Tufting machine and tufting method

Abstract

A tufting machine for selectively forming tufts of yarn, used to create patterned tufted products such as carpets, the yarn comprising different colors or types of yarn. A series of needles reciprocate through the base fabric of the tufting machine and engage by a series of needle spacing components to pick up loops of yarn from the needles. The needle spacing components are selectively controlled by actuators to extend or retract to a position or height sufficient to pick up or not pick up loops of yarn from the needles. The yarn feed to the needles is further controlled to retract yarn not picked up by the needle spacing components, while the base fabric feed is controlled to enable tufting to be formed with a pattern spacing larger than the pattern spacing of the pattern of the tufted product being formed.

Description

[0001] Cross-references to related applications

[0002] This patent application claims priority to U.S. Provisional Application No. 63 / 149,957, filed February 16, 2021.

[0003] U.S. Provisional Patent Application No. 63 / 149,957, filed on February 16, 2021, is incorporated herein by reference in its entirety. Technical Field

[0004] This disclosure generally relates to tufting machines and methods for forming tufted fabrics. In particular, this disclosure relates to tufting machines including selectively controllable stitch length components and modules or stitch length blocks for carrying such stitch length components, and methods for forming patterned tufted fabrics. Background Technology

[0005] In the tufting industry, particularly in commercial and hospitality carpets, there is a growing demand for carpets and blankets with novel visual patterns. These patterns incorporate a variety of colors to cater to evolving consumer tastes and address increasing market competition. Consequently, carpet designers and manufacturers are increasingly focused on creating more novel, distinctive, and eye-catching patterns for carpets, blankets, and other tufted fabrics. These patterns involve the selective arrangement and display of specific colors or types of yarn within their patterned areas, resulting in a tufted fabric with a substantially realistic pattern density of visible tufting. Specifically, there is a desire to replicate as closely as possible the look and feel of patterned carpets, blankets, or other fabrics formed on a loom, but where this look and feel can be created and formed on a wide-width tufting machine to improve the efficiency of producing such patterned tufted carpets, blankets, and / or other fabrics.

[0006] Furthermore, it is generally desirable to increase the operating speed of tufting machines to increase their output. This means that gauge components, such as loopers or hooks, and other components, such as needles, are subjected to increased machine cycles. As a result, these gauge components, as well as the modules or blocks carrying them, suffer from a higher rate of wear and require replacement.

[0007] Therefore, it can be seen that there is a need for systems and methods for forming tufted fabrics such as carpets and blankets, which solve these problems in the field and other related and unrelated problems. Summary of the Invention

[0008] In short, this disclosure generally relates to tufting machines and methods for forming patterned tufted articles, wherein the placement and pile height of the tufts of yarns or stitches formed in a base fabric can be selectively controlled to enable the formation of patterned tufted articles (e.g., carpets) with a variety of pattern effects, including the formation of tufted articles with free and flexible multi-color and / or multi-pile height patterns and with an appearance that is substantially woven or knitted.

[0009] In one aspect, a tufting machine will typically include a control system for controlling the operating elements of the tufting machine to form or create tufted articles according to a desired or designed pattern. The resulting tufted articles may include: various pattern effects, which include different types of tufting with multiple varying or different pile heights in the same and / or varying tufted rows; other texture effects; and the placement of various colors and / or types of yarns and pile heights on the base fabric visible at selected locations; wherein, in at least some embodiments, the resulting tufted articles are provided with a density per inch of retained and / or visible colored yarns / stitches, said density substantially matching the pattern density or stitches per inch desired or specified for the pattern being formed / tufted.

[0010] In an embodiment, the tufting machine will include one or more needle bars having a series of needles mounted thereal. The needles may be arranged in a straight line, staggered, or other configuration. As the base fabric is fed through the tufting area of ​​the tufting machine and as the needles reciprocate into and out of the base fabric, yarn is introduced into the base fabric. A moving mechanism may also be provided for causing one or more needle bars to move laterally through the tufting area, and multiple moving mechanisms may be used as needed. The one or more moving mechanisms are generally responsive to instructions or communications from a control system for causing one or more needle bars to step or move laterally across the base fabric according to programmed and / or designed pattern movement steps for the pattern being tufted, to present the yarn thereby to a tufting or stitch position along or across the base fabric.

[0011] Tufting machines typically also include at least one yarn feed mechanism or accessory for controlling the feeding of yarns to their respective needles. This yarn feed mechanism or pattern accessory can include, but is not limited to, various rollers, spools, servo spools, single-ended yarn feed accessories, double-ended yarn feed accessories, or multi-ended yarn feed accessories (e.g., Yarntronics manufactured by Card-Monroe). TM or Infinity TM / Infinity IIE TM(Yarn feed attachment). Other types of yarn feed control mechanisms may also be used. The at least one yarn feed mechanism or pattern attachment can be operated to selectively control the feed of yarn to its needles to form yarn tufts (this may include forming tufts with selected pile heights and / or not forming tufts) to produce a desired pattern appearance.

[0012] In some embodiments, the control system may further include or operate in conjunction with a stitch distribution control system, such as that disclosed in U.S. Patent No. 8,359,989 (the disclosure of which is incorporated herein by reference as if fully set forth herein); by such a control system, control of the base fabric feed and control of the operation of one or more movement mechanisms for moving at least a portion of the needles may be coordinated with control of at least one yarn feed mechanism, such that various yarns may be presented to various stitch positions or pixels, and the yarns displayed on the face or surface of the tufted article may generally be fed in an amount sufficient to form tufting of the desired height, while non-displaying yarns not displayed in the tufted area will be retracted or otherwise pulled low enough and / or pulled out from the base fabric. For each pixel or stitch position of the pattern, a series of yarns may be presented, and yarns not selected as visible or present at such stitch positions may be pulled low enough to be hidden and not interfere with the selected visible yarns. In some embodiments, this may include pulling out unexposed or unselected yarns from the base fabric, or leaving a sufficient portion of the unexposed yarns within the base fabric, while substantially minimizing interference with the retained and visible tufting of the patterned face or yarns, to retain or coarsely sew the unselected or unexposed yarns onto the base fabric. Thus, in embodiments, only the desired or selected yarn / color to be placed at a particular stitch location can be retained at that stitch location, while the remaining yarn / color can be hidden so as not to be visible or displayed in the pattern area being sewn at the time. The control system may also control and coordinate the operation of the stitch length component assembly to control the selective formation of yarn loops and / or tufts, and the length or pile height of said yarn loops and / or tufts, wherein the yarn is fed at least according to instructions for the pattern being formed.

[0013] Additionally, in embodiments, the stitch length component assembly typically includes a series of stitch length components, such as, but not limited to, loopers, hooks, flat-cut loopers, cut / loop clamps, etc., positioned below the tufted area, and these stitch length components are movable in a first direction to reciprocate and engage with the needle as the needle penetrates the base fabric material to pick up loops of yarn from the needle. In some embodiments, each stitch length component may also be selectively movable in a direction generally perpendicular to its reciprocating direction, for example, moving in a generally vertical direction (i.e., up-down direction) relative to the needle's travel or reciprocating motion on and away from the base fabric, and moving toward and away from the needle's reciprocating motion to selectively pick up yarn and form loops of yarn in the base fabric material. Furthermore, the vertical movement of the stitch length components can be controlled to form different loops of yarn with different pile heights in the base fabric material, including forming loops of yarn with different pile heights in the base fabric or even not forming loops at all. In further embodiments, other configurations and / or combinations of loop needles, cut loop hooks, cut / loop hooks, flat cut loop needles or hooks, and / or other stitch length components may also be used.

[0014] For example, in some embodiments, the stitch length component may include a bent needle or hook, each of which has a body slidably mounted within a stitch length module or block, and the body has a first portion and a second portion, the second portion including an elongated throat terminating at a proximal end of a tip or a beak. The first portion of the body may extend through the stitch length block or module and may be connected to an actuator at a distal end. In some embodiments, each stitch length module may include a module or block body having: a first or rearward section adapted for coupling or mounting along a stitch length bar; and a second or forward section having at least one groove or channel formed therethrough, through which a stitch length component will be received. The module may also include a replaceable insert that may be received within a channel or groove formed within the module body, the replaceable insert further including a slot or recess adapted to receive and guide the stitch length component during movement of the stitch length component through the channel of the module body / along the channel of the module block body. Alternatively, the insert can be integrated with the module, for example, by adhesive or otherwise substantially permanently attaching or securing it to the body of its module or pin block, and in some embodiments, the insert can be substantially adhesive, but at the same time still be removable as needed, at least usably.

[0015] In embodiments, the replaceable insert will be formed of a hardened material, which may include, but is not limited to, various metal carbides, metals, ceramics, and / or synthetic materials, while the body of the module may be made of a lightweight material, such as aluminum and / or other metals, as well as various composite or synthetic materials. The insert may also include an opening or slot configured to receive a guide pin or other positioning device, and one or more fasteners for securing the insert in the stitch gauge module. The opening is typically further configured to allow adjustment of the insert in at least one direction (e.g., longitudinal) and / or in multiple directions (e.g., longitudinal and / or transverse) to adjust the position of the insert and thus adjust the arrangement or positioning of the stitch gauge components across and / or along the stitch gauge module. The insert may also be interchangeable to allow easy removal of the insert and thus replacement of one or more stitch gauge components received therein, for example, to replace worn or damaged stitch gauge components, or to change the spacing between the stitch gauge components.

[0016] As an alternative, in some embodiments, the module or stitch block itself can be removed and replaced with other stitch blocks or modules, each of which includes a set or series of stitch components mounted therein, to provide replacement of the stitch spacing between stitch components, replacement of the type of stitch component of the size used, or substantially all or at least most of the replacement of worn or damaged stitch components as a whole. Additionally, guide slots or recesses formed within the insert are typically configured to receive the body of the stitch component with a gap, said gap generally sufficient to allow the stitch component to slide substantially freely through the slot or recess, but without causing excessive movement or twisting of the stitch component, resulting in misalignment of the beak or throat of the stitch component with its respective needle. The slot or recess of the insert may also terminate at a rear end or rear portion, which may be configured or adapted such that the edge of the body of the stitch component can sit on or engage a base or engagement area and / or be provided with a base or engagement area, the edge of the body of the stitch component being slidable along the base or engagement area to help maintain the required alignment of the stitch component as it reciprocates or moves through its module.

[0017] The stitch spacing components can also be arranged to engage needles, including being arranged as needed in substantially straight, offset, or staggered, and / or other configurations to engage in straight, staggered, and / or double needle bar arrangements. In embodiments, each of the stitch spacing components can also be arranged at an angle relative to the needle as the needle penetrates the base fabric. For example, in some embodiments, the stitch spacing components can be arranged along a travel path and / or be extendable / retractable, the travel path being oriented at an angle of approximately 1° to approximately 10° relative to the needle and / or its travel or vertical movement with respect to the vertical direction, while in other arrangements, no offset (i.e., 0° angle) may be provided. The offset of the stitch spacing components relative to the needle can also vary, such that the stitch spacing components extend and retract as needed along an angled or offset travel path relative to the needle to minimize potential engagement between the stitch spacing components and the needles during movement, based on the needle spacing and / or arrangement.

[0018] In various embodiments, the actuators driving the movement of the stitch length components may include hydraulic cylinders, electric cylinders, air or pneumatic cylinders, electric motors, or other similar actuators. The actuators of each stitch length component can be selectively controlled according to pattern instructions to move the stitch length component relative to the associated needle to a desired vertical position for picking up loops of yarn from the needle. This includes picking up loops of yarn at different points in the needle stroke to form loops / tufts with different pile heights, and retracting to a “seamless” position, in which loops of yarn will generally not be picked up. In a further embodiment, the actuators can be controlled / triggered to move the stitch length component on which loops of yarn are captured, such that one or more such captured loops are elongated or pulled to provide additional pile heights and / or other effects, such as end cuts or other pattern or texture effects.

[0019] In various aspects, the stitch spacing components can also be coupled to their respective actuators via connectors or gates configured to extend between the actuator shaft or rod and the distal end of the associated or corresponding stitch spacing component. In some embodiments, the connector or gate may include an arm or link having a first end portion configured to engage or connect to the drive rod of its actuator, an intermediate section projecting from the first end portion, and a second end portion typically configured to engage the distal end of the associated stitch spacing component. When each actuator is actuated or deactivated, it extends or retracts its actuator shaft to cause its associated stitch spacing component to move relative to the needle in a desired direction.

[0020] For example, in some embodiments, the actuator can drive the stitch length component in a substantially vertical direction relative to the directional reciprocating motion of the needle entering and leaving the base fabric, for example, to adjust the height of the stitch length component relative to the needle as the stitch length component reciprocates toward and away from the needle. In other embodiments, actuation of the actuator and movement of the connector can help control the movement of the stitch length component toward and away from the needle in a direction substantially along the directional reciprocating motion of the stitch length component toward and away from the needle.

[0021] Furthermore, in embodiments, the link or arm of the connector or door may also be received within a housing or support structure. In one example embodiment, such a housing or support structure may include a body formed of a durable, lightweight material (e.g., carbon-filled nylon, or other similar composite or plastic material), chosen to provide durability and support for the link or arm while reducing weight. Other materials, including various metals, synthetics, and / or composites, may also be used. The configuration of the support structure or housing may also vary as needed to accommodate different configurations and / or sizes of the link; and in various embodiments, the link or arm of the connector may also have a reduced thickness or structure to further aid in weight reduction, and in some embodiments, the link or arm of the connector may include a skeletal structure. When engaging and disengaging from the actuator, the link or arm of the connector is received within a groove or channel formed in the connector housing and moves through the groove or channel, thereby transferring this movement to its associated or corresponding pin pitch component.

[0022] In some aspects of this disclosure, a tufting machine is provided, the tufting machine comprising at least one needle bar having needles mounted thereal thereon; a base fabric feed roller that feeds base fabric material to inserts, each insert having a series of slots in which one of the stitch length components is slidably received; at least one yarn feed mechanism that feeds yarn to the needles; and a stitch length component assembly located below the base fabric material.

[0023] In some embodiments, the stitch spacing component assembly may include at least one module carrying a series of stitch spacing components that reciprocate in directions toward and away from engagement with the needle as the needle reciprocates into the base fabric material. The at least one module includes a module body that may be cast, molded, or otherwise formed from a metal, polymer, composite or synthetic material, or a combination thereof, and will have a first hardness. The module body will be adapted for mounting along the stitch spacing bar and will be configured with a channel defined therethrough. Inserts will be mounted to the module body on opposite sides of the channel, each insert having a series of spaced slots formed therein, each slot configured such that at least a portion of one of the stitch spacing components is slidably received therein. In embodiments, the inserts may be cast, molded, or otherwise formed from a metal or metal carbide or powdered metal material with a hardness greater than that of the module body, and the slots are formed or defined therein. In an embodiment, each stitch length component may include a body that is at least partially received within an opposing slot of the insert and is movable in other directions relative to the travel of the needle through a channel of the module body. The body of each stitch length component has a first portion extending through a channel through the at least one module and a second portion having a throat with a loop configured to pick up yarn from the needle.

[0024] In an embodiment, the tufting machine will include: a series of actuators coupled to the stitch length members for controlling the movement of the stitch length members through the module body; and a control system including a program for controlling the yarn feed mechanism to coordinate with the control of actuation of one or more of the actuators to control the yarn feed to the needle to extend or retract selected stitch length members, such that the throat of the selected stitch length members moves between a seamless position and an engagement position relative to the travel of the needle into the base fabric material for selectively forming yarn tufts in the base fabric material according to the pattern being formed.

[0025] In various embodiments of the tufting machine, the stitch length component includes a flat-cut looper, a looper, a cutter hook, or a cutter / loop clamp, and / or combinations thereof. In yet another embodiment of the tufting machine, the actuator may include a hydraulic or pneumatic cylinder, a servo motor, or other types of actuators.

[0026] In other embodiments of the tufting machine, the stitch length component assembly may also include a series of connectors extending between each stitch length component and an associated actuator, each of the connectors including a link received within a housing and movable through the housing.

[0027] In some embodiments, the housing of each connector will include a body that may be formed of a polymer, composite or synthetic material, or a combination thereof and has a channel extending therethrough; and wherein each link comprises a metal or composite material, or a combination thereof.

[0028] In other embodiments, the body of each housing may comprise a composite material comprising a polymer or plastic having a fiber-filled material, and the body of each housing has a channel defined therein and a link movable along the channel; and wherein the link of each connector comprises a hardened metal body coupled to the body of the housing and having a proximal end and a distal end configured to engage a first portion of one of the stitch members, the distal end being configured to engage by an actuator associated with the stitch member for transmitting motion of the actuator to the stitch member.

[0029] In some other embodiments, the inserts of the at least one module include a first insert and a second insert, each insert including a tab or flange portion that covers and / or mounts to the top or first surface, or the bottom or second surface, of the module body. In other embodiments, the body of each insert may have an upper or proximal portion, a lower or distal portion, and an intermediate section extending between the upper or proximal portion and the lower or distal portion and extending along a channel defining a passage through the module body; wherein the slot of the first or left insert is spaced apart from and opposite to the corresponding slot of the second or right insert and substantially aligned.

[0030] Furthermore, in an embodiment, the tab or flange portion of each of the first and second inserts is configured to overlap with the upper surface of the module body and includes a slotted opening adapted to receive a fastener passing through it, for adjustably mounting each of the first and second inserts to the module body, wherein the inserts are arranged spaced apart from each other at a selected interval and positioned relative to a selected location defining a channel through the module body. Additionally, the inserts may be molded or packaged, encapsulated, or otherwise substantially integrated within the module body. The inserts may also include tab or flange portions that can engage opposing side surfaces of the module body; and a plate or intermediate section may be provided therebetween. The intermediate section may connect the tabs or flanges of the inserts, wherein a slot of the insert is at least partially formed therein and extends thereal. Alternatively, a support plate of the support member may be received between the tabs or flanges of the inserts along a first and second side surface of the channel.

[0031] Therefore, in some aspects of this disclosure, a gauge component assembly for a tufting machine includes: at least one module having a module body having a channel defined therethrough; and a series of gauge components received within the channel of the module body, each gauge component including a body having a first portion and a second portion, the second portion having a throat, wherein the gauge component is carried by its module along a first direction toward and away from engagement with an associated needle of the tufting machine to pick up loops of yarn from the needle along the throat of the gauge component, and wherein the gauge component is selectively movable along the channel of the module body in a second direction; a first insert and a second insert are arranged along opposite sides of the channel of the module body, each insert being made of rigid material. A material with a hardness greater than that of the metal or composite material of the module body is formed and has a series of spaced slots configured to receive at least a portion of one of the stitch length components along the slots; wherein the slots of the first insert and the second insert are substantially aligned across a channel; and a plurality of actuators, each actuator being coupled to a first portion of a related stitch length component in the series of stitch length components and adapted to move its related stitch length component in a second direction through a channel of the at least one module, whereby the stitch length component extends through or retracts through the module body so that the throat of the stitch length component moves between an extended position for engaging the needle and picking up the yarn from the needle and a retracted position for substantially avoiding picking up the yarn from the needle.

[0032] In some embodiments, the claimed pitch component assembly may further include connectors extending between each actuator and the pitch component associated with that actuator, each connector having a housing formed of a polymer material in which a connecting rod is mounted. In some embodiments, the module body of the at least one module is molded or cast from metal or composite material.

[0033] In some other embodiments, the pin spacing component assembly may include a first insert and a second insert, each insert including a body molded or cast from a metal, carbide, or powder metal material and including tabs or flange portions in which slots are formed. Furthermore, the body of each of the first and second inserts further includes upper and lower tabs or flange portions on the upper and lower surfaces of the engagement module body, wherein the slots extend through the upper and lower tabs or flange portions.

[0034] In another embodiment, the pin spacing component assembly may include a first insert and a second insert, each insert including a body molded or cast from a metal, carbide, or powder metal material and including a tab or flange portion in which a slot is formed, and wherein the module body of the at least one module includes a metal or composite material molded or cast to form a module body having the first insert and the second insert substantially integrated therewith.

[0035] In some aspects of this disclosure, a method of operating a tufting machine is disclosed, wherein, according to an exemplary embodiment of this disclosure, when the needles of the tufting machine reciprocate in and out of a base fabric, actuators of the needle spacing components can be selectively engaged or disengaged such that their needle spacing components move between a fully retracted or seamless position and a varying extended or raised position, in which the needle spacing components will not engage with the associated or corresponding needle and therefore will not form loops of yarn, the varying extended or raised positions including a fully extended position. In their raised or extended positions, as the needles penetrate and exit the base fabric material, the needle spacing components engage the needles at their removed portions to pick up loops of yarn from the needles. The loops of yarn picked up from the needles may have different pile heights or lengths, depending on the position and / or movement of the needle spacing components relative to their associated or corresponding needles. For example, in the fully raised position, shorter or reduced yarn loops can be formed to create a lower pile height in the base fabric, or even to form substantially hidden yarn loops in the base fabric, which includes substantially removing these loops by controlling the yarn feed. When the looper moves to the lowered position, longer yarn loops can be picked up and formed by the looper, and as needed, the longer yarn loops can be pulled along with the looper to form yarn clusters with higher or greater pile heights in the base fabric. Furthermore, actuators can be controlled to selectively lower or retract the corresponding stitch length component on which the yarn loops are captured to form even longer yarn loops for additional patterning effects, such as for end-cutting.

[0036] The needle can also typically move laterally relative to the longitudinal movement of the base fabric through the tufted area, in order to present different colors or types of yarn to each stitch location in the pattern being formed in the base fabric material. For example, needles of one or more needle bars can be threaded in a range of desired colors in various threading sequences. Additionally, the base fabric material can typically be operated at an actual or effective weave rate significantly greater than the specified or desired stitch rate for the pattern being formed. As a result, a desired number of different colors or types of yarn can be presented to each stitch location as the needle moves. By controlling the positioning and / or movement of the stitch length components, loops of yarn can be selectively formed in the base fabric material, and in some embodiments, the formation of these loops can be further controlled to form different pile heights of the resulting tufts. For example, in various aspects, a range of different colors or types of yarn can be presented to each stitch location as the needle bar moves, and if a particular color or type of yarn tuft is not selected to be sewn at that stitch location, the corresponding stitch length component can be held in a retracted or lowered position so that such unselected yarn loops are not typically formed.

[0037] Additionally, as the needle reciprocates away from the base fabric, the yarn feed can be controlled to retract, back, or otherwise pull back or out of the base fabric material of unselected yarns, and to retract, back, or pull back some yarn loops to a degree sufficient to prevent the yarn from being displayed at the stitch location in the finished patterned product. With high operability, effectiveness, or actual weave control, the base fabric material can form a significantly increased number of yarn stitches within the base fabric material, thereby substantially avoiding the formation, display, or otherwise manifestation of missing yarn colors or types, or gaps, in the patterned areas of the patterned tufted product. Therefore, the finished patterned tufted product can be set with a tuft density per inch that substantially matches the desired or specified pattern weave; that is, for a pattern designed with a weave of 8, 10, or 12, or other numbers of stitches per inch, the density of visible and / or retained yarns or tufts per inch that can be formed in the resulting patterned tufted product can approximately match the pattern weave.

[0038] In some aspects of this disclosure, a tufting machine is provided. The tufting machine includes: at least one needle bar having a plurality of needles mounted along the needle bar; a base fabric feed roller for feeding base fabric material; at least one yarn feed mechanism for feeding yarn to the needles; and a needle spacing component assembly positioned below the base fabric material, the needle spacing component assembly including: a plurality of needle spacing components, each needle spacing component including a first portion and a second portion, the first portion and the second portion being configured to pick up loops of yarn from the needles; at least one module having a module body having a first rigidity formed of a metal, polymer, composite or synthetic material, or a combination thereof, the module body having at least one channel defined therethrough, and two opposing sides along the at least one channel. A side-positioning insert, each insert having a slot in which one of the needle spacing components is received; wherein the insert comprises metal, metal carbide, ceramic, or powdered metal material, the powdered metal material comprising metal powder containing tungsten, titanium, or a combination thereof, and the insert has a second hardness greater than the first hardness; wherein the needle spacing component moves in a first direction relative to the travel of the needle in and out of the base fabric material, such that it moves toward and away from engagement with the needle, and the needle spacing component is movable in a second direction relative to the travel of the needle along the at least one channel of the module body; a series of actuators coupled to the needle spacing component for controlling the movement of the needle spacing component through the module body in the second direction. The tufting machine also includes a control system comprising a program for controlling the actuation of one or more of the actuators to move, in a second direction, a selected stitch member of the stitch length component between a lowered position that substantially avoids the selected stitch member picking up a loop of yarn from the corresponding needle and one or more raised positions relative to the travel of the needle into the base fabric material for picking up a loop of yarn from the corresponding needle, and the program is further configured to control the at least one yarn feed mechanism to control the feeding of the yarn to the needle to selectively form tufts of yarn in the base fabric material according to the pattern being formed.

[0039] According to some embodiments, the tufting machine further includes a moving mechanism for laterally moving the at least one needle bar across the base fabric material, and wherein the control system further includes a program adapted to coordinate the movement of the at least one needle bar by the moving mechanism, control of an actuator coupled to the stitch length member, and control of the at least one yarn feeding mechanism for feeding yarn to the needle, so as to present a series of yarns along the base fabric material to selected stitch positions and to retract unselected yarns if loops of unselected yarns are not picked up by the stitch length member.

[0040] According to some embodiments, the control system further includes a procedure for controlling the feeding of the base fabric material by the base fabric feed roller, such that the base fabric material moves through the tufting zone at an actual weave pitch greater than the pattern weave pitch of the pattern being formed, to provide a number of retained tufts per inch of yarn in the base fabric material that is approximately equal to the pattern weave pitch.

[0041] According to some embodiments, the stitch length component assembly also includes a series of connectors extending between each stitch length component and an associated actuator, each connector including a link received within a housing and movable through the housing.

[0042] According to some embodiments, the housing of each connector includes a polymer material, a composite material, a synthetic material, or a combination thereof; and each link includes a metal, a composite material, or a combination thereof.

[0043] According to some embodiments, the housing of each connector further includes a composite material comprising a polymer or plastic material having a fiber-filled material and having a channel defined therein, along which the link is movable; and wherein the link of each connector includes a hardened metal body extending through the housing and having a proximal end and a distal end, the proximal end being configured to engage a portion of one of the stitch members, and the distal end being configured to be engaged by an associated actuator of the stitch member for transferring motion to the stitch member via the actuator.

[0044] According to some embodiments, the inserts of the at least one module each include opposing inserts mounted to the upper and lower surfaces of the module body along opposite sides of the channel; and wherein the slots of the inserts are arranged in a relative and substantially aligned relationship.

[0045] According to some embodiments, each insert includes a molded or cast body having tabs or flanges, and the slot is formed in the tabs or flanges.

[0046] According to some embodiments, the module body includes steel, aluminum, aluminum alloy, steel alloy, low carbon steel, tool steel, or a combination thereof.

[0047] According to some embodiments, the first hardness is at least 60+RC, and the second hardness is at least 75+RC.

[0048] In some aspects of this disclosure, a stitch length component assembly for a tufting machine is provided, comprising: a plurality of modules, each module including a module body having a channel defined through the module body; opposing inserts positioned on opposite sides of the channel defined through the module body, each insert being formed of a metal, metal carbide, ceramic, or powdered metal material including metal powder containing tungsten, titanium, or a combination thereof, each insert having a hardness greater than that of the module body and having a series of slots formed therein; wherein the slots of the opposing inserts are substantially aligned across the channel; and a series of stitch length components slidably received within the slots of the opposing inserts, each stitch length component having a first portion and a second portion including a throat; wherein the slots of the opposing inserts are configured to A defined contact area is defined along which at least a portion of one of the gauge members is received; wherein the gauge member is carried by the module along a first direction toward and away from engagement with the needle of the tufting machine to selectively pick up loops of yarn from the needle along the throat of the gauge member, and wherein each gauge member is selectively movable along a slot of the opposing insert in a second direction, the gauge member being received in the slot; and a plurality of actuators, each actuator coupled to the gauge member, each actuator being selectively actuated to move the gauge member coupled thereto in the second direction such that the throat of the gauge member moves between a retracted position and one or more extended positions, the extended positions for engaging the needle and picking up loops of yarn from the needle, the retracted positions substantially avoiding picking up loops of yarn from the needle.

[0049] According to some embodiments, the pin pitch component assembly further includes a connector extending between each pin pitch component and an associated actuator, each connector having a housing formed of a polymer material, within which a connecting rod is encapsulated.

[0050] According to some embodiments, each housing further includes a composite material comprising a polymer or plastic having a fiber-filled material and having channels defined therein, along which the link is movable; and wherein the link of each connector includes a hardened metal body extending through the housing and having a proximal end and a distal end, the proximal end being configured to engage a portion of one of the stitch members, and the distal end being configured to engage an associated actuator for the stitch member for transferring motion to the stitch member via the actuator.

[0051] According to some embodiments, the upper portion of each of the opposing inserts is configured to overlap with the upper surface of the module body and include a slotted opening adapted to receive a fastener passing through it for adjustable mounting of the opposing insert to the module body at a selected location relative to a channel defined through the module body.

[0052] According to some embodiments, the opposing insert has a hardness of at least 75+RC.

[0053] According to some embodiments, the module body includes steel, aluminum, aluminum alloy, steel alloy, low carbon steel, tool steel, or a combination thereof.

[0054] In some aspects of this disclosure, a tufting machine is provided. The tufting machine includes: one or more needle bars having a plurality of needles mounted along the needle bar; a base fabric feed roller configured to feed base fabric material through the tufting machine; at least one yarn feed mechanism feeding yarn to the needles; and

[0055] A needle spacing component assembly positioned beneath the base fabric material, the needle spacing component assembly comprising: at least one module having a module body formed of metal, polymer, composite or synthetic material, or a combination thereof, the module body having a channel defined through the module body; a plurality of needle spacing components received within the channel of the module body, each needle spacing component including a body having a first portion and a second portion configured to pick up loops of yarn from the needle; wherein the needle spacing component is positioned by its module along the direction toward and away from the tufting machine. The tufting machine includes a first direction for picking up loops of yarn from the needle and is selectively movable in a second direction along a channel of the module body; an insert receiving within the channel of the module body, the insert being arranged along opposite sides of the channel of the module body and having a series of opposing slots configured to receive the needle spacing members; wherein the insert comprises a material with a hardness greater than that of the material of the module body; and a series of actuators coupled to the needle spacing members and configured to control the movement of the needle spacing members along the channel of the module body in the second direction. The tufting machine also includes a control system comprising a program for controlling the at least one yarn feed mechanism to control the yarn feed to the needle in coordination with the actuation control of the one or more actuators, thereby moving a selected needle spacing member in the second direction such that a second portion of the selected needle spacing member moves between a lowered position and one or more raised positions relative to the travel of the needle into the base fabric material for forming tufts of yarn in the base material according to the pattern being formed.

[0056] According to some embodiments, the insert includes metal carbides, ceramics, or powdered metal materials, wherein the powdered metal material includes metal powders containing tungsten, titanium, or a combination thereof.

[0057] According to some embodiments, each insert includes a body molded or cast from a metal, carbide, or powder metal material, the body of the insert having a tab or flange portion, the slot being formed in the tab or flange portion.

[0058] According to some embodiments, the tufting machine also includes a connector extending between each stitch member and an associated actuator, each connector having a housing formed of a polymer material, within which a connecting rod is encapsulated.

[0059] According to some embodiments, the housing of each connector further includes a composite material comprising a polymer or plastic material having a fiber-filled material and having channels defined therein, along which the link is movable; and wherein the link of each connector includes a hardened metal body extending through the housing and having a proximal end and a distal end, the proximal end being configured to engage a portion of one of the stitch members, and the distal end being configured to be engaged by an associated actuator for transferring motion to the stitch member via the actuator.

[0060] According to some embodiments, the tufting machine further includes a movement mechanism for laterally moving the one or more needle bars across the base fabric material, and wherein the control system further includes a program adapted to coordinate the movement of the at least one needle bar by the movement mechanism, control of an actuator coupled to the stitch length member, and control of the at least one yarn feeding mechanism for feeding yarn to the needle as the needle reciprocates in and out of the base fabric material, so as to present a series of yarns along the base fabric material to selected stitch positions and to retract unselected yarns if loops of those unselected yarns are not picked up by one of the stitch length members.

[0061] According to some embodiments, the control system further includes a procedure for controlling the feeding of the base fabric material by the base fabric feed roller, such that the base fabric material moves through the tufting zone at an actual weave pitch greater than the pattern weave pitch of the pattern being formed, to provide a number of retained tufts per inch of yarn in the base fabric material that is approximately equal to the pattern weave pitch.

[0062] 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 and claims. Furthermore, it should be understood that the foregoing summary of the invention and the following detailed description are exemplary and intended to provide further explanation without limiting the scope of the disclosure. Attached Figure Description

[0063] The accompanying drawings, which are included to provide a further understanding of embodiments of the present disclosure and are incorporated in and form part of this specification, illustrate embodiments of the present disclosure and, together with the detailed description, serve to explain the principles of the embodiments discussed herein. No more detailed depiction of the structural details of the present disclosure is attempted than those necessary for a basic understanding of the exemplary embodiments discussed herein and the various ways in which these exemplary embodiments may be practiced. Those skilled in the art will also recognize and understand that, by convention, various features of the drawings discussed below are not necessarily drawn to scale, and the dimensions of various features and elements in the drawings may be enlarged or reduced to more clearly illustrate the embodiments of the present disclosure described herein.

[0064] Figure 1 This is a side view of an example embodiment of a tufting machine with a selectively controllable bend needle assembly, based on the principles of this disclosure.

[0065] Figure 2 yes Figure 1 A side view of the tufting area of ​​the tufting machine.

[0066] Figure 3 yes Figures 1 to 2 A perspective view of a tufting machine.

[0067] Figure 4 This is a perspective view of an exemplary embodiment of a stitch gauge module or stitch gauge block and stitch gauge component based on the principles of this disclosure.

[0068] Figure 5 yes Figure 4 A cross-sectional view of the stitch spacing module or stitch spacing block and stitch spacing component.

[0069] Figures 6A-6B yes Figure 4-5 A plan view of the stitch spacing module or stitch spacing block.

[0070] Figures 7A-7B An embodiment of a connector for connecting a pin pitch component to its actuator, based on the principles of this disclosure, is shown.

[0071] Figures 8A-8B Another embodiment of a connector for connecting a pin pitch component to its actuator, based on the principles of this disclosure, is shown.

[0072] Figures 9A-9B Another embodiment of a connector for connecting a pin pitch component to its actuator, based on the principles of this disclosure, is shown.

[0073] Figures 10A-10B This is a perspective view of a portion of a series of needles and their corresponding needle spacing components in an exemplary embodiment based on the principles of this disclosure.

[0074] Figure 11A-11C This is a side view illustrating an embodiment of the operation of a selectively actuated needle pitch component according to the principles of this disclosure. Detailed Implementation

[0075] Referring now to the accompanying drawings, in which the same reference numerals denote the same parts in several figures. Figure 1-11CThe present invention illustrates an embodiment of a tufting machine 10 and a method for forming patterned tufted articles according to the principles of the present invention, wherein the placement of stitches or tufts 5 of yarn Y at desired locations in the base fabric B can be controlled. Such tufts or stitches can be formed into a tufted appearance with multiple pile heights and can also be placed with enhanced selectivity and / or controllability to form further different or freely flexible patterned effects. For example, tufted articles can be formed from yarn tufts formed at different pile heights to provide a embossed appearance, and various geometric and / or freely flexible multicolor patterns can be formed using different colors or types of yarn. Furthermore, it should be understood that patterned tufted articles with multiple pile heights can be formed using various numbers of different types and / or colors of yarn (i.e., two colors, three colors, five colors, six colors, etc.) according to the principles of this disclosure.

[0076] like Figure 1 As generally shown, in one embodiment, the tufting machine 10 will include a frame 11, which may include a receiving needle bar drive mechanism 13 and define a head or upper portion 12 of the tufting region T. The needle bar drive mechanism 13 ( Figure 1 and Figure 2 It typically includes a series of push rods 14, which can be connected to a connecting rod 17. Figure 1 The needle bar drive 16 (e.g., gearbox / assembly) or similar mechanism shown may be connected to and driven by the main drive shaft 18 of the tufting machine, for example, via one or more drive belts or drive chains 19, wherein the main drive shaft 18 itself is driven by an electric motor such as a servo motor. Alternatively, the push rod 14 of the needle bar drive mechanism 13 may be connected to the main drive shaft 18 via a connecting rod 17 so as to be driven directly by the main drive shaft or by a separate drive system (not shown).

[0077] In addition, an encoder or similar sensor can be provided to monitor the rotation of the main drive shaft and report the position of the main drive shaft to the control system 25 that controls the operation of the tufting machine 10. Figure 1The control system 25 may typically include a tufting machine control device, which includes a computer / processor or system controller 26 having an operator interface 26A (e.g., a touchscreen, keyboard, mouse, etc.) through which the operator can input patterns, make adjustments, etc. In some embodiments, the control system 25 may include or include stitch distribution control systems, such as those disclosed in U.S. Patent No. 8,359,989, the disclosure of which is incorporated herein by reference as fully set forth herein, wherein the controller 26 also includes a program for controlling the formation of tufted patterns, including embossed patterns having tufts formed at multiple pile heights and patterns having controlled placement of various colors / stitches, such as the patterns disclosed in U.S. Patent No. 8,359,989.

[0078] The control system 25 will typically include a program capable of monitoring and controlling the operating elements of the tufting machine 10 according to calculated / determined pattern instructions, such as the needle bar drive mechanism 13, yarn feed attachment 27, base fabric feed roller 28, main drive shaft 18, and needle bar movement mechanism 40. Figure 3 ) and the stitch length component assembly 30 installed below the tufting area T of the tufting machine, as discussed more fully below. Control system 25 ( Figure 1 Pattern information can also be received, executed, or stored in the memory of the system controller 26. In response to developed / programmed pattern instructions, the control system 25 will control the operating elements of the tufting machine 10 to form a desired tufted pattern in the base fabric material B as the base fabric material passes through the tufting region T in the direction of arrow 33 via the base fabric feed roller 28. Figures 1 to 3 As shown.

[0079] In some embodiments, the system controller 26 of the control system 25 may typically be programmed with instructions for forming one or more desired patterns for one or more tufted articles. These instructions include a series of patterning steps that can be created or calculated manually or by using a design center or design software as understood by those skilled in the art, or the steps can be received via input from a disk, USB, or other external drive device, or via a network connection. Alternatively, the controller 26 may include image recognition software to enable scanned and / or designed pattern images (e.g., designed patterns including pile height and other features such as loop pile and cut pile placement in the pattern) displayed by, for example, different colors or similar marks or indicators, and photographs, portraits, and other images, to be input into, programmed, recognized, and processed by the control system. This includes input from a design center or via various design software systems or via a scanner or other imaging device 31. Figure 1The control system receives input. It can identify and recognize various pattern features, including color and / or texture differences in design pattern images that indicate texture effects (e.g., placement or position of loops and / or cut pile), and the control system can assign selected yarns to the various pattern features.

[0080] Additionally, in embodiments such as control system 25 operating together with or including or incorporating a stitch distribution control system, as disclosed in U.S. Patent No. 8,359,989 (incorporated herein by reference, as fully set forth herein), for example, but not limited to, the control system may incorporate a program to provide the functionality of such a stitch distribution control system, or a separate stitch distribution control may be linked to said control system. The control system may also be equipped with software / programs to enable reading and recognizing the colors of the input scanned pattern and to allocate individual needles from the supply position of the yarn supplied from the yarn feeder based on the threading sequence of the needles on the needle bar, in order to optimize the supply of various colors of yarn in the yarn feeder for optimal utilization to form a recognizable pattern area from the pattern image. The control system may also include a program that enables it to create a pattern area or pattern map, the program comprising mapping a series of pattern pixels or cluster / stitch placement positions in a space or location where various colors of yarn and / or cut / loop pile tufts will be selectively placed to form an imaged pattern. You can also select the desired pattern density, that is, you can select the desired number of stitches per inch to appear on the surface of the finished patterned tufted product, and calculate the actual effective or workable processing distance for the pattern to achieve the appearance of the pattern with the desired fabric distance.

[0081] The control system 25 of this disclosure may also include programs for receiving, determining, and / or executing various movement or cam profiles, or for calculating suggested movement profiles based on scanned, input, or other design pattern images or pattern files. For example, in a non-limiting embodiment, design pattern file images, photographs, drawings, etc., may be loaded, scanned, or otherwise input at the tufting machine or via a network connection, and the control system may read, identify, and calculate pattern steps / parameters, including controlling yarn feed, controlling base fabric movement, and / or needle reciprocating motion to form tufts in the base fabric under effective weave conditions to obtain desired pattern density, cam / movement profiles, and yarn arrangement to match scanned and / or designed pattern images, and then the operation of the tufting machine may be controlled to form the selected pattern. The operator can also select or modify the weave pitch, yarn feed, selected cam profile, or calculated movement profile (e.g., by indicating whether the pattern has 2, 3, 4, 5, 6 or more colors or the desired number of pattern repetitions), and / or can manually calculate, input, and / or adjust or change the yarn feed allocation, movement profile, and / or color mapping generated by the control system as needed via manual override control / programming.

[0082] like Figure 1-3 As shown, the tufting machine 10 will also include one or more needle bars 35, which are attached to and driven by a push rod 14. The one or more needle bars 35 cause a series of needles 36 to move in and out of the base fabric material B in a reciprocating motion (as indicated by arrows 37 / 37') to transport or insert yarn Y into the base fabric. In some embodiments, the needles may be arranged in a single straight row along one or two needle bars. In other embodiments, the needles 36 may be mounted in a staggered arrangement along a single needle bar or along a pair of needle bars, wherein the offset rows of needles are laterally spaced along the length of each or more needle bars and staggered across the tufting area of ​​the tufting machine. One or more needle bars 35 may also move laterally across the width of the base fabric material to cause the needles 36 to move or step in a direction laterally or substantially perpendicular to the longitudinal travel path through the tufting machine. Therefore, although an exemplary embodiment including a single needle bar 35 with a straight row of needles 36 arranged along the needle bar is shown in the figures, this disclosure is not limited to the use of a single needle bar or a particular needle configuration. Conversely, those skilled in the art will understand that other arrangements of double needle bars and single needle bars may also be used in the tufting machine 10 that includes the system according to this disclosure, the other arrangements of double needle bars and single needle bars having spaced rows of needles 36, the spaced rows of needles 36 being arranged in a straight configuration or an alternating configuration or an offset configuration, and both the double needle bars and single needle bars being movable.

[0083] Each needle will typically include a shank or body 38, which terminates at a tip 38A and includes a pick-up point or area 39, at which the needle spacing member 32 can engage the needle and pick up the yarn Y from the needle, such as Figure 10A-11A As shown. When the needle follows arrows 37 and 37' ( Figure 2 When the direction of the reciprocating motion is substantially vertical, they carry the yarn Y along the stroke to penetrate and exit the base fabric material B to achieve the desired or predetermined penetration depth and will be selectively engaged by the stitch spacing component 32 of the stitch spacing component assembly 30, such as Figure 11A-11C As shown, loop L is used to pick up the yarn from the needle. Additionally, as... Figure 3 As shown, the moving mechanism 40 can also be connected to the needle bar 35 (or multiple needle bars), which is used to move the needle bar laterally across the tufted area in the direction of arrows 41 and 41' according to a calculated or computer-generated pattern instruction. The moving mechanism 40 may include a Smart Step manufactured by Card-Monroe. TM The moving device may be a single type, or alternatively may include various other types of moving mechanisms (including moving devices controlled by servo motors or hydraulics and / or conventionally used pattern cam moving devices). Other moving mechanisms, including a base fabric material or jute moving device, may also be used, which may operate alone or in combination with a needle bar moving device, for laterally moving the base fabric material relative to the needle.

[0084] like Figure 1 As further shown, one or more yarn feeding mechanisms or accessories 27 can be mounted on the frame 11 of the tufting machine 10 for controlling the feeding of yarn Y-axis to each needle 36 during operation of the tufting machine. For example, as Figure 3 As shown, a series of different types or colors of yarn (Y1-Y4) can be fed to each needle in a selected threading sequence or series (e.g., ABCD), wherein the threading sequence is typically determined or selected based on the pattern being run. Additionally, although one yarn feed unit 27 is shown along one side of the tufting machine 10 (for illustrative purposes), in other embodiments, multiple yarn feed units may be mounted on one or both sides of the tufting machine for feeding yarn to the needles 36 of one or more needle bars 35.

[0085] Various yarn feed accessories are available for use with the stitch distribution control system of this disclosure, for controlling the feed of different needles 36 in the Y direction of different yarns. Pattern yarn feed accessory or mechanism 27 ( Figure 1This may include a conventional yarn feed / drive mechanism, such as an attachment in the form of a roller or spool having a series of rollers that extend at least partially along the tufting machine and are driven by an electric motor under the guidance of a control system 25 to control the feeding of the yarn on the tufting machine to form pattern repetition and / or multiple pile heights and / or other texture effects over the entire width of the base fabric. Such a yarn feed mechanism or attachment may include Quick Thread manufactured by Card-Monroe. TM Enhanced Graphics TM And / or multi-pile height spool type yarn feed control device / accessory.

[0086] In some embodiments, a patterned yarn feed attachment may be used, which has a plurality of yarn feed drives 45, such as Figure 1 As shown, each of the yarn feed drives includes a motor 46 and a feed roller 47 for controlling the repeated feeding of yarn to a specific number of selected needles. This includes using separate yarn feed rollers or drives 45 to control the feeding of the ends of a single yarn (or end) or multiple yarns (i.e., 2-4 or more yarns) to the needle 36. These separate yarn feed rollers or drives are, for example, single-end and multi-end attachments / servo reel attachments, including the Infinity series manufactured by Card-Monroe. TM and Infinity IIE TM System. Therefore, although in Figure 1 The diagram illustrates, for example, a single-ended or multi-ended yarn feed mechanism 27, but those skilled in the art will also understand that the patterned yarn feed mechanism for controlling the yarn feed can include single-ended or double-ended yarn feed control devices, spools, rollers, and / or similar accessories, and / or various combinations thereof, and can also be mounted along one or both sides of the tufting machine. Furthermore, in embodiments, the control system 25 can perform yarn feed compensation and / or yarn feed modeling to help control and reduce or minimize the amount of non-retained / non-manifested yarn to be fed, to avoid overfeeding yarn and thus minimize waste during tufting operations.

[0087] The yarn feed attachments can be controlled to selectively feed yarn to their respective needles in cooperation with other operating systems of the tufting machine. This includes base fabric feed, needle bar movement, and operation of the needle spacing component assembly 30, so as to enable control over the loops of selected or desired yarns (e.g., yarns selected to appear on the surface of the finished patterned article) that present various colors or types of yarns into the base fabric and selectively pick up and hold the presented yarns to form a tuft of such yarns with a selected or desired pile height. Additionally, the surface yarns or tufts or tufts to be displayed on the surface of the tufted product can be controlled to feed the surface yarns or tufts or tufts in an amount sufficient to form tufts of selected color or type of yarn under desired or specified pile height conditions, while undisplayed yarns to be hidden in specific color and / or texture areas of the pattern will be retracted and / or sufficiently pulled down or pulled out from the base fabric to a certain extent, such that interference with the tufts or retained tufts that will be visible in the pattern area is avoided, and undesirable spaces or gaps are avoided between the retained tufts or tufts.

[0088] In one embodiment, each color or type of yarn that can be placed / tufted at each pixel or stitch position can typically be presented to such pixel or stitch position for tufting, wherein only one or more yarns selected to be displayed or shown at the pixel or stitch position are retained and formed at the desired pile height. Thus, for a 4-color pattern, for example, each of the four colors of yarn A, B, C, and D that can be tufted at a specific pixel or stitch position can be presented to such a pixel, wherein only the selected yarn or multiple yarns of the pattern (e.g., “A” yarn) are retained, while the remaining unselected yarns B, BC, BD, and / or other combinations can be presented at the pixel or stitch position and retracted / pulled back and / or removed from the base fabric. Therefore, when yarn is presented to a pixel or stitch position, if the yarn will be retained or shown at that pixel or stitch position, the yarn feeding device 27 can be controlled to feed a certain amount of yarn to form a yarn tuft at that pixel or stitch position. If the presented yarn will not be retained or displayed at a pixel or stitch location, the yarn can be controlled so that loops or clusters are not formed, or loops or clusters can be pulled back and / or removed. If the yarn is not selected for insertion at a specific pixel or stitch location, the stitch length component can also be controlled to selectively pick up or not pick up loops of yarn presented to a specific pixel.

[0089] like Figure 1-3 As further shown, the needle spacing component assembly 30 is typically mounted below the bed 34 and tufting area T of the tufting machine 10. As needles penetrate the base fabric, they are engaged by a series of needle spacing components 32 of the needle spacing component assembly 30 to form loops L of the yarn Y. Figure 2-3This is used to form clusters 5 of yarn of a selected color or type, and the clusters have a selected length or pile height. In various embodiments, the stitch length component 32 of the stitch length component assembly 30 may include a series of loopers or hooks 50, each of which may be slidably mounted within a stitch length module, stitch length block, or other support that may be mounted along a stitch length bar 52 or similar base or accessory for connecting the stitch length component to a drive mechanism 53 to cause the stitch length component to reciprocate toward and away from the needle 36 in a first direction, such as... Figure 1-3 Arrows 54 and 54' are shown in the diagram. Those skilled in the art will also understand that various other types of stitch length components can also be used, including cut loop hooks, loop needles, flat-cut loop needles, cut / loop clamps, or other stitch length components.

[0090] like Figure 4-5 As shown, in one embodiment, the stitch spacing component 32 may include a looper or hook 50, each of which has an elongated body 55 slidably mounted within and movable through its stitch spacing module 51. The body 55 of each looper or hook 50 will include a first portion 60 and a second portion 61, the second portion including an elongated throat 62, the elongated throat being... Figure 4-5 In one embodiment shown, the portion typically extends at an angle relative to the middle portion 56 of the body 55 and may terminate at a generally pointed proximal end or beak 63. For example, the throat 62 and proximal end 63 may be configured similarly to a looper needle. Other configurations of the stitch length component may also be used. Figure 4-5 As further shown, the first portion 60 of the body of each looper or hook 50 will typically protrude through the stitch gauge module or block 51 and may have a slot or recess 64 formed therein, through which the looper or hook can pass, for example, via a gate or connector 67. Figure 2 ) Engage and / or connect to actuator 66.

[0091] Figure 4-5An embodiment of a gauge module or gauge block 51 is shown, comprising a body 75, which may have a substantially rectangular or square configuration as shown, but other configurations may also be used, and a series or group of gauge components 32 (e.g., loopers or hooks 50) are received in said configuration. In some embodiments, the module body 75 of each gauge module 51 will be formed of a metallic or metal alloy material, but various composite materials, synthetic materials, and / or other materials may also be used. For example, but not limited to, the body of the gauge module may be made of lightweight steel, such as low-carbon steel or tool steel, or aluminum, or other similar lightweight but substantially rigid and durable materials. In embodiments, the module body may be cast, molded, or otherwise formed. The material forming the body of the gauge module may also be selected to reduce the weight of the gauge module while still providing sufficient durability and rigidity to maintain and / or substantially retain the alignment or positioning of the gauge components for engaging the removed portion of the needle during the reciprocating motion of the gauge components into and out of engagement during tufting machine operation.

[0092] like Figure 4-6B As shown overall, the module body 75 of each stitch gauge module 51 will include a first front or front section 76 and a second rear or back section 77. The rear section 77 of the body 75 of each stitch gauge module 51 will typically be configured to engage and mount to the stitch gauge bar, as shown below. Figure 3 As shown. For example, the rear section of the body may include a tab or other positioning device 77A for aligning the stitch gauge module along the stitch gauge bar. Figure 5 And further includes at least one fastener opening along the rear section, such as Figures 6A-6B As shown in 78, a removable fastener (such as a socket, hex screw, or other similar removable fastener or attachment) will be inserted through the fastener opening 78 and into the corresponding opening 79 in the pin spacing bar. Figure 6B In this embodiment, the stitch spacing module 51 is releasably mounted to the stitch spacing bar. As a result, in some embodiments, the stitch spacing module and the stitch spacing components contained therein can be removed and replaced as a whole, without having to replace the individual stitch spacing components; for example, to expedite the replacement of broken or damaged stitch spacing components, or to change the stitch spacing or arrangement of the stitch spacing components of the tufting machine.

[0093] like Figure 4-6B As further shown, the channel 80 will typically be formed as passing through the body 75 of each stitch module 51, wherein the channel 80 is typically located along the middle portion 81 of the body between its first segment 76 and second segment 77. The channel 80 is sized and / or configured to receive multiple stitch components, such as loopers or hooks 50, therein. In such cases... Figures 4 to 5In the illustrated embodiment, the body 55 of each of the bends or hooks 50 is typically received within and extends through the channel 80, wherein the first portion 60 of each bend or hook typically protrudes downward through the lower or bottom surface 82 of the module body 75, while the second portion 61 of each bend or hook may extend upward from or protrude from the upper or top surface 83 of the module body 75 and lie above it.

[0094] Additionally, one or more inserts 85 can be mounted to positions or locations along the channel 80 defining the entire body of each pin-pitch module on opposite side surfaces (e.g., upper and lower surfaces), such as... Figure 4-5 As generally shown. The insert will be configured to engage and guide the stitch member as it moves through and along the channel of the stitch module body. For example, in some embodiments, such as Figure 4-6A As shown, inserts 85A and 85B in pairs or groups can be provided, wherein one of the inserts (e.g., the first insert 85A) is mounted along a first, left, or front side 80A of the channel 80, while an insert (e.g., the second insert 85B) is mounted along a second, right, or rear side 80B of the channel 80, and wherein each of the inserts 85A and 85B is generally arranged in a substantially facing, opposite, and parallel relationship to the stitch spacing member 32, which engages between the inserts and is movable between the inserts. Moreover, in some embodiments, such as... Figure 4-5 As shown, a pair of first inserts can be installed along the top and bottom surfaces of the module body along the first or left side of the channel, and a pair of second inserts 85B can be installed along the top and bottom surfaces of the module body along the second or right side of the channel.

[0095] Each of the inserts 85 is typically formed of a hardened metal or metal alloy, a metal carbide, a ceramic, and / or a powdered metal material (the powdered metal material includes metal powders, such as tungsten, titanium, or other materials with a hardness greater than that of the material of the insert module body). For example, in some embodiments, the insert may be formed of a metal carbide material with a hardness of approximately 74+RC or greater, while the module body may be formed of low-carbon steel. In other embodiments, the insert may be formed of ceramic, a powdered metal material (which includes tungsten, titanium, or similar hard metal components), a metal carbide, or other materials with a hardness between approximately 74+RC and approximately 85+RC or greater.

[0096] Each of the inserts 85 may further include an insert body 86 having a tab or flange portion 87 extending forward or backward from a channel in the body of the pin pitch module, such as Figure 5As shown, the tab or flange portion typically sits on the upper surface 83 and lower surface 82 of the module body and engages with the upper surface 83 and lower surface 82. Additionally, as... Figure 4 and Figures 6A-6B As shown, each of the inserts 85 will also include at least one opening or slot 89 formed along its tab or flange portion, and is capable of receiving fasteners such as retaining screws 90 or other similar removable fasteners through said opening or slot. The slots or openings 89 formed in the tab or flange portion of the insert can generally be aligned with corresponding slots or locator openings 91 formed along the upper surface 83 and / or lower surface 82 of the module body to aid in positioning and mounting each insert to the body of its module and along the channel of its pin pitch module. Also as Figure 6B As shown, the insert can move laterally across the module body and substantially parallel to the channel 80, and can also be adjusted to face away from each other across the channel of the module body. Fasteners can then be inserted and tightened to secure the insert 85 to its module body. Additional locator guide pins 92 can also be received in slots on locator openings 93 formed along the flange or tab portions 87 of each insert to further aid in positioning the insert along and across the channel of the module body as needed.

[0097] In another embodiment, the insert 85 may be substantially integrated with its module. The insert may be bonded, molded, encapsulated, and / or otherwise secured to the body of its module, wherein the insert is substantially integrated with the module body to form a substantially integral construction of the module body, and wherein the insert forms or defines part of its channel. For example, in some cases, the insert may be located within or received in a channel of the module body and substantially permanently mounted thereto, while in other embodiments, the insert may be molded or cast as part of the module body itself, thereby defining channels and slots for bends or hooks, and the insert may be coated or treated with a hard metal coating (e.g., carbides or other substantially abrasion-resistant coatings). In this case, the stitch length component may be provided in a group with its stitch length module and can be replaced as a group by removing and replacing or substituting the stitch length module and stitch length component as a whole. In other embodiments, the inserts may substantially engage or lock to their modules, having limited capability to disassemble or remove one or more inserts as needed for maintainability.

[0098] Other examples Figure 4 and Figures 6A-6BAs shown, the inserts will also typically include a series of slots or slits 95 arranged in series at intervals along the rear portion 88 of the body 86 of each insert. The dimensions of each of the slots 95 are typically designed or each of the slots 95 is configured to receive a stitch length component 32 (e.g., a hook or looper 50) therein, as... Figure 4 and Figure 5 As shown. The slots 95 of the inserts will also typically be arranged at a selected spacing, such as the pin spacing of the pin-pitch components, and wherein each slot 95 of the first insert 85A is substantially aligned with a corresponding or associated one of the slots 95 of the second insert 85B, as shown. Figure 6A As shown. The aligned, corresponding or associated slot of each insert will receive at least a portion of the body of each of the stitch components, for example, portions of the front edge 55A and rear edge 55B of the body 55 of each looper or hook 50, and wherein the insert defines a reduced or minimized contact area 98 of the area or contour between the stitch module and the looper or hook.

[0099] In addition, for example, Figure 6A As shown, the end 96 of the slot 95 may also be formed with a substantially flat or slightly curved or arcuate configuration to define a seat 97, on which the first and second edges of each of the loopers or hooks received in each slot can sit and abut against the seat for mounting the looper or hook within the insert and subsequently securing the insert together with the looper or hook received therein to each stitch module. The slot of the insert guides the looper or hook as it extends, retracts, or otherwise moves through the channel of its stitch module, and the slot helps maintain the alignment of the looper or hook, thus keeping its throat and beak aligned with the needle as the needle reciprocates in and out of the base fabric and is engaged by the looper or hook.

[0100] In another embodiment, each insert 85 may include an insert body 86 having a first top or upper portion and a second lower or bottom portion, and having a middle section extending therebetween and connecting the first and second portions of the body of each insert. At least one of the upper and / or lower portions of the body of each insert may also be formed as a tab or flange extending forward or backward from the middle section and channel of the needle gauge module body, the tab or flange typically covering and engaging the upper surface 83 and lower surface 82 of the module body to facilitate positioning and securing each insert within the channel of its needle gauge module. Thus, the first insert 85A and the second insert 85B may have a substantially integral construction comprising upper and lower portions, and slots of the first insert and the second insert extend through their upper and lower sections and along the middle body section, thereby enabling further engagement and guidance of at least a portion of the first and second edges of the looper or hook. In embodiments, the insert of this configuration can be molded or cast to have a substantially integral body, which reduces the number of parts and the need for separate inserts on the upper and lower surfaces of the module body and on opposite sides of its channels, while increasing the contact points / areas between the insert and the bend or hook to enhance the consistency and / or control of movement.

[0101] Alternatively, the first, second, and intermediate body sections of each insert can be formed as separate components and mounted together along a channel in the module body. For example, in some other embodiments, an intermediate guide or support plate can also be used to aid in guiding the movement of the bend or hook, wherein the guide or support plate extends along a channel between the inserts positioned along the upper and lower surfaces of the module body. Such a guide or support plate can provide a body or surface along which the first and second edges, or front and rear edges, of the bend or hook can travel / slide as the bend or hook moves along the channel in the module body. The guide or support plate can also function as a connecting member or section between multiple inserts, or between each pair or group of inserts 85A and / or 85B. Such a guide or support plate can be formed of a similar high-hardness material (e.g., hardened metal or carbide or powder metal or other high-hardness material) to provide a hardened surface against which one or both edges of the bend or hook can slide; or, in some cases, it can function as an easily replaceable sacrificial plate and protect the module body along the side of the channel.

[0102] During operation of a tufting machine such as those disclosed in embodiments of this disclosure, loopers, hooks, or other gauge components move in multiple directions, including reciprocating motion to engage and disengage with needles, and also moving along a second direction through their gauge modules or gauge blocks, for example, vertically between raised and lowered positions of the engaged needle, including moving to a seamless position, and in some operations after a loop of yarn has been picked up from the needle, for example, to form an extended or longer loop. Thus, the tufting machine enables the formation of highly detailed tufted patterns, which may include different pile heights and other engraved and multi-colored pattern effects. However, this repetitive cyclical motion of the gauge components causes significant and rapid wear of the gauge components, and particularly their gauge modules, as the loopers, hooks, or other gauge components slide and their edges frictionally engage the body of their modules. Due to this wear, their ability to engage with their needles and form yarn loops to create tufted patterns with sufficient precision is diminished. For example, the stitch spacing component may become misaligned, and / or may not engage the needle properly or at the desired level of precision, thus requiring more frequent replacement of the stitch spacing component / stitch spacing module.

[0103] By using metals (e.g., high-hardness heat-treated steel), metal carbides, ceramics, and / or other hardened metallic materials (including powdered metals containing tungsten, titanium, or other similar high-hardness materials, providing the insert with a hardness of at least 75+RC or greater) and by configuring the insert with a contact area 98 defined between the looper or hook and the needle spacing module with a minimized area or profile, the wear life of the needle spacing module and the looper or hook is significantly increased. The high hardness of the insert protects the needle spacing module from direct contact and rapid wear with the looper or hook as it circulates through it, while the reduced size of the contact area 98 defined by the insert is configured to reduce frictional engagement between the insert and the looper or hook, while substantially continuously guiding and maintaining the alignment of the looper or hook during such movement. The bevel or hook is typically pre-hardened or heat-treated to harden the bevel or hook body; and in some embodiments, the surface of the bevel or hook body may be coated, treated, or bonded with a friction-reducing material to help reduce friction along the slot engagement of the insert and between the sliding edges 55A / 55B of the bevel or hook body, and thus contribute to increasing its wear life. For example, in some applications, wear lives of bevels or hooks exceeding 50 million to 100 million machine cycles have been found, and in some embodiments between at least about 100 million to 500 million cycles or more.

[0104] The increased rigidity of the insert protects the pitch module and allows it to be formed from a significantly lighter and less rigid material (e.g., low-carbon steel, aluminum, or alloys thereof). For example, instead of requiring the pitch module to be formed from a material with considerably high hardness (e.g., tungsten) and / or subjected to extensive heat treatment to attempt to significantly increase its rigidity, the pitch module can be cast, molded, or otherwise formed from a lightweight metal, composite material, or other similar material whose rigidity can be significantly lower than that of the insert (e.g., the body of the pitch module can be made from low-carbon steel or aluminum alloy with a rigidity less than about 60 RC). This helps reduce the weight and cost of the entire pitch component assembly without compromising cycle performance. This reduction in the weight of the pitch module or block also enhances control over the movement of the looper through its channel in the pitch module and the reciprocating motion of the looper or hook toward and away from the needle, for example, by reducing the inertia that may need to be overcome during the reciprocating motion of the looper or hook toward and away from the needle.

[0105] Figure 7A-9B It is shown that it can be connected to a stitch spacing component (e.g., for connecting the stitch spacing component to its associated actuator 68). Figure 2-3 ) of loops or hooks 50 ( Figure 4 Various non-limiting embodiments of the door or connector 67 used together. However, those skilled in the art will understand that... Figure 7A-9B The connectors or gates shown in the embodiments are not limited to use with machines of a specific tufting type or a specific type of stitch length component, but can be used with a variety of different types of stitch length components (including such as Figure 4-6B and Figure 10A-11C It is used in conjunction with the looper or hook 50 shown, as well as with various other types of stitch length components (e.g., flat-cut looper or hook and / or other stitch length component arrangements).

[0106] Roughly as Figure 7A-9BAs shown, each connector or door 67 typically includes a housing or support structure 101, within which a link or connector arm 102 may be substantially contained, enclosed, or received. The housing 101 of each connector or door typically includes a first or proximal portion 103, a middle portion 104, and a second or distal portion 106. Furthermore, each connector body will include a channel or groove 107 defined therethrough, along which the link or connector arm 102 will be received and movable. The housing 101 of each connector 67 may typically be formed of a lightweight, durable material, such as a composite, plastic, or synthetic material, or a combination thereof. For example, composite or polymeric materials (e.g., nylon, polyamide, polyamide-nylon, or other similar polymeric materials) may be used and may be mixed with, or provided with, or otherwise included in, a fiber-filled material (e.g., carbon fiber, glass fiber, or other support fibers that may provide additional reinforcement to the housing body material). The material of the housing body can also be adapted or selected to not only provide reduced weight, such as helping to reduce inertia during start-up / stop and movement (e.g., the extension and / or retraction of the needle element by its associated actuator), but also to provide elasticity and shock absorption or damping or cushioning effects during such movement and start-up / stop operations.

[0107] like Figure 7A-9B As shown, in some embodiments, the housing 101 of each connector may be overmolded onto its link or connector arm 102, or may be segmented and applied around the link or connector arm such that its link or connector arm is substantially enclosed or contained within the housing. The link or connector arm 102 may also be made of a metal such as steel or other similar high-strength materials selected to provide sufficient strength and rigidity to enable each link or connector arm to withstand repeated impacts and increased motion cycles during operation of the tufting machine. For example, but not limited to, the link or connector arm 102 may comprise a hardened steel material and, in some cases, may be further heat-treated or annealed, for example, at its ends, in areas of contact and / or engagement with the bevel or hook, and between the connector arm or link and its associated actuator or drive shaft or rod of the actuators.

[0108] In some embodiments, the link or connector arm 102 may also include a skeletonized metal body configured to reduce its weight. In such embodiments, each connector or door housing 101 can provide further support and rigidity to the link or connector arm 102, thereby helping to guide and maintain its consistent reciprocating motion or movement during operation. As a result, the connector or door 67 can provide a more economical connector or door design, allowing the link or connector arm with a skeletonized or reduced profile and lighter weight to be used with the additional support and impact resilience and damping effects provided by the housing 101 applied to and / or encapsulated or packaged on the link or connector arm.

[0109] like Figure 7A-9B As further shown, each of the connectors or doors 67 can be formed with different dimensions and configurations. For example, the middle section of each connector housing can have a shorter or longer span depending on the stitch pitch, distance, travel length, or length of the link or connector arm, and thus can be varied for different tufting machines and / or tufting applications. This is merely an example, such as... Figure 7B , Figure 8B and Figure 9B As shown, the connectors or doors may include different configurations for use with tufting machines of different gauges, such as 1 / 8 gauge or 1 / 10 gauge machines, but it should be understood that other gauges (5 / 16, 1 / 16, 1 / 12, 1 / 14, etc.) and / or types of machines may also be used. The middle section of the housing passing through each connector may also be oriented at an angle, in some cases downward and in others upward, wherein adjacent connectors are in opposite angular orientations or configurations to minimize the space or floor space occupied.

[0110] Each connector or door 67 link or connector arm 102 ( Figure 7A , 8A (9A) It can also be formed in different lengths as needed or desired. Each link will typically have a first end or proximal end 110, which may be adapted or configured to engage or connect to one or more actuator shafts or drive rods 68 of one or more associated actuators, wherein a generally angled body section or portion 111 extends along a channel or groove of the housing through the housing of the connector and terminates at a distal flanged or hooked end 112. The body portion 111 of each link will be further positioned and / or aligned within a channel of its housing and enclosed therein to help provide stability and / or help guide the movement of the link along the channel of its housing.

[0111] For example, in some cases, during the formation of a housing around or on its connecting rod, pins or other inserts may be used to align and support the connecting rod in place, after which the pins can be removed. Alternatively, guide pins may be provided to help maintain and guide movement along one or more portions of the connecting rod or connecting arm, which includes or acts as bearings. Furthermore, in some other embodiments, slots may be provided along the body of each housing through which guide pins can be received to help guide the movement of the connecting rod and may further help provide additional impact resilience.

[0112] In another embodiment, the guide pin or fastener 114A may be inserted through the housing into the body of the link and may engage a slot or guide rail, or a channel or groove 107 for assisting in guiding and controlling or maintaining the link along its connecting housing. Figure 7B , 8B Similar to 9B) that allows movement without twisting, rotating, or otherwise becoming misaligned. In other embodiments, guide pin 114A may act as a pivot point about which a link or connecting arm may move or pivot, rather than moving in a substantially linear manner.

[0113] like Figure 7A , Figure 8A and Figure 8B As further shown, the distal hook-shaped end 112 of each of the link or connector arms 102 may be supported along at least one side by the second end or distal end 106 of its connector housing 101 to assist in guiding and supporting the hook-shaped end during the sliding movement of the link. The hook-shaped end of the link or connector arm will engage a corresponding hook-shaped portion, recess, or slot of the corresponding needle pitch component; for example, in an embodiment, engagement occurs in a slot or recess 64 formed in the first portion 60 or distal end of a corresponding or associated one of the looper or hook 50. Figure 5 In other embodiments, the hook-shaped end of the linkage may engage a clamp for a flat-cut looper, flat-cut looper, or other movable stitch length component. When each actuator is selectively activated or deactivated, movement of its actuator shaft or drive rod is transferred via the linkage or connector arm of its corresponding connector or gate to an associated one of the stitch length components. Therefore, the connector or gate can provide an economical, rigid, and high-strength connection between each actuator and its associated stitch length component, wherein the stitch length component can be removed or replaced as needed without replacing its associated actuator.

[0114] In one embodiment, generally as follows Figure 2 and Figure 11A-11CAs shown, the actuator may include a hydraulic cylinder, an air cylinder, an electric cylinder, or a pneumatic cylinder 68, each cylinder including a piston rod or shaft 69, which is typically connected to an associated or corresponding one of the needles or hooks via a connector or door 67. In some embodiments, the actuator may also be used to control the operation of more than one needle or hook 50. Furthermore, as those skilled in the art will understand, other types of actuators may also be used, including solenoids, electric motors, or other similar actuation mechanisms.

[0115] Each of the actuators is typically linked to a control system 25, which selectively controls the actuation of the actuators to control the initiation and / or movement of each of the loopers relative to the needle. The actuators are controlled to selectively extend and retract their loopers or hooks such that the position of their throats / beaks can vary in a second direction relative to the needle, reciprocating into and out of the base fabric and in a second direction relative to the looper or hook 50 along the direction of arrows 54 / 54'. For example, in an embodiment, when the looper or hook reciprocates along the direction toward and away from the needle 36 along arrows 54 and 54', the looper or hook will move in a substantially vertical direction relative to the needle (i.e., substantially up and down), such as... Figure 2 , 10A As indicated by arrows 71 and 71' in 11A-11C. The actuator can be controlled to extend and retract the looper or hook not only between extended and / or seamless positions, but also selectively controlled to cause the looper to extend and / or retract to a series of different positions or heights relative to the needle's puncture stroke or depth. Therefore, the position or location of the looper or hook's throat relative to the needle can be controlled and varied so that the selected needle picks up and / or forms loops of yarn at different pile heights or lengths, or does not pick up yarn, as... Figure 11A-11C As shown.

[0116] For example, in the fully extended position, a selected looper or hook of looper or hook 50 can pick up loops of yarn from the needle it engages with, the loops typically forming a first selected or desired pile height, while other loopers or hooks can extend or retract to a position or location between the fully extended and retracted positions to pick up and form loops of yarn with a second or other different length or pile height. Alternatively, an actuator of the looper or hook can move some of the loopers or hooks to a fully lowered or retracted position to place them in a seamless position, such that the throat / beak of such loopers or hooks is below the full penetration depth or end of the stroke of the needle, and therefore does not pick up loops of yarn from their corresponding or respective needles. In other operations, actuators can be selectively controlled or triggered to retract or lower the respective loops or hooks of the actuators after capturing a loop of yarn on a bevel or hook, in order to pull down such captured yarn loops to lengthen or produce higher pile or increased yarn length for additional patterning effects, such as end cuts and / or other texture effects.

[0117] like Figures 10A-10B As shown, each of the stitch length components 32 (e.g., loopers or hooks 50) can typically be arranged in sets or groups, each set and group being contained within module 51, wherein the modules are mounted in series along the stitch length bar to provide multiple stitch length components arranged across the tufted area at prescribed intervals (e.g., stitch length intervals, such as 1 / 10, 1 / 8, 5 / 16, etc.). The stitch length components 32 will be positioned to engage needles, which includes, depending on the configuration of the needles on the needle bar or multiple needle bars (e.g., if the needles are arranged in a straight, staggered, and / or other configuration scheme along a single or double needle bar), as needed in a straight, offset, staggered, and / or other configuration. Each of the loopers or hooks 50 can also be arranged at an angle or offset relative to the needle penetrating the base fabric to move or be extendable / retractable along an angled travel path 71 / 71' relative to the needle and / or its removal point. This biased movement of the looper or hook can also be varied as needed to minimize the possible engagement of the looper or hook with the needle when the looper is retracted, depending on the spacing and / or arrangement of the needles.

[0118] For example, in some embodiments, when the looper or hook is retracted, the looper or hook may deviate from the vertical direction along the travel path and / or be offset at an angle / bias relative to the needle's travel (e.g., Figure 10BThe looper or hook (as shown in θ) is arranged and / or moved at an angle between about 1° and about 10° or greater, and in one exemplary embodiment, the looper or hook forms an angle of about 4° to 6° relative to the path or direction of the needle's reciprocating motion as the needle completes its entry and exit from the base fabric; while in other embodiments, there may be substantially no offset between the looper or hook and the needle, i.e., the looper or hook forms an angle of about 0° relative to the needle. Therefore, when the looper or hook extends to the removal area 39 sufficient to engage the needle... Figure 10A-11A When the looper or hook is in position / height, its throat / beak will typically be properly aligned or positioned to engage and pick up loops of yarn from its corresponding needle. As the looper or hook retracts, it can typically move further along an offset path of travel, allowing its throat / beak to be positioned or positioned outside the needle's path of travel to minimize the possibility of unintentional yarn pickup when the looper or hook moves to and / or is in a retracted, seamless position.

[0119] In operation, according to some embodiments, tufted articles can be formed according to the systems and methods of this disclosure. These tufted articles can be formed with various patterns and pattern effects, including the use of multiple different colors and / or types of yarn for forming such patterns, and effects including embossed or multiple pile heights. For example, the systems and methods of this disclosure can be operated in conjunction with a stitch distribution control system or a yarn color placement system, such as those disclosed and described in U.S. Patent Nos. 8,141,505, 8,359,989, and 8,776,703, the disclosures of which are incorporated herein by reference as fully set forth herein.

[0120] In such embodiments, the stitches or tufts of yarn formed in the base fabric material can also be formed with an increased or higher actual operating or effective working pitch compared to the desired or specified fabric or pattern pitch for the tufted pattern being formed. If the pattern or fabric pitch or the density of the pattern being formed requires the tufted article to have the appearance of 8, 10, 12, etc. stitches per inch formed therein and / or shown on its surface, then the actual, operating, or effective number of stitches per inch formed during tufting machine operation will be much greater than the desired or specified pattern or fabric pitch. Therefore, the actual formation of the stitches or tufts of yarn in the base fabric material will be accomplished with an increased actual, operational, or effective processing distance, thereby effectively forming a larger number of stitches per inch in the base fabric material than the number of stitches per inch required to be shown in the finished pattern. Those stitches or tufts that are not desired to be displayed or retained in the patterned area or the sewn area are retracted or pulled out from the base fabric material, or pulled down sufficiently to allow such yarns to remain or be rough-stitched in the base fabric, while substantially avoiding the creation of undesirable or unnecessary gaps or spaces between the retained yarns or tufts of the pattern (i.e., tufts of yarn that remain visible or apparent in the finished pattern of the tufted product).

[0121] For illustrative purposes, in one exemplary embodiment, the effective processing distance can be determined based on or by increasing the fabric or pattern distance of the pattern being formed by approximately the number of colors selected or tufted in the pattern. For a desired fabric or pattern distance with approximately 10-12 stitches per inch and using a pattern with between 2 and 4 colors, the effective or operational processing distance (i.e., the distance at which stitches are actually formed in the base fabric material) can be from approximately 18-20 stitches per inch to approximately 40 or more stitches per inch. However, those skilled in the art will further understand that such operational or effective processing distance for a particular pattern can be further varied or adjusted depending on the yarn type and / or size and / or other factors. For example, if a thicker, larger, or heavier yarn is used, the effective processing distance can be further varied as needed to account for the use of such a larger yarn (e.g., for a 4-color pattern, the effective processing distance can be further varied, for example, running at approximately 25-38 stitches per inch, but further variations can be used as needed). Therefore, in cases where the selected or programmed pattern being run can be designed or expected to have 10 to 12 stitches per inch as the desired pattern density or weave distance, the system can actually operate on a number of times depending on the color and / or type of yarn to form up to 20 to 48 or more stitches per inch, even though the desired / selected 10 to 12 stitches are usually only visually apparent from the surface of the finished tufted garment.

[0122] Additionally, when tufting involves a series of different colors, the needles 36 of the needle bar 35 are typically equipped with the desired thread ends; for example, for a four-color pattern, thread ends A, B, C, and D can be used on the needles. Alternatively, when using two needle bars, the needles on each needle bar can be configured with an alternating threading sequence, i.e., threading A / C on the front needle bar and threading B / D on the rear needle bar. Furthermore, the needles on these front and rear needle bars can be arranged in a staggered or offset alignment. The needle bar mover 40 is typically controlled according to the movement profile used for the formed pattern. Figure 2 The needle bar or multiple needle bars are moved to control the base fabric material and control the yarn feed in order to effectively present each color of the yarn (i.e., 2, 3, 4, 5, etc.) or each different type of yarn. As the base fabric material is fed through the tufted area, the needle bar is moved laterally relative to the base fabric material, and the yarns can be sewn into loops or hooks at selected pattern pixels or tuft / stitch positions.

[0123] For example, in a four-color pattern, each of the one to four colors of yarn that can be sewn at the next pixel or stitch position (i.e., the first, second, third, and fourth), or yarns that can be left unpresented at selected pixel or stitch positions, will be presented to the desired looper or hook as the base fabric material gradually moves approximately 1 / 8 inch to 1 / 40 inch during each movement or cam motion cycle. The looper or hook will engage and form a yarn loop, wherein one or more desired yarns are retained to form the selected cluster, while the remaining yarns can typically be pulled down or retracted by controlling a yarn feed mechanism (multiple yarn feed mechanisms), which includes pulling these unretained yarns out of the base fabric material so that they float along the base fabric material. Therefore, during each movement sequence and the corresponding incremental movement of the base fabric, for each pattern pixel or the tuft / stitch position associated with each pattern pixel, each looper or hook has the ability to tuft any one or possibly more than one (i.e., 2, 3, 4, 5, 6, etc.) of pattern color, or may not present any color to each looper or hook. As described above, if none of the different types or colors of yarn will tuft or be placed at a particular tuft or stitch position or pixel, the yarn feed can be controlled to limit or otherwise control the yarn of the needle that may be presented at such stitch position or pixel, to substantially pull back all yarn or otherwise prevent the yarn from being placed or appearing at the stitch position, and / or the needle bar can also be controlled to skip or otherwise bypass or circumvent the presentation of the needle / yarn to the stitch position or pixel.

[0124] The feeding of the base fabric material B can be further controlled, i.e., controlled in various ways by the stitch distribution control system. For example, the base fabric roller 28 of the tufting machine can be controlled to hold the base fabric material in place within a certain number of stitches or cycles on the needle bar, or the base fabric material can be moved at a desired number of stitches per inch, i.e., when four stitches are introduced into the base fabric for a pattern with four colors and an effective weave of 40 stitches per inch, the base fabric material moves approximately 1 / 40 inch or a variation thereof for each penetration, to move approximately 1 / 10 inch. The movement of the base fabric material can also be changed or manipulated on a stitch-by-stitch or pixel basis, wherein the average amount of movement of all stitches in one cycle is substantially matched to the incremental amount of movement of the calculated operating or effective processing weave. For example, for a 4-color cycle, the first stitch can run at 1 / 80 inch, the next two stitches at 1 / 40 inch, and the fourth stitch at 1 / 20 inch. The average amount of movement of the base fabric throughout the entire 4-stitch cycle is 1 / 40 inch for each stitch that needs to be presented, in order to achieve the desired stitch / color placement.

[0125] Therefore, when forming a pattern in the base fabric, each different yarn / colored yarn that can be tufted at a specific stitch position or pixel can be presented to such stitch position or pixel. To achieve this yarn presentation at each pixel or stitch position, based on the number of colors running in the pattern and the area of ​​the pattern region formed by each specific color, the needle bar (multiple needle bars) can typically be moved as needed / desired according to a calculated or selected cam profile or the movement profile of the pattern to be run / formed (e.g., using a combination of single and / or double jumps or movements). This combination of single and double movement jumps or steps can be used to avoid over-tufting or joining previously sewn tufts as the needle bar moves laterally and the base fabric advances at its effective or operating weave length. The base fabric can also be moved either in conjunction with or separately from a needle bar movement mechanism via a base fabric movement device or a jute movement device, etc.

[0126] When the needle penetrates the base fabric B, as Figure 1 and Figure 2 As shown, the looper or hook 50 of the stitch length component assembly 30 will reciprocate toward the needle in the direction of arrow 54 to engage its associated or corresponding needle and to pick up or pull out loops of yarn from its associated or corresponding needle. Additionally, the actuator 66 for the looper or hook can be selectively controlled and engaged to extend or retract a selected looper or hook such that its beak 63 and throat 62 are positioned relative to the needle as the needle 36 penetrates and completes its journey into and out of the base fabric. Figure 10A-11CAs shown, the position or orientation of the beak and / or throat of the looper or hook can vary between a fully extended position or height and a lowered or retracted "seamless" position, where such looper or hook picking up and / or forming of yarn loops can generally be prevented to provide selective picking up of yarn loops (this includes not picking up one or more yarn loops) and control over the length of the yarn loops (which are selectively picked up from the yarn presented at each stitch position or pixel according to the instructions for the pattern being formed). As a result, the position of the loops of selected or desired yarn shown in the "finished" pattern picked up from the needle by the looper or hook can be controlled, while further control can be exercised over the clusters formed by these picked-up yarn loops retained in the base fabric, so that the clusters can be formed at various different pile heights.

[0127] Typically, the type / color of each yarn series to be presented at each pixel or stitch position is determined according to the pattern instructions or program used to form the tufted pattern. The type / color of each yarn series will be retained or displayed on the base fabric at a specific stitch position. By controlling the activation and / or positioning of the looper or hook 50 corresponding to or associated with the needle carrying this yarn, the tufting machine can selectively pick up and retain loops of the yarn at each stitch position (where the yarn will be retained according to the pattern) to form a final tuft of this yarn at a selected pile height. For example, if the presented yarn will not be displayed or shown, the corresponding looper or hook can retract to a seamless position, so that loops of yarn are not picked up, and its yarn feed is controlled so that the yarn is not retained at the pixel or stitch position. For the retained yarns / colors (i.e., the yarns that appear on the surface of the patterned tufted fabric), the position or height of the looper or hook and the yarn feed mechanism that feeds these yarns can usually be controlled cooperatively to pick up and form loops of these yarns sufficient to form tufts of the desired type and pile height.

[0128] Further control of the base fabric feed by increasing the effective or operational processing pitch (e.g., the actual pitch at which stitches are formed in the base fabric) according to the principles of this disclosure also provides a denser or compressed area of ​​stitches or tufts per inch, such that retracting yarns are removed or pulled down to a degree sufficient to avoid creating undesirable spaces or gaps between the retained face yarns (those yarns that appear on the surface of the tufted article according to the pattern) or to avoid interference with such retained face yarns formed in the base fabric material or to avoid visibility through such retained face yarns formed in the base fabric material. Additionally, the control system can perform yarn feed compensation and / or yarn feed modeling to help control and reduce the amount of non-retained or unvisible yarns that may “float” on the back side of the base fabric material, further helping to reduce / minimize excess yarn feed and / or waste.

[0129] Additionally, the yarn feeding mechanism that controls the feeding of each yarn to each needle can be selectively controlled to substantially retract or pull the yarn carried by the needle from the base fabric or to move back and forth with the needle; and some yarn loops can be retracted or pulled back / lowered to a sufficiently low position to substantially prevent the ends of such unselected yarns from occupying selected stitch positions, or otherwise interfere with the placement of selected face yarns or threads to be displayed in specific color areas formed according to the pattern.

[0130] For example, in some embodiments, when a selected or specific looper or hook is retracted to the fully retracted or "seamless" position, loops are typically not picked up from the needle associated with such a fully retracted looper or hook. Simultaneously, the yarn feed is controlled accordingly to allow the yarn to move in and out of the base fabric as the needle moves. Additionally, in some cases where yarn loops are formed, such as when the looper or hook is in the fully extended position and forming a low loop, the yarn feed can be controlled to leave a certain amount of yarn engaged with or "rough-stitched" onto the base fabric, while substantially removing these yarns to such an extent that the ends of these unselected yarns generally do not interfere with the placement of the selected yarn face at specific stitch locations within the color area being sewn. This allows the final yarn loop to be retracted or pulled low enough or pulled out of the base fabric.

[0131] The placement of inconspicuous yarns, either burr-stitched or otherwise secured to the base fabric, can also be controlled to prevent the formation of tails of extended length that could subsequently be caught or cause other defects in the finished tufted product. For example, the control system can also be programmed / set to burr-stitch or form such inconspicuous yarns at desired intervals (e.g., every 1 to 1.5 inches, but larger or smaller intervals may also be used). Yarn compensation can also often be used to help ensure that a sufficient amount of yarn is fed when needed so that inconspicuous yarns can be burr-stitched into the base fabric while preventing yarns from showing through or bulging out of the other color, i.e., in the case of several yarns placed together, where the yarn is burr-stitched in and protrudes through one of the stitched yarns. Additionally, if an extended length or tail is to be formed for multiple unseen yarns, the spacing of these different yarns in the burr stitch within the base fabric can be varied (i.e., one spacing is 1 inch and another is 1.5 inches) to avoid these burr stitched yarns interfering with each other and / or with the yarns in the forming color area.

[0132] Furthermore, the actuator 66 can be controlled in conjunction with the control of the yarn feed mechanism to form extended or elongated yarn loops (e.g., by engaging and retracting or lowering their respective loopers or hooks on which the yarn loops are captured). Thus, the captured yarn loops can be further pulled and / or elongated, while the corresponding yarn feed can be controlled to feed additional amounts of these yarns. As a result, even longer or greater lengths of yarn loops can be formed in the base fabric to produce higher pile clusters and / or to create other desired pattern effects, such as for end cuts and / or other patterned features. Selective control of the actuator 66, allowing for the selective retraction and extension of its loopers or hooks 50, can also be used to provide additional variations or transition steps or pile heights in the pattern, for example, to provide more gradual or subtle differences or variations in pile height, or to provide more abrupt or defined intervals between the pile heights of the forming yarn clusters.

[0133] Therefore, across the entire width of the tufting machine, the control system controls the movement and feed of yarns for each color or desired pattern texture effect, ensuring that each color that can or may be sewn at a specific tufting position or pattern pixel is presented within that pattern pixel space or tufting position, but the selected yarn tufts used only for a specific color or pattern texture effect remain in that tuft / stitch position or pattern pixel. As further noted, additional or more colors can be presented to each looper or hook during the tufting step to form mixed color tufts or to provide a tweed effect as needed, wherein two or more stitches or yarns are placed at the desired pattern pixel or tufting position. Thus, the operational result of the stitch distribution control system provides a multi-color visual effect of selectively placed pattern colors or texture effects to achieve the desired density and pattern appearance of the finished tufted article. This further enables the production of a wider variety of geometric, flexible, and other pattern effects by controlling the placement of tufts or yarns at selected pattern pixels or tufting positions.

[0134] Therefore, the system and method of this disclosure for tufted embroidery and multi-pile high-pattern articles enable operators to develop and run various tufted patterns with a variety of appearances, textures, etc., on a tufting machine without the need to utilize a design center to draw and create patterns. Alternatively, for this disclosure, as an additional and / or alternative to manually preparing patterns or using a design center, the operator can scan images (i.e., photographs, drawings, jpegs, etc.) or upload pattern files of the design at the tufting machine, and the stitch distribution control system can read the images and develop program steps or parameters to subsequently control the tufting machine, essentially eliminating the need for further operator input or control necessarily required to form the desired tufted pattern article.

[0135] The foregoing description generally illustrates and describes various embodiments of the present invention. However, those skilled in the art will understand that various changes and modifications can be made to the above-described structure of the present disclosure without departing from the spirit and scope of the present disclosure disclosed herein, and it should be understood that all content included in the foregoing description or shown in the accompanying drawings should be interpreted as illustrative and not as limiting. Furthermore, the scope of the present disclosure should be interpreted to cover the various modifications, combinations, additions, substitutions, etc., and various modifications, combinations, additions, substitutions, etc., of the above-described embodiments, all of which should be considered within the scope of the present disclosure. Therefore, the various features and characteristics of the present disclosure discussed herein can be selectively interchanged and applied to other embodiments of the present disclosure shown and not shown, and further various changes, modifications, and additions can be made without departing from the spirit and scope of the present disclosure set forth in the appended claims.

Claims

1. A tufting machine, the tufting machine comprising: At least one needle bar, the needle bar having a plurality of needles mounted along the needle bar; A bottom fabric feed roller, wherein the bottom fabric feed roller feeds the bottom fabric material; At least one yarn feeding mechanism that feeds yarn to the needle; and A stitch spacing component assembly, positioned below the base fabric material, the stitch spacing component assembly comprising: At least one module, wherein the at least one module carries a series of needle spacing components in reciprocating motion toward and away from engagement with the needle as the needle reciprocates into the base fabric material, wherein the at least one module comprises: The main body of the module is composed of metal, polymer, composite material, Or a combination thereof, formed and having a first hardness, the module body being adapted for mounting along the pin spacing bar and having a channel defined through the pin spacing bar; and Inserts positioned along the main body of the module on opposite sides of the channel, each insert having a slot in which one of the pin spacing components is slidably received, each of the slots being configured to slidably receive at least a portion of one of the pin spacing components therein; The insert comprises a metal or metal carbide material having a second hardness greater than the first hardness of the module body; Each stitch spacing component includes a body that is at least partially received within opposing slots of the insert and is movable in other directions relative to the travel of the needle through the channel of the module body. The body of each stitch spacing component has: a first portion extending through the channel of the at least one module; and a second portion having a throat configured to pick up a loop of yarn from the needle; and A series of actuators, coupled to the needle spacing component, for controlling the movement of the needle spacing component through the module body; and A control system comprising a program for controlling the at least one yarn feeding mechanism to coordinate with control implemented on actuation of one or more actuators to control the feeding of the yarn toward the needle to extend or retract a selected stitch member in the stitch length component, such that the throat of the selected stitch member moves between a non-sewing position and an engagement position relative to the travel of the needle into the base fabric material for selectively forming clusters of yarn in the base fabric material according to the pattern being formed.

2. The tufting machine of claim 1, further comprising a moving mechanism for laterally moving the at least one needle bar across the base fabric material, and wherein, The control system further includes programs to coordinate the movement of the at least one needle bar caused by the moving mechanism, the feeding of the base fabric material caused by the base fabric feed roller, control implemented on the actuator coupled to the stitch length member, and control implemented on the at least one yarn feed mechanism feeding the yarn to the needle as the needle reciprocates into and out of the base fabric material, so as to present a series of yarns along the base fabric material to selected stitch positions and to withdraw unselected yarns if a loop of those unselected yarns is not picked up in the stitch length member, and wherein the base fabric material moves through the tufting area at an operating weft greater than the pattern weft of the pattern being formed, so as to provide a number of retained tufts per inch of face yarn in the base fabric material that is approximately equal to the pattern weft.

3. The tufting machine according to claim 1, wherein, The stitch length component includes a flat-cut looper, a looper, or a cut-down hook.

4. The tufting machine according to claim 1, wherein, The actuator includes a hydraulic cylinder or a pneumatic cylinder.

5. The tufting machine according to claim 1, wherein, The needle spacing component assembly also includes a series of connectors extending between each needle spacing component and its associated actuator, each connector including a link received within a housing and movable through the housing.

6. The tufting machine according to claim 5, wherein, Each connector housing comprises a polymer, a composite material, or a combination thereof, and also includes a channel extending therethrough; and each link comprises a metal or a composite material, or a combination thereof.

7. The tufting machine according to claim 5, wherein, Each housing body also includes a composite material comprising a polymer or plastic having a fiber-filled material and having channels defined therein, along which the link is movable, and wherein each connector's link includes a hardened metal body coupled to the housing body and having a proximal end and a distal end, the proximal end being configured to engage a first portion of one of the stitch members, and the distal end being configured to engage by an actuator associated with the stitch member for transferring motion of the actuator to the stitch member.

8. The tufting machine according to claim 1, wherein, Each of the inserts in the at least one module includes: a first pair of inserts mounted to the upper and lower surfaces of the module body along a first side of the channel of the module body; and a second pair of inserts mounted to the upper and lower surfaces of the module body along a second side of the channel of the module body, the second pair of inserts being spaced apart from the first pair of inserts and facing the first pair of inserts; and wherein the slots of the inserts in the first pair of inserts are arranged to be opposite to and substantially aligned with the corresponding slots of the inserts in the second pair of inserts.

9. The tufting machine according to claim 8, wherein, The first pair of inserts and the second pair of inserts are configured to cover the upper and lower surfaces of the module body, and each insert includes a slotted opening adapted to receive a fastener passing through it for adjustably mounting each of the first pair of inserts and the second pair of inserts to the module body, wherein the inserts are arranged spaced apart from each other at a selected distance and positioned at a selected location relative to the channel defined through the module body.

10. The tufting machine according to claim 1, wherein, The at least one needle bar includes a pair of needle bars, each needle bar having a series of needles spaced apart and connected in series along the needle bar.

11. A gauge component assembly for a tufting machine, the gauge component assembly comprising: Multiple modules, each module comprising a module body and having a passage defined therethrough; A series of needle spacing components, each of which is slidably received within each of the plurality of modules, wherein the needle spacing components have a throat terminating at a beak, wherein the needle spacing components are carried by their modules along a first direction toward and away from engagement with the needles of the tufting machine in order to selectively pick up loops of yarn from the needles, and wherein each of the needle spacing components is selectively movable along the channel of its module in a second direction; A first insert and a second insert are mounted to the module body of each module on opposite sides of the channel defined by the module body. Each of the first insert and the second insert is formed of a metal or metal carbide material with a hardness greater than that of the module body and has a series of slots formed therein. The slots of the first insert and the second insert are substantially aligned across the channel and configured to define a contact area along which at least a portion of one of the pin spacing components can be slidably received. A plurality of actuators, each actuator coupled to an associated stitch member in the stitch member and adapted to move the stitch member associated with that actuator through a channel of its module along the second direction, whereby the stitch member extends or retracts such that the stitch member moves between an extended position for engaging the needle and picking up the yarn from the needle and a retracted position for substantially avoiding picking up the yarn from the needle; and A connector extends between each actuator and the pitch component associated with the actuator, each connector having a housing made of polymer material within which a connecting rod is encapsulated.

12. The stitch spacing component assembly according to claim 11, wherein, Each housing also includes a composite material comprising a polymer or plastic having a fiber-filled material and having channels defined therein, along which the link is movable; and wherein the link of each connector includes a hardened metal body extending through the housing and having a proximal end and a distal end, the proximal end being configured to engage a portion of one of the stitch components, and the distal end being configured to engage an actuator associated with each stitch component for transferring motion of the actuator to the stitch component.

13. The stitch spacing component assembly according to claim 11, wherein, The upper portion of each of the first and second inserts is configured to overlap with the upper surface of the module body and includes a slotted opening adapted to receive a fastener passing through it for adjustably mounting each of the first and second inserts to the module body, wherein the first and second inserts are arranged spaced apart from each other by a selected distance and positioned at a selected location relative to a channel defined through the module body.

14. The stitch spacing component assembly according to claim 11, wherein, The first insert and the second insert comprise a metal carbide material with a hardness of at least 75+RC.

15. The stitch spacing component assembly according to claim 11, wherein, The first insert and the second insert comprise metal carbide material, and the module body of each module comprises aluminum material, steel material, or a combination thereof.

16. A gauge component assembly for a tufting machine, the gauge component assembly comprising: At least one module, the at least one module having a module body formed of a first material and having a channel defined therethrough; A series of needle-pitch components are received within a channel of the module body. Each needle-pitch component includes a body having a first portion and a second portion having a throat. The needle-pitch components are carried by their module along a first direction toward and away from engagement with the needle associated with the tufting machine to pick up loops of yarn from the needle. The needle-pitch components are selectively movable along a second direction along a channel of the module body. Inserts are arranged along opposite sides of a channel in the module body. Each insert is formed of a material with a hardness greater than that of the first material of the module body and has a series of spaced-apart slots configured to receive at least a portion of one of the pin spacing components; and A plurality of actuators, each actuator coupled to a first portion of an associated stitch member in the series of stitch members and adapted to move its associated stitch member along a second direction through a channel of the at least one module, whereby the stitch member extends through or retracts through the module body, so as to move the stitch member between an extended position for engaging the needle and picking up yarn from the needle and a retracted position for substantially avoiding picking up yarn from the needle.

17. The stitch component assembly of claim 16, further comprising a connector extending between each actuator and its associated stitch component, each connector having a housing formed of a polymer material in which a connecting rod is encapsulated.

18. The stitch spacing component assembly according to claim 16, wherein, The main body of the at least one module is molded or cast from metal or composite material.

19. The stitch spacing component assembly according to claim 18, wherein, Each insert includes a body molded or cast from metal or carbide, the body of the insert having tabs or flanges, and the slots being formed in the tabs or flanges.

20. The stitch spacing component assembly according to claim 18, wherein, Each insert comprises a body molded or cast from powder metal material.

21. The stitch spacing component assembly according to claim 16, wherein, Each insert includes a body molded or cast from metal or carbide, the body of the insert having tabs or flanges with slots formed in the tabs or flanges, and wherein the module body of the at least one module comprises metal or composite material molded or cast to form a module body substantially integrated therewith.

22. A tufting machine, the tufting machine comprising: At least one needle bar, the needle bar having a plurality of needles mounted along the needle bar; A bottom fabric feed roller, wherein the bottom fabric feed roller feeds the bottom fabric material; At least one yarn feeding mechanism that feeds yarn to the needle; and A stitch spacing component assembly, positioned below the base fabric material, the stitch spacing component assembly comprising: Multiple needle spacing components, each needle spacing component including a first part and a second part, the first part and the second part being configured to pick up loops of yarn from the needle; At least one module having a module body having a first hardness formed of metal, polymer, composite material, or a combination thereof, the module body having at least one channel defined therethrough and inserts positioned along opposite sides of the at least one channel, each insert having a slot in which one of the pin spacing components is received; The insert comprises metal, metal carbide, or ceramic, and the insert has a second hardness greater than the first hardness. The needle spacing component moves in a first direction relative to the travel of the needle in and out of the base fabric material, thereby moving toward and away from engagement with the needle, and the needle spacing component is capable of moving in a second direction relative to the travel of the needle along at least one channel of the module body; A series of actuators, coupled to the pin spacing component, for controlling the movement of the pin spacing component through the module body in a second direction; and The control system includes a program for controlling the actuation of one or more of the actuators to move, in a second direction, a selected stitch member of the stitch member between a lowered position that substantially avoids the selected stitch member picking up a loop of yarn from the corresponding needle and one or more raised positions relative to the travel of the needle into the base fabric material for picking up a loop of yarn from the corresponding needle, and the program is further configured to control the at least one yarn feed mechanism to control the feeding of the yarn to the needle to selectively form clusters of yarn in the base fabric material according to the pattern being formed.

23. The tufting machine according to claim 22, wherein the insert comprises a powdered metal material, the powdered metal material comprising metal powder containing tungsten, titanium, or a combination thereof.

24. The tufting machine according to claim 22 or 23, further comprising a moving mechanism for laterally moving the at least one needle bar across the base fabric material, and wherein, The control system further includes a procedure adapted to coordinate the movement of the at least one needle bar by the moving mechanism with the control of an actuator coupled to the stitch length member and the control of the at least one yarn feeding mechanism for feeding yarn to the needle, so as to present a series of yarns along the base fabric to selected stitch positions and to retract unselected yarns if loops of unselected yarns are not picked up by the stitch length member.

25. The tufting machine according to claim 24, wherein, The control system also includes a procedure for controlling the feeding of the base fabric material by the base fabric feed roller, such that the base fabric material moves through the tufting area at an actual weave pitch greater than the pattern pitch of the pattern being formed, so as to provide a number of retained tufts per inch of yarn in the base fabric material that is approximately equal to the pattern pitch.

26. The tufting machine according to claim 22, wherein, The pin pitch component assembly also includes a series of connectors extending between each pin pitch component and its associated actuator, each connector including a link received within the housing and movable through the housing.

27. The tufting machine according to claim 26, wherein, The housing of each connector comprises a polymer material, a composite material, or a combination thereof; Furthermore, each link comprises metal, composite material, or a combination thereof.

28. The tufting machine according to claim 26, wherein, The housing of each connector also includes a composite material comprising a polymer or plastic material having a fiber-filled material and having a channel defined therein, along which the link is movable; and wherein the link of each connector includes a hardened metal body extending through the housing and having a proximal end and a distal end, the proximal end being configured to engage a portion of one of the stitch members, and the distal end being configured to engage by an associated actuator of the stitch member for transferring motion of the associated actuator to the stitch member.

29. The tufting machine according to claim 22, wherein, The inserts of at least one module each include opposing inserts mounted to the upper and lower surfaces of the module body along opposite sides of the channel; and wherein the slots of the inserts are arranged in a relative and substantially aligned relationship.

30. The tufting machine according to claim 22, wherein, Each insert includes a molded or cast body having tabs or flanges, and the slot is formed in the tabs or flanges.

31. The tufting machine according to claim 22, wherein, The main body of the at least one module comprises steel, aluminum, aluminum alloy, steel alloy, or a combination thereof.

32. The tufting machine according to claim 22, wherein, The main body of the at least one module comprises low-carbon steel, tool steel, or a combination thereof.

33. The tufting machine according to claim 22, wherein, The first hardness is at least 60+RC, and the second hardness is at least 75+RC.

34. A gauge component assembly for a tufting machine, comprising: Multiple modules, each module including a module body having a channel defined through the module body; Opposite inserts are positioned on opposite sides of the channel defined by the module body. Each insert is formed of metal, metal carbide, or ceramic, and each insert has a hardness greater than that of the module body and has a series of slots formed therein. The slots of the opposing inserts are substantially aligned across the channel; A series of needle-pitch components are slidably received within the slots of the opposing inserts, each needle-pitch component having a first portion and a second portion including a throat; The slots of the opposing inserts are configured to define a contact area along which at least a portion of one of the pin spacing components is received; The needle spacing component is carried by the module along a first direction toward and away from engagement with the needle of the tufting machine to selectively pick up loops of yarn from the needle, and each of the needle spacing components is selectively movable along a slot of the opposing insert in a second direction, the needle spacing component being received in the slot. and Multiple actuators, each coupled to the needle spacing component, each actuator being selectively actuated to move the needle spacing component coupled thereto in a second direction, such that the needle spacing component moves between a retracted position and one or more extended positions, the extended positions being for engaging the needle and picking up loops of yarn from the needle, the retracted positions substantially avoiding picking up loops of yarn from the needle.

35. The pin spacing component assembly of claim 34, wherein each insert is formed of a powdered metal material, said powdered metal material comprising metal powder containing tungsten, titanium, or a combination thereof.

36. The pin pitch component assembly of claim 34, further comprising a connector extending between each pin pitch component and an associated actuator, each connector having a housing formed of a polymer material, the housing encapsulating a connecting rod.

37. The stitch spacing component assembly according to claim 36, wherein, Each housing also includes a composite material comprising a polymer or plastic having a fiber-filled material and having channels defined therein, along which the link is movable; and wherein the link of each connector includes a hardened metal body extending through the housing and having a proximal end and a distal end, the proximal end being configured to engage a portion of one of the stitch members, and the distal end being configured to engage an associated actuator for the stitch member for transferring motion of the associated actuator to the stitch member.

38. The stitch spacing component assembly according to claim 34, wherein, The upper portion of each of the opposing inserts is configured to overlap with the upper surface of the module body and includes a slotted opening adapted to receive a fastener passing through it for adjustable mounting of the opposing insert to the module body at a selected location relative to a channel defined through the module body.

39. The stitch spacing component assembly according to claim 34, wherein, The opposing insert has a hardness of at least 75+RC.

40. The stitch spacing component assembly according to claim 34, wherein, The main body of each module includes steel, aluminum, aluminum alloy, steel alloy, or a combination thereof.

41. The stitch spacing component assembly according to claim 34, wherein, The main body of each module comprises low-carbon steel, tool steel, or a combination thereof.

42. A tufting machine, the tufting machine comprising: One or more needle bars, the needle bars having a plurality of needles mounted along the needle bars; A base fabric feed roller, the base fabric feed roller being configured to feed base fabric material through the tufting machine; At least one yarn feeding mechanism feeds yarn to the needle; and A stitch spacing component assembly positioned beneath the base fabric material, the stitch spacing component assembly comprising: At least one module having a module body formed of metal, polymer, composite material, or a combination thereof, the module body having a channel defined through the module body; Multiple needle spacing components are received within a channel of the module body. Each needle spacing component includes a body having a first portion and a second portion, the first portion and the second portion being configured to pick up loops of yarn from the needle. The needle spacing component is carried by its module along a first direction toward and away from engagement with the needle of the tufting machine to pick up loops of yarn from the needle, and is capable of selectively moving along a channel of the module body in a second direction. An insert is received within a channel in the main body of the module, the insert being arranged along opposite sides of the channel and having a series of opposing slots configured to receive the pin pitch component; The insert comprises a material with a hardness greater than that of the material of the module body; A series of actuators, coupled to the pin pitch component and configured to control the movement of the pin pitch component along a channel of the module body in a second direction; and A control system, comprising a program for controlling the at least one yarn feeding mechanism to control the feeding of yarn toward the needle in coordination with the control of actuation of the one or more actuators, thereby moving a selected needle spacing member in the second direction such that a second portion of the selected needle spacing member moves between a lowered position and one or more raised positions relative to the travel of the needle into the base fabric material, for selectively forming clusters of yarn in the base fabric material according to the pattern being formed.

43. The tufting machine according to claim 42, wherein, The insert includes metal carbides and ceramics.

44. The tufting machine according to claim 42, wherein, The insert comprises a powdered metal material, which includes metal powder containing tungsten, titanium, or a combination thereof.

45. The tufting machine according to claim 42, wherein, Each insert includes a body molded or cast from metal or carbide, the body of the insert having tabs or flanges, and the slots being formed in the tabs or flanges.

46. ​​The tufting machine of claim 42 further includes a connector extending between each stitch member and the associated actuator, each connector having a housing formed of a polymer material, the housing encapsulating a connecting rod.

47. The tufting machine according to claim 46, wherein, The housing of each connector also includes a composite material comprising a polymer or plastic material having a fiber-filled material and having a channel defined therein, along which the link is movable; and wherein the link of each connector includes a hardened metal body extending through the housing and having a proximal end and a distal end, the proximal end being configured to engage a portion of one of the pin spacing components, and the distal end being configured to engage by the associated actuator and a pin spacing component connected to the associated actuator for transferring motion of the associated actuator to the pin spacing component.

48. The tufting machine of claim 42, further comprising at least one moving mechanism for laterally moving the one or more needle bars across the base fabric material, and wherein, The control system further includes a procedure adapted to coordinate the movement of the one or more needle bars by the at least one moving mechanism, control of the actuator coupled to the stitch length member, and control of the at least one yarn feeding mechanism for feeding yarn to the needle as the needle reciprocates in and out of the base fabric material, so as to present a series of yarns along the base fabric material to selected stitch positions and to retract unselected yarns if loops of those unselected yarns are not picked up by one of the stitch length members.

49. The tufting machine according to claim 48, wherein, The control system also includes a procedure for controlling the feeding of the base fabric material by the base fabric feed roller, such that the base fabric material moves through the tufting area at an actual weave pitch greater than the pattern pitch of the pattern being formed, so as to provide a number of retained tufts per inch of yarn in the base fabric material that is approximately equal to the pattern pitch.

Images