Tufting machine and tufting method

Abstract

A tufting machine for selectively forming yarn tufts comprising different colored or types of yarn to form a patterned tufted product, such as a carpet. A series of needles reciprocate into and out of a backing material fed through the tufting machine and are engaged by a series of pitch members to pick up loops of yarn from the needles. The pitch members are selectively controlled by an actuator to extend or retract to a position or height sufficient to pick up or not pick up loops of yarn from the needles. The feed of yarn to the needles can also be controlled in conjunction with the motion of the pitch members, while the backing feed can also be controlled to enable the formation of yarn tufts at an increased stitch pitch above the pattern stitch pitch of the pattern being formed in the tufted product.

Description

[0001] Cross-reference to related applications

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 212,770, filed on June 21, 2021.

[0003] By incorporating references

[0004] The disclosure of U.S. Provisional Patent Application No. 63 / 212,770, filed on June 21, 2021, is incorporated herein by reference in its entirety. Technical Field

[0005] This disclosure generally relates to tufting machines and methods for forming tufted fabrics. In particular, this disclosure relates to tufting machines including selectively controllable needle pitch components and methods for forming patterned tufted fabrics. Background Technology

[0006] 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. There is also a desire to replicate as closely as possible the look and feel of patterned carpets, blankets, or other fabrics formed on a loom, but in a way that allows for creation and formation on a wide-width tufting machine, thereby increasing the efficiency of producing such patterned tufted carpets, blankets, and / or other fabrics. In addition, there is often a desire to provide enhanced control over the formation of tufts of a selected color or type of yarn used to form patterned carpets, or the output of such tufting machines, without materially affecting the operation of the tufting machine (which includes increased requirements for maintenance or placement of components, such as its needle pitch components).

[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 brief, the present disclosure relates generally to tufting machines and methods of forming patterned tufted articles, wherein placement and pile height of tufts of yarn or stitches formed in a backing can be selectively controlled to enable the formation of patterned tufted articles (e.g., carpets) having a variety of pattern effects, including the formation of tufted articles having freely flexible multi-color and / or multi-pile height patterns and having a substantially woven or knit formed appearance.

[0009] In one aspect, the tufting machine will generally include a control system for controlling the operating elements of the tufting machine to form or create a tufted article according to a desired or designed pattern. The resulting tufted article can include a variety of pattern effects, including different types of tufts having multiple varying or different pile heights in the same and / or varying tuft rows, and other texture effects, as well as placement of various colors and / or types of yarns visible at selected locations and pile heights on the backing; wherein, at least in some embodiments, the resulting tufted article is provided with a density of retained and / or visible colored yarns / stitches per inch that substantially matches the desired or prescribed pattern density or stitch per inch for the pattern being formed / tufted.

[0010] In embodiments, the tufting machine will include one or more needle bars having a series of needles mounted therealong. The needles can be arranged in a straight, staggered, or other arrangement. As the backing material is fed through the tufting area of the tufting machine and as the needles reciprocate into and out of the backing material, yarns will be introduced into the backing material. A displacement mechanism can also be provided for laterally displacing the one or more needle bars across the tufting area, and multiple displacement mechanisms can be used as desired. The one or more displacement mechanisms will generally be operable in response to instructions or communications from the control system for moving the one or more needle bars laterally across the backing in steps according to the programmed and / or designed pattern for the pattern being tufted to present the yarns carried thereby to tuft or stitch locations along or across the backing.

[0011] The tufting machine will generally also include at least one yarn feed mechanism or attachment for controlling the feed of yarns to their respective needles. Such yarn feed mechanisms or pattern attachments can include, but are not limited to, various rolls, spools, servo spools, single end yarn feed attachments, double end yarn feed attachments, or multiple end yarn feed attachments (such as Yarntronics® or Infinity® / Infinity IIE® by Card-Monroe Industries, Inc.). TM or Infinity TM / Infinity IIE TMyarn feed control mechanisms. The control system will typically include a program for controlling the at least one yarn feed mechanism or pattern attachment, which program can be run to selectively control the feed of yarn to its needle, in order to form tufts of yarn (which can include forming tufts with selected pile heights / or not forming tufts), to create the desired pattern appearance.

[0012] In some embodiments, the control system can also include or operate with a stitch distribution control system; through which control of the feed of the base cloth and operation of one or more displacement mechanisms for displacing at least a portion of the needles can be coordinated with control of the at least one yarn feed mechanism, so that various yarns can be presented to various stitch locations or pixels, and yarns that will be displayed on the face or surface of the tufted product can typically be fed in amounts sufficient to form the desired height of tufts, while non-appearing yarns that will not be displayed in the tufted area are typically not picked up when the needle spacing component is lowered to the seamless sewing position. Thus, for each pixel or stitch location of the pattern, a series of yarns can be presented, and yarns that are not selected to be visible or appearing at that stitch location can be avoided from being picked up when the needle spacing component is in the seamless sewing position. Additionally, in some embodiments, yarn feed can also be controlled to include withdrawing or pulling down some yarns to form a carved or varying pile height effect, and / or to extend the loops of picked up yarn by moving the needle spacing component in conjunction with yarn feed control. Furthermore, some yarns can be withdrawn or pulled out to a level or extent that leaves enough unappearing portions within the base cloth to keep or baste the non-selected or unappearing yarns to the base cloth without interfering with the face or retained visible tufts of yarn of the pattern by substantially minimizing the unappearing yarns. Thus, in embodiments, only the desired or selected yarns / colors to be placed at a particular stitch location can be retained at such stitch location, and tufts or different pile heights and colors can be formed; while the remaining yarns / colors can be removed or withdrawn to an extent that the remaining yarns / colors can be basted or kept to the base cloth without appearing or being displayed in the pattern area being sewn at the time. The control system can also control and coordinate the operation of one or more selected needle spacing component assemblies with one or more yarn feed mechanisms of the tufting machine according to instructions for the pattern being formed, to control the selective formation of yarn loops and / or tufts and the length or pile height of the yarn loops and / or tufts.

[0013] Additionally, a needle spacing component assembly is positioned beneath the base material. The needle spacing component assembly will generally include a series of needle spacing components including, for example, but not limited to, bent needles, hooks, flat cut loop pile bent needles, cut / loop hooks, etc. The needle spacing components will be positioned along the tufted area and are movable in a first direction so as to reciprocate into engagement with the needles as the needles penetrate the base material to pick up loops of yarn from the needles. In some embodiments, each needle spacing component can also be selectively movable in a second or other direction that is generally perpendicular to the direction of its reciprocation. For example, the needle spacing components can be movable in a generally vertical direction (e.g., up and down direction) relative to the travel or reciprocation of the needles into and out of the base, as well as with the reciprocation toward and away from the needles, so as to selectively pick up yarn and form loops of yarn in the base material. Further, the movement of the needle spacing components along their second direction (i.e., along the vertical direction or other direction) can be controlled so as to form varying lengths of loops of yarn in the base material having varying pile heights, including loops of yarn of different pile heights in the base or even no loops of yarn. In further embodiments, other configurations and / or combinations of loop pile bent needles, cut pile hooks, cut / loop pile hooks, flat cut bent needles or hooks, and / or other needle spacing components can also be used.

[0014] In some embodiments, the needle spacing components can include bent needles or hooks each having a body slidably mounted within a needle spacing module or block, and the body having a first portion and a second portion that can include an elongated throat terminating in a proximal end or beak that is pointed. The first portion of the body of each needle spacing component can extend through the needle spacing block or module and can be coupled at a distal end to a drive system including a plurality of actuators each of which can be selectively actuated to control the movement of the associated or corresponding one of the needle spacing components in its second direction, and the actuators will be coupled to the associated or corresponding one of the needle spacing components by a connector assembly.

[0015] In some embodiments, each needle spacing module can include a module or block body having a first or rearward section adapted to be coupled or mounted along a needle spacing bar and a second or forward section having at least one channel or passage formed therethrough and through which a needle spacing component is to be received. The module can further include a replaceable insert that can be received within the passage or channel formed within the module body, the replaceable insert further including a slot or recess adapted to receive and guide the needle spacing component during movement of the needle spacing component through the passage of the module body / along the passage of the module block. Alternatively, the insert can be integrated with the module, such as by being adhered or otherwise substantially permanently affixed or secured to the body of its module or needle spacing block, and in some embodiments, the insert can be substantially adhered but at the same time still be able to be at least useably removed as desired.

[0016] In embodiments, the replaceable insert is to be formed of a hardened material that can include, but is not limited to, various metal carbides, metals, ceramics, and / or synthetic materials, while the body of the module can be made of a lighter weight material, such as aluminum and / or other metals as well as various composite or synthetic materials. The insert can further include an opening or slot configured to receive a guide pin or other positioning device as well as one or more fasteners for securing the insert in the needle spacing module. The opening is generally further configured to enable adjustment of the insert in at least one direction (e.g., longitudinally) and / or in multiple directions (e.g., longitudinally and / or laterally) for adjusting the position of the insert, and thus the arrangement or positioning of the needle spacing components across and / or along its needle spacing module. The insert can also be interchangeable so as to enable easy removal of the insert and thus replacement of one or more needle spacing components received therein, such as to replace a worn or damaged needle spacing component or for changing the spacing between the needle spacing components.

[0017] As another alternative, in some embodiments the module or gauge block itself can be removed and replaced with other gauge blocks or modules each including a set or series of gauge components mounted therein to provide for replacement of the gauge spacing between the gauge components, replacement of the type of gauge component used, or replacement of substantially all or at least a majority of the gauge components that are worn or damaged as a whole. Additionally, the guide slots or recesses formed within the insert will generally be configured to receive the body of the gauge component with a clearance generally sufficient to enable the gauge component to move in substantially free sliding motion through the slot or recess, but at the same time not cause excessive movement or twisting of the gauge component resulting in misalignment of the beak or throat of the gauge component with their respective needles. The slots or recesses of the insert can also terminate in a rear end or portion that can be configured or adapted to enable the edge of the body of the gauge component to seat against or engage a land and / or be provided with a land or engagement area along which the edge of the body of the gauge component can slide to help maintain the required alignment of the gauge component as it reciprocates or moves through its module.

[0018] The gauge components can also be arranged to engage the needles, including being arranged in a substantially straight, offset or staggered, and / or other configuration as desired to engage straight, staggered and / or double needle bar arrangements. In embodiments, each of the gauge components can also be arranged at an angle relative to the needles as the needles penetrate the base cloth. For example, in some embodiments the gauge components can be arranged and / or extendable / retractable along a travel path oriented at an angle of about 1° to about 10° relative to the needles and / or their travel or vertical motion from the vertical, while in other arrangements no offset (i.e., 0° angle) can be provided. The offset of the gauge components relative to the needles can also vary such that the gauge components can extend and retract along an angled or offset travel path relative to the needles as desired to minimize potential engagement of the gauge components with the needles as the gauge components move based on the spacing and / or arrangement of the needles.

[0019] In various embodiments, the drive system will include a series of selectively controllable actuators that drive the motion of the needle spacing components, which can include electric cylinders, hydraulic or pneumatic cylinders, solenoids, motors such as stepper motors, servo motors or other motors, linear actuators, moving coil actuators or voice coil actuators, and other similar actuators, and / or combinations thereof. The actuators associated with or corresponding to each of the needle spacing components can also be selectively controlled in accordance with the pattern instructions in order to move the needle spacing components to desired vertical positions relative to the needles for picking up loops of yarn from the needles, which includes picking up loops of yarn at different points in the needle travel in order to form loops / piles having different pile heights, and retracting to a "no-sew" position in which loops of yarn of a selected type or color are not generally picked up by such needle spacing components.

[0020] For example, the actuators can be connected to the associated or corresponding ones of the needle spacing components through a connector assembly for selectively driving such needle spacing components in motion relative to the needles in a second direction when the needle spacing components are reciprocated along their first direction toward and away from engagement with the needles. The control system can also include programming to selectively engage each of the actuators to control the motion of the needle spacing components for forming loops of yarn in accordance with the pattern being run on the tufting machine (which includes moving the needle spacing components to form or not form loops), and / or for forming loops of varying pile height.

[0021] In other embodiments, the actuators can be controlled / triggered to move their needle spacing components with loops of yarn captured thereon in order to elongate or pull such captured loop or loops to provide other pile heights and / or for other effects, such as for end shearing or other pattern or texture effects. For example, a needle spacing component can engage and receive a loop of yarn from a selected needle, and thereafter the needle spacing component can be moved, e.g., retracted to a lowered position, while also controlling the feed of yarn for such loop in order to pull or draw the loop to a lowered or elongated length position to create a varying pile height effect. The control system can also control the motion of needle spacing components with loops of yarn captured thereon to a raised or extended position, while further controlling the feed of yarn for such loops of yarn to pull back such yarn to maintain tension in the yarn and / or to form various pattern pile height effects.

[0022] In another aspect of the tufting machine and method of forming a patterned tufted product, the needle gauge members can be configured to move or pivot between a raised operative position (including a fully raised first operative position) and a lowered seamless sewing position in which the distal end or tip of the needle gauge member is generally oriented and / or disposed below the penetration depth or stroke of the needle, typically below the pick point or take down area of the needle, and possibly below the tip of the needle. The needle gauge members can include a bent needle, a hook, a flat loop bent needle, or other needle gauge member, the body of which is pivotably mounted to a support or bracket, and the throat of which protrudes forward from the body and terminates in a generally pointed tip or distal end. Actuators corresponding to such needle gauge members can be selectively engaged or operated in order to pivot the body of their respective or associated needle gauge members for moving the throat and distal end of the needle gauge member relative to the needle to a desired lowered height.

[0023] In various aspects, the needle gauge members are coupled to their respective or corresponding actuators of their drive system by a link assembly that includes a link or gate configured to extend between the actuator shaft or rod and the distal end of the associated or corresponding needle gauge member. In some embodiments, the link or gate can include an arm or linkage having a first end portion configured to engage or connect to the drive rod of its actuator, an intermediate section protruding from the first end portion, and a second end portion generally configured to engage the distal end of the associated needle gauge member. In embodiments, the linkage or arm of each of the links or gates can also be received within a housing or support structure. In one exemplary embodiment, such a housing or support structure can include a body formed of a durable lightweight material (e.g., a carbon-filled nylon material or other similar composite or plastic material) selected to provide durability and support to the linkage or arm while enabling weight reduction. Other materials including various metals, synthetic materials, and / or composites can also be used. The configuration of the gate and its housing can also vary as desired.

[0024] As each actuator is activated or deactivated, it extends or retracts the actuator shaft to cause the link or gate coupled thereto to move its associated or corresponding needle gauge member relative to the needle in a desired direction. For example, in some embodiments, the actuator can drive the needle gauge member in a generally vertical direction with respect to the orientation of the needle into and out of the base fabric, e.g., to adjust the height of the needle gauge member relative to the needle as the needle gauge member is reciprocated toward and away from the needle. In other embodiments, the actuation of the actuator and movement of the link can help control the movement of the needle gauge member or portions of the needle gauge member therein, thereby controlling the movement of the clamp of the flat loop bent needle toward and away from the needle in a direction generally along the direction of the reciprocation of the needle gauge member toward and away from the needle.

[0025] In other aspects, the pitch components are coupled to associated or corresponding actuators of the drive system by link assembly, each link assembly including a gate or link that includes a body having a first end portion receiving a first portion of the body of the corresponding pitch component therealong and a second end portion. In some configurations, a series of biasing members can be located between the second end portion of each gate and the spring plate. One or more linkages can extend between the actuators and the links or gates, and in some embodiments, the one or more linkages can be coupled to the pitch components, which can include arms, rods, cables, or other similar members.

[0026] Each linkage can generally have a first end portion extending through the spring plate and adapted to connect to the second end portion of its corresponding gate or to the pitch component and a second end portion coupled to the corresponding or associated actuator. In embodiments, the linkages will extend along a path from the actuator to its corresponding or associated pitch component / gate. In some embodiments, the linkages can also extend through a guide. In such embodiments, the guide can be configured to adjust the pull force exerted by the actuator.

[0027] Upon actuation, each selected actuator moves the linkage connected thereto, for example by pulling or retracting, to move the gate and / or corresponding pitch component in its second direction toward its retracted position and against the biasing force of one or more of the biasing members, generally compressing the biasing members as the pitch component moves toward its retracted position. Upon deactivation of the actuator, the linkage can be released so that the one or more biasing members can decompress and / or bias or urge the corresponding pitch component toward its fully extended position. In embodiments, the biasing members can assist in controlling the movement of the pitch components in their second direction relative to the needle to enable substantially incremental movement and positioning of the pitch components at varying height positions. Such position changes can be used to create or change the length of the loops of yarn picked up by the pitch components and thus enable changes in the pile height of the yarn tufts formed in the base fabric as well as enable movement to a seamless sewing position in which the pitch components are moved to a position in which they do not engage the yarn being carried by the needle.

[0028] In other embodiments, the link assembly can include a body coupled to one of the needle pitch components and a linkage coupled to a corresponding or associated actuator. For example, the actuator can include a motor and the linkage includes a cable, rod, arm, or combination thereof. In embodiments, the motor can also include a drive member, which in embodiments can include an eccentric, cam, or pulley or similar drive member configured to convert rotational motion to linear motion. When the drive member is rotated by its actuator, the linkage is caused to extend or retract, which in turn drives the corresponding or associated needle pitch component to move along a second direction between its extended and retracted positions, including moving the needle pitch component to the seamless sewing position.

[0029] In some embodiments, the link assembly can include a linkage that includes a first arm or rod having a first end coupled to a drive member (e.g., eccentric or pulley) coupled to and driven by an associated one of the actuators and a second end coupled to a second arm or rod at its first end. The second arm can have a second end pivotally connected to a first portion of the body of its corresponding needle pitch component. When each drive member is rotated by its motor, the first arm extends and retracts along a first axis of motion, causing the second arm to move the corresponding needle pitch component along a second axis of motion between its extended and retracted positions.

[0030] In yet other embodiments, each link assembly can include a linkage that can include or be connected to an extension connected to or integral with the body of the corresponding needle pitch component. Opposite ends of the linkage can be coupled to an actuator, such as a drive member (e.g., eccentric or pulley) driven by a motor. When the motor rotates its drive member, the linkage can extend or retract to move the corresponding or associated needle pitch component between its extended and retracted positions.

[0031] In some aspects of the present disclosure, a tufting machine is provided, the tufting machine comprising at least one needle bar having needles mounted therealong; a base fabric feed roller that feeds a base fabric material; at least one yarn feed mechanism; the at least one yarn feed mechanism feeds yarn to the needles; a needle gauge component assembly positioned below the base fabric material and having a plurality of needle gauge components that are movable along a first direction toward and away from the needles as the needles reciprocate into and out of the base fabric along a second direction; and a control system comprising a program for controlling the at least one yarn feed mechanism to control the feed of yarn to the needles in coordination with the control or actuation of one or more actuators linked to the needle gauge components to cause selected ones of the needle gauge components to retract or extend such that the throat of the selected ones of the needle gauge components moves relative to the travel of the needles into the base fabric material between a fully retracted, in-seam stitching position and a fully extended position for engaging the needles and forming tufts of yarn in the base fabric material according to a pattern being formed.

[0032] In some embodiments, the needle gauge component assembly can comprise at least one module that carries a series of needle gauge components that reciprocate in a direction that engages and disengages from the needles as the needles reciprocate into the base fabric material; wherein the at least one module comprises a module body that can be machined, cast, molded, or otherwise formed from a metal, polymer, composite or synthetic material, or combinations thereof and will have a first hardness. The module body will be suitable for mounting along a needle gauge bar and will be configured with a channel defined therethrough. An insert will be mounted to the module body on opposite sides of the channel, each insert having a series of spaced apart slots formed therein, each slot configured to slidably receive at least a portion of one of the needle gauge components therein. In embodiments, the insert can be machined, cast, molded, or otherwise formed from a metal or metal carbide or powdered metal material having a second or other hardness that is greater than the first hardness of the module body and the slots are formed or defined in the insert.

[0033] In some embodiments, the module can comprise a module body and one or more inserts.

[0034] In embodiments, each needle gauge component can comprise a body that is at least partially received within the opposing slots of the insert and is movable in other directions along the channel of the module body relative to the travel of the needle, the body of each needle gauge component having a first portion that extends 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.

[0035] In embodiments, a series of actuators are coupled to the needle spacing components for controlling movement of the needle spacing components through the module body; and a control system including programming for controlling at least one yarn feed mechanism in coordination with control of actuation of one or more of the actuators to control the feed of yarn to the needles so as to extend or retract the selected one of the needle spacing components such that the throat of the selected one of the needle spacing components moves between a seamless stitching position and an engaged position relative to the travel of the needles into the base material for selectively forming yarn tufts in the base material according to the pattern being formed.

[0036] In various embodiments of the tufting machine, the needle spacing components include a flat cut loop needle, a loop pile needle, a cut pile hook, or a cut / loop clip, and / or combinations thereof. In other embodiments of the tufting machine, the actuators can include hydraulic or pneumatic cylinders, solenoids, motors such as stepper motors, servo motors, or other motors, linear actuators, moving coil actuators or voice coil actuators, and other similar actuators, and / or combinations thereof.

[0037] In further embodiments of the tufting machine, the needle spacing component assembly can further include a series of links extending between each needle spacing component and the associated actuator, each of the links including a linkage received within and movable through a housing. In some embodiments, the housing of each link will include a body that can be formed of a polymer, composite, or synthetic material, or combinations thereof, and having a channel extending therethrough; and wherein each linkage includes a metal or composite material, or combinations thereof.

[0038] In other embodiments, the body of each housing can include a composite material including a polymer or plastic with a fiber fill material, and the body of each housing has a channel defined therein and along which the linkage is movable; and wherein the linkage of each link can include a hardened metal body or arm or series of arms extending along the channel defined through the body of the housing and having a proximal end configured to engage a first portion of one of the needle spacing components and a distal end configured to be engaged by the actuator associated with the needle spacing component for transmitting movement of the actuator to the needle spacing component.

[0039] Further, in embodiments, the inserts of the module will generally be configured to overlap the upper surface of the module body and each include a slotted opening adapted to receive a fastener therethrough for adjustably mounting each of the first and second inserts to the module body, with the inserts arranged at a selected spacing from one another and at selected positions relative to the channel defined through the module body. Additionally, the inserts can be molded or packaged, encapsulated or otherwise substantially integrated within the module body. The inserts can also include tab or flange portions that can engage opposing side surfaces of the module body; and therebetween can be provided a plate or intermediate section. The intermediate section can connect the tabs or flanges of the inserts, with the slots of the inserts at least partially formed therein and extending therealong. Alternatively, the support plates of the support can be received between the tabs or flanges of the inserts along the first and second side surfaces of the channel.

[0040] Thus, in some aspects of the present disclosure, a stitch length component assembly for a tufting machine includes at least one module having a module body with a channel defined therethrough; and a series of stitch length components received within the channel of the module body, each stitch length component including a body having a first portion and a second portion, the second portion having a throat, wherein the module carries the stitch length components along a first direction toward and away from engagement with an associated needle of the tufting machine with the throat of the stitch length component to pick up a loop of yarn from the needle, and wherein the stitch length components are selectively movable in a second direction along the channel of the module body; wherein first and second inserts are arranged along opposite sides of the channel of the module body, each insert formed of a material having a hardness that can be greater than a hardness of a metal or composite material of the module body and having a series of spaced apart slots configured to receive at least a portion of one of the stitch length components along the slots; wherein the slots of the first and second inserts are substantially aligned across the channel; and a plurality of actuators each coupled to the first portion of an associated stitch length component of the series of stitch length components and adapted to cause its associated stitch length component to move in the second direction through the channel of the at least one module, whereby the stitch length component is extended through the module body or retracted through the module body to move the throat of the stitch length component between an extended position for engaging the needle and picking up a loop of yarn from the needle and a retracted position substantially avoiding picking up a loop of yarn from the needle.

[0041] In yet other embodiments, the stitch component assembly can include first and second inserts each including a body machined, molded, or cast from a metal, carbide, or powdered metal material and including a tab or flange portion having a slot formed therein. Further, the body of each of the first and second inserts further includes an upper and lower tab or flange portion that engages an upper and lower surface of the module body, with the slot extending through the upper and lower tab or flange portions.

[0042] In some aspects of the disclosure, a method of operating a tufting machine is disclosed in which, according to one exemplary embodiment of the disclosure, stitch components will reciprocate in a first direction toward engagement with the needles as the needles of the tufting machine reciprocate into and out of the base fabric. In addition, actuators of at least selected ones of the stitch components can be selectively engaged or disengaged so as to move their respective stitch components between a fully retracted position or no-stitch position at which the stitch component will not engage the associated or corresponding needle and thus will not form a loop of yarn therefrom and a variable extended position or raised position including a fully extended position. In their raised or extended positions, the stitch components engage the needles at their take-down portions as the needles penetrate into and out of the base fabric material so as to pick up loops of yarn from the needles.

[0043] Further, in embodiments, yarn feed can also be controlled as the needles reciprocate out of the base fabric so as to generally retain by their needles and retract, withdraw, or otherwise be pulled back or out of the base fabric material with the needles, yarns that are not selected (e.g., that are not engaged or picked up by the associated stitch component of the stitch components as it is in a lowered no-stitch position). In other instances, the stitch components can be moved to a raised or elevated position prior to or upon engaging a loop of yarn and yarn feed can be controlled to retract, withdraw, or pull back some loops of yarn to an extent sufficient to prevent the yarn from showing in the finished, patterned article at that stitch location. Loops of yarn picked up from the needles can also have varying pile heights or lengths depending on the position and / or motion of the stitch component relative to its associated or corresponding needle. For example, in a fully raised position, a loop of yarn of lesser or reduced length can be formed by controlling the yarn feed of one or more such yarns for controlling the pile height thereof, e.g., for creating a lower pile height in the base fabric, or even substantially hiding the loop of yarn in the base fabric, including by controlling the yarn feed thereof to substantially remove the loops (e.g., with the stitch components retaining / reserving the loops with their needles and in a lowered no-stitch position not picking up the loops).

[0044] In embodiments, as the needles move to the lowered position, longer loops of yarn can be picked up and formed by the needles, drawing the loops of yarn as needed with the needles, in order to create higher or greater pile height yarn tufts in the base cloth. In addition, the actuators can also be controlled to selectively lower or retract their corresponding stitch member on which a loop of yarn is captured, to form longer loops of yarn, in order to achieve additional patterning effects, such as for end shearing, etc.

[0045] The needles can also typically be transversely displaced relative to the longitudinal motion of the base cloth through the tufted area, in order to present different colors or different types of yarn to each stitch location of the pattern being formed in the base material. For example, the needles of one or more needle bars can be threaded with a variety of thread sequences of desired colors. In addition, the base material can typically be run at a real or effective stitch rate that is substantially greater than the pattern stitch rate prescribed or desired for the pattern being formed. As a result, when the needles are moved, the desired number of different colors or types of yarn can be presented to each stitch location. In some embodiments, by controlling the positioning and / or motion of the stitch members, loops of yarn can be selectively formed in the base material, and the formation of such loops of yarn can be further controlled for forming varying pile heights of the resulting tufts. For example, in various aspects, as the needle bars are moved, a series of different colors or types of yarn can be presented to each stitch location, and if a tuft of a particular color or type of yarn is not selected to be sewn at that stitch location, the corresponding stitch member can be held in a retracted or lowered position, such that such unselected loops of yarn will typically not be formed.

[0046] In addition, in embodiments, the feed of the base material will be controlled. For example, in embodiments, the base feed can be controlled in conjunction with the movement of the needles, the control of the yarn feed, and the control of the positioning of the stitch members, such that the base feed can be fed at a higher operative, effective or real stitch rate, to enable the formation of a significantly increased number of presentations of yarn in the base material, to provide substantially full stitch coverage of the selected colors or types of tufts of yarn that are retained in the face of the tufted product and substantially avoid the creation, display or otherwise appearance of missing yarn colors or types or voids in the patterned tufted product in the pattern area. Thus, the completed patterned tufted product can be provided with a tuft density per inch that substantially matches the desired or prescribed pattern stitch rate, i.e., for a pattern designed with a pattern stitch rate of 8, 10 or 12 or other number of stitches per inch, the resulting finished patterned tufted product can form a density of visible and / or retained face yarn or tufts per inch that can approximately match the pattern stitch rate.

[0047] The foregoing and other advantages and aspects of embodiments of the present disclosure will become apparent and more readily appreciated from the following detailed description, taken in conjunction with the accompanying drawings, and the claims. Further, it should be understood that the foregoing summary of the present disclosure and the following detailed description are examples only and are intended to provide further explanation of the present disclosure. BRIEF DESCRIPTION OF DRAWINGS

[0048] The accompanying drawings, included to provide a further understanding of the embodiments of the present disclosure and are incorporated in and constitute a part of this specification, illustrate embodiments of the present disclosure and together with the description serve to explain the principles of the embodiments discussed herein. No attempt is made to show structural details of the present disclosure in more detail than is necessary for a fundamental understanding of the exemplary embodiments discussed in the present context, and the description taken with the drawings make apparent to those having ordinary skill in the art how the embodiments discussed herein can be embodied in practice. One skilled in the art will also recognize the design of the various features of the drawings discussed below are not necessarily to scale, and that the dimensions of the various features and elements of the drawings can be expanded or reduced for the sake of clarity of the embodiments of the present disclosure described herein.

[0049] Figure 1 is a side elevational view of an exemplary embodiment of a tufting machine having selectively controllable bent needle assemblies in accordance with the principles of the present disclosure.

[0050] Figure 2 is a side elevational view of a tufting area of a tufting machine of Figure 1

[0051] Figure 3 is a perspective view of a tufting machine of Figures 1-2

[0052] Figure 4 is an exploded perspective view of an exemplary embodiment of a needle gauge module or block and a needle gauge component moveable therethrough and a gate or connector assembly connecting the needle gauge component to an actuator in accordance with the principles of the present disclosure.

[0053] Figures 5A-5B is a perspective view of a portion of a series of needles and their corresponding needle gauge components in one exemplary embodiment in accordance with the principles of the present disclosure.

[0054] Figures 6A-6C is a side elevational view showing an embodiment of the operation of a selectively actuatable needle gauge component in accordance with the principles of the present disclosure.

[0055] Figures 7A-7D shows an embodiment of a drive system and connector assembly for controlling the movement of a needle gauge component in accordance with the principles of the present disclosure.

[0056] Figures 8A-8B is a perspective view showing an embodiment of a drive system and connector assembly for controlling Figures 7A-7D ​​side view of an example variation of an embodiment of a drive system and link assembly for controlling the motion of a stitch component.

[0057] Figures 9A-9C Another embodiment of a drive system and link assembly for controlling the motion of a stitch component is shown in accordance with the principles of the present disclosure.

[0058] Figures 10A-10B Another embodiment of a drive system and link assembly for controlling the motion of a stitch component is shown in accordance with the principles of the present disclosure.

[0059] Figures 11A-11B Another embodiment of a drive system and link assembly for controlling the motion of a stitch component is shown in accordance with the principles of the present disclosure. DETAILED DESCRIPTION

[0060] Reference is now made to the drawings wherein like reference numerals refer to like parts throughout several views, Figures 1-9B Embodiments of a tufting machine 10 and method for forming a patterned tufted article in accordance with the principles of the present disclosure are generally shown in which the placement of stitches or tufts 5 of yarn Y can be controlled at desired locations in a base material B. Such tufts or stitches can be formed to have a carved appearance of multiple pile heights and can also be placed with enhanced selectivity and / or control to form other varied or freeform pattern effects. For example, a tufted article can be formed of yarn tufts formed at varied pile heights to provide a carved appearance and multiple color patterns of various geometries and / or freeform designs formed with different colors or types of yarn. Additionally, it should be appreciated that various numbers of different types and / or colors of yarn (i.e., two colors, three colors, five colors, six colors, etc.) can be used to form patterned tufted articles of multiple pile heights in accordance with the principles of the present disclosure.

[0061] As Figure 1 As generally shown in the Figures, in one embodiment, the tufting machine 10 will include a frame 11 which can include a head or upper portion 12 which houses a needle bar drive mechanism 13 and defines a tufting area T. The needle bar drive mechanism 13 Figure 1 and Figure 2 generally includes a series of push rods 14 which can be connected to a series of Figure 1The shown needle bar drive 16 (e.g., gear box / assembly) or similar mechanism, which in turn can be connected to and driven by the main drive shaft 18 of the tufting machine, e.g., by one or more drive belts or drive chains 19, and wherein the main drive shaft 18 itself is driven by a motor, such as a servo motor. Alternatively, the push rods 14 of the needle bar drive mechanism 13 can 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 an independent drive system (not shown).

[0062] Furthermore, an encoder or similar sensor can be provided for monitoring the rotation of the main drive shaft and reporting the position of the main drive shaft to a control system 25 Figure 1 ) controlling the operation of the tufting machine 10. The control system 25 can generally include a tufting machine control device including a computer / processor or system controller 26 having an operator interface 26A (e.g., touch screen, keyboard, mouse, etc.) through which an operator can input a pattern, make adjustments, etc. In some embodiments, the control system 25 can include or incorporate a stitch assignment control system, such as those disclosed in U.S. Patent No. 8,359,989, the disclosure of which is incorporated by reference as if fully set forth herein, wherein the controller 26 also includes programs for methods of controlling the formation of tufted patterns including inlaid 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.

[0063] The control system 25 will generally include programs capable of monitoring and controlling the operation of the elements of the tufting machine 10, such as the needle bar drive mechanism 13, the yarn feed accessories 27, the base fabric feed rollers 28, the main drive shaft 18, the needle bar displacement mechanism 40 Figure 3 ) and the gauge package assembly 30 mounted beneath the tufting area T of the tufting machine, as discussed more fully below, in accordance with the computed / determined pattern instructions. The control system 25 Figure 1 ) can also receive and execute or store pattern information in the memory of the system controller 26. In response to the developed / programmed pattern instructions, the control system 25 will control the operation of the elements of the tufting machine 10 so as to form the desired tufted pattern in the base fabric material B as the base fabric material is passed through the tufting area T in the direction of arrow 33 by the base fabric feed rollers 28, as Figures 1-3 shown.

[0064] In some embodiments, the system controller 26 of the control system 25 can be programmed generally with instructions for forming one or more desired patterns for one or more tufted products, including a series of pattern 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 or by a network connection. Alternatively, the controller 26 can include image recognition software so that a scanned and / or designed pattern image (e.g., a designed pattern including pile heights and other features such as placement of loop pile and cut pile tufts in the pattern) displayed by, for example, different colors or similar indicia or indicators, as well as photographs, drawings and other images, can be input, programmed, recognized and processed by the control system, including receiving input from a design center or by various design software systems or via a scanner or other imaging device 31 Figure 1

[0065] Additionally, in embodiments such as the control system 25 operates in conjunction with or can also include or incorporate a stitch distribution control system as disclosed in U.S. Patent No. 8,359,989 (incorporated by reference as if fully set forth herein). For example, but not limited to, the control system can incorporate a program to provide the functionality of such a stitch distribution control system or can link a separate stitch distribution control to the control system. The control system can also be equipped with software / programming to enable reading and recognizing the colors of an input scanned pattern and can assign the supply locations of yarns supplied from a creel to individual ones of the needles in the needle bar based on the threading sequence of the needles of the needle bar in order to optimize the supply of various color yarns in the creel for optimal utilization to form the identified pattern areas from the pattern image. The control system can also include programming that enables it to create a pattern area or pattern map that includes a series of pattern pixels or tuft / stitch placement locations that map the identified spaces or locations at which various color yarns and / or cut / pile tufts will be selectively placed to form the imaged pattern. A desired pattern density can also be selected, i.e., a desired number of stitches per inch that will appear on the face of the patterned tufted product of the finished product can be selected and the actual effective or operable stitch length for that pattern calculated to achieve the appearance of the pattern with the desired fabric stitch length.

[0066] ​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.

[0067] like Figures 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. The 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 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.

[0068] Each of the needles will typically include a shank or body 38 that terminates at a tip 38A and includes a take-off point or area 39 at which the needle can be engaged by the gauge member 32 and pick the loop of yarn Y from the needle as Figures 5A-6A illustrated. As the needles reciprocate in the direction of arrows 37 and 37'( Figure 2 ), they carry the yarn Y in and out of the base material B along the stroke to achieve a desired or predetermined penetration depth and will be selectively engaged by the gauge member 32 of the needle gauge member assembly 30 as Figures 6A-6C illustrated to pick the loop L of yarn from the needle. In addition, as Figure 3 illustrated, a displacement mechanism 40 can also be linked to the needle bar 35 (or needle bars) for displacing the needle bar laterally across the tufted area in the direction of arrows 41 and 41' according to a calculated or computer calculated pattern instruction. The displacement mechanism 40 can include a Smart Step TM type displacement device manufactured by Card-Monroe Corporation, or alternatively can include various other types of displacement mechanisms including displacement devices controlled by servo motors or hydraulic controls and / or conventional pattern cam displacement devices. Other displacement mechanisms including base material or hessian moving devices can also be used, either alone or in combination with the needle bar displacement devices, for laterally displacing the base material relative to the needles.

[0069] As further illustrated in Figure 1 , one or more yarn feed mechanisms or accessories 27 can be mounted to the frame 11 of the tufting machine 10 for controlling the feed of the yarn Y to each of the needles 36 during the operation of the tufting machine. For example, as Figure 3 illustrated, a series of different types or colors of yarn (Y1-Y4) can be fed to each of the needles in a selected threading sequence or series (e.g., ABCD), where the threading sequence is typically determined or selected based on the pattern being run. In addition, while one yarn feed unit 27 is shown along one side of the tufting machine 10 (for purposes of illustration), in other embodiments, multiple yarn feed units can 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.

[0070] There are a variety of yarn feed accessories that can be used with the stitch assignment control system of the present disclosure for controlling the feed of different yarns Y to individual ones of the needles 36. The pattern yarn feed accessories or mechanisms 27( Figure 1) can include a conventional yarn feed / drive mechanism, such as a roller or spool form attachment having a series of rollers extending at least partially along the tufting machine and driven by a motor under the direction of the control system 25 for controlling the feed of the yarns over the tufting machine to form pattern repeats and / or multiple pile heights and / or other texturing effects over the entire width of the base material. Such a yarn feed mechanism or attachment can include the Quick Thread TM , Enhanced Graphics TM and / or multiple pile height spool type yarn feed control devices / attachments manufactured by Card-Monroe Corporation.

[0071] In some embodiments, a pattern yarn feed attachment can be used having a plurality of yarn feed drives 45, as shown in Figure 1 each including a motor 46 and feed roller 47 for controlling the repeat feed of yarns to selected groups of needles, which includes the use of individual yarn feed rollers or drives 45 for controlling the feed of a single yarn (or end) or ends of multiple yarns (i.e., 2-4 or more yarns) to the needles 36, such as single end and multiple end attachments / servo spool attachments including the Infinity TM and Infinity IIE TM systems manufactured by Card-Monroe Corporation. Thus, while yarn feed of the yarn feed mechanism 27, such as a single end or multiple end type, is shown in Figure 1 , those skilled in the art will also appreciate that the pattern yarn feed mechanism for controlling the feed of the yarns can include single end or double end yarn feed controls, spools, rollers, and / or similar attachments, and / or various combinations thereof, and can also be mounted along one or both sides of the tufting machine. Still further, in embodiments, the control system 25 can include programming to implement yarn feed compensation and / or yarn feed modeling to help control and reduce or minimize the amount of non-reserve / non-appearing yarn to be fed to avoid overfeeding of the yarns and thus minimize waste during the tufting operation.

[0072] The yarn feed attachments can be controlled to selectively feed yarns to their respective needles in cooperation with other operating systems of the tufting machine, including the base fabric feed, the movement of the needle bar, and the operation of the stitch length component assembly 30, to enable control over the presentation of multiple different colors or types of yarns into the base fabric and the selective picking and holding of selected or desired ones of the presented yarn loops (e.g., the ones selected to appear in the face of the finished patterned article) for forming tufts of such yarns having selected or desired pile heights. In addition, the surface or face yarns or surface or face tufts to be shown on the face of the tufted article can be controlled to be fed in an amount sufficient to form tufts of the selected color or type of yarn at the desired or prescribed pile height conditions, while the un-presented yarns to be hidden in the particular color and / or texture areas of the pattern can not be picked by the stitch length components to avoid such yarns from interfering with the face yarns or retained tufts that are to be visible in the pattern areas, and to avoid creating unwanted spaces or voids between the retained tufts or face yarns.

[0073] In an embodiment, each color or type of yarn that can be placed / tufted at each pixel or stitch location can generally be presented to such pixel or stitch location for tufting, with only the one or more yarns selected to be displayed or shown at the pixel or stitch location being retained and formed at the desired pile height. Thus, for a 4-color pattern, each of the 4-color yarns A, B, C, and D that can be tufted at a particular pixel or location can be presented to such pixel with only the selected yarn or yarns of the pattern, e.g., the “A” yarn being retained, while the remaining unselected yarns B, B-C, B-D, and / or other combinations can be presented and not picked by the stitch length components at the lowered in-seam position so as to generally avoid forming loops of such yarns at these pixel or stitch locations, while thus controlling the yarn feed to withdraw these yarns with their needles. In some cases, if the loops of yarns are picked, they can be further pulled back to an extent sufficient to sew or hold the yarns with the base fabric, but not interfere with the retention of the selected yarn as the pixel or stitch location. Thus, when a yarn is presented to a pixel or stitch location, if the yarn is to be retained or shown at the pixel or stitch location, the yarn feed device 27 can be controlled to feed an amount of the yarn so as to form a tuft of the yarn at the pixel or stitch location. If no yarn is selected for insertion at a particular pixel or stitch location, the stitch length components can be controlled to move to the in-seam position where they will not pick loops of the yarns presented to the particular pixel.

[0074] As Figures 1-3As further shown, the stitch component assembly 30 is generally mounted beneath the bed 34 of the tufting machine 10 and below the tufting area T. As the needles penetrate the base material, they are engaged by a series of stitch component 32 of the stitch component assembly 30 to form loops L of the yarn Y Figures 2-3 ) for forming tufts 5 of a selected color or type of yarn and having a selected length or pile height. In various embodiments, the stitch component 32 of the stitch component assembly 30 can include a series of bent needles or hooks 50, each of which can be slidably mounted within a stitch module, stitch block or other carrier that can be mounted along a stitch bar 52 or similar chassis or attachment for coupling the stitch components to a drive mechanism, such as a pivot arm 53, that can be driven off the main draft shaft of the tufting machine or can be driven by a separate motor / drive for reciprocating movement in the first direction toward and away from the needle 36 as indicated by arrows 54 and 54' in Figures 1-3 It will also be understood by those skilled in the art that various types of stitch components can be used, including cut-pile hooks, loop-pile bent needles, flat-cut loop bent needles, cut / loop clips or other stitch components.

[0075] As further shown in Figure 4 one embodiment, the stitch component 32 can include a bent needle or hook 50 having an elongated body 55 that can be slidably mounted within and movable through its stitch module 51. The body 55 of each bent needle or hook 50 will include a first portion 60, a second portion 61 including an elongated throat 62 that in one embodiment as shown in Figure 4 may generally extend at an angle relative to the intermediate portion 56 of the body 55 and can terminate in a generally pointed proximal end or beak 63. For example, the throat 62 and proximal end 63 can be configured similar to a loop-pile bent needle. Other configurations of stitch components can also be used. As further shown in Figure 4 The first portion 60 of the body of each bent needle or hook 50 will generally protrude through the stitch module or block 51 and can have a slot or recess 64 formed therein through which the bent needle or hook can be engaged and / or coupled to a drive system 65 for individually or in sets or groups controlling the selective movement of one or more of the stitch components. In embodiments, the drive system 65 / 150 will include an actuator 66 Figure 2 each of which will be connected or coupled to a corresponding or associated one of the stitch components by a gate or connector 67 Figure 4 of the connector assembly 70.

[0076] Figure 4One exemplary embodiment of a gauge module or gauge block 51 is shown, which includes a body 75 that can have a substantially rectangular or square configuration as shown, although other configurations can be used, and a series or set of gauge components 32 (e.g., bent needles or hooks 50) are received in the configuration. In some embodiments, the module body 75 of each gauge module 51 will be formed from a metal or metal alloy material, although various composite, synthetic and / or other materials can be used. For example, but not by way of limitation, the body of the gauge module can be made from a lightweight steel, such as a low carbon steel or tool steel, or aluminum, or other similar lightweight but substantially rigid and durable material. In embodiments, the module body can be machined, molded or cast or otherwise formed. The material forming the body of the gauge module can also be selected to reduce the weight of the gauge module, while at the same time still providing sufficient durability and rigidity to maintain and / or substantially retain the alignment or position of the gauge components for engaging the withdrawn portions of the needles during reciprocation of the gauge components into and out of engagement with the needles during operation of the tufting machine.

[0077] As Figure 4 Generally, the module body 75 of each gauge module 51 will include a first, front or forward section 76 and a second, rear or back section 77. The rear section 77 of the body 75 of each gauge module 51 will also generally be configured to engage the gauge bar and be mounted to the gauge bar, as Figure 3 shown. For example, the rear section of the body can include a tab or other positioning device 77A for aligning the gauge module along the gauge bar and further will include at least one fastener opening 78. A removable fastener, such as a sleeve, hex screw or other similar removable fastener or attachment device, will be inserted through the fastener opening 78 and into a corresponding opening in the gauge bar for releasably mounting the gauge module 51 to the gauge bar. As a result, in some embodiments, the gauge module and the gauge components contained therein can be removed and replaced as a unit, without having to necessarily replace individual gauge components; for example, to expedite replacement of broken or damaged gauge components, or to change the gauge spacing or arrangement of the gauge components of the tufting machine.

[0078] For example, but not by way of limitation, as Figure 4 shown, a fastener 79A, such as a bolt, or other similar removable fastener, can be received within a sleeve or guide member 79B that can extend through the needle bar or block or other component mounted to the needle bar and that can also include a projection that extends through an upper portion of the body 75 of the gauge module 51. The fastener can include a threaded body that engages the body of the module to secure the body of the module to the needle bar, while at the same time allowing the gauge module to be removed and replaced as needed.

[0079] AsFigure 4 Further shown, a channel 80 will generally be formed through the body 75 of each needle spacing module 51, wherein the channel 80 is located generally along the middle portion 81 of the body between the first section 76 and the second section 77 thereof. The channel 80 is sized and / or configured to receive a plurality of needle spacing components therein, such as the curved needles or hooks 50. In embodiments, the body 55 of each of the curved needles or hooks 50 will generally be received within the channel 80 and extend through the channel 80, wherein the first portion 60 of each of the curved needles or hooks generally projects downwardly past the lower or bottom surface 82 of the module body 75, while the second portion 61 of each curved needle or hook can extend / project upwardly from and above the upper or top surface 83 of the module body 75.

[0080] Additionally, one or more inserts 85 can be mounted to the opposing side surfaces (e.g., upper and lower surfaces) of each module body at locations or positions along the channel 80 defined through the entire body of each needle spacing module, such as shown generally at Figure 4 The inserts will be configured to engage and guide the needle spacing components as they move through and along the channel of the needle spacing module body. For example, in some embodiments, such as shown at Figure 4 one of the inserts (e.g., the first insert 85A) is mounted along the first, left or front side 80A of the channel 80, while the other insert (e.g., the second insert 85B) is mounted along the second, right or back side 80B of the channel 80, and wherein each of the inserts 85A and 85B are generally arranged in a substantially facing, opposing, parallel relationship with the needle spacing components 32 engaged between and movable between the inserts. Also, in some embodiments, a pair of first inserts can be mounted 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 mounted along the top and bottom surfaces of the module body along the second or right side of the channel.

[0081] Each of the inserts 85 is generally formed of a hardened metal or metal alloy material, a metal carbide, a ceramic, and / or a powdered metal material including a metal powder including tungsten, titanium, or other material having a hardness that can be greater than the hardness of the material of the needle module body. For example, in some embodiments, the inserts can be formed of a metal carbide material having a hardness of about 74+ RC or greater, while the module body can be formed of a low carbon steel. In other embodiments, the inserts can be formed of a ceramic, a powdered metal material including tungsten, titanium or similar hard metal composition, a metal carbide, or other material having a hardness between about 74+ RC to about 85+ RC or greater.

[0082] Each of the inserts 85 can also include an insert body 86 having a tab or flange portion 87 extending forward or rearward from the channel of the needle module body, which generally seats on and engages the upper and lower surfaces 83, 82 of the module body. Each of the inserts 85 will also include at least one opening or slot 89 formed along the tab or flange portion thereof, and through which a fastener such as a set screw 90 or other similar removable fastener can be received. The slots or openings 89 formed in the tab or flange portion of the insert can generally align with corresponding slots or locator openings 91 formed along the upper and / or lower surfaces 83, 82 of the module body to help position and mount each insert to the body of its module and along the channel of its needle module. The inserts can be displaced laterally across the module body and substantially parallel to the channel 80, and can also be adjusted toward and away from each other across the channel of the needle module body, after which a fastener can be inserted therein and tightened to secure the insert 85 to the body of its module. Additional locator guide pins 92 can also be received in the slots or locator openings formed along the flange or tab portion 87 of each of the inserts to additionally help position the inserts along and across the channel of the module body as desired.

[0083] In further embodiments, the inserts 85 can be substantially integrated with their modules. The inserts can be bonded, molded, encapsulated, and / or otherwise secured to the body of their modules, with the inserts being substantially integrated with the module body so as to form a substantially unitary construction of the module body, and with the inserts forming or defining a portion of their channels. For example, in some cases, the inserts can be located or received within the channels of the module body and substantially permanently mounted thereto, while in other embodiments, the inserts can be machined, molded, or cast as part of the module body itself, defining the channels and slots for the looper or hook, and the inserts can be coated or treated with a hard metal coating, such as carbide or other substantially wear resistant coating. In such cases, the looper spacing components can be provided in groups with their looper spacing modules and replaced as a group by removing and replacing the looper spacing module and looper spacing components as a unit. In other embodiments, the inserts can be substantially joined or locked to their modules, with limited ability to remove or dislodge one or more of the inserts as needed for serviceability.

[0084] As further shown Figure 4 , the inserts will also generally include a series of slots or slits 95 arranged in series along the body 86 of each insert, spaced apart along the rear portion 88 thereof. Each of the slots 95 will generally be sized or configured to receive a looper spacing component 32, such as a hook or looper 50, therein, as shown Figure 4 . The slots 95 of the inserts will also generally be arranged at a selected spacing, such as the looper spacing pitch of the looper spacing components, and with each slot 95 of the first insert 85A generally aligned with a corresponding or associated one of the slots 95 of the second insert 85B. The aligned, corresponding, or associated slots of each insert will receive at least a portion of the body of each of the looper spacing components therein, such as the portion of the front edge 55A and the rear edge 55B of the body 55 of each looper or hook 50; and with the inserts defining a reduced or minimized area or profile contact region 98 between the looper spacing module and the looper or hook.

[0085] In some embodiments, the end 96 of the slot 95 can also be formed with a structure that substantially defines a seat or bearing surface on which the first and second edges of each of the looper or hook received in each slot can seat and be able to bear against for mounting the looper or hook within the insert and thereafter securing the insert to each needle spacing module with the looper or hook received therein. As the looper or hook extends or retracts or otherwise moves through the channel of its needle spacing module, the slot of the insert will guide the looper or hook and will help maintain the alignment of the looper or hook and thus the alignment of its throat and beak relative to the needle as the needle reciprocates in and out of the base material and is engaged by the looper or hook.

[0086] In embodiments, each insert can 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 can also be formed as a tab or flange extending forward or rearward from the middle section and channel of the needle spacing module body that generally covers and engages the upper and lower surfaces 83, 82 of the module body to help position and secure each insert within the channel of its needle spacing module. Thus, the first and second inserts 85A, 85B can have a substantially unitary construction including upper and lower portions and slots of the first and second inserts extending through their upper and lower sections and along the middle body section to enable further engagement and guidance of at least a portion of the first and second edges of the looper or hook. In embodiments, the inserts can be machined, molded or cast so as to have a substantially unitary body which can reduce parts, thereby reducing the need for separate inserts on the upper and lower surfaces of the module body and along the opposite sides of its channel while increasing the contact points / areas between the insert and the looper or hook for enhanced consistency and / or control of motion.

[0087] Alternatively, the first body segment, second body segment, and intermediate body segment of each insert can be formed as separate components and installed together along the channel of the module body. For example, in some embodiments, an intermediate guide or support plate can also be used to help guide the motion of the bent needles or hooks, with the guide or support plate extending along the 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 leading and trailing edges of the bent needles or hooks can travel / slide as they move along the channel of the module body. The guide or support plate can also act as a connecting member or segment between the plurality of inserts, or between each pair or set of inserts. Such a guide or support plate can be formed of a similar high hardness material (e.g., a metal or carbide, a powdered metal or other high hardness material, or a material that has been hardened or coated or bonded with a material having increased wear resistance or can include a sacrificial material) to provide a hardened surface against which one or both of the edges of the bent needles or hooks can slide; or, in some cases, can act as an easily replaceable sacrificial plate and protect the module body along the sides of the channel.

[0088] During operation of a tufting machine such as disclosed in embodiments of the present disclosure, the bent needles, hooks, or other stitch length components move in multiple directions, including reciprocating or moving along a first direction in and out of engagement with the needles, while also moving along a second direction through their stitch length modules or blocks, for example between a raised or extended position in which the needles are engaged and a lowered position, including to a position of seamless stitching. In some operations, the stitch length components can also be moved after a loop of yarn has been picked from the needle in order to form an elongated or longer loop. Thus, the tufting machine enables the formation of highly detailed tufted patterns that can include varying pile heights as well as other inlay and multi-color pattern effects. However, this repeated cyclical motion of the stitch length components can cause significant rapid wear of the stitch length components and particularly their stitch length modules as the bent needles, hooks, or other stitch length components slide and their edges frictionally engage the body of their modules. As these components wear, their ability to engage the needles and form loops of yarn in order to create tufted patterns with sufficiently high precision can be diminished. For example, the stitch length components can become misaligned, and / or can not properly or with the desired level of precision engage the needles, requiring more frequent replacement of the stitch length components / stitch length modules.

[0089] By using a metal (e.g., a high hardness heat treated steel), a metal carbide, a ceramic, and / or other high hardness metallic material (including a powder metal containing tungsten, titanium, or other similar high hardness material, which provides the insert with a hardness of at least 75+ RC or greater) and by the configuration of the insert defining a contact area 98 between the needle bend or hook and the needle spacing module having a minimized area or profile, the wear life of the needle spacing module and the needle bend or hook is significantly increased. The high hardness of the insert protects the needle spacing module from direct contact and rapid wear by the needle bend or hook as it cycles therethrough, while the reduced size of the contact area 98 defined by the insert is configured to reduce the frictional engagement of the insert with the needle bend or hook while substantially continuously guiding and maintaining the alignment of the needle bend or hook during such movement. The needle bend or hook is also typically pre-hardened or heat treated so as to harden the needle bend or hook body; and in some embodiments, the surface of the needle bend or hook body can be coated, treated or bonded with a friction reducing material to help reduce the friction between the edges 55A / 55B of the needle bend or hook body as it engages along the slot of the insert and slides, and thus help increase its wear life. Other coatings that can be applied can include materials with enhanced wear resistance to help protect the needle bend or hook from wear during use. For example, in some applications, the wear life of the needle bend or hook has been found to exceed 50 to 100 million machine operating cycles, and in some embodiments between at least about 100 to 500 million cycles or more.

[0090] The increased hardness of the insert protects the needle spacing module and enables it to be formed from a significantly lighter weight and lower hardness material (e.g., low carbon steel, aluminum or alloys thereof). For example, instead of requiring the needle spacing module to be formed from a fairly high hardness material (e.g., tungsten) and / or be sufficiently heat treated to attempt to significantly increase its hardness, the needle spacing module can be machined, molded or cast or otherwise formed from a lightweight metal, composite material or other similar material that can have a hardness that is significantly lower than that of the insert (e.g., the body of the needle spacing module can be made from a low carbon steel or aluminum alloy having a hardness of less than about 60 RC), which helps reduce the weight and cost of the overall needle spacing component assembly while at the same time not reducing operating cycle performance. Such reduction in the weight of the needle spacing module or block can also enhance the control of the movement of the needle bend through its needle spacing module and the reciprocating movement of the needle bend or hook toward and away from the needle, e.g., by reducing the inertia that can need to be overcome during the reciprocating movement of the needle bend or hook toward and away from the needle.

[0091] In one embodiment, as Figure 2 and Figures 6A-6CAs shown generally, the actuator may include a hydraulic cylinder, an electric cylinder, or a pneumatic cylinder 68, and in some embodiments may also include, for example, a servo motor, a stepper motor, a linear actuator, a voice coil actuator, or a moving coil actuator, a solenoid, or may include other types of actuators, and / or combinations thereof. Each of the actuators may include a cylinder rod or drive shaft 69, which is typically connected to an associated or corresponding bend or hook in the bend or hook via a connector or door 67. In some embodiments, the actuator may also be used to control the operation of more than one bend or hook 50. Furthermore, as those skilled in the art will understand, other types of actuators may also be used, including solenoids, motors, or other similar actuation mechanisms.

[0092] Each of the actuators will typically be connected to a control system 25, which will selectively control the actuation of its actuators to control the initiation and / or movement of each of the loopers relative to the needle. The actuators will be 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 reciprocating motion of the looper or hook 50 in the direction of arrows 54 / 54'. For example, in an embodiment, when the looper or hook reciprocates in the direction of arrows 54 and 54' toward and away from the needle 36, the looper or hook will move relative to the needle in a substantially vertical (i.e., substantially up-and-down) manner, such as... Figure 2 , 5A Arrows 71 and 71' in -5B and 6A-6C indicate this. The actuator can be controlled so that the looper or hook not only extends and retracts between extended and / or seamless positions, but can also be selectively controlled to extend and / or retract to a series of varying positions or heights relative to the needle's penetration stroke or depth. Therefore, the position or location of the looper or hook's throat relative to the needle can be controlled and changed to cause the selected needle in the needle to pick up and / or form a loop of yarn at varying pile heights or lengths, or not pick up yarn, as... Figures 6A-6C As shown in the figure.

[0093] 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 thus engaged, the loops typically being formed with a first selected or desired pile height, while other loopers or hooks can extend or retract to a position or portion 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, actuators of the loopers or hooks can be used to move some of them to a fully lowered or retracted position to place them in a seamless position, whereby 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 their respective loopers or hooks after yarn loops have been captured thereon, to pull down these captured yarn loops to lengthen or create higher pile or longer yarn lengths for additional patterning effects, such as end cuts and / or other texture effects.

[0094] like Figures 5A-5B As shown, each of the stitch length components 32 (e.g., loopers or hooks 50) can be arranged in sets or groups, each set or 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 a specified interval (e.g., stitch length spacing, such as 1 / 10, 1 / 8, 5 / 16, etc.). The stitch length components 32 will be positioned to engage needles, which includes the needle configuration depending on one or more needle bars (e.g., if the needles are arranged in a straight, staggered, and / or other arrangement scheme along a single or double needle bar) as needed in a substantially 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 extend / retract 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 needle spacing and / or arrangement.

[0095] 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 relative to the needle's travel by a certain angle / offset (e.g., Figure 5Band / or movement (as indicated by the angle Θ in FIG. 6) can be between about 1° to about 10° or greater, and in one exemplary embodiment, the bent needles or hooks are angled at about 4° to 6° relative to the path or direction of reciprocation of the needles when the needles complete their stroke or reciprocation into and out of the base cloth; while in other embodiments, there can be substantially no bias between the bent needles or hooks and the needles, i.e., the bent needles or hooks are angled at about 0° relative to the needles. Thus, when the bent needles or hooks are extended to a position / height sufficient to engage the take-down regions 39( Figures 5A-6A ) of the needles, their throats / beaks will generally be properly aligned or positioned to engage their corresponding needles and pick up loops of yarn from their corresponding needles. When the bent needles or hooks are retracted, they can generally be further moved along the biased travel path so that their throats / beaks can be placed or positioned at a location outside of the travel path of the needles to minimize the possibility of accidentally picking up yarn when the bent needles or hooks are moved to and / or in the retracted, seamless stitching position.

[0096] Figure 4 Further shown are non-limiting embodiments of gates or links 67 that can be used with needle pitch members (e.g., bent needles or hooks 50( Figure 4 ) to join the needle pitch members to their associated actuators 68 / 151( Figures 2-4 and 7A-11B). However, those skilled in the art will appreciate that the links or gates shown in any of the embodiments discussed herein are not limited to use with a particular tufting type machine or with a particular type of needle pitch member, and can be used with a variety of different types of needle pitch members, including, for example, Figures 2-6C and Figures 7A-11B as shown in FIGS. 1-3 and 6-7, as well as prepped for use with various other types of needle pitch members (e.g., flat cut loop tufting bent needles or hooks and / or other arrangements of needle pitch members).

[0097] Generally as Figure 4As shown, the links or gates 67 will generally each include a housing or support structure 101 within which the link arm 102 can be substantially contained, enclosed or received. The housing 101 of each link or gate can generally include a first or proximal portion 103, an intermediate portion 104, and a second or distal portion 106. In addition, each link body will also include a channel or channel 107 defined therethrough, and along which the link arm 102 will be received and can be moved. The housing 101 of each link 67 can generally be formed of a lightweight, durable material, such as a composite material, a plastic or synthetic material, or a combination thereof. For example, a composite or polymeric material (e.g., nylon, polyamide nylon, or other similar polymeric material) can be used and can be mixed or provided with or otherwise include a fiber fill material (e.g., carbon fiber, glass fiber, or other support fiber that can additionally provide reinforcement to the housing body material). The material of the housing can also be adapted or selected so as to not only provide a reduced weight, such as to help reduce inertia during start / stop and movement (e.g., the stitch length component elongates and / or retracts through its associated actuator), but also to provide a resilient and shock absorbing or damping or cushioning effect during such movement and start / stop operation.

[0098] In some embodiments, the housing 101 of each of the links can be overmolded on its link arm 102, or can be formed in segments and applied around the link arm such that its link arm is substantially enclosed or contained in the housing. The link arm 102 can also be made of a metal, such as steel, or other similar high strength material selected to provide a high strength and rigidity sufficient to enable each link arm to withstand repeated impacts and increased cycles of movement during operation of the tufting machine. For example, and without limitation, the link arm 102 can include a hardened steel material, and in some cases can be further heat treated or annealed, such as at its ends, at areas of contact and / or engagement with the beaters or hooks, and between each link arm and the drive shaft or rod 69 of its associated actuator or actuators 68, as shown. Figure 4 In embodiments, a bushing or sleeve can also be provided at the area of contact or engagement and connection between the drive shaft or rod of each actuator and its associated gate or link arm.

[0099] In some embodiments, the link arm 102 can also include a skeletalized metal body configured to enable a reduction in its weight. In such embodiments, the housing 101 of each link or door can provide further support and rigidity to the link arm 102, thereby helping to guide and maintain its consistent reciprocating motion or movement during operation. As a result, the link or door 67 can provide a more economical link or door design, enabling a linkage or link arm having a skeletalized or reduced profile and lighter weight to be used with the additional support and impact resilience and damping effects provided by the housing 101 of each link or door, which is applied to and / or encloses or encapsulates the linkage or link arm.

[0100] In various embodiments, each of the links or doors 67 can be formed to have different sizes and configurations. For example, the intermediate section of each link housing can have a shorter or longer span according to the gauge, distance, length of travel, or length of the link arm, and thus can be varied for different tufting machines and / or tufting applications. By way of example only, in embodiments, the links or doors can include varying configurations for use with different gauge tufting machines, such as 1 / 8 gauge or 1 / 10 gauge machines, although it should be understood that other gauges (5 / 16, 1 / 16, 1 / 12, 1 / 14, etc.) and / or types of machines can also be used. The intermediate section of the housing of each link can also be oriented at an angle, in some cases oriented at an angle extending downward, while in other cases can be oriented at an angle extending upward, with adjacent links being oriented or configured at opposite angles to minimize the space or footprint occupied thereby.

[0101] The link arm 102 of each link or door 67 can also be formed to different lengths as needed or desired. Each linkage will generally have a first or proximal end 110 that can be adapted or configured to engage or connect to one or more actuator shafts or drive bars of the associated one or more actuators, with a generally angled body section or portion 111 extending through the housing of the link along the channel or trough 107 of the housing and terminating at a distal flanged or hooked end 112. The body portion 111 of each linkage will be further positioned and / or aligned within the channel of its housing and enclosed therein to help provide stability and / or help guide the motion of the linkage along the trough of its link housing.

[0102] For example, in some cases, during the process of forming a housing around or over its linkage mechanism, a pin or other insert can be used to align the linkage mechanism and support it in place, after which the pin can be removed. Alternatively, some guide pins can be provided to help maintain and guide the movement along one or more portions of the connector arm, which includes or acts as a bearing. Still further, in some other embodiments, a slot can also be provided along the body of each housing, through which a guide pin can be received to help guide the movement of the linkage mechanism and can further help provide further impact resilience.

[0103] In further embodiments, guide pins or fasteners can be inserted through the housing and along a slot or rail or similar device for helping to guide and control or maintain the movement of the linkage mechanism along its channel or groove of the connector housing without twisting or turning or otherwise becoming misaligned. In yet other embodiments, a pivot pin can be provided around which the connector arm can move or pivot rather than in a substantially linear manner.

[0104] As Figure 4 Further shown, the distal hooked end 112 of each of the connector arms 102 can be supported along at least one side thereof by the second or distal portion 106 of its connector housing 101, which can assist in guiding and supporting the hooked end during the sliding movement of the linkage mechanism. The hooked end of the connector arm will engage a corresponding hooked portion, recess or slot of the corresponding needle spacing component; for example, in embodiments, the slot or recess 64 formed in the first portion 60 or distal end of the corresponding or associated one of the curved needles or hooks 50. In other embodiments, the hooked end of the linkage mechanism can engage a clamp for a flat fell curved needle, a flat fell looped pile curved needle or other movable needle spacing component. As each actuator is selectively activated / deactivated, the movement of its actuator shaft or drive rod will be transferred to the associated one of the needle spacing components via its corresponding connector or gate connector arm. Thus, the connector or gate can provide an economical, rigid and high strength connection between each of the actuators and its associated needle spacing component, where the needle spacing component can be removed or replaced as needed without having to replace the actuator associated therewith.

[0105] Figures 7A-11B Further shown is a non-limiting embodiment of a drive system 150 for controlling the movement of the needle spacing component 32 (e.g., curved needle or hook 50, or other type of needle spacing component) in a second direction relative to the path or travel of the needle as the needle reciprocates into and out of the base material. In Figures 1-6C In the exemplary embodiment, an actuator such as an electric cylinder, pneumatic cylinder or hydraulic cylinder is shown in its entirety, but those skilled in the art will appreciate that other types of actuators can also be used. For example, inFigures 7A-11B In the drive system 150 shown, the actuator 151 is shown as including a motor 152, such as a stepper motor, torque motor or other type of motor, although other types of actuators may also be used, such as moving coil actuators or voice coil actuators, electric cylinders, linear actuators, solenoids, and / or combinations thereof.

[0106] Furthermore, as discussed above, the control system 25 of the tufting machine ( Figure 7A and Figure 9A The system will also include a program for controlling actuator 151, for controlling the movement of needle spacing components 32 (e.g., looper or hook 50) along their secondary directions, for example, causing the needle spacing components to move in a generally vertical direction as indicated by arrows 71 and 71', to control the movement of the needle spacing components between extended and retracted positions, including retracting the needle spacing components to a fully lowered, seamless position; and for controlling the variable position or height of the throat / beak of the needle spacing components. Using actuators such as motors, electric cylinders, linear actuators, etc., that are not driven by compressed gas or fluid can substantially minimize or avoid the need for compressors typically required to drive other types of driven actuators, and also makes it possible to program and control the movement of the needle spacing components between different positions or heights with greater precision. Therefore, with the control of such actuators, the needle spacing components can be moved relative to the needle in smaller increments between multiple positions or heights. For example, but not limited to, the stitch length component can move in increments relative to the needle, the increments ranging from approximately 1 / 32 inch to approximately 1 / 16 inch to approximately 1 / 4 inch to approximately 3 / 4 inch, to position the stitch length component in varying locations to create yarn bundles with varying pile heights. For example, the stitch length component can move vertically or in directions other than the reciprocating motion direction of the stitch length component toward and away from the needle to lowered or differential positions of approximately 1 / 16 inch, approximately 1 / 8 inch, approximately 1 / 4 inch, 1 / 2 inch, 5 / 8 inch, and / or to a fully lowered position where no yarn loops are picked up.

[0107] The control system 25 will also include a program that enables control of one or more yarn feed attachments 27 in conjunction with or in association with the position of the looper or hook. For example, in applications such as using single-ended or double / multi-ended yarn feed mechanisms (e.g., the Infinity from Card-Monroe), TMIn embodiments of the yarn feeding device), the motor 46 of each yarn feed drive 45 can be controlled in coordination with the control exercised by the actuator 151 that controls the positioning of the looper or hook, so as to minimize or prevent significant variations in yarn tension in the yarns captured by such loopers or hooks across the width of the pattern. In some embodiments, the control system can control the motor to control the motion of the looper or hook relative to the needle 36 in its second direction, which can depend on a multiple or percentage of the amount of yarn being fed by the yarn feed mechanism; for example, if the yarn feed motor selected is controlled by the control system to feed about 1 / 2 inch of yarn to the needle selected, the actuator of the looper or hook corresponding to engaging such selected needle can move about 1 / 4 inch. In other embodiments or examples, if the yarn feed motor feeds 1 / 4 inch of yarn, the corresponding looper or hook can move about 1 / 8 inch. Other multiples or variations of the motion of the looper or hook in combination with or related to the feed of yarn to the selected needle can also be used as desired to substantially maintain yarn tension and substantially minimize or prevent variations thereof across the pattern width of the tufted pattern being formed.

[0108] In Figure 7A and Figures 7C-7D embodiments, the actuators 151 of the drive system 150 are shown as including a series of motors 152 arranged beneath the drive arms or mechanisms 53 Figure 7A ) that carry the needle spacing components 32 (e.g., loopers or hooks 50 (or other needle spacing components)) in reciprocating motion toward and away from engagement with the needles in first directions shown by arrows 54 and 54’ as the needles 36 reciprocate into and out of the base material. The motors 152 can include servo motors or stepper motors or other programmable motors (as well as programmable drive mechanisms or actuators including electric cylinders, linear actuators, or moving coil or voice coil actuators, which can eliminate or reduce the need for a compressor to supply fluid for driving needle spacing component motion); and will be coupled through a connector assembly 153 to corresponding or associated ones of the loopers or hooks 50.

[0109] As Figures 7B-7CAs shown, each of the link assemblies 153 will include a gate or link 154 that can be connected to or will receive the lower or distal end 64 of the needle spacing component. Each gate or link 154 will also be connected to one or more of the motors 152 via a linkage 156 (e.g., a cable, rod, wire, band, or other similar linkage). In some embodiments, a pair of linkages 156 can be connected to each gate or link 154. However, those skilled in the art will appreciate that a single linkage or multiple linkages can be used to connect each of the needle spacing components to an associated or corresponding one of the motors 152.

[0110] As Figures 7B-7D Further shown, in embodiments, the linkages 156 can extend through one or more guides 157 and through a spring plate or support 158. A biasing member 159 can be mounted between the distal end of the link and the spring plate 158. The biasing member can include a spring, such as a compression spring, wave spring, or other similar biasing member (including a gas cylinder); and will be positioned such that when the linkage for a selected needle spacing component is retracted, its corresponding needle spacing component is pulled toward or lowered toward the retracted position, and the biasing member will be compressed. When the tension in the linkage is released (e.g., by reverse operation of the motor to which it is connected, or otherwise disengaging the linkage from driven engagement with its motor), the biasing member will exert a biasing force against the gate or needle spacing component such that when the biasing member is decompressed, it will urge the needle spacing component in its second direction, e.g., such that the needle spacing component moves toward the extended position or raised height.

[0111] The motors 152 can also be controlled by the system controller to maintain a desired tension in the linkages, which can require offsetting the biasing force exerted by the biasing members as well as controlling the motion and / or positioning of the needle spacing components relative to the needles. Still further, the motors can be controlled by the control system in conjunction with the control of the yarn feed to additionally cause the needle spacing components having loops of yarn captured thereon to move between the raised and lowered positions in order to further enable the pile height of the yarn tufts formed thereby to be varied. Additionally, the biasing force exerted by the biasing members can be used to help control the motion of the needle spacing components in their second direction, e.g., can help control the motion of the needle spacing components between the lowered and raised positions caused by the motors 152.

[0112] In some embodiments, the linkages can include a substantially rigid rod, wire, arm, or other similar connecting member, and the motors can be controlled to move the linkages in opposite directions in order to control the motion of the needle spacing components along a path in a second direction as the needle spacing components are reciprocated toward and away from the needles in a first direction. In this embodiment, a biasing member can or can not be used.

[0113] Figure 8A and Figure 8B It shows Figures 7A-7D A variation of the drive system 150 shown. In Figures 8A-8B In this embodiment, the stitch spacing component 32 is shown as including a flat-cut looper 161, which includes a looper or hook body 162 having an extendable clamp 163. In this embodiment, each flat-cut looper 161 can be mounted within a module or stitch spacing block 164 mounted along an arm or drive mechanism 53, which causes the flat-cut looper to reciprocate toward and away from the needle in a first direction of motion. Each of the clamps 163 of each flat-cut looper 161 will typically include an extended body 166 having a first end or proximal end 163A and a second end or distal end 163B. The distal end of each of the clamps will typically also be received within a door or connector 154 of the connector assembly 153. A biasing member 159 can typically be positioned between the distal end or rear end of each of the door or connector 154 and a spring plate 158, for example, see reference to... Figures 7A-7D As discussed in the embodiments. Each connector assembly 153 will also include one or more linkage mechanisms 156, such as cables, rods, threads, belts, arms, etc., which extend through the spring plate and may extend through the biasing member, and may be coupled at one end 156A to the distal end of each door in the door, and at the opposite end 156B to one or more motors 152.

[0114] In addition, Figures 8A-8B In the illustrated embodiment, actuator 151 may be oriented toward one side of the flat-cut bend. In such an embodiment, the linkage mechanism will extend laterally and will be coupled to the motor and gate of the clamp for the flat-cut bend.

[0115] In the operation of drive system 150; such as Figure 8A and Figure 8B As shown, when the flat-cut looper 161 reciprocates toward and away from the needle of the tufting machine in the first direction, the clamp of the flat-cut looper can also be selectively controlled to extend or retract the clamp as needed to form a cut pile or a loop pile. For example, when the flat-cut looper reciprocates toward the needle (e.g. in... Figure 7A When moving along the path indicated by the middle arrow 54 / 54, the linkage mechanism 156 can be moved in the second direction along the movement path by controlling one or more motors connected to it to retract or extend the clamp. Figure 8A The clamp for the selected cut looper in the cut looper is retracted. When the clamp is in the retracted position, the cut looper can pick up and hold the yarn loops on it to form a cut pile.

[0116] Thereafter, the motor can be reversed or disengaged from the linkage to allow the biasing member to apply a biasing force to the gate to return the clamp connected thereto to the extended position to move along the body of the flat loop bending needle and into a position that prevents the flat loop bending needle from capturing a loop of yarn such that any loop of yarn picked up thereby will be released to form a pile loop. The biasing force applied by the biasing member can also be used in conjunction with operation of the motor or other actuator to help control the movement of the needle spacing members in their second direction, e.g., can help control the movement of each of the needle spacing members between various lowered and raised positions in smaller and / or more defined increments or distances.

[0117] Additionally, the control system of the tufting machine will include programming for controlling the yarn feed to each of the needles in conjunction with the operation of the flat loop bending needles and their clamps to control the length of the loops of yarn picked up or captured by the needle spacing members to form various pattern effects, such as discussed further below.

[0118] Figures 9A-9C Another variation or embodiment of a drive system 150 for selectively controlling the positioning of the needle spacing members 32 of a tufting machine is shown. As Figure 9B and Figure 9C shown, the needle spacing members 32 can include bending needles, hooks or other needle spacing members in which the elongated body 175 has a first or proximal end 176 defining a throat 176A and terminating in a tip or beak 177 and a second or distal end 178 pivotally attached to a bracket or module 179. The second or distal end 178 of each of the needle spacing members can also include a slot or recess 181 configured to engage or receive a mating pin or other connector 182 located at a first or proximal end 183A of the gates or connectors 183 of the link assembly 153. The link assembly 153 can also include a biasing member 186, e.g., a spring or the like, disposed between the second or distal end 184 of each of the gates or connectors 183 and a spring plate or support 187; wherein a linkage 188 connects the gates or connectors of the needle spacing members to the corresponding or associated actuators 151.

[0119] The linkages 188 can include cables, rods, wires, belts, or other similar connections, and in embodiments extend through the spring plate and each linkage will be connected at a first end 188A to a distal end 183B of one of the doors or connections 183 and can be connected at a second end 188B to a corresponding actuator 151, such as one or more motors 152 (e.g., servo motors, stepper motors, torque motors, moving coil actuators, linear actuators, electric cylinders, etc.). The linkages can also extend through one or more guides 189 as needed to help control the motion of the linkages and / or the tension in the linkages. As Figures 9A-9B shown, as the needle pitch members reciprocate in the first direction toward and away from the needles 36, the actuators connected to the corresponding or associated ones of the needle pitch members can be selectively controlled by the control system so that the linkages for the selected needle pitch members can be retracted or extended. When the linkages are retracted, the doors connected thereto will be pulled back toward the spring plate 187 in the direction of arrow 191 against the one or more biasing members 186 and thereby generally cause compression of the biasing members. In response, the needle pitch members will generally pivot or move in the second direction toward the retracted or lowered position as indicated by arrow 71’ in Figure 9C .

[0120] After the linkages are disengaged or the actuators are reversed (e.g., the motors are reversed or release the linkages therefrom), the biasing force exerted by the biasing members when the biasing members are decompressed will cause the doors to be pushed forward in the direction of arrow 191’ which in turn can cause the needle pitch members to pivot in the opposite direction as indicated by arrow 71 so that the first or proximal ends thereof are raised toward the extended or raised position for engaging the needles and picking up the loops or loops of yarn from the needles. The control system can control the actuators to provide an offset to the biasing force from the biasing members to control the motion and / or positioning of the needle pitch members to the extended position. The actuators can also be controlled by the control system in conjunction with the control of the yarn feed to additionally cause the first or proximal ends of the needle pitch members having the loops of yarn captured thereon to move between the raised and lowered positions so as to further enable the pile height of the tufts formed thereby to be varied.

[0121] Figure 10A and Figure 10B Another variation of the drive system 150 is shown for controlling the motion of the needle pitch members 32 in a second direction in addition to controlling the motion of the needle pitch members in the first direction toward and away from the needles of the tufting machine. As Figure 10A and Figure 10BAs shown, each of the stitch spacing components 32 (shown here as including a looper or hook 50) may have an elongated body 196 having: an upper end portion 197 including an elongated throat projecting toward the needle and terminating at a beak or end portion 198; and a lower end portion or distal end portion 199 protruding through the module or bracket 201 and being coupled to a drive member 202 connected to an actuator 151. In this embodiment, the actuator may include a motor 152, such as a servo motor, stepper motor, torque motor, and other types of motors, although a cylinder or drive mechanism may also be used. Additionally, in some embodiments, the lower distal end portion of each of the stitch spacing components may be coupled or connected to a linkage mechanism or extension 204, which may be coupled to the drive member of an associated or corresponding actuator.

[0122] In an embodiment, the drive member 202 may include an eccentric wheel, pulley, disc, or other rotatable drive member. The drive member may be driven to rotate by an actuator; and, as the drive member rotates, a linkage mechanism coupled thereto extends or retracts, causing the stitch length component to move in a substantially linear motion along its second direction. Thus, the throat of the stitch length component will move between an extended or raised position and a retracted lowered position, including a fully lowered seamless position in which the throat of the stitch length component will generally not participate in picking up yarn loops from the needle. When the actuator further rotates the drive member in the opposite direction or toward a substantially full loop, the stitch length component can return to a desired height or position relative to the needle.

[0123] Figures 11A-11B Another variation or embodiment of the drive system 150 is shown, which controls the movement of the needle spacing component 32 of the tufting machine to move the needle spacing component relative to the needle travel in a second direction (e.g., vertically or up and down) as the needle reciprocates toward and away from the needle in a first direction. Figure 2 , 7A (As shown in 9A and discussed above) to control or adjust the position or height of the stitch length component relative to the needles of the tufting machine. Figures 11A-11B In the illustrated embodiment, the drive system 150 will typically include an actuator 151, such as a motor 152 (e.g., a servo motor, stepper motor, torque motor, or other type of motor), but cylinders or other drive mechanisms may also be used. Each motor may also include a rotatable drive member 210 coupled thereto. The drive member 210 may include an eccentric wheel, pulley, cam, or other similar drive member coupled to the motor for eccentric rotation.

[0124] The link assembly 215 connects the needle spacing components to corresponding or associated ones of the actuators, wherein the link assembly includes a linkage 216. In the present embodiment, the linkage is shown as including a rod, arm, bar, or segment. Other types of linkages can also be used. As shown in Figure 11A and Figure 11B The linkage can include a first arm 218 that is connected at one end 218A to a drive member of an associated or corresponding one of the actuators and that is connected at an opposite end 218B to an intermediate arm 219 that is in turn pivotally connected at a first or proximal end 221A of a second arm 221; and wherein a second or distal end 221B of the second arm engages or is connected to a lower or distal end 222 of a corresponding or associated one of the needle spacing components. As shown in Figure 11B Rotation of the drive member will cause the first arm of the associated linkage to extend or retract in the direction of arrows 223 / 233', which in turn will cause each of the second arms of such linkage to pivot. This in turn will cause the corresponding or associated needle spacing component connected to the distal end of the second arm to move in its second direction so as to position the beak or throat of the needle spacing component at a selected position or height relative to the travel of the needle as the needle penetrates the base cloth.

[0125] In operation, according to some embodiments, tufted articles can be formed in accordance with the systems and methods of the present disclosure that can be formed with a variety of patterns and pattern effects, including using a plurality of different colors and / or types of yarns for forming such patterns, as well as including sculpting or multiple pile height effects. For example, the systems and methods of the present disclosure can operate in conjunction with a stitch distribution control system or a yarn color placement system, such as those disclosed and illustrated in U.S. Patent Nos. 8,141,505; 8,359,989; and 8,776,703, the disclosures of which are incorporated by reference herein as if fully set forth herein.

[0126] In such embodiments, the stitches or tufts of yarn formed in the base material can also be formed at an increased or higher actual operational or effective processing gauge as compared to the fabric or pattern gauge desired or prescribed for the tufted pattern being formed. If the pattern or fabric gauge or density of the pattern being formed requires that the tufted article have an appearance of 8, 10, 12, etc. stitches per inch formed therein and / or shown on the face thereof, the actual, operational or effective number of stitches per inch formed during the tufting machine operation will be substantially greater than the desired or prescribed pattern or fabric gauge. Thus, the actual formation of the stitches or tufts of yarn in the base material will be accomplished at an increased actual, operational or effective processing gauge, whereby effectively, a greater number of stitches per inch will be formed in the base material than the number of stitches per inch that will be required to be shown in the finished pattern, wherein those stitches or face yarns that are not desired to be shown or retained in the face of the pattern area or sewn area are not picked up by the stitch length component and, in some cases, are pulled back or out of the base material or to a degree such that these yarns are retained or basted in the base material while substantially avoiding the creation of undesirable or unnecessary voids or spaces between the retained yarns or face yarns of the pattern (i.e., the tufts of yarn that remain visible or apparent in the finished pattern of the tufted article).

[0127] For purposes of illustration, in one exemplary embodiment, the effective processing gauge can be determined based on or by increasing the fabric or pattern gauge of the pattern being formed by approximately the number of colors selected or tufted in the pattern. For a pattern having a desired fabric or pattern gauge of approximately 10-12 stitches per inch and using between 2 to 4 colors, the effective or operational processing gauge (i.e., the gauge at which the stitches are actually formed in the base material) can be approximately 18-20 stitches per inch to approximately 40 or more stitches per inch. However, those skilled in the art will further appreciate that additional variations or adjustments to such operational or effective processing gauges for a particular pattern can be made depending on the type and / or size of the yarn and / or other factors. For example, if a thicker, larger size or heavier yarn is used, the effective processing gauge can be additionally varied as needed to account for the use of such larger yarn (e.g., for a 4 color pattern, the effective processing gauge can be further varied, e.g., to run at approximately 25-38 stitches per inch, but further variations can be used as needed). Thus, where the selected or programmed pattern being run can be designed or desired to have 10 to 12 stitches per inch as the desired pattern density or gauge, the system can actually operate to form up to 20 to 48 or more stitches per inch depending on the number of colors and / or types of yarn, even though only the desired / selected 10 to 12 stitches per inch will typically be visually apparent from the face of the finished tufted article.

[0128] Additionally, in the case of tufting a series of different colors, the needles 36 of the needle bar 35 will typically be provided with the desired thread ends, e.g., for a four color pattern, A, B, C, D thread ends can be used for the needles. Alternatively, in the case of using 2 needle bars, the needles of each needle bar can be provided with alternating thread sequences, i.e., A / C thread on the front needle bar and B / D colors of thread on the back needle bar. Additionally, the needles of such front and back needle bars can be arranged in an interlaced or offset alignment. The needle bar or needle bars will also typically be moved in accordance with the moving profile for the pattern being formed by controlling the needle bar mover 40 Figure 2 ) in combination with controlling the base material and controlling the thread feed to effectively present each color of thread (i.e., 2, 3, 4, 5, etc.) or each different type of thread at the selected pattern pixel or tuft / needle location by laterally displacing the needle bar relative to the base material as the base material is fed through the tufting area.

[0129] For example, for a four color pattern, each of the one to four colors of thread that can be stitched at the next pixel or needle location (i.e., first, second, third, fourth) or that can not be presented at the selected pixel or needle location will be presented to the desired latch or hook as the base material is incrementally moved by about 1 / 8 inch to 1 / 40 inch in each moving cycle or camming motion. The latch or hook will engage and form a loop of thread, wherein the desired one or more threads are retained to form the selected tuft, while the remaining threads can typically be held by their needles without being picked up by the latch or hook. Some threads can be picked up as desired and one or more thread feed mechanisms can thus be controlled to pull the unretained threads that are pulled out of the base material to float along the base material. Thus, during each moving sequence and corresponding incremental movement of the base material, each latch or hook has the ability to tuft any one or possibly more than one (i.e., 2, 3, 4, 5, 6, etc.) pattern color or possibly no color is presented to each latch or hook for each pattern pixel or tuft / needle location associated with said each pattern pixel. As noted above, if any of the different types or colors of thread are not tufted or placed at a particular tuft or needle location or pixel, the thread feed can be controlled to limit or otherwise control the thread of the needle that can be presented at such needle location or pixel to essentially pull back all of the thread or otherwise prevent the thread from being placed or presented at the needle location, and / or the needle bar can also be controlled to skip or otherwise bypass or omit the needle / thread presentation to the needle location or pixel.

[0130] 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 be 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 4-stitch cycle is 1 / 40 inch for each stitch to be presented as needed, in order to achieve the desired stitch / color placement.

[0131] Therefore, when a pattern is formed 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 operating in the pattern and the area of ​​the pattern area being formed by each specific color, one or more 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 operated / formed (e.g., using a combination of single and / or double jumps or movements). This combination of single and double shift jumps or steps can be used to avoid over-tufting or joining previously sewn tufts as the needle bar shifts laterally and the base fabric advances at its effective or operating weave length. The base fabric can also be shifted either in conjunction with or separately from a needle bar shifting mechanism via a base fabric shifting device or a jute shifting device, etc.

[0132] 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 yarn loops 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 the 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.

[0133] like Figures 5A-6CAs shown, the position or location of the beak and / or throat of the latch needle or hook can be varied between a fully extended position or height and a lowered or retracted "no-sew" position at which such latch needle or hook can generally be substantially prevented from picking up and / or forming loops of yarn to provide for selective picking up of loops of yarn (which includes not picking up one or more loops of yarn) as well as control over the length of loops of yarn that are selectively picked from the yarn presented at each stitch location or pixel according to the instructions for the pattern being formed. As a result, the position from which the selected or desired loops of face yarn that are displayed in the "finished" pattern are picked up from the needle by the latch needle or hook can be controlled while further controlling the resulting tufts that are formed from these picked loops of yarn that are left in the base fabric to enable the tufts to be formed at a variety of different pile heights.

[0134] The type / color of yarn for each series of yarns that will be presented at each pixel or stitch location that will be retained or displayed on the surface of the base fabric at a particular stitch location will generally be determined according to the pattern instructions or program for forming the tufted pattern. By controlling the activation and / or positioning of the latch needle or hook 50 corresponding to or associated with the needle carrying such yarn, the tufting machine can be enabled to selectively pick up and retain the loops of yarn at each stitch location at which the yarn will be retained according to the pattern in order to form the final tufts of such yarn at a selected pile height. For example, if the presented yarn is not to be displayed or presented, the corresponding latch needle or hook can be retracted to the no-sew position so that the loop of yarn is not picked up and control of the yarn feed is such that the yarn is not retained at the pixel or stitch location. For retained yarns / colors (i.e., yarns that are presented on the surface of the patterned tufted article), the position or height of the latch needle or hook and the yarn feed mechanisms that feed these yarns can generally be cooperatively controlled in order to enable the loops of these yarns to be picked up and formed in sufficient number to form the desired type and pile height of tufts.

[0135] Further control of the base fabric feed by increasing the effective or operational stitch spacing (e.g., the actual stitch spacing formed in the base fabric) according to the principles of the present disclosure also provides for a more dense or compressed per inch stitch or pile area such that the yarns that are not picked can be at least removed to a degree sufficient to tack or hold such yarns to the base fabric as desired, while at the same time not creating undesirable spaces or gaps between the retained face yarns (those yarns that are to appear on the face of the pile product according to the pattern) and not interfering with or not appearing through such retained face yarns formed in the base fabric material. In addition, the control system can perform yarn feed compensation and / or modeling of the yarn feed to help control and reduce the amount of non-retained or non-appearing yarns that can "float" on the back of the base fabric material to further help reduce / minimize excess yarn feed and / or waste.

[0136] In addition, the yarn feed mechanisms that control the feed of each of the yarns into each of the needles can be selectively controlled to pull the yarns carried by the needles substantially out of the base fabric material or with the needle reciprocation; and some of the loops of yarn can be retracted or pulled back / lowered to a low enough position to substantially avoid the ends of such non-selected yarns occupying the selected stitch positions or otherwise interfering with the placement of the selected face yarns or yarns to be displayed in the particular color areas formed according to the pattern.

[0137] For example, in some embodiments, when a selected or particular looper or hook is retracted to a fully retracted position or "seamless sewing" position, the loops will generally not be picked from the needle associated with such fully retracted looper or hook, while the yarn feed is correspondingly controlled such that the yarns are allowed to move with their needles into and out of the base fabric material. In addition, in certain instances where a loop of yarn is formed, such as when the looper or hook is in a fully extended position and a low loop is formed, the yarn feed can also be controlled to a degree to leave an amount of the yarn engaged or "tacked" to the base fabric, while substantially removing the yarns to a degree such that the ends of the non-selected yarns generally do not interfere with the placement of the face of the yarns appearing or selected at the particular stitch positions within the color area being sewn, such that the resulting loop of yarn can be backed up or pulled low enough or out of the base fabric material.

[0138] The placement of non-appearing yarns that are tacked or otherwise secured to the base fabric material can also be controlled to prevent the formation of such elongated lengths of tail that can subsequently be captured or result in other defects in the finished product pile tufted product. For example, the control system can also be programmed / programmed to tack or form such non-appearing yarns at desired intervals (e.g., every 1 to 1.5 inches, but larger or smaller intervals can also be used). Yarn compensation can also generally be used to help ensure that sufficient amounts of yarn are fed when needed to enable the non-appearing yarns to be tacked into the base fabric material while preventing the yarns from showing through another color or bunching, i.e., where several yarns are placed together, the yarns are tacked and protrude through one of the stitch yarns. Additionally, if elongated lengths or tails are formed for multiple non-appearing yarns, the intervals at which these different yarns are tacked within the base fabric material can be varied (i.e., one at 1 inch and another at 1.5 inches) to avoid these tacked yarns interfering with each other and / or with the yarns of the color field being formed.

[0139] Still further, the actuators, such as the actuators 66 of the Figures 1-6C and the actuators 151 of the Figures 7A-11B can also be controlled to vary the position, location and / or height of the stitch members relative to the needles to enable the stitch members not only to pick up loops of yarn or not pick up loops of yarn, but also to pick up loops of yarn of different lengths. In embodiments, the position and movement of the stitch members can be incrementally controlled in conjunction with the control of the yarn feed mechanisms to, for example, form elongated or stretched loops of yarn by engaging and retracting or lowering their respective crimpers or hooks with loops of yarn captured thereon. Thus, the captured loops of yarn can be further pulled and / or stretched while the corresponding yarn feeds for these yarns can also be controlled to feed additional amounts of such yarns as needed. As a result, even longer or greater lengths of loops of yarn can be formed in the base fabric in order to produce higher pile tufting and / or for producing other desired pattern effects, such as for end shearing and / or other pattern features.

[0140] The selective control of the actuators to selectively retract and extend their crimpers or hooks can also be used to provide additional variations or transition steps or pile heights in the pattern. For example, by individually controlling their actuators or in relation to the biasing force applied by the biasing members, the stitch members can be incrementally moved relative to the needles to buffer as needed and / or enable the movement of the stitch members to be controlled in smaller increments to provide more gradual or more subtle differences or variations in pile height or to provide more abrupt or defined spacing between the pile heights of the yarn tufts being formed.

[0141] Thus, across the entire width of the tufting machine, the control system will control the movement and feed of the yarns of each color or desired pattern texture effect such that each color that can or can be stitched at a particular tuft location or pattern pixel will be present within the pattern pixel space or tuft location for stitching, but only the selected yarn tufts for the particular color or pattern texture effect will remain in that tuft / needle location or pattern pixel. As further noted, additional or more colors can also be presented to each latch or hook during the tufting step in order to form mixed color tufts or to provide a tweed effect as desired, wherein two or more stitches or yarns will be placed at a desired pattern pixel or tuft location. Thus, the operational result of the stitch dispensing control system provides a multi-color visual effect of the selectively placed pattern colors or texture effects in order to achieve the desired density and pattern appearance of the finished tufted product. This further enables the creation of more geometric, free-form, and other pattern effects by controlling the placement of the tufts or yarns at selected pattern pixels or tuft locations.

[0142] Thus, the system and method of the present disclosure for tufted cut-pile and multi-pile height patterned products can enable an operator to develop and run a variety of tufted patterns on a tufting machine having a variety of appearances, textures, etc. without having to utilize a design center to draft and create the patterns. Instead, for the present disclosure, as an additional and / or alternative to manually preparing a pattern or using a design center, an operator can scan an image (i.e., a photograph, drawing, jpeg, etc.) or upload a designed pattern file at the tufting machine, and the stitch dispensing control system can read the image and develop the program steps or parameters to subsequently control the tufting machine without substantially requiring further operator input or control necessary to form the desired tufted pattern product.

[0143] The foregoing description generally illustrates and describes various embodiments of the present disclosure. However, those skilled in the art will understand that various changes and modifications of the above described structures can be made therein without departing from the spirit and scope of the present disclosure as disclosed herein, and it is understood that all matter contained in the above description or shown in the accompanying drawings should be interpreted as illustrative and not in a limiting sense. Furthermore, the scope of the present disclosure should be interpreted to cover various modifications, combinations, additions, substitutions, etc. of the above described embodiments, and the above should be considered as being within the scope of the present disclosure. Thus, various features and characteristics of the present disclosure as discussed herein can be selectively interchanged and applied to other illustrated and unillustrated embodiments of the present disclosure, and various changes, modifications and additions can be made thereto without departing from the spirit and scope of the present disclosure as set forth in the following claims.

Claims

1. A tufting machine comprising: at least one needle bar having a plurality of needles mounted along the needle bar; a base fabric feed roller that feeds base fabric material; at least one yarn feed mechanism that feeds yarn to the needles; a plurality of needle spacing members positioned below the base fabric material, each of the plurality of needle spacing members comprising a body having a first portion and a second portion, the second portion having a throat configured to pick up loops of yarn from the needles; wherein the needle spacing members are movable in a first direction toward and away from engagement with the needles and are movable in a second direction; a drive system for moving the needle spacing members along their second direction, the drive system comprising: a plurality of actuators; and linkages coupled to each needle spacing member and to an associated actuator, wherein each linkage is retracted or extended by its associated actuator to move the needle spacing member in the second direction; a plurality of connectors configured to connect each needle spacing member to at least one linkage for an associated actuator, each of the connectors comprising a body having a first end portion receiving the first portion of the body of one of the plurality of needle spacing members along the first end portion and a second end portion connected to the at least one linkage; and a series of biasing members between the second end portion of each connector and a spring plate; and a control system comprising a program for controlling the at least one yarn feed mechanism to control the feed of the yarn to the needles in coordination with selective actuation of one or more of the plurality of actuators to extend or retract the linkages coupled thereto to move the selected needle spacing members along the second direction into travel relative to the needles into the base fabric material between a seamless stitching position and an extended position for engaging the needles and forming loops of yarn in the base fabric material according to a pattern being formed.

2. The tufting machine of claim 1, wherein, The tufting machine further includes a displacement mechanism for laterally displacing the at least one needle bar across the base material, and wherein the control system further includes a program for coordinating the displacement of the at least one needle bar by the displacement mechanism, the feed of the base material by the base feed roller, the control exerted on the actuators coupled to the needle gauge components, and the control exerted on the at least one yarn feed mechanism to feed the yarn to the needle as the needle reciprocates into and out of the base material, so as to present a series of yarns to selected stitch locations along the base material and to withdraw those unselected yarns in the event that one of the needle gauge components does not pick up a loop of those unselected yarns, and wherein the base material moves through a tufted area at an actual stitch rate that is greater than a pattern stitch rate of a pattern being formed, to provide a number of retained tufts of face yarns per inch in the base material that is equal to the pattern stitch rate.

3. The tufting machine of claim 1 wherein, The needle gauge components include flat cut loop bobbins, loop pile bobbins, or cut pile hooks.

4. The tufting machine of claim 1 wherein, The actuators include one or a combination of hydraulic cylinders, pneumatic cylinders, stepper motors, servo motors, electric cylinders, linear actuators, moving coil or voice coil actuators, solenoids.

5. The tufting machine of claim 1 wherein, The tufting machine further includes at least one module that carries a series of needle gauge components that reciprocate in a direction toward and away from engagement with the needle as the needle reciprocates into the base material; The at least one module includes: a module body adapted to be mounted along a needle gauge bar and having a channel defined therethrough, the module body being formed of one or a combination of metal, polymer, composite, or synthetic materials and having a first hardness; and an insert positioned along the channel, each insert having a slot configured to slidably receive at least a portion of one of the needle gauge components therein; wherein the insert includes a metal or metal carbide material having a second hardness that is greater than the first hardness of the module body.

6. The tufting machine of claim 1 wherein, Each linkage includes a cable, wire, rod, or band and includes a first end that extends through the spring plate and is connected to a second end of one of the links and a second end that is coupled to an associated actuator of the linkage; wherein to retract a selected needle gauge component, one or more of the actuators retracts the linkage coupled to the selected needle gauge component, causing the selected needle gauge component to move along the second direction toward a retracted position, thereby causing compression of the at least one biasing member, and wherein to extend the selected needle gauge component, the at least one biasing member is able to decompress the selected needle gauge component and urge the selected needle gauge component toward an extended position of the selected needle gauge component.

7. The tufting machine of claim 1 wherein, The actuators include motors, and wherein each linkage includes a cable, wire, rod, or belt having a first end portion adapted to connect to one of the links and a second end portion coupled to one of the motors.

8. The tufting machine of claim 1 wherein, The actuators include motors, and the linkages include one or a combination of a cable, wire, rod, belt, arm.

9. The tufting machine of claim 1 wherein, The actuators include motors, each motor including a drive member coupled to and driven by the motor for rotational movement; and wherein the linkages are coupled to the drive member of one of the motors such that when the drive member is rotated by the motor, the linkages extend or retract.

10. The tufting machine of claim 9, wherein, Each of the linkages includes a first arm or rod having a first end coupled to the drive member of the motor and a second end coupled to a second arm or rod at a first end of the second arm or rod, the second arm having a second end pivotally connected to a first portion of a body of one of the needle pitch members; and wherein when the drive member is rotated by its motor, the first arm extends or retracts along a first axis of movement, causing the second arm to pivot and move the one of the needle pitch members between its extended and retracted positions.

11. The tufting machine of claim 1 wherein, Each linkage includes an extension member connected to or integral with a first portion of a body of a corresponding needle pitch member.

12. The tufting machine of claim 1, wherein, The at least one needle bar includes a pair of needle bars, each needle bar having a series of needles mounted in series along the needle bar at intervals.

13. A tufting machine, the tufting machine comprising: at least one needle bar having a plurality of needles mounted along the needle bar, the at least one needle bar moving in a reciprocating motion to move the plurality of needles into and out of a backing fabric passing thereunder; at least one yarn feed mechanism feeding yarn to the needles; and a needle pitch member assembly positioned under the backing fabric, the needle pitch member assembly comprising: a plurality of modules, each module including a module body defining a channel therethrough, and one or more inserts mounted to the module body along the channel defined through the module body; a series of needle pitch members slidably received within the channel of each of the plurality of modules, each needle pitch member having a throat portion, wherein the needle pitch members are carried by their modules along a first direction toward and away from engagement with the needles of the tufting machine to selectively pick a loop of yarn along the throat portion of the needle pitch members from the needles, and the needle pitch members are selectively movable along a second direction through the channel of their modules; and a drive system including: a plurality of actuators coupled to the needle pitch members; and a series of link assemblies configured to connect a needle pitch member to an actuator, each of the link assemblies including a link engaging a portion of a needle pitch member, and at least one linkage coupled to each link and actuator; and ​ a control system including programming for controlling the at least one yarn feed mechanism to control the feed of the yarn to the needles in coordination with actuation control of one or more actuators to cause the linkage mechanism coupled thereto to retract or extend to move the selected gauge member of the gauge members from at least one extended position for engaging the needles and picking up loops of yarn from the needles and a retracted position substantially avoiding picking up loops of yarn from the needles for selectively forming tufts of yarn in the base fabric according to a pattern being formed; wherein the actuators include motors each having a drive member coupled to the motor and to the linkage mechanism connected to the corresponding gauge member; wherein the linkage mechanism is adapted to convert rotational motion of the drive member caused by its motor to linear motion for moving the corresponding gauge member along the second direction; and wherein the linkage mechanism includes one or a combination of cables, rods, arms, wires, belts.

14. The tufting machine of claim 13, wherein, The link assembly further includes at least one biasing member between each link and the spring plate, and wherein each linkage includes a first end portion extending through the spring plate and connected to the link and a second end portion coupled to the drive member of a motor; wherein retraction of the at least one linkage upon actuation causes the link and the corresponding gauge member to move toward the retracted position and against the biasing member, and wherein upon release or extension of the at least one linkage, the biasing member urges the corresponding gauge member toward its at least one extended position.

15. The tufting machine of claim 13, wherein, The tufting machine further includes one or more biasing members positioned between each link and the spring plate; and wherein actuation of a selected one of the motors causes each linkage associated therewith to retract the link coupled thereto and move the corresponding gauge member toward the retracted position thereby compressing the one or more biasing members; and wherein upon decompression of the one or more biasing members, the corresponding gauge member moves toward its at least one extended position.

16. The tufting machine of claim 13, wherein, Each linkage includes an extension connected to or integral with the corresponding gauge member.

17. The tufting machine of claim 13, wherein, The module further includes an insert disposed on opposite sides of the channel of each module, wherein each insert has a hardness greater than a hardness of the module body and includes a series of slots in which the gauge members are received.

18. The tufting machine of claim 17, wherein, The module body of each module is machined, molded, or cast from a metal or composite material, and wherein each insert includes is machined, molded, or cast from a metal, carbide, or powdered metal material, wherein the slots are formed in tab or flange portions.

19. A tufting machine for forming tufts of yarn in a base fabric, the tufting machine comprising: at least one needle bar having a plurality of needles mounted along the needle bar; at least one yarn feed mechanism feeding the yarn to the needles; a plurality of gauge components positioned beneath the base cloth, at least some of the plurality of gauge components being movable in a first direction toward the needles and in a second direction substantially parallel to the travel of the needles; a drive system coupled to the gauge components along the second direction of the gauge components and comprising: a plurality of actuators; and a link assembly connecting the gauge components to the actuators, each of the link assemblies comprising a link configured to be connected to each gauge component and linked to at least one actuator, and one or more biasing members adjacent to each link, each biasing member configured to exert a biasing force on at least one link; and a control system comprising programming for controlling the at least one yarn feed mechanism to control the feed of the yarn to the needles in coordination with actuation of one or more selected actuators to move the selected gauge components associated therewith along the second direction relative to the travel of the needles into the base cloth between a seamless stitching position and at least one extended position for engaging the needles and forming a cluster of yarn in the base cloth according to a pattern being formed; wherein actuation of the one or more selected actuators causes the links linked thereto to move the selected gauge components toward a retracted position and against the biasing force exerted thereon by the one or more biasing members; and upon deactivation of the one or more selected actuators, the one or more biasing members urge the selected gauge components toward their at least one extended position.

20. The tufting machine of claim 19, wherein, The tufting machine further comprises at least one module on which at least some of the gauge components are mounted; the at least one module comprising: a module body adapted to be mounted along a gauge bar and having a passage defined therethrough, wherein the module body is formed of one of metal, polymer, composite or synthetic material or combinations thereof and has a first hardness; and an insert positioned along the passage, each insert having a slot configured to slidably receive at least a portion of one of the gauge components therein; wherein the insert comprises a metal or metal carbide material having a second hardness greater than the first hardness of the module body.

21. The tufting machine of claim 19, wherein, The drive system further comprises at least one linkage extending between each of the links and the actuators associated therewith; wherein each of the links comprises a body having a first end portion in which a first end portion of a corresponding gauge component is received, and a second end portion connected to the at least one linkage; and wherein the one or more biasing members of each link assembly are located between the second end portion of each link and a spring plate.

22. The tufting machine of claim 21, wherein, The actuators comprise motors, and wherein each linkage comprises a cable, wire, rod or belt and comprises a first end portion adapted to be connected to one of the links and a second end portion coupled to one of the motors. The actuators comprise motors, and wherein each linkage comprises a cable, wire, rod or belt and comprises a first end portion adapted to be connected to one of the links and a second end portion coupled to one of the motors.

23. The tufting machine of claim 19, wherein, The actuators include one or a combination of hydraulic cylinders, pneumatic cylinders, stepper motors, servo motors, electric cylinders, linear actuators, moving coil or voice coil actuators, solenoids; and the tufting machine further includes at least one linkage coupled between each link and the actuator associated therewith.

24. The tufting machine of claim 23, wherein, The at least one linkage includes a cable, wire, rod, or belt, and includes a first end portion extending through a plate positioned adjacent the actuator and coupled to one of the links, and a second end portion coupled to the associated actuator; wherein to retract the selected gauge members, the associated actuator retracts the at least one linkage coupled to each of the selected gauge members, causing the selected gauge members to move toward a retracted position, thereby compressing at least one of the one or more biasing members, and wherein to extend each of the selected gauge members, the at least one biasing member can be decompressed and the at least one linkage extended to cause each of the selected gauge members to move toward its extended position.

25. The tufting machine of claim 19, wherein, The actuators include motors, each motor having a drive member, at least one linkage coupled to the drive member of the motor coupled to the associated gauge member; wherein each linkage is adapted to convert rotational motion of the drive member caused by its motor to linear motion for moving the associated gauge member along the second direction; and wherein the linkage includes one or a combination of a cable, rod, arm, wire, belt.

26. The tufting machine of claim 19, wherein, The tufting machine further includes a displacement mechanism for laterally displacing the at least one needle bar across the base fabric, and wherein the control system further includes programming for coordinating displacement of the at least one needle bar caused by the displacement mechanism, feed of the base fabric, control exercised over the actuators coupled to the gauge members, and control exercised over the at least one yarn feed mechanism feeding the yarn to the needles as the needles reciprocate into and out of the base fabric to present a series of yarns to selected stitch locations along the base fabric and to withdraw an unselected yarn in the event that one of the gauge members does not pick up a loop of the unselected yarn, and wherein the base fabric is moved through a tufting area at an actual stitch rate that is greater than a pattern stitch rate of a pattern being formed to provide a number of retained tufts of face yarn per inch in the base fabric that is equal to the pattern stitch rate.

27. The tufting machine of claim 19, wherein, Actuation of the one or more selected actuators causes the links coupled thereto to move against a biasing force exerted thereon by the one or more biasing members to incrementally move the associated gauge members toward a retracted position.

28. A method of forming tufts of yarn in a base fabric, the method comprising: moving a base fabric along a path of travel through a tufting machine; feeding different colored or types of yarn to a plurality of needles as the plurality of needles reciprocate into the base fabric for presenting the yarns for picking up by a plurality of bent needles or hooks; causing the plurality of bent needles or hooks to move toward the needle reciprocations as the needle reciprocations enter the base cloth; positioning at least some of the plurality of bent needles or hooks in a retracted position or an extended position so as to avoid picking up loops of yarn from the needle or to pick up loops of yarn having one or more selected lengths for forming tufts having one or more pile heights; at each stitch position where a loop of yarn is presented that is not picked up by one or more bent needles or hooks from one or more selected needles, moving the one or more bent needles or hooks to a retracted position sufficient to avoid picking up loops of yarn from the selected needles and controlling the feed of these yarns to pull these yarns back with their selected needles; and at each stitch position where a loop of yarn is presented that is picked up by a bent needle or hook of the plurality of bent needles or hooks, controlling the feed of the picked up loop of yarn to retain it at each stitch position; where positioning at least some of the plurality of bent needles or hooks includes controlling one or more selected actuators to incrementally retract a link positioned between the one or more selected actuators and a selected bent needle or hook in a first direction in a manner sufficient to overcome a biasing force exerted on the link by a biasing member to move the selected bent needle or hook between a fully extended position, through one or more intermediate incremental positions, and a fully retracted stitchless position, or to allow the biasing force to urge the link in a second direction opposite the first direction to extend the selected bent needle or hook as needed between its fully retracted stitchless position, through the one or more intermediate incremental positions, and its fully extended position.

29. The method of claim 28, wherein, incrementally extending or retracting a selected bent needle or hook includes raising or lowering the selected bent needle or hook relative to a stroke or penetration depth of the needles.

30. The method of claim 28, wherein, The method further includes laterally displacing at least some of the needles across the base cloth.

31. The method of claim 28, wherein, moving the base cloth along its path of travel includes feeding the base cloth at an actual sett determined by increasing a desired sett by a number of different colors or types of yarn in a selected thread sequence.

32. A method of forming a patterned tufted article, the method comprising: moving a base cloth material along a path of travel through a tufting machine; and presenting a plurality of yarns to a plurality of stitch positions as the base cloth material moves along its path of travel; where presenting the plurality of yarns to the plurality of stitch positions includes: reciprocating a plurality of needles carrying the yarns into and out of the base cloth material; causing a plurality of needle pitch members to move toward the needle reciprocations as the needles reciprocate into the base cloth material; feeding the yarns to the needles as the needles reciprocate into the base cloth material; at each stitch position where an unselected yarn is present and is not picked up by a corresponding needle pitch member from a needle, positioning the corresponding needle pitch member to a stitchless position sufficient to avoid picking up the unselected yarn from the needle and controlling the feed of the unselected yarn so as to pull back the unselected yarn with their needle; and at each stitch location where a selected one of the presented yarns is to be picked up by the needle spacing member, positioning the needle spacing member to an extended position sufficient to enable the needle spacing member to pick up the selected yarn; with at least some of the needle spacing members, picking up selected yarns from at least some of the needles and controlling the feed of the yarns that are picked up and selected to be held at each stitch location; and laterally displacing at least some of the needles relative to the path of travel of the base material; wherein positioning the needle spacing member includes controlling a plurality of actuators to retract the needle spacing member against one or more biasing members in a manner sufficient to overcome a biasing force exerted by the one or more biasing members on the needle spacing member and move the needle spacing member toward the needleless stitch position, or allow the one or more biasing members to bias the needle spacing member to an extended position.

33. The method of claim 32, wherein, moving the needle spacing member includes raising or lowering the needle spacing member relative to the travel or penetration depth of the needles.

34. The method of claim 32, wherein, moving the base material along its path of travel includes feeding the base material at an actual stitch rate determined by adding the number of different colored or type yarns in the selected thread sequence to the desired stitch rate of the pattern being formed.

35. The method of claim 32, wherein, the method further includes threading a series of different colored or type yarns through at least some of the needles with the selected thread sequence.

36. The method of claim 32, wherein, the method further includes controlling the feed of the unselected yarns to the needles so as to pull these yarns out of the base material, or low enough to hold the unselected yarns against the base material, when the unselected yarns are not picked up by the needle spacing members that have been moved to their needleless stitch position.

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