Apparatus according to claim 27, including means associated with said backing advancing means for adjustably supporting said backing for movement in predetermined spaced relation below said severing means, and means for varying the extent of each increment of feed of said means for incrementally feeding the pile yarns from said container whereby the length of tufts deposited onto the backing may be varied.

30. Apparatus according to claim 27, including guide means for guiding the backing in a path converging forwardly toward and into close proximity to said severing means and said path of said container, and said guide means also including means for guiding the backing in a forwardly diverging path away from said severing means and away from said forward path of said container, and means positioned forwardly of said severing means and between said path of said container and said diverging path of said backing for pressing the tufts and the backing together to aid in securing the tufts to the backing.

31. Apparatus according to claim 27, wherein said severing means comprises an elongate cutting blade extending transversely across the path of said container, and said container including a transverse shield member having an elongate forwardly facing recess therein and disposed at the trailing edge of said compact block of pile yarns, the recess in said shield member being so positioned as to receive said cutting blade therein during the forward movements of said container past said severing means so that said shield member will aid in supporting each successive increment of the pile yarns at the rear end of the pile yarn block during the severing thereof in the course of each forward movement of said container.

32. Apparatus according to claim 27, including means forwardly of said severing means for heating the pile fabric formed from the tufts and the backing for drying and curing the adhesive on the adhesive-coated backing.

33. Apparatus according to claim 32, including means downstream of said heating means for cooling the previously heated pile fabric during the advancement of the pile fabric.

34. Apparatus for making pile fabric such as carpets, rugs and the like, from pile yarns and a backing, said apparatus comprising a container having an open lower end and containing therein a compact block of substantially parallel pile yarns, container guide means for guiding said container in a substantially horizontal path with the axes of the pile yarns substantially vertically disposed and projecting from the open lower end of said container, means for moving said container forwardly and rearwardly along said path in alternation, severing means positioned closely adjacent and below the path of said container and arranged to sever the lower ends of the pile yarns projecting from the open lower end of said container to form tufts thereof during each forward movement of said container past said severing means, backing guide means for guiding the backing in an abruptly changing path converging forwardly and upwardly toward and into close proximity to said severing means and said path of said container, adhesive applying means disposed rearwardly of said severing means for applying an adhesive coating to the upper surface of the backing in its course to said severing means, means operatively associated with said container for incrementally feeding the pile yarns downwardly from the open lower end of said container in increments of an amount equal to the desired length of pile while the container occupies a position rearwardly of said severing means, and means operable periodically and in timed relation with the forward movements of said container for advancing the adhesive-coated backing forwardly along said abruptly changing path past and adjacent said severing means at a faster rate than the rate of each respective forward movement of said container during the severing of tufts from the lower ends of the pile yarns in the block so that the tufts being formed are progressively deposited onto the backing and joined thereto to form the pile fabric during the severing of the pile yarns.

35. Apparatus according to claim 34, including a variable speed mechanism operatively connected to said backing advancing means for varying the rate of advancement of said backing relative to the rate of forward movement of said container to thereby vary the density of the tufts deposited onto the backing.

36. Apparatus according to claim 35, including an additional adhesive applying means disposed rearwardly of said backing guide means, and said additional adhesive applying means being disposed adjacent the path of the pile yarn block projecting from the open lower end of said container for applying adhesive to the lower ends of said pile yarns in the course of each forward movement thereof into operative relation to said severing means.

37. Apparatus according to claim 34, wherein said backing guide means comprises a first endless conveyor having an upper reach on which the backing is supported and advanced past said severing means, and means including an additional endless conveyor positioned closely above and extending in substantially parallel relation to the upper surface of said first endless conveyor and forwardly of said severing means but below the path of travel of said container for pressing the tufts and the adhesive-coated backing together.

38. Apparatus according to claim 34, wherein said feeding means operatively associated with said container comprises a substantially horizontal pusher plate positioned for substantially vertical movement in and relative to said container for pushing downwardly against the upper ends of the pile yarns in the yarn block, and means operatively connected to said pusher plate for imparting incremental downward movements thereto to push corresponding increments of the pile yarns out of the open lower end of said container.

39. Apparatus according to claim 34, including means responsive to forward movement of said container into a position closely adjacent said severing means for initiating operation of said backing advancing means, and means responsive to forward movement of said container relative to said severing means for stopping operation of said backing advancing means following the severing and depositing of each successive slice of tufts onto the backing.

40. Apparatus according to claim 39, including means automatically operable during each rearward movement of said container for elevating said container and maintaining the same in an elevated position so that the lower ends of the pile yarns in said block will clear and be positioned out of engagement with said severing means in the course of each rearward movement thereof.

41. Apparatus according to claim 34, including means upstream of said backing guide means for feeding said backing in a substantially continuous manner from a source toward said backing guide means, and said backing feeding means including a supporting roll for the backing and spaced rearwardLy of said backing guide means for cooperating therewith so that a length of the backing may be accumulated between said supporting roll and said backing guide means to facilitate the periodic advancement of the backing past said severing means as the backing is being fed continuously by said backing feeding means.

42. Apparatus according to claim 34, wherein said backing guide means includes a fabric supporting roll at its front end, fabric take-up means downstream of said backing guide means, means for driving said take-up means in a substantially continuous manner, an additional fabric supporting roll spaced forwardly of said first-named fabric supporting roll and supporting the pile fabric in its course to said take-up means, and said supporting rolls being arranged so that a length of the pile fabric may accumulate therebetween to facilitate continuous take-up of the pile fabric during the periodic advancement of the backing past said severing means.