Systems and methods of forming patterned tufted products

Abstract

A system, apparatus, and method for forming tufted products may include a tufting machine for forming patterned tufted products, such as carpets, carpets, and artificial grass or turf products, in which indicia of other designs are integrated, including yarns of multiple colors. The tufting machine may include a series of hollow needles arranged at a needle gauge pitch along a needle bar, and may receive a series of yarns of different colors and / or types from a yarn feed system. A yarn selection system may be controlled to selectively block or retract yarn from the needle. The needle reciprocates into and out of the backing to deliver a series of yarns into the backing and may be engaged by a corresponding cutter to form a yarn cluster.

Description

[0001] Cross-references This application claims the benefit of U.S. Provisional Application No. 63 / 533,171, filed August 17, 2023, U.S. Provisional Application No. 63 / 555,590, filed February 20, 2024, and U.S. Provisional Application No. 63 / 683,097, filed August 14, 2024.

[0002] Reference inclusion The disclosures of U.S. Provisional Application No. 63 / 533,171, filed August 17, 2023; U.S. Provisional Application No. 63 / 555,590, filed February 20, 2024; and U.S. Provisional Application No. 63 / 683,097, filed August 14, 2024, are incorporated herein by reference for all purposes, as if their entire contents were set forth herein. Technical Field

[0003] This disclosure generally relates to tufted fabrics or products, and more specifically, to systems and methods for forming tufted fabrics or products in which patterned designs are formed, including forming patterned artificial / synthetic sports grass or turf fabrics or products. Background Technology

[0004] Tufted products bearing company branding (such as logos, font designs, and other graphic patterns), such as rugs, tarpaulins, and turf, have become increasingly popular. Furthermore, with the widespread installation of artificial or synthetic grass or turf products in indoor and outdoor applications, the demand for turf products with a wider range of colors and / or patterns (such as team or sponsor logos, or various graphic designs) is also growing. Previously, creating large tufted product fields (such as turf or artificial turf fields) with graphic patterns or designs (such as logos, numbers, or other features) required first installing sections of ordinary turf or artificial turf on the field. Then, either the desired design or logo was drawn on the turf or artificial turf, or a portion of the installed turf or artificial turf was cut and removed, and pre-cut logos, numbers, or other design features in the desired colors were inserted and secured (e.g., glued) into place. This process was typically labor-intensive, time-consuming, and costly, and could lead to increased material waste and, in some cases, inaccuracies in the alignment of the subsequently applied logos or other complex designs. Additionally, as athletes grow larger and stronger, the force exerted on the turf or artificial turf during a match may also increase, which could make the turf or artificial turf more prone to separation along the seams where the turf has already separated and where markings or other designs have been applied.

[0005] Therefore, it can be seen that there is a need for a system and method for forming patterned tufted products (including artificial / synthetic grass or sports turf products) to address the aforementioned problems as well as other related or unrelated problems in the art. Summary of the Invention

[0006] In summary, this disclosure generally relates to systems and methods for forming patterned tufted products, including carpets, rugs, tumblers, sports rugs (including but not limited to artificial grass or turf), products for landscaping applications, and / or other tufted products for commercial and residential applications. In embodiments, the tufted products may include patterned designs comprising a variety of different colors, different pile heights, and / or loop piles and / or cut piles. In one example embodiment, the patterned tufted products formed using the systems and methods of this disclosure may be formed from various colors and / or types of yarns, including synthetic grass or turf-type filaments or yarns and / or other yarns, which may be inserted into a backing material to form patterned artificial / synthetic grass or turf products, as well as tufted products including carpets and tumblers.

[0007] In embodiments, the yarn may include one or more yarns for forming carpets and rugs (e.g., shag carpets) or for forming sports carpets or turf products, and may include combinations of one or more filaments and / or ribbon yarns for forming sports field and landscaping applications. In embodiments, the systems and methods of this disclosure generally include and / or can be adapted for use in a tufting machine comprising at least one row of needles that reciprocate by entering and exiting a backing material passing beneath the needles to insert multiple yarns into the backing material for forming tufts therein. In embodiments, the tufting machine may include a hollow needle type tufting machine having multiple hollow needles arranged in a spaced-apart series along a needle bar. In some embodiments, the tufting machine may include more than one needle bar having multiple needles spaced apart therefrom (e.g., a pair of needle bars, each driving multiple needles, may be provided).

[0008] Additionally, in one embodiment, the tufting machine may include a needle stroke support assembly configured to guide a pusher that drives the needle bar in reciprocating motion. In another embodiment, each needle stroke assembly may include a series of support plates, including an upper support plate and a lower support plate, through which the pusher is received. The lower support plate may serve as a bracket or support, which may have a first guide mounted thereal. The pusher extends through the support plate and connects to a pusher foot coupled to the needle bar. The pusher foot may have a second guide that interacts with the first guide on the lower support plate to help guide linear movement of the pusher and needle bar during each needle stroke and to help reduce the pressure applied to the pusher and to resist and limit excessive vibration and / or lateral movement of the pusher during the needle's entry and exit from the backing.

[0009] In some embodiments, yarns of a specific color can be assigned to or associated with each needle. For example, needles can be configured with selected color threading patterns, such as ABC, ABCD, ABCDE, ABCDEF, etc., where one or more selected colors of yarn are directly fed into a single needle. In some embodiments, two or more yarns can be directly fed into each needle. In other embodiments, yarns can be directly fed into their associated needles using gas from at least one ejector, and in some embodiments, two ejectors can be provided, one on each side of the needle. Thus, one or more selected colors of yarn can be directly fed into the associated needles without having to feed multiple colors of yarn into the funnel of each hollow needle and then selectively feed one color of yarn into the hollow needle.

[0010] Additionally, in some embodiments, the yarn tube may be mounted along the needle bar and communicate with each needle to help retain the yarn within the needle. In some embodiments, the yarn tube may extend at an angle into and through an opening in the needle bar to guide the yarn to its corresponding needle. In some embodiments, the yarn tube may be positioned adjacent to the needle bar and may communicate with and be fed into a channel extending through the needle bar for feeding into a channel defined by an associated needle. In other embodiments, the yarn is fed directly into a channel formed along the needle bar and into a hollow needle.

[0011] In some embodiments, the needle bar may be coupled to a shifting mechanism, such as a servo motor-driven shifting mechanism, a rack-and-pinion shifting mechanism, or other shifting mechanisms, for laterally shifting the needle relative to the backing material. In some embodiments, a backing support or shuttle supporting the backing material during tufting operations may be coupled to the shifting mechanism and may shift in coordination with the needle shifting, or in some embodiments, shift independently of the needle shifting. In alternative embodiments, the backing may shift or the needle bar may shift laterally, or both the backing and the needle bar may shift laterally. In other embodiments, only the shuttle supporting the backing is coupled to the shifting mechanism, such that the backing can shift in such a way that the lateral position of the needle is substantially consistent when the backing moves laterally relative to the needle, or the needle shifts in different increments and / or in different directions.

[0012] In some embodiments, the system of this disclosure may further include a tufting machine having multiple hollow needles, a yarn feeding system, a yarn selection system, a yarn cutting system, and a control system. In embodiments, the yarn feeding system may include a yarn feeding mechanism or pattern attachment having multiple yarn feeding devices, each configured to feed one or more yarns into the hollow needles. For example, in embodiments, the yarn feeding mechanism may include a single-end or double-end yarn feeding mechanism having multiple individual yarn feeding devices that can be selectively controlled to feed one or two yarns, or in some embodiments, more than two yarns into one or more associated needles. Additionally, in some embodiments, the yarn feeding device of the yarn feeding system may include a yarn feeding roller driven by a servo motor, the yarn feeding roller being sized or otherwise configured to control the feeding of a selected length of yarn per revolution to form individual stitches or tufts and / or tufts of a selected pile height. For example, in one embodiment, at least some yarn feeding devices may include one or more feed rollers and a drive roller, the feed rollers being configured to have a larger diameter to feed a predetermined amount of yarn per revolution and assist in feeding the yarn, such as polymer yarns or filaments typically used for artificial turf or grass, the drive rollers having a smaller diameter than the feed rollers to compensate for a possible reduction in the torque of the fed yarn due to the increased size of the feed rollers.

[0013] In one embodiment, the yarn selection system can be arranged along the yarn's travel path or passage from the yarn feed system to the needle. In another embodiment, the yarn selection system may include a series of yarn jerkers, each coupled to an actuator and positioned along the yarn's travel path from the yarn feed system to the needle, for selectively engaging the yarn being fed into the needle. The yarn jerkers can be selectively controlled to extend and retract along a selected length or stroke, which in this embodiment can be set or adjusted to a selected distance. The yarn jerkers can move between an extended position and a retracted position to allow selected yarn to be fed into the needle according to a forming pattern, or to retract or prevent unselected yarn from being fed through the needle.

[0014] Additionally, in some embodiments, the yarn pullback device may be coupled to or integrated with a pullback module, which may include actuators for controlling the movement of the yarn pullback device between its extended and retracted positions. For example, in some embodiments, the pullback module may include multiple orifices, each receiving a piston rod therein, but other types of actuators may also be provided. In some example embodiments, the pullback module (and / or its actuators) may include a double-acting cylinder configured without a mechanical spring return, and in some embodiments, gas supplied to different portions of the orifices of the pullback module (and / or its actuators) may be used to cause selective movement of the piston along the orifices to control the extension and retraction of the yarn pullback device.

[0015] In one embodiment, the cutting system is positioned below the backing support and can be selectively actuated by the yarn driven by the cutting needle to form yarn clusters in the backing material. In another embodiment, the cutting system may include a series of cutters or one or more cutting blades. In some embodiments, the cutters or one or more cutting blades may be mounted individually along a cutter shank or received in a module that can be mounted along a cutter shank.

[0016] In some embodiments, the cutter or one or more cutting blades may be maintained in a substantially stationary position, wherein the cutting edge of the cutter or one or more cutting blades is arranged at a substantially fixed height or position relative to the lower portion of the puncture depth or travel of the needle into the backing. In embodiments, as the needle pierces the backing, the cutter or one or more cutting blades may move up and down, toward and away from the needle, wherein the cutter or one or more cutting blades may move individually or together between a retracted, non-engaging, or non-cutting position and one or more extended cutting positions for engaging and cutting the yarn driven into the backing by the needle.

[0017] In some embodiments, the cutting system may include: a plurality of individually controllable tool modules or blocks, each tool module or block having a body in which a tool or at least one cutting blade is mounted; and a multi-position actuator, such as a cylinder, which may be selectively controlled or selectively activated to move its corresponding or associated tool or at least one cutting blade between a non-cutting position and at least a first and second cutting position (e.g., a non-engaging position and one or more engaging positions) in relation to the needle stroke during reciprocating motion of the needle entering and exiting the backing.

[0018] In one embodiment, the cutter may have a substantially flat cutting edge or surface, which is suitable for cutting flat, flat yarns or filaments, for example, those used for artificial grass or turf.

[0019] In other embodiments, the cutting system may include at least one elongated cutting blade or plate, which may replace at least a portion of a series of cutters. In embodiments, the at least one cutting blade may have an elongated, substantially flattened cutting edge. Additionally, the at least one cutting blade or plate may be movable between a non-engaged / non-cutting position and an engaged / cutting position to cut a series of yarns.

[0020] Additionally, in embodiments, the cutting system may include one or more multi-position actuators. In embodiments, a controlled flow of pressurized gas or other fluid can be supplied from a gas source to the multi-position actuator via a control system to move a cutter or at least one cutting blade between various selected cutting positions for forming a cut pile tuft of a selected pile height and non-interlocking or non-cutting positions for forming a loop pile tuft. For example, in embodiments, the multi-position actuator may include a three-position actuator (e.g., a three-position pneumatic or hydraulic cylinder), a servo or stepper motor, or other actuators. In embodiments, the multi-position actuator may include a four-way fluid valve for selectively controlling the supply of fluid (e.g., gas) to the multi-position actuator. In embodiments, at least two positions may be provided for each cutter or at least one cutting blade; for example, a high-cutting position, a low-cutting position, and a non-cutting or looping position may be provided.

[0021] In some implementations, in addition to the cutting tool or at least one cutting blade of the cutting system, other needle gauge components (e.g., loopers, hooks, level cut loop loopers, clips, etc.) may be provided.

[0022] In one embodiment, the control system may be connected to the yarn feeding system, the yarn selecting system, the cutting system, and other actuators of the tufting machine (e.g., the spindle and / or one or more drive motors therefor). The control system may be connected to one or more drive motors of the backing feed system and to a gas source (in some example embodiments, the gas source may include a compressor, blower, or canister) to control the flow of pressurized gas to the pullback module of the yarn selecting system and / or the actuators of the cutting system. In another embodiment, the control system may include one or more processors and programs configured to cooperatively: control the yarn feeding system to feed yarn to the hollow needles; control the engagement of one or more yarn pullback modules of the yarn selecting system to pull back unselected yarn; and / or control the movement of one or more cutters or one or more cutting blades of the yarn cutting system to form a selected pattern.

[0023] In implementations, the control system may include instructions or programs that can be executed to cooperatively control various actuators or components of the tufting machine to form patterns using more colors or types of yarn, patterns that can be formed without increasing the needle gauge spacing. For example, but not limited to, in implementations, patterned articles comprising four, eight, sixteen, or possibly more colors of yarn can be formed, wherein the hollow needles of the tufting machine are arranged at a selected needle gauge spacing. For example, the needle gauge spacing is approximately 1 inch, and the yarn is fed substantially uniformly into each needle. Other needle gauges may also be provided.

[0024] In some embodiments, the needles can be arranged at a certain spacing, which can be selected based on the tufting needle gauge of the tufted product. For example, in embodiments, the needles can be arranged at a needle gauge spacing of approximately ¼ inch to 1 inch, and in some embodiments, needle gauge spacings of approximately ¼ inch, 3 / 8 inch, ½ inch, 5 / 8 inch, ¾ inch, 7 / 8 inch, 1 inch, 1 1 / 4 inch, 1 3 / 8 inch, 1 ½ inch, 1 5 / 8 inch, 1 ¾ inch, 1 7 / 8 inch, and / or 2 inches can be used. Therefore, in embodiments, the needle bar can be configured with needles arranged according to a true needle gauge spacing, which typically matches the needle gauge of the tufting machine, which can also typically match the required or selected needle gauge of the tufted product being produced.

[0025] Additionally, it is conceivable that in some embodiments, by shifting the backing, shifting the needles, or both, various different colors can be presented and tufted at various needle gauge spacings, and fabrics with other desired needle gauges based on multiples or fractions of the needle gauge spacing can be produced. Needles can also be installed at closer spacing. The backing, needles, or both can be shifted laterally as needed to form a selected pattern. For example, in some embodiments, the backing can be shifted laterally while the needles remain stationary, maintaining a substantially fixed lateral position as the needles reciprocate into and out of the backing. Thus, patterns with a configuration having yarn tufts or groups arranged at different spacings in the needle gauge direction (e.g., along the needle bar or laterally through the backing) and the longitudinal direction (e.g., the direction of feeding the backing).

[0026] According to various aspects of this disclosure, a tufting machine is provided, the tufting machine comprising at least one needle bar having a plurality of needles spaced apart therebetween, a yarn feeding system including a pattern attachment (e.g., a single-end yarn feeding mechanism), a needle bar shifting mechanism (e.g., a servo motor or rack and pinion driven shifting mechanism) coupled to at least one needle bar and configured to control the shifting of needles on a backing, and an air-induced yarn selection system defining a yarn feeding path for yarn.

[0027] Alternatively, a backing displacement mechanism may be provided, which in various embodiments may be used in conjunction with a needle bar displacement mechanism (controlled independently of or independently of the needle bar displacement mechanism) and / or used as a substitute for the needle bar displacement mechanism.

[0028] In one embodiment, the needle and / or backing can be displaced, and the yarn feed system and yarn selection system can be controlled to provide a measured length of feed yarn to each cluster in the backing per revolution of the main drive shaft. In one embodiment, each individual yarn feed device of the yarn feed system can feed one yarn into each needle. In one embodiment, the yarn selection system can be positioned between the yarn feed system and the needle and can include a series of yarn pullers. In one embodiment, the yarn pullers can be selectively controlled to retract or pull back the unstitched end of unselected yarn (e.g., by controlling the supply of pressurized gas to the actuator associated with each yarn puller to control the extension and retraction of the yarn pullers), and only selected yarns (e.g., yarns of the desired color or type) are allowed to be fed into the needle.

[0029] In some embodiments, the yarn feeding system of the tufting machine may include a single-end or double-end yarn feeding mechanism. In some embodiments, the single-end or double-end yarn feeding mechanism may also be provided with an enlarged feed roller system configured to feed yarn of a certain tuft length for use in turf or coarse-pile carpets, fields, rugs, or other tufted products having a selected pile height, such as based on industry standard heights for artificial turf or grass fields. In some embodiments, yarn or tuft lengths for forming pile heights exceeding three inches may be provided.

[0030] In one embodiment, the tufting machine is controlled by a control system, which may include one or more processors and programs to control yarn feeding, yarn pull-back actuator actuation, backing feed roller, yarn feed pull roller, needle bar shifting mechanism and / or backing shifter.

[0031] According to other aspects of this disclosure, a method is provided for operating a tufting system to form tufted turf or artificial products in which logos or other designs are integrated. In embodiments, the tufting system may include a hollow needle type tufting machine having a plurality of spaced-apart hollow needles that can be threaded or directly fed a series of different colors or types of yarn based on a desired threading pattern. For example, in embodiments, if 3-4 colors are used in the pattern, the yarn threading sequence of the needles may be ABC or ABCD, wherein at least two yarns are different colors or types of yarn (e.g., yarns A and B, C and / or D, or any combination thereof, may be one color, while the other yarns in the threading sequence may be different colors or types of yarn; or each of yarns A, B, C, and D may have a different color and / or type).

[0032] In some implementations, such as for forming sports carpets or sports turf fields, more colors can be used. For example, in some applications, such as for forming sports turf fields, six colors can be used, including at least one green yarn and a white yarn for most of the field, while the remaining yarns are accent colors for forming markings, etc.

[0033] In some embodiments, the needles can be grouped into several sets of needles and can include different threading patterns. For example, in an embodiment, for a tufted turf product, for areas where the tufting is primarily done with green yarn, one set of needles can be configured with ABCD, ABCDE, ABCDEF, or other threading sequences, wherein, in an embodiment, multiple or all yarns in the threading sequence are of one color (e.g., green), while for other areas where the tufting is done with different colors or types of yarn, another set of needles can have threading sequences with several different colors or types of yarn.

[0034] In implementations, the needle bar shifting mechanism can be controlled to move the needle on the backing, changing the color and / or type of yarn as needed, thereby enabling the presentation and blending of different colors and / or types of yarn on the working surface of the tufted product. This can enhance color control in finished carpet design. For example, in some implementations, the needle can be shifted by one or more needle gauge steps or segments so that multiple colors and / or types of yarn can be presented at one or more stitch positions in the forming pattern; and when a specific color or type of yarn is not needed on the working surface, one or more yarn feeding devices of the yarn feeding system that are feeding such unselected color or type of yarn can be controlled to stop feeding said color or type of yarn. A corresponding yarn puller for such unselected yarn can be actuated to hold or otherwise maintain the unselected yarn with its needle.

[0035] In some implementations, unselected yarns can retract as their needles retract from the backing and can be held inside the needles or in the yarn tubes connected thereto, in order to help keep the unselected yarns together with their needles when the unselected yarns are held back by the yarn pullback mechanism.

[0036] In one embodiment, when the yarn is selected to be reserved for forming clusters or stitches of a pattern, the yarn feeding system can be controlled to feed each selected yarn the desired length or amount to form clusters or stitches of the desired length or pile height, while the yarn puller is moved to a position allowing each selected yarn to pass through, the yarn length being sufficient to form clusters of the selected pile height, so that it can be blown over and / or flowed over its associated needle. In another embodiment, in the yarn feeding system, the yarn feeding roller of the yarn feeding device that controls this selected yarn feeding can be configured to have a diameter / size corresponding to the required or selected amount or length of yarn fed per revolution, the yarn being sufficient to form clusters of substantially a predetermined length, thereby forming clusters or stitches of the desired or selected pile height. In one embodiment, as the needle reciprocates into and out of the backing, the selected yarn exits the yarn tube and is guided into the channel of its associated needle, such that the selected yarn is presented / inserted into the backing and can engage with the corresponding needle gauge component (e.g., engaged and cut by a cutter or cutting blade, or engaged by other needle gauge components, such as a looper, hook, horizontally cut looper, clamp, etc.) to form stitches or clusters in the backing.

[0037] In some implementations, the backing may move incrementally, while in others, it may be fed substantially continuously through the tufted area or region. In some implementations, such as when the backing is laterally displaced while the needles remain in a substantially predetermined position, the backing may be displaced so that the stitch positions of the tufted pattern are substantially aligned with the selected color yarn driven by the needles. The backing may be laterally displaced in various increments or steps, which may include displacing the backing by a distance based on the needle gauge spacing, and in some implementations, this distance may not be associated with the needle gauge spacing (e.g., the displacement distance or length of the backing may be less than or greater than the needle gauge spacing). The backing may be displaced multiple times in both directions over the tufted area so that the selected color yarn is present at the corresponding stitch positions of the pattern, and the backing moves along its path of travel according to the pattern steps.

[0038] In this implementation, the backing feed can be controlled such that the actual stitch rate of the backing feed can include an effective process stitch rate greater than the desired pattern stitch rate for the pattern being formed. In this implementation, the control system can control the yarn feed of the yarn feed system and the yarn selection system, as well as the control of the backing material at a higher effective or actual stitch rate, to significantly increase the number of needle insertions per inch into the backing material (e.g., each needle in the threading sequence can be inserted into each stitch position of the pattern). Unselected colors or types of yarn may not be placed in the backing, and selected colors or types of yarn may be placed in the backing to form the desired tufts, thereby substantially avoiding the formation and appearance of missing yarns or gaps of color or type in the patterned areas of the patterned tufted fabric, or otherwise such occurrences. Therefore, finished patterned tufted products can be configured with a number of tufts per inch, or other number of stitches per inch, that substantially matches the desired or specified pattern stitch rate, such that the resulting finished patterned tufted products can be formed with a density of visible and / or retained yarn or tufts that substantially matches the desired density of the pattern.

[0039] In some cases, the needle tip can be configured to have a flattened and / or extended cutting surface, which is configured to better cut flat, flat yarn. For example, in one embodiment, the distal end of the needle can be formed with a modified cutting angle and an increased cutting surface, which are configured to increase the needle's shearing angle and shearing surface, thereby cutting flat, flat yarn used in typical turf applications more consistently. Additionally, in one embodiment, the cutting system may include a series of generally flat blades; or in some embodiments, one or more cutting blades may be used instead of a series of blades.

[0040] In one embodiment, the cutter or cutting blade can move between various cutting positions, including a first retracted position and at least a second extended cutting position, in which the cutting edge of the cutter or cutting blade contacts the cutting surface of the needle when the needle pierces the backing. In another embodiment, the cutter or cutting blade can be positioned in modules that can be mounted in series along a shank, and the cutter or cutting blade can be selectively moved as a whole, in groups, to their cutting positions via a control system, or individually as selected yarns are presented at each needle position. When a needle of an unselected yarn pierces the backing at such needle positions, the cutter or cutting blade can be maintained in a lowered, non-engaged, or non-cutting position.

[0041] In some embodiments, the tool or cutting blade may be mounted at a position substantially fixed relative to the needle's travel or puncture depth into the backing. In some embodiments, the tool or cutting blade may be positioned to engage with an associated or corresponding needle. In some embodiments, the cutting surface of the needle may engage the cutting edge of the tool when the needle pierces the backing.

[0042] Additionally, in some embodiments, the yarn feeding and actuation of the yarn return mechanism in the yarn feeding system can be controlled by a control system to actuate based on the position or sequence of the spindle's rotation. In some embodiments, the position or sequence of the spindle's rotation can be related to the stitches or clusters of the forming pattern to actuate the yarn return mechanism in a first and second direction (e.g., between a retracted and extended position). For example, in some embodiments, different stitch lengths or amounts of yarn can be fed at increasing or decreasing rates during different portions of the tufting cycle, or at different times based on the spindle's rotation or position. These stitch lengths or amounts constitute the total stitch length of each selected yarn to be fed to form clusters or stitches of the desired pile height (e.g., in some embodiments, the yarn feeding device of the yarn feeding system can be used to feed different percentages or amounts of yarn depending on the position of the spindle's rotation, unlike the case where a substantially uniform amount of yarn is fed during the rotation of the main drive shaft). In this implementation, such control over the feeding of different amounts or lengths of yarn during different portions of the spindle's rotation can enhance color control in the finished pattern / design.

[0043] Various aspects of this disclosure may include a tufting machine for forming artificial grass or turf products with patterned designs, comprising: at least one needle bar with a plurality of needles positioned along the at least one needle bar, wherein the needles include hollow needles; a yarn feeding system configured to feed a plurality of yarns into the needles, wherein the needles move toward and away from a backing in reciprocating motion, the backing moving along a travel path through the tufting machine to introduce selected yarns into the backing to form tufts as the needles pierce the backing; at least one displacement mechanism for displacing at least some of the needles or for laterally displacing the backing relative to the travel path of the backing; and a yarn selection system arranged along the travel path of the yarns between the yarn feeding system and the needles, the yarn selection system being configured to retract and / or block unselected yarns supplied by the yarn feeding system to one or more needles.

[0044] In an embodiment, the tufting machine may also include a cutting system disposed below the backing and including at least one cutter or cutting blade configured to cut the selected yarn as it is fed into the backing with the reciprocating motion of the needle entering and exiting the backing.

[0045] In an embodiment, the tufting machine may further include a control system comprising a program configured to: control the operation of a yarn feeding system to feed each selected yarn of a selected yarn into a needle at a length sufficient to form a tuft of a predetermined pile height; control the operation of a yarn selection system; and control the operation of at least one shifting mechanism to enable different colors or types of yarn to be presented at each of the multiple stitch positions in the pattern being formed.

[0046] In an embodiment of the tufting machine, the yarn selection system further includes a plurality of yarn pullers and a plurality of actuators, the plurality of yarn pullers being adapted to engage yarn fed into the needles, each of the plurality of actuators being connected to at least one yarn puller and adapted to move the yarn puller between an extended position and a retracted position; wherein each of the yarn pullers is movable between an extended position and a retracted position, the extended position allowing selected yarn to pass through the needles from the yarn feeding system, and the retracted position retracting and / or blocking unselected yarn supplied by the yarn feeding system within one or more needles.

[0047] In an embodiment of the tufting machine, the control system includes a program configured to dynamically drive the operation of the yarn feed system and the yarn pullback or yarn selection system prior to the next stitch placement step of the pattern being formed.

[0048] In an embodiment of a tufting machine, at least one needle bar may include a series of openings spaced apart along the at least one needle bar and communicating with channels extending through corresponding needles; wherein yarn is guided through the openings in the at least one needle bar and into the channels of the needles.

[0049] In some embodiments of the tufting machine, the needle gauges of the artificial grass or turf product based on the tufting machine are arranged along at least one needle bar at a selected needle gauge spacing.

[0050] In some embodiments, the tufting machine may further include a series of yarn tubes mounted along the upper surface of at least one needle bar, each yarn tube communicating with a corresponding needle positioned along at least one needle bar; and an airflow-driven yarn feed device coupled to an air source and configured to guide airflow through the yarn tubes to assist in feeding the yarn through the yarn tubes and the needles. In other embodiments, yarn tubes may not be used.

[0051] In the implementation of the tufting machine, the shifting mechanism includes a rack and pinion type shifting mechanism.

[0052] In an embodiment of a tufting machine, at least one tool or cutting blade includes a substantially flat cutting surface or cutting edge.

[0053] In an embodiment of a tufting machine, each needle includes a body defining an internal channel therein, a first end received within a needle bar, and a second end, the second end terminating at a tip and having a planarized cutting surface configured for cutting flat, flat yarns or filaments.

[0054] In an embodiment of the tufting machine, as the needle reciprocates into and out of the backing, the feeding of selected and unselected yarns is controlled by a yarn feeding system, and the yarn puller moves between a retracted position and an extended position to allow the selected yarn to be inserted into the backing, thereby forming looped or cut tufts of the selected yarn according to the pattern of positive tufting.

[0055] In other aspects, a tufting machine includes: a plurality of needles configured to pierce a backing; a yarn feeding system configured to selectively feed a plurality of yarns into the needles; a yarn selection system including a plurality of yarn pullers adapted to move between an extended position and a retracted position, the extended position allowing selected yarn to be transferred from the yarn feeding system to the needles, the retracted position retracting and / or blocking unselected yarn supplied by the yarn feeding system within one or more needles; and at least one shifting mechanism for causing... The needle is displaced on the backing or the backing is displaced relative to the needle; wherein the needle includes hollow needles, each hollow needle having a first end and a second end, a channel defining between the first end and the second end through which one or more yarns are fed; and wherein as the needle reciprocates into and out of the backing, the feeding of selected and unselected yarns is controlled by a yarn feeding system, and a yarn puller moves between a retracted position and an extended position to enable the insertion of selected yarns into the backing, thereby forming loop pile or cut pile tufts of the selected yarns according to a positive tufting pattern.

[0056] In an embodiment, the tufting machine may also include a cutting system comprising at least one cutter or cutting blade configured to cut selected yarns to form yarn tufts in a backing.

[0057] In an embodiment, the tufting machine may further include a control system having a program configured to control the operation of a yarn feeding system to feed selected yarn into needles, and a program configured to dynamically drive the yarn feeding system to feed the yarn before the next needle placement step of the pattern being formed, and to move the yarn puller between an extended position and a retracted position.

[0058] In one embodiment, the tufting machine may further include at least one needle bar, along which needles are mounted; wherein the needle gauges based on the artificial grass or turf products produced by the tufting machine are arranged along the at least one needle bar at a selected needle gauge spacing.

[0059] In an embodiment, the tufting machine may further include an air source and an airflow-driven yarn feeding device, the airflow-driven yarn feeding device being connected to the air source for guiding the yarn through the needle.

[0060] In an embodiment of the tufting machine, at least one shifting mechanism may include a rack and pinion shifting mechanism.

[0061] In an embodiment of a tufting machine, the second end of each needle includes a tip and a planarizing cutting surface, the tip having an opening through which one or more yarns exit the needle, and the planarizing cutting surface being configured to cut flat, flat yarns or filaments.

[0062] In embodiments of tufting machines, the tufting machine is configured to produce tufted turf or artificial turf products or patches of tufted turf or artificial turf products with integrated designs (e.g., logos), the patches including portions of larger designs and which can be attached together to form sports carpets or artificial turf or turf fields.

[0063] According to other aspects, a method is provided, comprising: moving a backing along a travel path; feeding multiple yarns along the travel path into each of multiple needles from multiple yarn feeding devices; reciprocatingly moving the needles into and out of the backing; displacing the backing or displacing the needles in a direction transverse to the travel path of the backing; selectively controlling the yarn feeding devices to substantially stop or slow down the feeding of unselected yarns to the needles; actuating one or more yarn pull-back devices to engage and impede or pull back the unselected yarns, such that the unselected yarns... Essentially maintained within the needle; selectively controlling the yarn feeder and yarn puller as the movement of the backing along its path of travel is controlled, so that different yarns can be presented at each of the multiple needle positions; and forming multiple selected yarn tufts in the backing; wherein the yarns include artificial grass or turf yarns, the artificial grass or turf yarns including one or more colors to form tufted artificial grass or turf products, the tufted artificial grass or turf products integrating one or more designs, decorative features, logos or portions thereof.

[0064] In an implementation, displacing the backing or the needle includes displacing the backing support, on which the backing moves.

[0065] In one embodiment, the method may include: moving at least one cutting blade to engage with the cutting surface of each needle as the needle pierces the backing, and cutting selected yarns to form clusters of selected yarns in the backing.

[0066] In another aspect, a tufted artificial grass or turf product may be provided, comprising: a backing; and a plurality of spaced-apart tufts of artificial grass or turf yarn formed in the backing to define a patterned area or pattern formed along the backing; wherein the artificial grass or turf yarn includes a variety of different colors; wherein only a selected color of the artificial grass or turf yarn displayed at each stitch position of the pattern being formed is presented for cutting and retained in the backing; and wherein the artificial grass or turf yarn is arranged in a threading sequence comprising at least two artificial grass or turf yarns of different colors and two artificial grass or turf yarns of the same color.

[0067] Therefore, embodiments of tufting machines, systems, and methods for forming patterned tufted products (e.g., carpets, rugs, artificial grass or turf, and / or other tufted products) are disclosed, wherein patterned designs (e.g., logos, pictures, areas of different colors, and combinations thereof) are disclosed to meet the above and other requirements. The foregoing and other advantages and aspects of the embodiments of this disclosure will become apparent and more readily understood from the following detailed description taken in conjunction with the accompanying drawings. Furthermore, it should be understood that the foregoing overview and the following description of this disclosure are exemplary and intended to provide further explanation without limiting the scope of this disclosure. Attached Figure Description

[0068] The accompanying drawings, which are included and incorporated in and form a part of this specification to provide a further understanding of embodiments of this disclosure, illustrate embodiments of the disclosure and, together with the Detailed Description section, serve to explain the principles of the embodiments discussed herein. For the exemplary embodiments and various implementations discussed herein, only the structural details necessary for a basic understanding are shown, and no attempt is made to show more detailed content.

[0069] Figure 1A This is a perspective view of an embodiment of a tufting system or device based on the principles of this disclosure.

[0070] Figure 1B This is a perspective view of an embodiment of a tufting system or device based on the principles of this disclosure.

[0071] Figure 1C This is a perspective view of a portion of the tufting area in an embodiment of a tufting system or device according to the principles of this disclosure, schematically showing the use of the backing displacement mechanism.

[0072] Figure 2A-2H An embodiment of a tufting area or region of a tufting system or device according to the principles of this disclosure is shown.

[0073] Figures 3A-3B An embodiment of a hollow needle for a tufting system or device according to the principles of this disclosure is shown.

[0074] Figure 3C This is a perspective view schematically showing the needle stroke support assembly of a tufting system or device according to the principles of this disclosure.

[0075] Figure 3D yes Figure 3C Cross-sectional view of the needle stroke assembly Figure 3E yes Figure 3C-3D An exploded perspective view of the needle stroke component.

[0076] Figures 4A-4DAn embodiment of a yarn feeding system for a tufting system or apparatus according to the principles of this disclosure is shown.

[0077] Figures 5A-5C An embodiment of a yarn selection system for a tufting system or device according to the principles of this disclosure is shown.

[0078] Figures 6A-6B An embodiment of a cutting system for a tufting system or apparatus according to the principles of this disclosure is shown.

[0079] Figure 6C This is an exploded perspective view of a cutting system of a tufting system or apparatus according to the principles of this disclosure, the cutting system including individually actuable cutting tools.

[0080] Figures 7A-7C An embodiment of a cutting tool module of a tufting system or device according to the principles of this disclosure is shown.

[0081] Figures 8A-8C An example of a multicolored tufted fabric and back stitches formed by a tufting system or device and method according to the principles of this disclosure is shown.

[0082] Figures 9A-9B Examples of a portion of a sports carpet are shown, with particular examples of tufted turf or artificial turf fields, in which various colors and designs are formed as part of the tufted or artificial turf field and its back stitching using tufting systems or devices and methods according to the principles of this disclosure.

[0083] Figures 10A-10B Examples of multicolored tufted fabrics formed by tufting systems or devices and tufting methods according to the principles of this disclosure and their back stitches are shown, with particular examples of sports carpets using flat yarns and / or filaments.

[0084] Figure 11A-11B Examples of multicolored tufted fabrics formed by tufting systems or devices and tufting methods according to the principles of this disclosure and their back stitches are shown, with particular examples of coarse-haired style rugs or carpets shown.

[0085] Figure 12 Examples of multicolored tufted artificial turf or grass products with seamless designs are shown, formed by a tufting system or device and a tufting method according to the principles of this disclosure. Detailed Implementation

[0086] This disclosure will be more readily understood by referring to the following detailed description, examples, drawings, and claims, as well as the descriptions preceding and following them. However, it should be understood that, unless otherwise specified, this disclosure is not limited to the specific apparatus, system, and / or method disclosed, and therefore these can, of course, vary. It should also be understood that, unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains, and the terminology used herein is for the purpose of describing specific aspects of the systems, features, elements, methods, and exemplary embodiments discussed herein, and is not intended to be limiting. Therefore, the following description is provided as an illustration of the principles of this disclosure and not as a limitation thereof.

[0087] By way of example, and throughout the text, unless the context explicitly indicates otherwise, the singular forms “a”, “an”, and “the” include plural references. Thus, for example, unless the context explicitly indicates otherwise, a reference to “a processor” may include two or more such processors. The terms “or” and “and / or” as used herein should be interpreted as inclusive or meaning either one or any combination thereof.

[0088] Additionally, as used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “have,” or any other variations thereof are intended to cover non-exclusive inclusion. For example, a process, method, article, or apparatus that includes a list of features is not necessarily limited to those features, but may include other features not expressly listed or inherent to such process, method, article, or apparatus. Furthermore, unless expressly stated otherwise, “or” means inclusive or not exclusive.

[0089] For ease of description, spatial relative terms such as "below," "under," "lower," "above," and "upper" may be used herein to describe the relationship of one element or feature to other elements or features as shown in the figures. It should be understood that spatial relative terms are intended to cover different orientations of the apparatus, system, or component in use or operation other than those depicted in the figures.

[0090] The dimensional information in the following description should also be understood as intended to cover dimensional variations that typically occur in production; and terms such as “approximately,” “about,” and “substantially” may be used to define the dimensional information in the following description. It will be appreciated that some variations in the dimensions provided for various features may occur without affecting the functionality or availability of the various features. In this document, a range may also be expressed as from “about” one specific value and / or to “about” another specific value. When expressing such a range, the other side includes from said one specific value and / or to said other specific value. Similarly, when a value is expressed as an approximation using the antecedent “about,” it should be understood that a specific value forms the other side.

[0091] As used herein, the terms “tuft” and “stitch” encompass both cut pile tufts or stitches of yarn and loop pile tufts or stitches of yarn, and the term “tufting” encompasses both the action of forming cut pile yarn or cut pile stitches or tufts of yarn and the action of forming loop pile yarn or loop pile stitches or tufts of yarn.

[0092] As used herein, the term "yarn" encompasses yarns, threads, filaments, fibers, and / or combinations thereof used to form tufted products, which may include, but are not limited to, carpets (e.g., cut pile, loop pile, coarse pile, etc.), rugs, artificial grass or turf, and other similar tufted products. By way of example and not limitation, such yarn may include yarns of natural fibers such as cotton, wool, or other similar fibers, and synthetic fibers or filaments such as nylon, polypropylene, acrylic, and / or other polymeric materials, or combinations thereof; and may include two or more yarns fed into each needle. For example, in the production of sports carpets such as artificial turf or grass, the yarn may include a combination of at least one filament (e.g., a polymeric monofilament) and a flat ribbon yarn having a flattened structure.

[0093] Referring to the accompanying drawings, in which similar numbers throughout several views indicate similar portions, Figures 1-6D illustrate exemplary embodiments of a tufting system or device constructed according to the principles of this disclosure and its various actuators and / or features. Figure 8A-12 Examples of tufted products produced using the tufting system or apparatus and methods of this disclosure, and their back stitches, are shown. In various embodiments, such tufted products may include carpets and rugs (e.g., coarse-pile carpets, and loop-pile or cut-pile tufted carpets or rugs with selected pile heights), sports carpets (including, but not limited to, artificial turf or grass for sports fields and / or for various landscaping applications), and other types of tufted products.

[0094] In some example implementations, for example Figure 1A-2HAs shown, a tufting system or device may include a tufting machine 10, which typically includes a plurality of needles 12 that can be mounted in series along a needle bar 11. In an embodiment, the plurality of needles may include hollow needles. Tufting machine 10 ( Figure 1A-1B It may also include other actuating components, such as needle bar drive assembly or system 20, backing feed system 25, yarn feed system 60, yarn selection system 70, and cutting system 80, as well as control system 15 for controlling the operation of these components. In an embodiment, needle 12 may include a hollow needle configured to pierce backing material B to penetrate the backing material B along the travel path P through the tufting machine 10. Figure 1A-1B During movement, a series of yarns Y fed through each needle are delivered and / or implanted into a backing B for forming multiple yarn stitches or tufts therein. Additionally, in embodiments, the tufting machine may include or be connected to an air source, such as a compressor or blower, which supplies pressurized gas to blow the yarns into and through the needles, and in embodiments, to drive the operation of other components of the tufting machine.

[0095] In one embodiment, the tufting machine 10 can feed a series of different colors and / or types of yarn into each needle, and then selectively insert or tuft these yarns into a backing material to form a patterned tufted article. In one embodiment, the yarn tufts can typically include cut pile tufts (but in other embodiments, loop pile tufts may also be formed). In some embodiments, the tufts can be formed with different or varying pile heights to provide texturing or other patterned effects. In some embodiments, various colors and / or types of yarn can be selectively presented by the needles to one or more of a plurality of needle positions of the tufted pattern to form tufted articles, such as carpets, rugs, artificial turf or grass, and other tufted products with patterned designs featuring tufting.

[0096] In one implementation, the tufted product may be formed with a selected design (e.g., a logo or part of a logo, text, markings, or other design), which may include, but is not limited to, areas or portions of a design pattern with different colors or types of yarn, textures, and / or other pattern effects. This selected design may be integrated as part of the tufted product during tufting, rather than having to be formed separately from the rest of the site and then attached to the site (e.g., cutting and sewing a separately created design into a tufted turf field).

[0097] For illustrative and not limiting purposes, exemplary embodiments of the systems and methods of this disclosure are shown and discussed with respect to the formation of tufted products (e.g., sports carpets, including patterned artificial grass or turf products in embodiments), wherein patterned designs (e.g., text, logos, images, areas of different colors, and combinations thereof) can be produced within a tufting area or space defined by a tufting machine frame. Additionally, in the example embodiments shown and discussed herein, the yarns are shown as artificial grass fibers, which can generally be formed from polymer or plastic materials and can have a substantially flat configuration that, upon installation, can mimic the look and feel of grass or turf. However, those skilled in the art will understand that other types of yarns can also be used.

[0098] For example, in, for example Figure 9A and 12 In the illustrated implementation, this tufted product can be formed as patches incorporating integrated patterns or designs, and can be attached together as part of a larger tufted product. Examples may include using base-colored grass fibers or yarns (typically green, but other colors may also be used) to form sections or strips of artificial turf or grass for sports fields, and using additional colored yarns to form designs or parts of designs (e.g., team or sponsor logos, yardage or yardage markings, sideline markings, etc.). The patches can be easily matched and joined (stitched together) to form a complete tufted installation incorporating integrated design or pattern features.

[0099] It should be understood, for example Figure 12 The patterned tufted artificial turf or grass products shown can be formed into larger sections or fields, thereby enabling the integration of a substantially multi-colored patterned design (e.g., the eagle and flag design shown within an integrated green artificial turf or grass field). This is achieved by utilizing a large / full-size tufting machine configured and operated to perform an embodiment of the method for forming tufted products according to the principles of this disclosure. Therefore, patterned designs can be substantially tufted within the artificial turf or grass field or its sections, and the transition between the design and the rest of the artificial turf or grass field is substantially seamless without the need to separately form the pattern before cutting the turf field and sewing the design into said field to produce the final patterned artificial turf or grass field.

[0100] It should also be understood that other tufted products, including carpets, rugs, etc., can also be formed using the tufting system, equipment, and methods disclosed herein. For example, coarse-pile carpets or other types of carpets or rugs with increased pile height can be formed with various designs, patterns, logos, etc., including yarns of various colors or types.

[0101] In example Figure 2A-2CIn the embodiments shown in 2E and 3A, needles 12 can be mounted in a straight line along needle bar 11, wherein the needles are arranged at a desired or selected spacing (e.g., a spacing of about 1 / 2 inch to about 1 inch, or other spacing). In some embodiments, needles can be arranged according to a desired needle gauge or spacing (e.g., a needle gauge spacing of about 3 / 8 inch or larger in some embodiments), including various half-gauges or other spacings. Additionally, in other embodiments, needles can be arranged in other configurations, such as staggered along one or two needle bars. Furthermore, although a single needle bar is shown in some embodiments, where needles can generally be arranged in a straight line along the needle bar, this disclosure is not limited to tufting machines having only one needle bar, nor is it limited to needle arrangements comprising only a single straight line of needles.

[0102] In implementations, needles can be arranged at a certain spacing, which can be selected based on the tufting gauge of the tufted product. For example, in one implementation, needles can be arranged at a gauge spacing that matches the selected gauge of the tufting machine, such that to produce a tufted product with, for example, a desired or selected gauge of 3 / 8 inch, needles can be arranged at approximately a 3 / 8 inch gauge spacing; to produce a tufted product with a desired or selected gauge of 1 / 2 inch, needles can be arranged at approximately a 1 / 2 inch gauge spacing; to produce a tufted product with a desired or selected gauge of 3 / 4 inch, needles can be arranged at approximately a 3 / 4 inch gauge spacing; and to produce a tufted product with a desired or selected gauge of 1 inch, needles can be arranged at approximately a 1 inch gauge spacing. In other implementations, approximately 1 / 4 inch, 3 / 8 inch, 1 / 2 inch, 5 / 8 inch, 3 / 4 inch, 5 / 8 inch, 3 / 4 inch, 7 / 8 inch, 1 inch, 1 1 / 4 inch, 1 3 / 8 inch, 1 1 / 2 inch, 1 5 / 8 inch, 1 3 / 4 ... 7 / 8 inch and / or 2 inch needle gauge spacing. Therefore, in an embodiment, the needle bar may be configured with needles arranged according to a substantially true needle gauge spacing, which typically matches the required or selected needle gauge of the tufting machine.

[0103] like Figure 1A-1B As shown, in an embodiment, the tufting machine 10 typically includes a frame 16 having an upper portion 17A and a lower portion 17B, a tufting area or region T defined through the frame, and a backing support or shuttle 18 on which a backing B moves and can be positioned along the tufting area. The tufting machine 10 will also include a main drive shaft 19 positioned along the frame 16. Figure 1AThe main drive shaft typically extends laterally through the frame. In one embodiment, the main drive shaft 19 may be connected to a needle bar drive assembly or system 20 for driving the needles 12 mounted thereon to reciprocate in a reciprocating (up and down) motion to allow the needles 12 to penetrate and exit the backing B for inserting yarn tufts into the backing as the backing moves through tufted areas or regions.

[0104] In one embodiment, the main drive shaft 19 can be driven by one or more motors M operably connected to the opposite end of the main drive shaft and mounted to the opposite end of the frame of the tufting machine for driving the rotation of the main drive shaft. The one or more motors can be controlled by a control system 15 of the tufting machine, wherein the rotational speed and position of the main drive shaft are monitored by the control system 15 (e.g., sensors such as encoders). In operation, each rotation of the main drive shaft causes a needle to pierce and then withdraw from the backing. In other words, each rotation of the main drive shaft causes a needle reciprocating motion cycle, also known as a tufting cycle, which includes a downstroke and an upstroke of the needle. In another embodiment, control of various operating systems or components can also be associated with the rotation or position of the main drive shaft.

[0105] like Figure 2C and 2G As shown, in an embodiment, at least one presser foot 22 may be provided along the tufting area adjacent to the needle. The presser foot may include a substantially flat plate 23 having a front edge 24, which in an embodiment may have a ridged or corrugated configuration, along which a plurality of grooves 21 are defined, such as... Figure 2C , 2D As shown in 2G and 3A-3B, when the needles 12 reciprocate into and out of the backing B, they can be received in the groove 21 and guided into and through the backing along a substantially straight path of travel. In an embodiment, the groove 21 may have an open end and may be further configured to help guide or direct the needle through it as it moves and reciprocates.

[0106] In other embodiments, the presser foot 22 may have a substantially straight or flat front edge 24 (e.g., without a groove or ridge along it). The needle 12 can reciprocate into and out of the backing without necessarily being received in the groove 21.

[0107] like Figure 1A-1BAs shown, backing B can be longitudinally pushed by backing feed system 25 along its travel path or feed direction P by a reciprocating needle. In embodiments, backing feed system 25 may include feed roller 26, which may include a needle roller and may be driven by motor 27 (e.g., a servo or stepper motor, or other driver). Additionally, in some embodiments, the backing feed system may also include a reduction gear coupled to the backing feed roller to help control its rotation and thus control the feeding of backing B along its travel path P. Backing feed system 25 can generally be controlled (e.g., by control system 100), and in some embodiments, a backing feed controller may be provided, which is programmed and configured to push backing B (…) under tension. Figure 2A The feed is delivered below the needle 12 and passes through the tufting area T of the tufting machine 10.

[0108] Alternatively, in an embodiment, the backing feed roller may be driven by the main drive shaft, for example by using a timing belt or other linkage that connects the backing feed roller to the main drive shaft and / or its motor, so that the backing feed roller is driven directly by or through the operation of the main drive shaft.

[0109] The backing feed system 25 can be controlled to move the backing B in a controlled motion (e.g., in an embodiment, in a stepping motion). As the needle 12 reciprocates into and out of the backing, a series of yarns Y can be placed or inserted into the backing to form a yarn tuft therein. Optionally, the backing can be fed substantially continuously through the tufting area.

[0110] In an embodiment, the needle bar drive assembly or system 20 for reciprocating the needle 12 may include a series of bearing assemblies 31 and a series of push rods 32, which are coupled to the main shaft so as to be driven, in a reciprocating, substantially up-and-down motion or cycle, in a first or vertical direction indicated by arrows 33 / 33′, when the main drive shaft 19 is rotated by the operation of one or more of its drive motors. Figure 2B and 2G As further shown in 3C, in the embodiment, the needle bar 11 can be connected to or linked to each of a series of push rods 32 via push rod feet 32A, so that the needle bar will be driven or moved to perform vertical reciprocating motion or cycle by the operation of the main drive shaft 19 of the tufting machine 10 as the push rods 32 move. Additionally, as... Figure 3D As shown, the push rod can be connected to the push rod foot via the bearing assembly 30. Therefore, the needle 12, mounted along the needle bar 11, will be driven in a reciprocating motion or stroke, entering and exiting the backing B between a raised or top position and a lowered or bottom position, in which the lowered or bottom position can pierce the backing B.

[0111] In one embodiment, the needle bar 11 can reciprocate along its stroke to drive the needles 12 into and out of the backing B, while remaining substantially fixed to prevent movement in the lateral direction. For example, in some applications, the needles can be arranged at regular intervals based on the needle gauge of the tufting machine, and in one embodiment, the tufted product is produced, and the lateral position of the needles relative to the backing B along its path of travel P is substantially fixed. As the needles reciprocate and remain in their lateral positions, the backing B can be displaced below the needles to form a patterned tufted fabric.

[0112] like Figure 2B-2E As further shown in 2G and 3C, in other embodiments, the needle bar 11 is typically slidably coupled to or connected to the push rod 32 of the needle bar drive assembly or system 20, for example, via a series of sliding supports 34 of the bearing assembly 31. In embodiments, the needle bar 11 can be coupled to the guide rail 36 via a bracket or link 36A, which can be slidably received within a bracket 34, the bracket being compatible with the push rod foot 32A (…). Figure 2H The needle bar 11 is formed together with or as part of the push rod foot, with the end of the push rod attached to the push rod foot. When the needle is laterally displaced or moved on the backing B under the control of the shifting mechanism, the guide rail 36 can guide the needle bar 11 to perform lateral or sideways displacement movements, as shown by arrows 37 and 37'. Figure 2E As shown in the figure.

[0113] In one example embodiment, the needle bar 11 can be mounted to or slidably supported in engagement with the push rod 32 of the needle bar drive assembly or system 20 via a series of linear bearing assemblies, the series of linear bearing assemblies comprising a series of linear bearings. Thus, the needle 12 can reciprocate vertically in a first direction, as indicated by arrows 33 / 33′, inserting into and exiting the backing B. In addition to displacement of the backing B, the needle 12 can also be displaced in a lateral direction, as indicated by arrows 37 and 37′.

[0114] In addition, in, for example Figure 3C In the illustrated embodiment, a series of needle stroke support assemblies 90 may be provided to support the push rods during the vertical reciprocating motion of the push rod 32 during each needle stroke. Although an embodiment with one needle stroke assembly 90 having one push rod 32 is shown, it should be understood that multiple push rods and needle stroke assemblies will typically be used in tufting machines, and it should also be understood that needle stroke assemblies can be used with various types of tufting machines and are not limited to machines with only hollow needles.

[0115] In the implementation method, such as Figure 3C-3EAs shown, each needle stroke support assembly 90 may include one or more upper support plates 91a and a support post or lower support plate 91b that can be mounted to a portion of the tufting machine frame. For example, in some embodiments, the upper support plate 91a may include a substantially flat plate that can be positioned along the lower portion of the head or upper frame portion of the tufting machine along the tufting area, wherein the lower support plate 91b is mounted to the lower surface of the upper support plate 91a and serves as a support or bracket for the needle stroke support assembly, such as... Figure 3D-3E As shown.

[0116] In one embodiment, the upper support plate 91a may further include an opening 92 through which the push rod 32 is received. In the illustrated embodiment, the push rod 32 may be received in a bearing assembly 30, which may be mounted together with the opening 92 of the upper support plate to secure the push rod within the upper support plate and to help support the push rod during its linear vertical reciprocating motion in each needle stroke. In another embodiment, the bearing assembly 30 may include one or two sections, for example, such as... Figure 3D As shown, it includes an upper section located on the upper surface of the upper support plate and a lower section along the lower surface of the upper support plate, and can be attached together.

[0117] like Figure 3D-3E As shown, a push rod foot 32a, adapted to receive the distal end of the push rod 32 therein, is positioned below the upper support plate 91a and can be configured to engage and mount along the needle bar 11 to attach the push rod to the needle bar. In an embodiment, the push rod foot may include a push rod foot assembly 93, which may include the push rod foot 32a, a collar or clamp 94 mounted along the upper surface of the push rod foot, and the collar or clamp being adapted to receive and clamp the distal end of the push rod therein to secure the push rod to the push rod foot. In an embodiment, the collar or clamp may be mounted to the upper surface of the push rod foot, wherein an adapter plate is positioned between the collar or clamp as needed.

[0118] Additionally, in one embodiment, each needle travel assembly 90 may further include a first guide 95 mounted along a lower mounting plate and configured to engage a second guide 96, which may be mounted to the push rod foot, such as... Figure 3EAs shown. In one embodiment, the first guide 95 may include a linear bearing slide, and the second guide 96 may include a linear bearing guide that travels along the linear bearing slide as the push rod reciprocates during the needle stroke. In other embodiments, the first or second guide may include a track formed of a friction-reducing material, which may be received in a channel or similar guide having a friction-reducing surface. In some embodiments, the push rod foot may include a linear bearing slide or track, and the lower support plate may include a linear bearing guide.

[0119] In some implementations, the adapter 97 can be mounted along one or both of the push rod foot and the lower plate. For example, as... Figure 3D-3E As shown, in one embodiment, an adapter that may include a plate can be mounted to the rear surface of the push rod foot for mounting a second guide 96 (e.g., a linear bearing channel) to the push rod foot.

[0120] In one embodiment, the needle travel assembly 90 will be configured to guide the push rod 32 and thus the linear vertical reciprocating motion of the needle bar 11 during each stroke of the needle bar. In another embodiment, as... Figure 3D As shown, the push rod 32 extends through a bearing assembly 30 within an opening 92 in the upper support plate 91a of the needle stroke assembly and is received within a push rod foot 32a. In an embodiment, each push rod 32 may be supported by the upper support plate 91a and further supported by engagement of a second guide 96 attached to its push rod foot with a first guide 95 mounted along the lower support plate 91b, which helps guide the linear movement of the push rod 32 during each needle stroke.

[0121] Furthermore, in some embodiments, the support and guidance provided by the needle stroke support assembly for the movement of the push rod during each needle stroke can be used to reduce the pressure or force transmitted to the push rod through the engagement of the cutter and the needle. Typically, the force generated when the cutter strikes the needle to form a tuft (particularly when cutting yarn used to form artificial turf or grass) produces pressure applied to the push rod, and over time, this pressure can cause excessive wear and / or damage to the push rod bushings, and may cause the push rod to vibrate or exhibit other undesirable movements. The needle stroke assembly 90 can help reduce the pressure or force applied to the push rod and can help guide the push rod to linear motion, thereby enabling increased production speed and extended lifespan of the push rod and its bearing assemblies. In some embodiments, the needle stroke support assembly can also facilitate reciprocating motion of the needle over extended or longer needle strokes, enabling the formation of tufts with greater pile height.

[0122] In various embodiments, the support plate 91a may have different dimensions (e.g., different thicknesses) or configurations to accommodate the movement of the push rod along different lengths of needle travel. Additionally, in some embodiments, the support plate may be slidably mounted to the tufting machine frame and may be configured to move with the push rod and needle bar.

[0123] In some embodiments, the shifting mechanism 40 may be coupled to the needle bar 11 and may be controlled to cause the needle to travel relative to the backing B through the travel path P of the tufting machine 10. Figure 2A Lateral displacement or movement occurs. Additionally, in some embodiments, multiple displacement mechanisms (e.g., positioned on opposite sides of the tufting machine) can be used to laterally displace the needle 12 on the backing B to form a tufted pattern. In embodiments, the displacement mechanism 40 can be driven by one or more servo motors or other actuators under the control of the control system 15. For example, in embodiments, the displacement mechanism 40 may include a cam or motor-driven displacement device, a servo motor-driven rack and pinion displacement mechanism (e.g., Card-Monroe's Smart Tech Shifter™), or other displacement devices.

[0124] In some embodiments, needles 12 can be laterally shifted / moved according to a desired or prescribed number of shift steps or jumps to form a desired pattern, said number of shift steps or jumps being, for example, based on the gauge spacing between each needle 12 or a multiple thereof. For example, in some embodiments, needles can be shifted in increments of one, two, or more gauge spacings or partial increments according to a pattern instruction for a tufted pattern being formed. Additionally, in some embodiments, the shifting mechanism 40 can shift needles by other selected or desired step sizes or distances, including moving needles by ½ gauge spacing or other non-standard step sizes or spacings.

[0125] In some implementations, for example Figure 1B As shown, a shifting mechanism 40 can be configured to shift the backing material B. For example, in one embodiment, the shifting mechanism 40 (which may include a servo-driven shifting mechanism, a cam-driven shifting mechanism, a servo motor-driven rack and pinion shifting mechanism, such as Card-Monroe's Smart Tech Shifter™, or other shifters) may be coupled to the backing support or shuttle 18 and may be controlled by a control system to shift the backing material B laterally (e.g., on or along the tufting area). In one embodiment, the backing material B may be shifted together with or independently of the shifting of the needle 12. In some embodiments, the backing material B may be shifted while the needle 12 remains in a substantially consistent lateral position relative to the travel path P of the backing material B through the tufting machine 10.

[0126] like Figure 1B-1CAs shown in the overall diagram, the shifting mechanism 40 can be coupled to the shuttle 18 or the backing support 18, over which the backing B passes and is supported as it is fed through the tufting machine along its travel path P. The shifting mechanism 40 can laterally shift the backing B relative to its travel path P. For illustrative purposes, Figure 1C The diagram shows a shifting mechanism 40, but it should be understood that multiple shifting mechanisms may also be used and mounted on one or both ends of the tufting machine.

[0127] In one embodiment, the shuttle 18 may include a carriage 38, which may be coupled to the shifting mechanism 40, wherein one or more plates 41 are mounted within a frame, or in another embodiment, integrated with the frame 38. In some embodiments, at least one plate 41 may be positioned along each side of the carriage 38 and may have an upper surface 41a supporting the backing B. In other embodiments, additional plates may be mounted along the lower portion of the shuttle 18.

[0128] In some implementations, for example Figure 1C As shown, the shuttle 18 can be incorporated as part of the backing feed system 25. For example, in one embodiment, the frame may include a pair of plates or supports 39 arranged to extend through the tufting area of ​​the tufting machine, and the backing feed roller 26 may be mounted to the supports 39 along the upstream and downstream ends 38a / 38b of the frame 38 of the shuttle 18. In some embodiments, additional backing feed rollers (e.g., additional needle-in rollers) may also be positioned along the shuttle 18 adjacent to the plate 41. The end 26a of the backing feed roller 26 may be coupled to a motor or to the main drive shaft of the tufting machine for driving the rotation of the backing feed roller.

[0129] like Figure 1C As further shown, in one embodiment, the bearing guide 42 can be mounted along the frame 38. In another embodiment, the bearing guide 42 can be mounted to the lower surface of the plate 41. In yet another embodiment, the bearing guide 42 may include a linear guide configured to engage with a corresponding slide or bearing mounted along the frame to guide the shuttle 18 as the shuttle moves by means of the shifting mechanism 40 to laterally shift the backing through the tufted area. Additionally, in some embodiments, the bearing guide 42 and / or its corresponding slide may be mounted to the frame or to an additional plate positioned below the shuttle 18.

[0130] In the implementation method, such as Figure 1CAs shown, the frame 38 of the shuttle 18 can be coupled to a first or proximal end 43a of a rod or drive shaft 43, which extends through the frame of the tufting machine 10 and can be coupled to a backing shifting mechanism 40 at its second or distal end 43b. In embodiments, the drive shaft 43 may include more than one segment or portion and can be coupled to the shuttle 18 and / or the shifting mechanism 40 via mounting blocks, brackets, or other similar connectors. Figure 2C and 2D As shown, in this embodiment, during the tufting operation, when the needle 12 pierces the backing B, the backing B will typically engage between the upper surface of the shuttle 18 and the presser foot 22. The backing B can also remain in place against the upper surface of one or more plates 41 as it is laterally displaced by the shifting mechanism 40. In this embodiment, the backing B can be incrementally displaced based on the needle gauge spacing, or incrementally displaced based on multiples or fractions of this needle gauge spacing, to reposition the backing for inserting the desired color or type of yarn at selected stitch positions. After a tuft or stitch is formed in the backing B and the needle 12 is retracted, the backing B can move in the direction of its travel path P. For example, in addition to being longitudinally fed or moved along its travel path P through the tufting machine 10, the backing B can also be laterally displaced relative to the needle 12 to allow for the presentation of multiple different colors and / or types of yarn approximately within selected pixel or stitch positions. In some implementations, the displacement of the backing can also maintain different numbers of yarn clusters in the longitudinal and transverse directions of the pattern as needed.

[0131] Additionally, in this embodiment, backing B can be laterally shifted by an amount less than the full needle gauge increment. For example, the backing can be shifted by 1 / 2, 1 / 4, 3 / 8, or other portions of the needle gauge spacing of needle 12. By way of example only, the needle gauge spacing of needle 12 can be set from 3 / 8 inch to 1 / 2 inch, and backing B can be shifted by 1 / 4 inch to 7 / 16 inch or other fractions of the needle gauge spacing increment to form a pattern.

[0132] like Figure 2B-3BAs shown, each needle 12 can be arranged along one end of a travel path or passage 44, along which yarn is fed from a yarn feeding system and passes through the needle to insert into the backing B. In an embodiment, each needle 12 may include a hollow needle having a body 45, which may be formed as, for example, a hollow tube of approximately three to four inches or greater in length. The body 45 may define a hollow passage or channel 46 along which yarn Y is fed. Other lengths of the body 45 may also be used (e.g., 4-6 inches, or greater, or less than 3-4 inches). Additionally, in an embodiment, multiple yarns may be fed through the channel 46 of each needle. For example, one to three yarns may be fed together through each needle, but in some embodiments, additional numbers of yarns may also be fed. The body 45 of each needle may also include a first or proximal end 47 and a second or distal end 48, the first or proximal end being received in an opening along the lower surface of the needle bar 11 and communicating with an internal channel and / or with a yarn tube for receiving yarn, the second or distal end being at the opposite end of the body 45.

[0133] In embodiments, the needle 12 may also be configured to have an extended length to provide an elongated channel, and / or to increase the length of the yarn inserted into the backing as needed (e.g., to form a cluster with increased pile height). Thus, in embodiments, yarn clusters with different pile heights and which may include multiple yarns within the same cluster can be formed, and in some embodiments, loop pile clusters of yarn can be formed as an addition to or alternative to the cut pile clusters formed in the backing.

[0134] like Figure 3B As shown, in one embodiment, the distal end 48 of each needle 12 may terminate at a tip 49 and may define an opening 50. In this embodiment, the opening may be substantially elliptical and allow the yarn Y to exit through the opening and exit the internal channel of the needle 12. In one embodiment, the opening 50 may have a cutting surface 51 formed around it, which may be configured to provide a shearing surface against which the yarn may be cut. For example, in... Figure 3B In the illustrated embodiment, the distal end 48 of the needle 12 may include a cutting surface 51 with a flattened cutting angle formed around the opening 50. The opening 50 may also include a reduced region or groove 52 in its upper portion opposite the tip 49 of the needle. In the embodiment, the groove 52 and cutting surface 51 of each needle 12 may be configured to provide a larger and substantially flattened shearing surface against which the cutting system can engage yarns, such as artificial grass or turf yarns, or filaments, or multiple combined ends of yarns.

[0135] In embodiments, such as those used to form turf fields, landscape fabrics, etc., the yarn may include artificial grass or turf yarn. Such artificial grass or turf yarn typically comprises one or more filaments, and in some embodiments, the filaments may be combined with one or more flat ribbon yarns. Artificial grass yarn may also typically be formed from various polymeric materials and may have a substantially flat configuration to mimic grass blades as closely as possible. In embodiments, the arrangement of the groove 52 and the opening 50 formed at the distal end 48 of the needle 12, and the cutting surface 51 defined around the opening, may typically be configured to guide and present the artificial grass filaments or yarn fed through each needle in a substantially flat, straight arrangement, so as to enable cleaner cutting of the artificial grass or turf yarn, thereby helping to avoid wear or other problems in the event that the yarn is not cleanly cut.

[0136] In the implementation method, such as Figure 2F-2H As shown in the general diagram, the yarn may include multiple yarns Y (e.g., two or more ends of yarn Y), which are fed into each needle 12 to be inserted together into the backing B. In one embodiment, the multiple yarns may be fed directly into the channels 46 of each needle. Figure 2F As shown, in an embodiment, the needle bar 11 can be configured to have needles 12 arranged at a selected needle gauge spacing, and an opening 57 of a channel 58 formed along the top of the needle bar 11 and communicating with the upper end of the needles 12. Each yarn Y can be fed directly through the opening 57 into the channel 46 of its associated needle. For example, Figure 2F The diagram shows that both ends of the yarn are fed directly into each opening 57 for feeding into the needle 12.

[0137] Additionally, in the embodiment, the yarn guide 53 ( Figure 2G-2H The yarn guide 53 may be installed near the needle bar 11. The yarn guide 53 may have a plurality of openings 54 defined thereal, which may be configured to receive two or more yarns Y passing through it. The needle bar 11 may also include a series of gas passages 55 defined thereal, wherein openings 55A are arranged on each side of the openings 57 leading to an internal passage 58 formed through the needle 12 for supplying airflow to the needle.

[0138] In one embodiment, the gas channel 55 may be connected to an airflow-driven yarn feeder 59 of the yarn selection system 70. This airflow-driven yarn feeder may include a plurality of gas injectors 67, which may be connected via gas lines 68 to the opening 55A or the gas channel 55, which are connected to a gas source. The gas injectors 67 supply airflow into the needle bar 11, which is guided along the gas channel 55 and into the needles 12. As the yarn (e.g., 1-3 or more yarns per needle) is fed and passes through the needle's channel 46, it is delivered into the backing B. The airflow may be selectively controlled by a control system to supply gas as needed for delivering the yarn into the backing to form a yarn bundle.

[0139] In implementations, for example, with 12 tufts of yarn Y (e.g., two or more yarns) per needle, supplying gas from both sides of the needle bar can help feed each yarn through the needle substantially simultaneously and at a substantially consistent and, in this implementation, the same feed rate. Additionally, the yarn can be fed uniformly into its associated needle without the need for a funnel to feed the yarn into a hollow needle.

[0140] In other alternative implementations, such as Figure 2E As further shown, multiple yarn tubes 56 can be mounted along the needle bar 11. The yarn tubes 56 are typically received through an opening 57 formed along the top of the needle bar 11, and each yarn tube is typically aligned with a corresponding needle 12 mounted along the lower side of the needle bar. In an embodiment, each yarn tube 56 may include an elongated body 58 extending downward from a first or proximal end to a second lower distal end, the elongated body being received through the opening in the needle bar 11. The distal end of the yarn tube may also be aligned with and communicate with the first or proximal end of its associated needle. Yarn can be fed from a yarn feeding system through a yarn selection system and into the yarn tube 56, wherein the yarn is guided at an angle through the tube and into the needle 12 communicating with the tube. In one embodiment, the yarn tube 56 may be oriented at an angle relative to the needle 12, and the angle and length of the yarn tube are configured to help keep the unselected yarns in their respective needles (or at least in the yarn tube 56 so as to be easily reinserted into the needles) during periods when the feeding of the selected yarn stops or is substantially slowed down, and during periods when such unselected yarns are not inserted into the backing.

[0141] like Figure 1A and 4AAs shown in -4C, a yarn feeding system 60 is configured to control the feeding of a series of yarns Y from a supply source (e.g., a yarn frame, tapered yarn, etc.) to each needle 12. In an embodiment, the yarn feeding to each needle 12 can be controlled such that the yarn is driven by the needle as it pierces the backing B and reciprocates in and out of the backing, wherein at least selected yarn is fed through the needle 12. As the needle pierces the backing B and moves toward a lower bottom position of its reciprocating stroke or cycle, sufficient yarn length can be fed to each needle by the yarn feeding system 60 to form a tuft of the desired pile height, and the needle can be engaged by one or more cutters or cutting blades of a cutting system mounted below the backing along the tufting zone T of the tufting machine. The yarn feeding to the needle 12 can also be controlled to substantially pull back and / or hold or otherwise maintain unselected yarns (e.g., yarns not tufted at a specific stitch position in the pattern) within their respective needles.

[0142] In one embodiment, the yarn feeding system 60 may include one or more yarn feeding accessories or mechanisms 61, which may be mounted to the frame 16 of the tufting machine adjacent to the upper end of the tufting machine 10, such as... Figure 4A As shown. In the implementation method, as Figures 4A-4C As shown, the yarn feeding mechanism 61 may include, for example, a single or single-ended yarn feeding pattern attachment or a multi-ended yarn feeding pattern attachment. In embodiments, such a yarn feeding mechanism 61 may also include a unit or have a modular construction, which may include a housing and / or frame in which a series of motor-driven yarn feeding devices 62 are mounted or received. In embodiments, multiple yarn feeding mechanisms may be mounted along the frame of the tufting machine for feeding at least one yarn to each needle, or in embodiments, feeding two or more yarns to each needle. In some embodiments, a single yarn may be fed into each needle by one associated yarn feeding device among the yarn feeding devices 62; and in other embodiments, multiple yarns may be fed into each needle or a series of needles by one associated yarn feeding device among the yarn feeding devices 62. Additionally, other yarn feeding mechanisms may be used.

[0143] In example Figure 4B-4DIn the embodiments shown, each yarn feeding device 62 may include a motor 65 and one or more feed rollers 63, which may be configured to feed at least one or more yarns into selected needles. In embodiments, the yarn feeding rollers 63 of the yarn feeding device 62 may be arranged in a group of 2-3 yarn feeding rollers, which may be arranged in an engaging relationship (e.g., the feed rollers may have gear teeth engaged in a meshing arrangement). In some embodiments, the yarn feeding rollers 63 may include a driven roller 64A and two feed rollers 64B / 64C, which may be driven by the motor 65, and yarn may extend around the feed rollers to feed yarn along their paths. The two feed rollers 64B / 64C may be driven by the rotation of the driven roller 64A. In an embodiment, the yarn feeding rollers 64B / 64C of the yarn feeding device 62 can be configured to feed a selected or predetermined amount or length of yarn in each individual tufting or stitching cycle, so as to form tufts or yarns with a selected or desired pile height.

[0144] For example, such as Figure 4D As shown, in some embodiments, the feed rollers 64B / 64C may have extended dimensions or diameters, which can be selected to feed a desired or selected length of yarn per revolution of the feed roller. For example, in embodiments, the feed rollers 64B / 64C may have a diameter up to about 1 inch or more, which can be selected to feed a set length of yarn per revolution (e.g., about 4 to 5 inches). Other feed rollers of different sizes can also be used to feed other amounts or lengths of yarn to form clumps of other pile heights. In some applications, such as for artificial turf or grass, such as sports fields, a standard pile height of at least 2 ½ inches may be required to provide sufficient fill, elasticity, and other parameters. Using this system and method, greater pile heights, as well as further variations in the pile height of the formed clumps that meet or exceed such standards, can be provided.

[0145] Additionally, in this embodiment, increasing the size of the feed rollers in each yarn feeding device can further assist in feeding the yarn, such as polymer yarns or filaments typically used in artificial turf or grass. In this embodiment, the driven roller 64A of the yarn feeding device can be configured to have a smaller diameter than the feed rollers 64B and 64C to compensate for any potential decrease in yarn feeding torque due to the increased size of the feed rollers. The size of the driven roller 64A can vary relative to the sizes of the feed rollers 64B / 64C to adjust the torque applied to the feed yarn and / or the amount of yarn fed per rotation of the feed rollers.

[0146] In embodiments, each yarn feed device 62 may be configured to feed one or more yarns into one or more associated needles 12. In some embodiments, a single yarn may be fed into each needle, while in others, multiple yarns may be fed into each needle to tuft into the backing B. For example, in some cases (e.g., forming artificial turf or grass products), two, three, four, or more yarns (e.g., artificial grass fibers, etc.) may be combined at the yarn feed system 60 before being received and fed together into the needles 12, with each needle inserting two to four or more yarns per tuft.

[0147] The yarn feeding mechanism 61 can be operated according to a program or pattern instruction for a pattern run by the tufting machine 10 to control the feeding of yarns Y along their travel path or passage 44 to each needle 12 or a series of needles. The feeding of yarn Y can be controlled to form tufts of a selected or desired pile height, and can also be controlled to significantly slow down or stop selected yarns or loops to prevent unselected yarns from inserting into the backing B, while still allowing the yarn to remain within the needles 12. The pile height of the remaining tufts of the selected yarn can also be controlled by the amount of yarn fed by the yarn feeding mechanism 61 to feed a certain length of yarn as needed, thereby producing tufts of different heights. Therefore, different surface effects can be created for each tuft or stitch to tuft / produce textured patterns with high / low and / or shading effects, in addition to displacement or different color placement effects.

[0148] It should also be understood that, in embodiments, multiple yarn feeding mechanisms or units may be provided, mounted along one side of the tufting machine or on both sides of the tufting machine. For example, one or more yarn feeding mechanisms may be mounted along the front side of the tufting machine for feeding a series of yarns into needles in a first or upstream needle bar, and an additional set of one or more yarn feeding mechanisms may be mounted on the rear or downstream side of the tufting machine for feeding a series of yarns into needles in a downstream or second needle bar.

[0149] In some embodiments, a front yarn feed mechanism and a rear yarn feed mechanism may be provided to feed yarn into alternating needles in the needle bar. For example, the front yarn feed mechanism may feed yarn into odd-numbered needles, while the rear yarn feed mechanism may feed yarn into even-numbered needles.

[0150] Additionally, in an embodiment, the tufting machine 10 may include a pull roller 66 arranged downstream of the yarn feeding mechanism 61 along the travel path or passage 44 of the yarn Y. Figure 1A , 2A(and 2C). The pull roller 66 may include a grooved roller that engages and pulls the yarn fed from the yarn feeding mechanism to provide a substantially uniform feed of the yarn. The rotation of the pull roller 66 may be controlled by the control system 15 to control the pulling of the yarn Y from the yarn feed rollers 63 of one or more yarn feeding mechanisms 61 for feeding the associated needles into the yarn along the yarn travel path.

[0151] In some embodiments, the tufting machine may also include an air-induced yarn feed device 59 configured to help guide / feed the yarn into and along the channel 58 of the needle 12. In some embodiments, the air-driven yarn feed device may be connected to a gas source and may include a gas line 68 connected to a series of gas ejectors, nozzles, or other devices 67 arranged along the yarn travel path or passage 44 from the yarn feed system 60 into the needle 12, and configured to supply / guide a pressurized airflow toward the yarn. In some embodiments, the air-driven yarn feed device may supply a pressurized airflow that can be guided along the yarn tube 56 and through the needle 12 to guide the yarn through the needle, helping to provide consistent feeding of each yarn (or multiple yarns) to the associated needle at a substantially uniform feed rate at substantially the same time. In some embodiments, the air-driven yarn feed device may supply a substantially continuous airflow that can be discharged into the atmosphere through an opening at the distal end of the needle.

[0152] In addition, in, for example Figure 5A In the embodiment shown in -5D, the tufting machine may further include a yarn selection system 70, which can be used to selectively retract or block the yarn fed from the yarn feed system 60 into the needle 12. In some embodiments, the yarn selection system 70 may include a series of yarn pullers 71 arranged along the travel path or passage 44 of the yarn Y from the yarn feed mechanism 61 or pattern attachment of the yarn feed system 60 to the needle 12. One or more yarn pullers 71 may be coupled to an actuator 72, such as a cylinder. The yarn pullers 71 can be selectively controlled to extend and retract along a selected length or stroke (e.g., in the embodiment, a stroke of approximately 1 / 2 inch to approximately 2 inches (but other distances may also be used)) to retract or pull the yarn from the needle.

[0153] In one embodiment, the actuator 72 may include cylinders, each cylinder including a piston rod 73 extending therefrom. Figure 5C ).like Figure 5CAs shown in Figure -5D, in an embodiment, each yarn puller 71 may include a body 74 in which an opening 76 is defined. Yarn Y may extend through the opening 76. The body 74 of each yarn puller may also be connected to a piston rod 73 of an associated actuator 72. The actuators can be selectively controlled to extend and retract their piston rods, thus moving the yarn puller 71 between an extended position and a retracted position. In an embodiment, the yarn puller 71 may move up and down, and when the yarn puller retracts, it may pull back or retract the yarn extending through it.

[0154] In other embodiments, the actuator 72 may be formed together with or integrated into the pullback module (e.g., a yarn pullback may be coupled to the pullback module), which may have multiple holes, each receiving a piston rod therein. The yarn pullback 71 may include a one-piece or two-piece structure. For example, in embodiments such as... Figures 5B-5C As shown, the body 74 of each yarn puller 71 may include a yarn holder portion 74a and a mounting portion 74b, wherein an opening 76 is formed in the yarn holder portion for the yarn to pass through, and the mounting portion may be coupled to the yarn holder portion 74a (e.g., by spline engagement or other locking device, or by fasteners, etc.) and coupled to the distal end of the piston rod 73 of an actuator 72.

[0155] In implementations, other types of actuators may also be provided. For example, in some implementations, the pullback module (or its actuator) may include a double-acting cylinder configured without a mechanical spring return and using gas supplied to different portions of the orifice of the pullback module to cause selective movement of a piston along the orifice to control the extension and retraction of the yarn pullback. In implementations, providing or forming the pullback module in the form of a double-acting cylinder can help improve the timing or speed of the yarn pullback actuation because no spring is used. Additionally, the lower air pressure used to operate the yarn pullback can also be used to operate the double-acting cylinder.

[0156] In addition, in, for example Figure 5AIn the illustrated embodiment, the actuator 72 (shown as a cylinder) can be connected to a gas source via a multi-way valve 77 (e.g., a three-way valve). Each actuator's valve 77 may include an inlet 78a, a first outlet 78b, and a second outlet 78c. The inlet is connected to the gas source via a gas line or conduit for supplying gas to the actuator. Gas is guided through the first outlet to control the extension and retraction of a yarn pull-back device connected thereto. The second outlet can serve as a vent to release excess gas. In some embodiments, the second outlet 78c can be connected via a gas line to a gas injector 67 of an airflow-driven yarn feeder for supplying gas to the gas injector to aid in feeding the yarn into the associated needle. In some embodiments, the gas injector, positioned along opposite sides of the needle bar, can be connected to and receive gas directly from the gas source.

[0157] Selective actuation of the yarn puller can be controlled simultaneously with the selected yarn feeding device of the yarn feed system to help control the amount of selected yarn fed into each needle, thereby helping to ensure that the length of each selected yarn provided is sufficient to form a cluster of the desired pile height (which may depend on the specific construction, application, and / or use of the artificial turf or grass field). In an embodiment, controlling the yarn through the yarn puller and the yarn feed system can maintain the yarn within the needle when it is being cut and when it is not selected for insertion into the backing.

[0158] Furthermore, in this embodiment, by maintaining a pressurized airflow along the passage or travel path 44 of the yarn entering and passing through the channel 55 of the needle bar 11 and the channel 46 of the needle 12 using an airflow-driven yarn feeding device, the yarn can be held within its passage and also within the channel 46 of the needle. For example, since the yarns typically used in artificial turf or grass tend to be flatter (e.g., to simulate grass blades) and have a natural elasticity that tends to spring back or retract when cut, the gas jet applying gas through the channel 55 of the needle bar 11 helps the yarn selection system 70 and the yarn feeding system 60 to substantially prevent the yarn from popping out of the needle. This is achieved by extending the yarn travel path or passage 44 into and through the needle so that the yarn can remain in contact with the corresponding needle in the passage.

[0159] Additionally, in some embodiments, the cutting system 80 may be positioned below the backing support or the shuttle 18. For example... Figures 6A-6B As shown, in one embodiment, the cutting system 80 may include a series of cutters 81, each cutter having a cutting edge 82. In some embodiments, the cutters may be arranged in a substantially flat orientation relative to the needle; and in some embodiments, each cutter may be mounted in a module or retainer 84, which may be mounted along the cutter shank 86.

[0160] For example, such as Figures 7A-7C As shown, in one embodiment, a series of cutting tools 81 can be mounted within a module 84, which may include a body 87 having a front portion 87a and a rear portion 87b. The front portion includes a series of slots 88 therein for receiving individual cutting tools 81, and the rear portion is configured to mount along a tool holder. Figures 7A-7C In the example embodiment shown, the module is depicted as having a series of mounting tabs 89a, but other mounting devices may also be used. In this embodiment, the tool can pass within its slot via fasteners 89 ( Figure 7B For example, fixing screws or other fasteners, to fix in the predetermined cutting position.

[0161] In one implementation, the module can be placed in a fixture to position the cutter 81 at a predetermined cutting position within the module, the predetermined cutting position being based on the needle stroke length or depth of the needle penetrating the backing to form a cluster of selected pile height. The cutter can be secured in the module using fasteners, after which the module can be mounted along the cutter shank. The cutter can be positioned at a predetermined location relative to the needle's downstroke or puncture depth to position it for cutting the yarn fed through the needle as it pierces the backing.

[0162] In other embodiments, for example Figure 6C As shown, each tool 81 can be mounted in its own module 84, with multiple tools 81 and modules 84 individually mounted along the tool holder 86. Each module 84 may include a module body 87 having a front portion 87a and a rear portion 87b configured to be mounted along the tool holder 86. For example, in one embodiment, one or more mounting tabs 89 may be provided along the surface of the rear portion 87a to assist in positioning the module along the tool holder, and the tool module may be secured to the tool holder using fasteners (e.g., set screws).

[0163] In addition, such as Figure 6C As further shown, in one embodiment, the body 87 of the tool module 84 may have a generally Y-shaped or C-shaped tool holder assembly having an opening 84a defined along the front portion 87a of the body. In one embodiment, Figure 6C The cutting tool of each module shown can be slidably received within the cutting tool mounting assembly 85. In an embodiment, the cutting tool mounting assembly 85 may include a first portion 85a and a second portion 85b, to which a cutting tool 81 may be attached (e.g., by a fastener), and the second portion may be configured to receive the cutting tool 81 therein and may be attached to the first portion 87a.

[0164] In one embodiment, the second portion 85b can be configured as a guide in which the cutters can be slidably received, such that each cutter can selectively move vertically relative to the needle stroke between a series of extended, engaged, or cutting positions and retracted, non-engaged, or non-cutting positions. In one embodiment, when the cutter is in its extended cutting position, it can cut the yarn driven by the needle to form selected yarn tufts in the backing, the tufts potentially having different pile heights. In other embodiments, the cutter can selectively move to its retracted position to form selected yarn loop tufts in the backing.

[0165] In one implementation, the actuator 83 may be associated with each individual tool; for example, the piston rod or other drive shaft 83a of the actuator is coupled to the first portion 85a and can be selectively actuated by a control system to move the tool associated with the actuator between its series of extended engagement or cutting positions. Other types of actuators may also be used (besides...). Figure 6C (In addition to the cylinder shown, or as a substitute for it).

[0166] In one embodiment, the first portion 85a of the tool mounting assembly can be configured to allow a tool to move thereal. For example, when the actuator is engaged by the control system, the tool associated with the actuator will extend or retract along the first portion 85a of the tool mounting assembly (e.g., along a channel or passageway of the first portion), which will guide and support the tool as it moves between its extended and retracted positions.

[0167] In one embodiment, the cutter 81 may be positioned in alignment with an associated or corresponding needle 12. In another embodiment, the cutter 81 may also be mounted along the shank 86 in a substantially fixed position, wherein the cutting edge 82 of the cutter is located at the height of the yarn driven by the needle 12 to form a cluster of yarn with a selected pile height. Typically, the cutter 81 may be positioned such that its cutting edge 82 is located at a selected height relative to the travel of the needle 12, such that when the needle pierces the backing B, the cutting surface 51 of each needle can engage the cutting edge of its associated cutter, wherein any yarn introduced (e.g., blown past the needle) is cut by the cutter.

[0168] In one embodiment, the cutter 81 can remain stationary when the needle 12 pierces the backing B. When the needle 12 reaches a selected piercing depth, the cutting surface of the needle can engage the cutting edge of the cutter. In another embodiment, the cutting edge 82 of the cutter can engage the cutting surface of the needle at a selected shearing angle to facilitate a substantially clean cut of relatively flat artificial grass or turf yarn. In yet another embodiment, the shearing angle between the cutting surface of the needle and the cutting edge of the cutter can be substantially flat, or it can be oriented at a small shearing angle.

[0169] In some embodiments, the tool holder 86 may be coupled to at least one actuator 83. Figure 6C The actuator can be controlled to move the cutter 81 between its non-engaging position and a cutting position. Alternatively, in some embodiments, one or more cutters 81 can be coupled to an associated actuator (e.g., a cylinder) and can be individually controlled to move between a non-cutting or non-engaging position and one or more cutting positions, thereby selectively cutting the yarn as it is inserted into the backing B. In other embodiments, all cutters 81, or at least a portion thereof, can be moved together as a set or group of cutters to a cutting position for cutting the yarn.

[0170] In the implementation method, the cutting tool 81 ( Figures 6A-6C The cutter 81 can typically be positioned fixed relative to the needle 12 in the lateral direction. The cutter 81 can move in a substantially straight path in the vertical direction, which can be generally aligned with the cutting surface 51 of the needle 12. For example, in one embodiment, the cutting edge 82 of the cutter 81 can be substantially centered with the cutting surface 51 formed at the distal end of the needle 12. The cutting edge 82 of the cutter 81 can engage with the cutting surface 51 of the needle, for example, at a substantially flat or slightly shearing angle, to facilitate substantially clean cutting of relatively flat artificial grass or turf yarn.

[0171] In some embodiments, a single cutting blade or a series of cutting blades may be used instead of the cutting tools of the cutting system. The cutting blade may have elongated cutting edges configured to engage and cut multiple yarns. In some embodiments, multiple cutting blades may be used instead of sets or clusters of cutting tools.

[0172] In one embodiment, the tufting machine 10 may include a control system 15. This control system may include a program for controlling the operation of various actuators and / or components of the tufting machine, such as a yarn feeding system, a backing feeding system, a needle bar drive system, a yarn selection system, a cutting system, a shifting mechanism (for shifting the needle and backing, or for shifting both the needle and backing), and components of each such system, to produce patterned tufted articles according to a selected pattern. The control system 15 may also be configured to control the supply of pressurized gas from a gas source (e.g., a blower, compressor, or other pressurized gas source) to the various actuators or components of the tufting machine.

[0173] In some embodiments, the supply of pressurized gas may also include or be connected to a distribution device (e.g., a manifold), which may be configured to supply gas to different actuators of the tufting machine, such as, but not limited to, actuators for controlling the actuation of the yarn puller, actuators for the cutters of the cutting system, airflow-driven yarn feeding devices, and / or one or more other components.

[0174] In some embodiments, the various execution systems of the tufting machine 10 can be controlled by the control system 15 based on a program configured to receive and execute / run the desired pattern. In some embodiments, the control system 15 may include a controller 100, which... Figure 1A The diagram schematically illustrates a control cabinet connected to the tufting machine 10 and may have a user interface 101, such as a touchscreen, keyboard, etc. It should also be understood that in some embodiments, the controller 100 may be integrated with the tufting machine 10, for example, mounted to a frame or otherwise included within the tufting machine; while in other embodiments, the controller may comprise a stand-alone unit or a controller located further away, or a central server / controller.

[0175] In one embodiment, the controller 100 may include one or more processors and a memory configured to receive and store pattern information. The controller may also include programs or instructions adapted to control the operation of the hollow needle tufting machine and its various actuators. For example, in one embodiment, the controller of the control system may include programs or instructions executed by one or more processors to selectively control the yarn fed into the needles based on received or programmed pattern information, enabling substantially consistent yarn feeding into each needle, in conjunction with the engagement / selective operation of the cutter and yarn pull-back mechanism and / or needle displacement (and in some embodiments, backing displacement), thereby forming a desired pattern with multiple colors and / or types of yarn.

[0176] Additionally, in some embodiments, the control system can control the feeding of the backing to feed it at an actual stitch rate, which is typically equal to the pattern stitch rate designed or adjusted for the tufted pattern, or the actual stitch rate includes an effective processing stitch rate that may be increased compared to the required stitch rate of the designed pattern. In some embodiments, the backing can be fed at an effective processing stitch rate determined based on the number of colors in the pattern or the number of colors used in the stitching sequence of the needles multiplied by the required stitch rate of the pattern (the required stitch rate can be determined by the stitch rate of the pattern, which is designed based on the number of yarn ends fed into each needle to form each tuft, the thickness and / or weight of the yarn, and other factors).

[0177] In some embodiments, the control system may also include a program adapted to apply dynamic feed parameters based on the operating speed (RPM) of the spindle of the hollow needle tufting machine to drive the operation of various actuators of the hollow needle tufting machine. For example, the control system may drive the operation of one or more actuators, such as engagement of selected yarn pullers, engagement (e.g., opening and closing) of blowers, yarn feeding of selected yarn into each needle, movement of the cutter between a cutting position and an unengaged or uncutting position, displacement, and other actuators, based on the rotation of the spindle of the tufting machine.

[0178] In an implementation, the control system can control the yarn feeding system (e.g., control a yarn feeding device or yarn feeding mechanism or unit selected from its yarn feeding devices or units) to feed a portion of yarn to be fed into each needle during each stitch or individual sewing operation that occurs within a portion of the rotation of the spindle of the hollow needle tufting machine.

[0179] In some implementations, the tufting machine can be configured to provide single-stage cut-tufted fabric, and the control system can include a program that can use yarn feed control to control the formation of multi-stage loop tufts of yarn, without necessarily requiring the cutter for cutting the yarn loops to move from the cut-tuft (cylinder extended) position to the loop tuft (cylinder retracted) position.

[0180] In embodiments, the length of the tufting machine, the needle spacing, and the number of needles can vary depending on the product to be produced and the required production rate. For example, in embodiments, the tufting machine can be configured to produce carpets, turf, rugs, or other articles of selected sizes or size ranges. For example, in embodiments, the needles can be arranged at a needle gauge spacing that substantially matches the selected or required needle gauge of the tufting machine, for example, a needle gauge spacing of about ¼ inch to 3 / 8 inch or greater, including ¼ inch, 5 / 16 inch, 3 / 8 inch, 7 / 16 inch, ½ inch, 5 / 8 inch, 9 / 16 inch, ¾ inch, 7 / 8 inch, 1 inch, or greater, said needles can be used to form tufted products that are substantially true needle gauges, and in some embodiments, said tufted products can be matched with the tufting machine.

[0181] For example, in an embodiment of the method according to the principles of this disclosure, the method may utilize a tufting machine configured with a single-end or double-end yarn feeding mechanism or pattern attachment with an expanding roller system, such that the yarn feeding mechanism can feed a length of yarn that may correspond to a selected tuft length or pile height of artificial turf, turf, or coarse-pile carpet, field, and / or rug. For example, in an embodiment, the tufting machine may feed tuft lengths with pile heights exceeding three inches.

[0182] In an embodiment of the method, the yarn passes through a series of yarn pullers controlled by a control system to be actuated in an appropriate / selected sequence based on the rotation of the spindle (e.g., actuated based on the position of the spindle during the tufting cycle). In an embodiment, actuators (e.g., cylinders) can be controlled to move the yarn pullers in two directions (e.g., up / down) between a first extended position and a second retracted position. In an embodiment, when the yarn pullers retract, the length of the yarn can be at least partially retracted and held within the corresponding needle to prevent it from being cut due to exposure. When the cylinder extends, thereby extending the yarn puller connected thereto, the yarn is allowed to flow through the needle to form the tuft length.

[0183] In an embodiment of the method, the yarn passes through a yarn puller and can be directly guided into the needle by an airflow-driven yarn feeder, such as... Figure 2F , 2H As shown in 5A, the yarns are propelled through the channels of the associated needles by an airflow-driven yarn feed mechanism. In some embodiments, the yarns may also be fed through a series of yarn tubes, each communicating with a corresponding needle. In one embodiment, as the needles reciprocate into the backing, the selected yarns (e.g., those selected for forming the holding clusters of the pattern) are guided by an airflow supplied by the gas injector of the airflow-driven yarn feed mechanism through the needle bar and through their associated needles.

[0184] In embodiments of the method, the yarn is cut by a cutting system. In these embodiments, the cutting system may include a series of flat blades that can selectively move to contact the lower portion of the needle as the needle pierces the main backing to cut the yarn and thus form a cluster in the backing. In some cases, the needle tip may be flat to better cut flat, thin yarn.

[0185] In embodiments of the method, each needle can be threaded with a selected different color or type of yarn. In other embodiments, multiple yarns (e.g., two or more) can be fed into each needle. Examples of applications used for forming turf fields (e.g., such as...) Figure 9A and 10A As shown), turf fields can include a variety of different colors, for example, for forming yard markings, lines, signs, etc. Artificial grass or turf yarn can be fed into needles, the artificial grass or turf yarn including at least one filament and at least one substantially flat ribbon yarn. In other example embodiments, such as for forming tufted rugs, carpets, and other tufted products, each needle can be assigned and fed with two or more colors of yarn (e.g., for forming such...). Figure 11A (The shown is a coarse-pile carpet).

[0186] Needles can be threaded with yarns of various specified colors to tuft the desired pattern according to a selected threading sequence. For example, for a pattern using 4-8 colors, the yarns can be threaded into the needles in a selected or desired threading sequence (e.g., ABCD, ABCDE, ABCDEF, ABCDEFG, ABCDEFGH), where two or more yarns of different colors are fed sequentially into selected needles, and the threading sequence can then be repeated along the length of the needle shank. In other embodiments, other threading sequences may also be used. Additionally, in some embodiments, where the pattern requires an extension or area of ​​one color, the needles can be grouped or arranged as a whole in different threading sequences.

[0187] For example, many sports fields today include areas featuring logos or other different color designs. In this implementation, the needles can be configured with a threading order based on the different colors to be used, and depending on the tufted portion of the sports field, the needles can be threaded with 4-6 colors of yarn. Figure 9A The illustrated example shows a section of a sports turf field comprising five colors—green, white, brown, black, and orange. A five-color threading sequence (e.g., ABCDE threading sequence) can be used, where at least two needles are assigned a base color, such as green and white, and the remaining needles are assigned the tufting's remaining (emphasis) colors, such as brown, black, and orange. In some embodiments, a six- or more-color threading sequence can also be used, for example, to selectively control the feeding of additional yarns, such that when not needed, these yarns may be absent from the area or even from some tufting processes.

[0188] In some embodiments, the backing may be displaced cooperatively with or separately from the needles. In some embodiments, the backing may be displaced without needle displacement. In some embodiments, the needles may be maintained in a substantially consistent lateral position such that they do not move laterally relative to the longitudinal path of travel of the backing. Instead, the backing may undergo other displacements besides longitudinal movement. In such cases, the backing may be displaced laterally in various increments or steps, which may include displacing the backing by a distance based on the needle gauge spacing, or in some embodiments, the distance may not be associated with the needle gauge spacing (e.g., the displacement distance or length of the backing may be less than or greater than the needle gauge spacing).

[0189] In one implementation, the backing may be moved multiple times through the tufted area in both longitudinal and transverse directions, so that yarns of a selected color can be presented at the corresponding stitch positions of the pattern and inserted or tufted at such stitch positions at an actual stitch rate, which is typically equal to the pattern stitch rate designed or adjusted by the backing as it moves along its path at each pattern step.

[0190] In some implementations, the longitudinal movement of the backing can also be controlled such that the backing is fed at an actual stitch rate substantially matching the pattern stitch rate of the tufted pattern, or in some implementations, the actual stitch rate of feeding the backing can include an effective processing stitch rate greater than the required stitch rate of the pattern. For example, some sports turf applications (e.g., fields for rugby, football, lacrosse, or other sports) have a required stitch rate of approximately 3-5 stitches per inch due to the need to establish a certain amount of infill between the tufts. In other turf applications, closer spacing may be required, especially where less infill is needed.

[0191] In some implementations, the backing can be fed at an actual stitch rate, which can be determined based on the selected pattern stitch rate and / or desired density of the turf product, the number of colors used in the needle threading sequence, or a combination thereof. For example, in some implementations, if a 6-color yarn threading sequence is used, the backing can be fed at an effective processing stitch rate of approximately 18 stitches per inch, even if the pattern only requires the use of 3-5 colors during a specific tufting process of the tufted product.

[0192] Furthermore, since in some embodiments the backing can be displaced to present each stitch position to a needle carrying a selected color yarn, thereby placing the yarn at that stitch position, closer cluster spacing can be provided. In some embodiments, such as with needle displacement, the backing can be fed at an effective stitch processing rate, and each needle can be fed, selectively presenting multiple yarns during each needle insertion into the backing. Thus, larger clusters comprising multiple yarns can be selectively formed at each stitch position or pixel of the pattern being formed.

[0193] In implementation methods, this type of backing feeding method can also enable the working surface of patterned tufted products to have a denser appearance, for example... Figure 8A , 9A As shown in 10A, 11A, and 12, the back stitches on the back side of the backing can be significantly minimized or reduced, and in some cases, such as Figures 8B-8C As shown in 9B, 10B and 11B, the back stitches can be formed such that no trailing length of yarn is left on the working surface of the patterned tufted product that was not selected to be retained and / or displayed.

[0194] In some cases, the effective stitch rate can be independent of the tufting machine's needle gauge (e.g., not based on the selected needle gauge spacing or the required needle gauge for the tufted product). This can provide a fabric construction in which the number of tufts in the longitudinal direction does not match the number of tufts in the lateral or transverse directions.

[0195] Additionally, in one embodiment, the needle bar 11 can be configured to have needles 12 arranged at a gauge spacing substantially matching that of the tufting machine, and two or more ends of the yarn can be fed into each needle while the backing moves at an effective needle rate based on the threading sequence and yarn feed rate. This allows for the presentation of multiple colors of yarn at each pixel or needle position during each puncture of each needle, to form larger retained tufts or clusters of yarn at each needle position, and / or to form tufts with smaller spacing between them. This can provide a fuller tufted appearance, where the amount of yarn required for the back stitches is reduced, for example, there are no trailing back stitches along the back side of the backing, e.g. Figures 8A-8C As shown in 10A-11B.

[0196] In implementations, shifting the needle with or without shifting the backing, or shifting the backing alone while the needle remains in its original position, combined with the needle threading method, can allow for increased variability in the resulting design. For example, the designer can use a selected / designed shift profile, yarn feed control, and a selected threading sequence that extends / repeates within the width of the machine to plan the placement of signs, decorative features, or portions thereof in the finished turf field. After forming such strips or patches, the patches can be matched and sewn together or otherwise joined to form a complete field, such as... Figure 9A As shown.

[0197] In the example, such as Figures 8A-8B As shown in the general overview, using the tufting system and method of this disclosure, tufted turf and artificial grass products can be formed, wherein a variety of different colors and / or types of yarns (e.g., flat, flat ribbon yarns of two, three, four or more colors) can be formed. Figure 8A Cross-sections of tufted turf products in various colors, mixed together as part of a single tufted turf product, are shown. Figure 8B It shows Figure 8A The back stitching of the product shows four different colored yarns tufted together. The back stitching exhibits a zigzag shifting motion, in which the needles move back and forth. In an embodiment, the needles, backing, or a combination thereof may be based on the use of the four colors in the pattern in a first direction (e.g., in...). Figure 8B Shift four times from center to right, then in the second direction (e.g., in...) Figure 8BShift four times from center to left. Other shifting motions can also be used.

[0198] The yarn feeding is controlled by the operation of the yarn feeding device and the yarn pull-backer. Combined with the displacement of the backing, needles, or a combination thereof, each color or type of yarn can be selectively fed to its corresponding needle, such that only the selected color or type of yarn will be actually introduced into the backing. The movement of the backing along its travel path P can also be controlled to feed the backing at an effective stitch rate or actual stitch rate, which is increased relative to the desired or selected stitch rate of the tufted pattern. In one example, for a four-color pattern, the effective or actual stitch rate can be approximately four times the desired or selected stitch rate of the tufted pattern (e.g., the pattern can be designed with a designed pattern stitch rate that can be operated by the tufting system at the desired or selected stitch rate). In some cases, this designed pattern stitch rate can be adjusted, for example, to achieve a desired weight, or to form the desired or selected stitch rate based on other factors.

[0199] Therefore, in this implementation, the tufting system can present and tuft yarns of the desired color or type only at specific stitch locations, while unselected yarns can remain in a retracted position without tufting, without creating gaps or reducing the coverage area of ​​the tuft. Thus, a mixture of multiple colors or types of yarns can be tufted to form various design or decorative features. Figure 8A and Figure 9A The image shows a four-color patterned turf product that includes a portion of a soccer ball within a green field. The soccer ball has lace / stripes and the team logo inside. Additionally, as... Figures 8B-8C and Figure 9B As shown, the back stitches formed on the back side of the backing can contain only the actual tufted yarn into the backing, which can help reduce yarn consumption.

[0200] Furthermore, in cases such as Figure 9A In the illustrated implementation, strips or patches of turf, such as 15-foot / 5-yard strips, can be tufted so that most or some sections are green, and designs, signs, site accessories, or parts thereof can be inserted at intervals in the formation of the strips or patches.

[0201] Figure 10A-12 Additional embodiments of tufted products and their backside stitches formed using the tufting system and method according to the principles of this disclosure are shown. Figure 10A-12The tufting system and method use a tufting machine having needles arranged at a gauge spacing substantially matching the tufting machine's gauge, and the backing being displaced while the needles are maintained in a lateral position substantially stationary relative to the longitudinal path of travel of the backing. The backing can be fed at an actual or effective needle rate based on a desired needle rate increased (e.g., multiplied) by the amount of yarn used in the needle bar threading or the number of yarn colors in the pattern.

[0202] Figure 10A Examples of sports carpets utilizing various colors of turf or artificial grass yarn are shown. Figure 10B An example of its back stitches is shown. Figure 11A An example of a shaggy rug featuring yarns in two colors is shown. Figure 11B An example of its back stitches is shown. It can be seen that different types of yarns, including yarns of various thicknesses and materials, filaments, etc., can be used to form patterned tufted products using embodiments of the tufting system and method of this disclosure. Unselected or unretained yarns / tufts present at each stitch location of the pattern may need to be removed; in some embodiments, this may include catching or pulling the yarn back into the hollow needle to which it is assigned, thereby providing a cleaner back stitch as shown.

[0203] Figure 12 Examples of artificial turf or grass fields are shown, wherein the artificial turf or grass field has a substantially seamless design integrally formed therein using a tufting machine and tufting method according to the principles of this disclosure. Figure 12 The image shows an artificial turf or grass field with an eagle pattern and an American flag background. The eagle pattern and American flag background are integrally tufted with the rest of the tufted artificial turf or grass field, such that no seams are formed at the transition between the pattern-colored yarns forming the eagle and flag patterns and the green base-colored yarns (e.g., green "grass" yarns) constituting the rest of the grass field, nor between the pattern-colored yarns defining the eagle pattern and the different pattern-colored yarns defining the American flag background. Although Figure 12 The illustration shows an implementation where narrower sections of artificial turf or grass fields (e.g., sections formed using a prototype-sized tufting machine) can be attached in series, but it can be seen that portions of the design itself within each section are substantially seamless with the green grass portion of each section. It should also be understood that, in the implementation, larger-sized tufting machines can also be used to produce larger or wider tufted turf fields or sections thereof, incorporating, for example... Figure 12 The entire design features an eagle and a national flag.

[0204] Significant savings in time, labor, and cost can be achieved in the installation of artificial turf or grass fields by producing artificial turf or grass tufted products in which the tufts are integrally formed, with substantially seamless designs or patterns (e.g., having boundaries or transitions between different colored patterned yarns defining the pattern and the base-colored yarns constituting the rest of the turf field, without seams or noticeable color bleeding). For example, using the tufting machine or equipment and tufting method of this disclosure, the need to separately form designs or patterns of different colors and then cut, stitch, and / or glue such designs into the entire turf field during installation can be avoided. This can reduce the installation time of turf fields from several days to, in some cases, far less than a day, and significantly reduce the labor required.

[0205] In embodiments, during operation of the tufting machine or equipment 10, the needle bar and / or backing support can be displaced using one or more displacement mechanisms coupled to the needle bar and / or backing support or shuttle to change the color or type of yarn used for needle bar threading, providing the ability to present each of the colors threaded into the needle at each pixel or needle position (e.g., threading of four or six or more colors), and in some embodiments, enabling the mixing of colors on the working surface of the tufted product / turf, allowing additional colors to be presented and retained as needed at selected or desired locations during the formation of tufted patches or strips to form designs, logos, or site accessories or part thereof. However, when it is not desired to use a certain color or type of yarn on the working surface, the yarn feeding system can be controlled to substantially stop feeding that color or type of yarn, and the yarn puller associated with the yarn can retract the yarn from the needle, which can enhance color control in the design.

[0206] Additionally, embodiments of the tufting machine and method disclosed herein may include a tufting machine for forming artificial grass or turf products with patterned designs, comprising: a plurality of needles configured to pierce a positioned backing during reciprocating motion of the needles; wherein the needles include hollow needles, each hollow needle having an upper end and a lower end, defining a channel between the upper end and the lower end; a yarn feeding system for supplying a plurality of yarns, the yarn feeding system being configured to selectively feed one or two yarns into each needle to deliver the yarn to the backing to form tufts or yarns therein; and a shifting mechanism for shifting the needles on the backing or shifting the backing relative to the needles, so as to enable the formation of multiple patterns within the backing. Each of the needle positions features a different color or type of yarn; a yarn selection system coupled to an air source and including multiple yarn pullers adapted to move between an extended position and a retracted position, the extended position allowing selected yarn to be fed from the yarn feed system to the needle, the retracted position for retracting and / or blocking the yarn supplied by the yarn feed system into one or more needles; and a cutting system disposed below a backing support and including at least one cutter or cutting blade configured to cut the selected yarn as it is fed into the backing through the reciprocating motion of the needle entering and exiting the backing.

[0207] In one embodiment, the tufting machine may further include a control system configured to control the operation of a yarn feeding system for feeding selected yarn into the needle and the operation of a yarn pull-back device.

[0208] In an implementation of a tufting machine, the control system may include a program configured to dynamically drive the operation of the yarn feed system and the yarn pullback device prior to the next stitch placement step of the pattern being formed.

[0209] In one embodiment, the tufting machine may further include at least one needle bar with needles mounted along it. The needle bar has a series of openings spaced apart along it and communicating with the channels of the corresponding needles; wherein yarn is guided through the openings in the at least one needle bar and into the channels of the needles.

[0210] In an embodiment of a tufting machine, the needle gauges of the artificial grass or turf product based on the tufting machine are arranged along at least one needle bar at a selected needle gauge spacing.

[0211] In one embodiment, the tufting machine may further include a series of angled yarn tubes mounted along the upper surface of the needle bar, wherein each yarn tube is in communication with a corresponding needle; and an air-driven yarn feeding mechanism connected to an air source for guiding the yarn through the yarn tubes and the needle.

[0212] In the implementation of the tufting machine, the shifting mechanism includes a rack and pinion type shifting mechanism.

[0213] In an embodiment of a tufting machine, at least one tool or cutting blade includes a substantially flat cutting surface or cutting edge.

[0214] In an embodiment of a tufting machine, the needles include hollow needles, each having a body having an internal channel therein, a first end and a second end received within a needle bar, the second end terminating at a tip and having a planarized cutting surface configured for cutting flat, flat yarns or filaments.

[0215] In other embodiments, a tufting machine may be provided, which is configured to produce tufted turf or artificial turf products or patches of tufted turf or artificial turf products having an integrated design (e.g., logo), the patches including portions of a larger design and which can be attached together to form a sports carpet or artificial turf or turf field.

[0216] Additionally, this disclosure also includes methods suitable for enabling the production of single-end designs within the machine frame of a tufting machine for producing tufted turf or artificial turf products or patches of tufted turf or artificial turf products having integrated designs (e.g., logos), the patches including portions of larger designs and which can be attached together to form a field.

[0217] In one embodiment, a method is provided that may include: feeding multiple yarns along a travel path into each of multiple needles from multiple yarn feeding devices; reciprocatingly moving the needles into and out of a backing; displacing the backing or displacing the needles in a direction transverse to the movement of the backing along the travel path; selectively controlling the yarn feeding devices to substantially stop or slow down the feeding of unselected yarns to the needles, and actuating one or more yarn pull-back devices to engage and pull back the unselected yarns; selectively controlling the yarn feeding devices and yarn pull-back devices while the movement of the backing feed along its travel path is controlled, such that different yarns are presented at each of a plurality of needle positions, thereby forming an artificial turf or turf product incorporating one or more of a design, decorative features, logo, or portions thereof.

[0218] In some embodiments, the method further includes reciprocating motion of multiple hollow needles entering and exiting the backing; selectively feeding multiple yarns into each hollow needle as the hollow needles reciprocate into and exiting the backing, and laterally displacing the backing relative to the longitudinal travel path.

[0219] Additionally, the tufting machines, equipment, and methods disclosed herein can be used to produce a variety of tufted articles, including artificial turf or grass that can have various colors, designs, texts, or other patterns, and said tufted articles can be formed as segments or pieces that are configured to be attached as part of a larger field or patterned article.

[0220] This disclosure has been described herein based on examples illustrating the principles and aspects of this disclosure. However, those skilled in the art will understand that a wide range of additions, deletions, changes, and modifications, whether minor or extensive, can be made to the presented examples without departing from the spirit and scope of this disclosure. All such modifications without departing from the spirit of this disclosure are intended to be included within the scope of any aspect and / or claim provided herein.

Claims

1. A tufting machine for forming artificial grass or turf products with various patterned designs, characterized in that, The tufting machine includes: At least one needle bar, with multiple needles positioned along the at least one needle bar; The multiple needles mentioned include hollow needles; A yarn feeding system configured to feed multiple yarns into the multiple needles; The multiple needles move toward and away from the backing in a reciprocating motion, the backing moving along a travel path through the tufting machine so as to introduce multiple selected yarns into the backing as the multiple needles pierce the backing; At least one shifting mechanism for laterally shifting the backing; A yarn selection system arranged along the yarn travel path between the yarn feed system and the plurality of needles, the yarn selection system being configured to retract and / or block unselected yarn supplied by the yarn feed system to one or more of the plurality of needles; and A cutting system disposed below the backing and comprising at least one cutter or cutting blade configured to cut the selected yarn as it is fed into the backing by the reciprocating motion of the plurality of needles entering and exiting the backing.

2. The tufting machine according to claim 1, characterized in that, The tufting machine also includes a control system comprising a program configured to: control the operation of the yarn feeding system to feed each of the plurality of selected yarns into the needle at a length substantially sufficient to form a tuft of predetermined height; control the operation of the yarn selection system; and control the operation of the at least one shifting mechanism to be able to present different colors or types of yarn at each of the plurality of stitch positions in the pattern being formed.

3. The tufting machine according to claim 2, characterized in that, The yarn selection system further includes a plurality of yarn pullers and a plurality of actuators, the plurality of yarn pullers being adapted to engage a plurality of yarns fed into the plurality of needles, each of the plurality of actuators being connected to at least one yarn puller and adapted to move the plurality of yarn pullers between an extended position and a retracted position, the extended position allowing a plurality of selected yarns to pass through the plurality of needles from the yarn feeding system, the retracted position causing a plurality of unselected yarns supplied by the yarn feeding system to the plurality of needles to retract and / or be blocked.

4. The tufting machine according to claim 3, characterized in that, The control system includes a program configured to dynamically drive the operation of the yarn feed system and the plurality of yarn pullers or the yarn selection system prior to the next stitch placement step of the pattern being formed.

5. The tufting machine according to claim 1, characterized in that, The at least one needle bar includes a series of openings spaced apart along the at least one needle bar and communicating with channels extending through corresponding needles; wherein the plurality of yarns are guided through the plurality of openings in the at least one needle bar and into the plurality of needles.

6. The tufting machine according to claim 1, characterized in that, Based on the needle gauge of the artificial grass or turf product of the tufting machine, the plurality of needles are arranged along the at least one needle bar at a selected needle gauge spacing.

7. The tufting machine according to claim 1, characterized in that, The tufting machine also includes an airflow-driven yarn feeder connected to an air source and configured to guide airflow through the at least one needle bar to assist in feeding multiple yarns through the multiple needles.

8. The tufting machine according to claim 1, characterized in that, The shifting mechanism includes a rack and pinion shifting mechanism.

9. The tufting machine according to claim 1, characterized in that, The at least one tool or cutting blade includes a substantially flat cutting surface or cutting edge.

10. The tufting machine according to claim 1, characterized in that, Each of the plurality of needles includes a body having an internal channel therein, a first end and a second end received within a needle bar, the second end terminating at a tip and having a flattened cutting surface configured for cutting flat, flat yarns or filaments.

11. A tufting machine, characterized in that, The tufting machine includes: Multiple needles, configured to pierce the backing; A yarn feeding system configured to selectively feed multiple yarns into the multiple needles; The plurality of needles includes a plurality of hollow needles, each hollow needle having a first end and a second end, and a channel is defined between the first end and the second end, through which one or more yarns are fed. The multiple yarns mentioned above include yarns of different types or colors; At least one shifting mechanism for shifting the plurality of needles on the backing or shifting the backing relative to the plurality of needles; A yarn selection system includes multiple yarn pullers adapted to move between an extended position and a retracted position. The extended position allows multiple selected yarns to be delivered from the yarn feed system to multiple needles, and the retracted position causes unselected yarns supplied by the yarn feed system to one or more of the multiple needles to retract and / or be blocked. As the multiple needles reciprocate in and out of the backing, the feeding of the selected and unselected yarns is controlled by the yarn feeding system, and the multiple yarn pullers move between their retracted and extended positions to allow the selected yarn to be inserted into the backing, thereby forming multiple loop piles or cut piles of the selected yarn according to the tufting pattern.

12. The tufting machine according to claim 11, characterized in that, The tufting machine also includes a cutting system comprising at least one cutter or cutting blade configured to cut the selected yarn to form a plurality of yarn tufts in the backing.

13. The tufting machine according to claim 11, characterized in that, The tufting machine also includes a control system comprising: a program configured to control the operation of the yarn feeding system to feed the plurality of selected yarns into the plurality of needles, and a program configured to dynamically drive the yarn feeding system to feed the plurality of yarns and the plurality of yarn pullers to move between the extended position and the retracted position before the next stitch placement step of the pattern being formed.

14. The tufting machine according to claim 11, characterized in that, The tufting machine also includes at least one needle bar, along which a plurality of needles are mounted; wherein the plurality of needles are arranged along the spacing of the at least one needle bar according to a selected needle gauge based on the needle gauge of the artificial grass or turf product produced by the tufting machine.

15. The tufting machine according to claim 11, characterized in that, The tufting machine also includes an air source and an airflow-driven yarn feeding device, which is connected to the air source and is used to guide the multiple yarns through the multiple needles.

16. The tufting machine according to claim 11, characterized in that, The second end of each of the plurality of needles includes a tip and a surrounding planarized cutting surface, the tip having an opening through which one or more yarns exit the needle, and the planarized cutting surface being configured to cut multiple flat, flat ribbon yarns or filaments.

17. The tufting machine according to claim 11, characterized in that, The tufting machine is configured to produce a variety of tufted turf or artificial turf products with a variety of integrated designs (e.g., logos) for the variety of tufted turf or artificial turf products.

18. A method, characterized in that, include: Move the backing along the travel path; feed multiple yarns from multiple yarn feeding devices into each of the multiple needles along the travel path; The backing is reciprocated by entering and exiting the multiple needles; the backing is displaced, or the multiple needles are displaced in a direction transverse to the travel path of the backing; the multiple yarn feed devices are selectively controlled to substantially stop or slow the feeding of multiple unselected yarns to the multiple needles, and one or more yarn pull-back devices are actuated to engage and impede or pull back the multiple unselected yarns, such that the multiple unselected yarns are substantially held within the multiple needles; as the backing travels along its path... When the movement of the yarn is controlled, the plurality of yarn feeding devices and the plurality of yarn pullers are selectively controlled, so that multiple different yarns can be presented at each of the plurality of stitch positions; and multiple selected yarn clumps are formed in the backing; wherein the plurality of yarns includes multiple artificial grass or turf yarns, the plurality of artificial grass or turf yarns including one or more colors, so as to form a tufted artificial grass or turf product, the tufted artificial grass or turf product integrating one or more designs, decorative features, logos or portions thereof.

19. The method according to claim 18, characterized in that, Displacement of the backing or displacement of the multiple needles includes displacement of the backing support, wherein the backing moves on the backing support.

20. The method according to claim 18, characterized in that, It also includes moving at least one cutting blade to engage with the cutting surface of each needle when the plurality of needles pierce the backing, and cutting the plurality of selected yarns to form a cluster of the plurality of selected yarns in the backing.

21. A tufted artificial grass or turf product, characterized in that, include: Backing; as well as Multiple spaced clusters of artificial grass or turf yarns formed in the backing; The artificial grass or turf yarns mentioned above include base color yarns and one or more pattern color yarns with colors different from the base color yarns; In selected stitch locations within the area of ​​the artificial turf or grass, multiple selected colors of the base color yarn and one or more pattern color yarns are retained in the backing to define at least one patterned area formed by the one or more pattern color yarns within the area of ​​the base color yarn in the backing; and The multiple transitions between the at least one patterned area formed by multiple patterned colored yarns and the area of ​​the base color yarn are substantially seamless.

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